Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “techno-economic”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Project-specific considerations for retrofitting carbon capture technology to power generating and industrial facilities

The National Energy Technology Laboratory (NETL) has previously reported on learnings from 7 FEED studies examining retrofitting power plants with capture. This presentation builds on this effort by highlighting learnings from 3 additional FEED studies examining retrofitting power plants with capture and 7 FEED and pre-FEED studies examining retrofitting industrial plants with capture. This includes a discussion of the design, performance, and cost implications associated with (1) site-specific considerations such as water availability, land availability, and site accessibility, and (2) host-plant-specific factors such as flue gas specifications, operational mode, and allowable degree of integration between the capture system and host plant.

FEED Studies↗
DOE OSTI2025

Front-end engineering design (FEED) studies: a quantitative analysis

NETL has devised a methodology for normalizing FEED study metrics of interest and allowing cautious quantitative comparison across FEED studies. This presentation introduces the novel quantitative comparison methodology and presents results from utilizing this methodology to examine data presented in recent FEED study reports. The quantitative methodology developed for the examination of FEED study performance and cost also allows comparison of real-world performance and costs against NETL TEA model predicted performance and cost. Learnings from examining NETL model predicted performance and cost versus real world reported values are highlighted. These learnings provide insight into NETL TEA model uncertainty and highlight opportunities for further model development.

FEED Studies↗
DOE OSTI2025

Combined Algae Processing (CAP): Progress, Challenges, Opportunities, and Future Directions

This white paper summarizes the historical progress and perspectives on future opportunities for Combined Algae Processing (CAP), a conversion approach centered around fractionating microalgae biomass and producing a slate of fuels and products. We discuss the critical challenges associated with the commercialization of algal biofuels and demonstrate how the CAP approach is uniquely suited to overcome these barriers. The versatility of applying CAP to various sources of algae is highlighted along with conversion to various fuels and product options.

09 BIOMASS FUELS↗
DOE OSTI2026

Feedstock/Pretreatment Screening for Bioconversion of Sugars and Lignin Residues

This project will conduct biomass deconstruction (pretreatment and enzymatic saccharification) on two representative biomass feedstocks and four different pretreatment processes, including three high temperature steam/chemical pretreatments and one low temperature chemical/mechanical pretreatment. A third biomass feedstock will undergo biomass deconstruction with three different pretreatment processes, including two high temperature chemical pretreatments and one low temperature chemical/mechanical pretreatment. Several pretreatment conditions will be performed in a screening study using NLR pilot-scale pretreatment equipment to generate a range of pretreated biomass substrates. A selected number of these substrates will be chosen for enzymatic saccharification evaluation, based on standard compositional analysis of the pretreated substrates as a primary indicator of pretreatment efficacy. Resulting enzymatic hydrolysis slurries will be analyzed to determine overall biomass sugar yields. Additional compositional analysis will be performed to determine oligomeric sugar composition and structure, to analyze structural characteristics of solids fractions on native, pretreated, and enzymatically saccharified biomass residues for one of the biomass feedstocks, corn stover. The enzymatically saccharified materials will undergo 2,3-butanediol fermentation in a shaker flask as bench scale. Using relevant process performance data collected in these various conversion steps, technoeconomic analysis activities will be performed to compare the economic potential of the various biomass feedstock and pretreatment processes and to identify key economic drivers and sustainability metrics.

09 BIOMASS FUELS↗
DOE OSTI2025

Long Duration Energy Storage Viability Survey

Energy storage technologies that can economically store and provide electricity over multi-day and seasonal timescales are likely to be a critical component of a sustainable and resilient energy system. This analysis performs a broad survey of energy storage technologies to find storage media that are promising for these long-duration energy storage applications.

levelized cost of storage↗
DOE OSTI2026

Solar Thermal Energy Planner (STEP 1): A New Decision Support Tool for Solar Industrial Process Heat Applications

Solar thermal technologies are a promising technology to supply low-cost thermal energy to industrial processes, but there are often significant barriers to entry to industrial owners considering these technologies for their energy demands. To overcome this barrier and convey economic value to customers, NREL and Sandia National Laboratories developed Solar Thermal Energy Planner (STEP 1), a new web-based decision support tool for solar industrial process heat systems. At SolarPACES 2024, the STEP 1 tool was still under development; progress, methodologies, and a preliminary case study was presented. With the STEP 1 tool launch in May 2025, in this work, the initial version of the full public tool will be presented with demonstrations of its capabilities using a few case studies. First, the user's process heat needs such as location, process media (e.g., steam, air), process temperature, land availability, electricity and fuel costs, among other parameters. STEP 1 features a mapping interface that allows users to draw land and roof boundaries. The process media and temperature inform technology selection criteria modules that determine the appropriate solar thermal collection technologies, as well as congruent heat transfer media (e.g., hot water, oil, salt). Once the solar thermal technology selected, its nominal thermal production for the given site is characterized using NREL's System Advisor Model (SAM). Then, a modified version of NREL's REopt optimal sizing and dispatch optimization tool determines cost-optimal sizing. Within minutes, the user receives the results of the technoeconomics analysis, including the size and performance of the cost-optimal solar-plus-storage system. The cost of the system is compared to business-as-usual (e.g., an existing, standalone natural gas boiler). Users can download key results to store for sensitivity analyses. Examples of flat plate collector, parabolic trough, and molten salt tower applications with and without PV hybridization for different industrial facility types are presented in this work. The STEP 1 tool aims to reduce barriers to the adoption of solar heating solutions stemming from a lack of familiarity and technical background with solar system design options and costs among industry stakeholders.

14 SOLAR ENERGY↗
DOE OSTI2026

Low-Cost All-Temperature Zinc-Pulp Battery for Stationary Storage

WH-Power Final Technical Report — Low-Cost All-Temperature Zinc-Pulp Battery This is the final scientific/technical report for ARPA-E CREATE program award DE-AR0001796, covering work from September 2023 through September 2025. The WHP–UMD–Yale team set out to develop a safe, low-cost, wide-temperature zinc battery for grid-scale stationary storage. What was built: A zinc-pulp (Zn/CNF) battery system pairing an aqueous high-entropy electrolyte (HEE) with a cellulose-derived ion-conducting membrane.

25 ENERGY STORAGE↗
DOE OSTI2026

Improved Microalgal Carbon Utilization Efficiency via Integrated CO 2 Electro-Conversion to Formate and Microalgal Sequestration

This project developed a process to convert industrial carbon dioxide (CO 2 ) emissions into high-value, sustainable products through genetically engineered algae cultivation. While traditional microalgae cultivation depends on sparging CO 2 gas through water, this method is often inefficient because much of the gas escapes into the atmosphere before the algae can consume it. To overcome this challenge, the project designed an integrated system that first uses a CO 2 to formic acid electrolyzer to convert CO 2 into water-soluble formic acid/formate, then introduces formic acid/formate into the algae pond for cultivation, which allows the algae to access and utilize nearly all of the provided carbon, greatly increasing the efficiency of carbon utilization. The project team has successfully scaled up the CO 2 to formic acid electrolyzer from lab-scale to 1000 cm² and demonstrated industrially relevant current densities with the scaled-up electrolyzers using a CO 2 source that simulates industrial CO 2 waste.

42 ENGINEERING↗
DOE OSTI2026

Design and Optimization of Processing Pathways for Rare Earth Element Recovery from End-of-Life Products

In this presentation, we first discuss the benefits of targeting end-of-life (EOL) products as a feedstock. We then discuss the problem statement of designing a processing facility for recovering rare earth elements (REEs) from EOL HDDs and motors from EOL EVs/HEVs. We then discuss the most profitable pathway, and then discuss the environmental impacts associated with the processing pathway, comparing it to a processing facility in China, and find it to have lower impacts overall. We also investigate the trade-off solutions for other pathways that are not as profitable, but have lower impacts by generating Pareto Fronts. In the next portion of the presentation, Critical Materials Recycling, Inc. is discussed. We discuss how their process was found to be the optimal pathway after performing superstructure optimization, and how we are currently working with them to further optimize their process to increase profits. Finally, we wrap up with conclusions summarizing the main takeaways of the presentation.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Combined Nitrogen and Phosphorous Recovery via Electrochemical Technology Integration into Municipal Wastewater Treatment Plants

This project developed electroN-P, an electrochemical technology for recovering nitrogen and phosphorus as a fertilizer product from anaerobic digester centrate, targeting an advancement from TRL 4 to 6. The reactor was scaled 220× from a 250 mL batch cell to a continuous 4-channel system treating 55 L of wastewater, recovering >80% of phosphorus. Energy consumption under constant-voltage operation was lower than the embedded energy of conventional fertilizers, while constant-current operation produced a cost-competitive product with a smaller reactor footprint. TEA and LCA outcomes were highly sensitive to the magnesium source; alternative magnesium salt configurations projected reduced costs and embedded energy compared to sacrificial rods, but at the expense of significantly longer operation times. The recovered fertilizer performed comparably to diammonium phosphate and triple superphosphate in soil and plant trials. Integrating the technology into a whole-plant model reduced aeration energy by nearly 50%, lowering the levelized cost of water treatment from $0.668/m 3 to $0.648/m 3 . Results support targeting commercialization at smaller (≤1 MGD) facilities with high-strength digester streams. Further investigation into the transport and corrosion kinetics governing sacrificial anode wear is recommended to support continuous, longer-term operation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Future Wind Energy Resources and Cost Uncertainties Across the United States

This dataset contains results estimating projections of change of annual capacity factors and levelized cost of energy for several turbine technologies in the 2024 Annual Technology Baseline (ATB). Projections of change are based on downscaled earth system model (ESM) data from Sup3rCC. There has been evidence of reductions in average wind speeds over land in North America since the 1980s, and several models project that average wind speeds will continue to decrease. Concurrently, the cost of wind energy systems in the United States has been decreasing since around 2010, a trend also projected to continue. There is considerable uncertainty in these future projections, with quantitative estimates of future wind resource and system costs varying widely. To study this, we run land-based wind energy models with a range of possible future system costs, turbine designs, and meteorological inputs from multiple downscaled earth system models over the contiguous United States to estimate critical system performance metrics such as annual energy production (AEP) and levelized cost of energy. Where multiple earth system models agree, changes in mean AEP from the time period 2000-2019 to 2040-2059 can be as high as +10% in South Texas or as low as -20% in Iowa. Several additional states in the Midwest that currently have considerable wind generation capacity show the possibility of substantial decreases in AEP by mid-century. Larger turbines and moderate reductions in system costs can offset even the largest projected decreases in wind resource, but much uncertainty remains in the extent to which wind resources will actually change into the future and to what extent wind energy systems can drive down future costs. An analysis of variance shows, in several states in the Midwest, the uncertainty in future wind resource can be almost as important for future changes in the cost of wind energy as the uncertainty in future system costs.

17 WIND ENERGY↗
DOE OSTI2025

A parcel-level evaluation of distributed wind opportunity in the contiguous United States

This study examines the potential for distributed wind (DW) energy across the contiguous United States, leveraging advancements in the National Renewable Energy Laboratory's distributed wind model, dWind. The novel modeling approach described here utilizes a high-resolution dataset and analyzes over 150 million parcels, a significant improvement from prior methods that extrapolated results from a smaller random sample. This achievement is enabled through key model performance improvements, such as transitioning to multiprocessing, which reduces runtime by 97 %. This optimized, high-resolution approach allows the inspection of technology deployment potential and impact on a variety of scales tailored to individual properties and regions. The results here align with prior work showing substantial opportunity for energy generation using DW technologies. Key findings reveal a substantial increase from prior results in estimated technical and economic potential for DW. Metrics tuned to highlight economic potential also show increased incentives supporting rural adoption. Results are spatially aggregated for usability and published via the U.S. Department of Energy Wind Data Portal and a custom scenario visualization platform, aiding policymakers, industry, and property owners in assessing DW viability across various scenarios and spatial scales.

17 WIND ENERGY↗
DOE OSTI2026

Heliostat Sizing Methodology for Solar Heat for Industrial Processes

This study presents a method to obtain a heliostat size that minimizes the levelized cost of a heliostat-based concentrating solar thermal system for industrial process heat (IPH) applications at operating temperatures from 565 to 1550 degrees Celsius. The method extends prior work by embedding a routine for system design that obtains near-optimal subsystem sizes, increasing the fidelity of drive cost functions, and adding an optical performance model. An illustrative business case is developed for Daggett, California, targeting specified annual thermal energy outputs of 50 to 400 GWhth. Optical performance is modeled using verified estimates from the literature. A surrogate heliostat cost model, derived from commercial heliostat designs and scaled for production volume, installation, and operations and maintenance costs, is used to develop cost functions. Results show that heliostat size strongly affects the levelized cost of heat (LCOH), producing a characteristic U-shaped trend with a robust near-optimal window of 8 - 12 m2; the heliostat size producing the lowest project cost in our study grows slightly as the project size increases, and is reduced as the operating temperature increases. The findings in this study are consistent with the general trend of smaller heliostats under deployment at existing projects for high-temperature industrial process heat and reflect the significant reduction in power electronics and other per-heliostat costs. The methodology we propose is general and can be tailored to revised cost curves as the technology continues to evolve.

14 SOLAR ENERGY↗
DOE OSTI2026

Updating PV and Battery Bill Savings Calculations for Net Billing: New Best Practices for Input Data and Uncertainty

Jurisdictions are increasingly adopting compensation structures for distributed PV and PV-battery systems that price exported energy lower than energy consumed onsite (net billing rates). Standard methods for calculating the bill savings from PV and PV-battery systems were developed for net metering structures, and applying these same methods to net billing structures (such as using Typical Meteorological Year weather with actual year load) introduces bias errors that underestimate PV-battery system bill savings by between 1.5\% and 9\%, depending on the utility rate. We assess the magnitude of these errors and compare them to other sources of uncertainty when estimating the bill savings from PV and PV-battery systems under more complex utility rates.

14 SOLAR ENERGY↗
DOE OSTI2025

Open Architecture for Cost Savings in Advanced Nuclear Reactors

Recently, nuclear power plant build projects in the West have run over budget due to high capital costs and schedule overruns. Compared to other sources of energy, nuclear power plants have higher capital costs. Reactors are often different at every site, resulting in a lack of standardization. Nuclear is expected to compete with other low carbon sources of energy which have lower capital costs making it essential for nuclear to develop ways of reducing costs. Strategies such as standardization, learning rates, modularization, and schedule reduction in advanced reactors can reduce nuclear costs by about 40%. Standardization as a way of cutting capital costs has been explored even in large nuclear power plants. Standardization of certain plant components can result in lower component and installation costs and higher learning from experience. Standardization can be achieved by adopting a criterion of key performance indicators and general design principles for a specific system or component such as the balance of plant. Modularization allows the construction of certain components of SMRs in a factory, which saves time, increases productivity, and encourages higher learning rates. Production learning decreases the time and the cost related to an activity. The potential for modularized components of advanced reactors to be manufactured in factories makes it conducive to achieving higher learning rates. Developing large-capacity nuclear programs through sequential builds cultivates a higher learning rate, which in effect may reduce schedule overruns. Open architecture has been identified as a way to drive standardization among advanced reactor designs and result in cost savings. Open architecture (OA) is defined as a design enabling a diverse supply chain by defining and publishing requirements of systems or equipment in functional and/or interface terms, utilizing technical standards in widespread use. Currently, the nuclear industry’s approach is to use closed architecture, making most designs proprietary. However, collaboration between various advanced reactor vendors and suppliers utilizing the concept of open architecture can result in modular and standardized architecture of subsystems or subcomponents of a nuclear power plant. Completely standardizing nuclear power plants may be impossible, however, certain common subsystems amongst the various reactor designs could be standardized and/or access a wider supply chain and leverage existing learning from other sectors. Open architecture will save time and allocate resources to the parts of the plants that have the most unique features. A key advantage of open architecture is its ability to improve production learning across advanced reactors (AR) types in the industry, by providing and utilizing the same kind of component. Sodium fast reactor (SFR), High Temperature Gas Reactor (HTGR) and Molten Salt Reactor (MSR) are the advanced reactors considered for this project. This paper aims to determine the cost savings in advanced reactor programs due to open architecture learning rate. This work is an extension of work done on light water reactor small modular reactors; the cost methodology was utilized to investigate the impact of open architecture on advanced reactors with a particular focus on sodium fast reactors. The cost data on sodium fast reactors used in the model presented the most adequate information required for the analysis.

Advanced Nuclear Reactors↗