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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.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

TCO Analysis Approach and Regional Analysis of dWPT for Class 8 Tractors

Dynamic Wireless Power Transfer (dWPT) is a method by which battery electric vehicles (BEVs) can charge their battery while traveling on the road without the need for a physical conductive connection to the power source. dWPT has been proposed as a strategy to enable a reduction in vehicle battery capacity and associated mass and cost. In this slide deck presented at the EVs@Scale Consortium - Wireless Power Transfer Pillar Deep-Dive Meeting on November 11th, 2023, NREL provides results from an evaluation of dWPT using data from Class 8 tractors driving in the Atlanta Metro Area. NREL selected data for archetypal days representing local, regional, and long-haul trips, defined according to trip length, that included travel on primary roadways. EVI-InMotion (Electric Vehicle Infrastructure - InMotion), a systems planning and optimization tool developed at NREL, was used to evaluate dWPT performance assuming dWPT charging on 120 road segments for a total roadway lane distance of 2,365 miles. The EVI-InMotion results and representative day drive cycles were analyzed with NREL's T3CO (Transportation Technology Total Cost of Ownership) tool to estimate the total cost of ownership (TCO) for scenarios comprising two model years - 2030 and 2040 - and two technology progress cases. TCO was calculated for diesel, fuel cell electric, BEVs with batteries sized assuming no dWPT capabilities, and 200kWh BEVs with dWPT installed. This analysis finds that en-route stationary charging frequency and downtime when not on electrified roadways are the main contributors to TCO for the dWPT vehicles and that these vehicles can achieve cost parity with FCEVs at low electricity costs. Based on the scenario assumptions used here, low electricity costs would further help the cost parity with diesel vehicles in regional and long-haul cases due to stationary fueling downtime. This presentation also concludes that key factors affecting the parity potential of dWPT-capable vehicles include more extensive dWPT road coverage, higher en-route charging power, less expensive power batteries, and higher hydrogen or diesel fuel costs.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2025

An evaluation of multi-fidelity methods for quantifying uncertainty in projections of ice-sheet mass change

Abstract. This study investigated the computational benefits of using multi-fidelity statistical estimation (MFSE) algorithms to quantify uncertainty in the mass change of Humboldt Glacier, Greenland, between 2007 and 2100 using a single climate change scenario. The goal of this study was to determine whether MFSE can use multiple models of varying cost and accuracy to reduce the computational cost of estimating the mean and variance of the projected mass change of a glacier. The problem size and complexity were chosen to reflect the challenges posed by future continental-scale studies while still facilitating a computationally feasible investigation of MFSE methods. When quantifying uncertainty introduced by a high-dimensional parameterization of the basal friction field, MFSE was able to reduce the mean-squared error in the estimates of the statistics by well over an order of magnitude when compared to a single-fidelity approach that only used the highest-fidelity model. This significant reduction in computational cost was achieved despite the low-fidelity models used being incapable of capturing the local features of the ice-flow fields predicted by the high-fidelity model. The MFSE algorithms were able to effectively leverage the high correlation between each model's predictions of mass change, which all responded similarly to perturbations in the model inputs. Consequently, our results suggest that MFSE could be highly useful for reducing the cost of computing continental-scale probabilistic projections of sea-level rise due to ice-sheet mass change.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Parametric Study of Lithium-Ion Batteries using BatPaC (Final Report)

The Battery Performance and Cost Model (BatPaC) is a tool developed by Argonne National Laboratory to design lithium-ion battery (LIB) packs for automotive applications. The material demand and design specifications are used to estimate the cost of manufacturing the battery pack in a large volume production plant (5-50 GWh/year). With the option to select from various electrode chemistries and materials with their associated properties and prices, the resultant battery pack mass, volume, and cost can vary considerably. This report is the result of a parametric sensitivity study that helps identify the key parameters and prices that affect the battery metrics – the specific energy (Wh/kg) and the pack cost ($/kWh). The study was conducted with LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) and graphite (G) electrodes as the baseline materials used in a battery pack for a 300-mile range battery electric vehicle (BEV300) and a 50-mile range plug-in hybrid electric vehicle (PHEV50).

25 ENERGY STORAGE↗
DOE OSTI2020

Evaluation of Steam Cycle Upgrades to Improve the Competitiveness of U.S. Coal Power Plants (Final Scientific / Technical Report)

Increasing the competitiveness of the existing pulverized-coal utility fleet in the United States may be achieved by decreasing heat rate, via increases in steam cycle efficiency through upgraded steam temperatures and use of latest technology available in steam turbine and blading design. The average net plant efficiency of the US coal-fired fleet is approximately 33% (HHV). Plant efficiency increases to approximately 41.4% (HHV) at 1,350°F (732°C) steam temperature. However, achieving these Advanced Ultra-Super Critical (AUSC) steam conditions requires the use of advanced high-temperature materials. While there has been a significant amount of DOE-funded materials R&D, most of the related design work has focused on new (greenfield) units, rather than on opportunities to retrofit this advanced technology to the existing utility fleet. If technology, based upon the advanced materials required for AUSC steam conditions, may be applied to the existing fleet, using an economically viable retrofit, a higher capacity factor can be expected as a result of the increased plant competitiveness. The Electric Power Research Institute (EPRI) was awarded a project by the US Department of Energy to examine the technical and economic feasibility of a series of steam cycle upgrades to the two most prevalent types of U.S. coal power plants: 2,400 psig (16.6 MPa) subcritical and 3,500 psig (24.1 MPa) supercritical pulverized coal units. The nine upgrade options that were originally being considered included increasing the main and reheat steam temperatures from 1,000°F (538°C) to 1,100°, 1,200°, and 1,350°F (593°C, 649°C, and 732°C) while holding the steam pressures constant at their original design values, and cases where just the main steam or reheat steam temperatures were increased. The objective was to minimize the modifications required to the existing power plant while still providing a significant improvement in heat rate. The upgrade options assumed that the boiler enclosure envelope remained unchanged from each base case, and that all applicable OEM design guidelines for normal commercial units were imposed. For the highest temperature supercritical case, an option of using a low-pressure molten salt loop to transfer heat from the furnace to the steam was examined. The first major task of the work scope was designed to examine the technical feasibility of various upgrade options, while the subsequent work determined economic viability of the technically feasible upgrade options. Prior to evaluating the effect of these increased temperatures, a “base case” model of a subcritical and supercritical PC boiler was created, which was used for comparative purposes. Upgrade options were evaluated at full-load, part-load and dynamic transient conditions. Once the technical feasibility of each upgrade option was evaluated, the economic value of the heat rate improvement of each feasible option was determined by detailed modeling of unit dispatch in several regional power markets. The dispatch model was used to estimate the amount of revenue from power sales the upgraded unit would receive in comparison to a non-upgraded version of the same power plant. As a parallel task to the dispatch analysis, the capital cost of implementing the upgrades was estimated. The capital cost estimates were then compared to the increased revenue estimated by the dispatch modeling to determine the economic attractiveness of each upgrade option. Several upgrade options were determined to be technically feasible. The net present value (NPV) of the costs for steam cycle upgrades considered in this study ranged from approximately $\$$111 to $\$$130 million. The economic modeling results show that the unit dispatch changes resulting from steam cycle upgrades are relatively small, due largely to heat rate (and operating cost) changes being relatively small. Additionally, the cost of each upgrade exceeds the net revenue increases associated with the upgrade case. Note that the breakeven values are higher for subcritical retrofits, but the capital costs for the subcritical upgrades are also slightly higher. In typical new pulverized coal plants, fuel accounts for approximately 25% of the cost of electricity (COE), while capital costs represent around 50% of the COE. Therefore, in order to improve the heat rate by 4% one can only afford to increase the capital cost by 2%, at the same cost of electricity. The conclusion of this study is that without a cost for emitting CO 2 , it will be difficult to pay for significant efficiency improvements on plants firing low cost coals.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

An Evaluation of Energy Storage Cost and Performance Characteristics

The energy storage industry continues to expand globally as costs continue to fall and opportunities in consumer, transportation and grid applications are defined. As the rapid evolution of the industry continues, it has become increasingly important to understand how varying technologies compare in terms of cost and performance. This paper defines and evaluates cost and performance parameters of six battery energy storage technologies (BESS) - lithium-ion batteries, lead-acid batteries, redox flow batteries, sodium-sulfur batteries, sodium metal halide batteries, and zinc-hybrid cathode batteries - four non-BESS storage technologies - pumped storage hydropower, flywheels, compressed air energy storage, and ultracapacitors - and combustion turbines. Cost and performance information was compiled based on an extensive literature review, conversations with vendors and stakeholders, and costs of systems procured at sites across the United States. Detailed cost and performance estimates are presented for 2018 and projected out to 2025. Annualized costs were also calculated for each technology.

Mongird, Kendall↗
DOE OSTI2026

A Systematic Review and Integrated Approach to Modeling of Aging Utility Scale PV Systems

The growing deployment of utility-scale photovoltaic (PV) systems has increased the importance of techno-economic modeling operational photovoltaic (PV) systems for predicting energy yield, optimizing asset management, and informing financial decisions. Through a systematic review of literature and current industry practices, we review the different common modeling practices of a system's configuration and age, performance and degradation, operation and maintenance (O&M), while also focusing on specific considerations for repowering, revamping, and decommissioning. Building on the synthesis, we develop a structured framework for techno-economic modeling of operating PV systems that integrate performance and degradation analysis, a decommissioning and repowering cost model that estimates the system's end-of-life costs to reduce uncertainty quantifications and improve consistency across the sector. This research contributes to improved modeling methodologies and potentially to reduced financial performance requirements by providing practitioners with input resources and practical approaches to estimate performance, degradation, and costs associated with continued operation, revamping, repowering, or decommissioning decisions.

14 SOLAR ENERGY↗
DOE OSTI2022

Valuing Resilience for Microgrids: Challenges, Innovative Approaches, and State Needs

The United States depends on the delivery of reliable, affordable, clean, and safe electricity. Electric utilities invest billions of dollars each year in generation, transmission, and distribution assets to meet this need. However, experiences with recent natural disasters of increasing frequency and duration demonstrate the shortcomings of this approach in the face of modern threats. Further, as customers rely on electricity for a broader range of important needs, such as transportation, as well as critical life-saving services and mission critical facilities such as water treatment, medical care, shelters, telecommunications, and more, the need to minimize the likelihood and impacts of outages grows. Against this backdrop, resilience has emerged as a key consideration to guide electricity spending, whether from utilities, customers, or taxpayers. Although reliability has been defined and measured for decades with broadly accepted metrics that measure how many customers lose power and at what frequency and duration, resilience considers the electricity system’s response to a disruption and its subsequent impacts on customers. Developing tools and methods to accurately assess the costs and benefits of resilience investments is a critical step toward the goal of mitigating the impacts of outages on customers and society. Today, electric system resilience is largely treated as an externality due to challenges estimating the costs of long-duration outages, impacts of outages on society, and increasing reliance on electricity for a growing set of interdependent services. These interdependencies include the water, wastewater, telecommunications, natural gas, and health sectors. Without knowing how much a given resilience investment will benefit customers or society more broadly, investors, policymakers, and regulators are less likely to make or approve such investments, and less able to prioritize those investments. State Energy Offices and public utility commissions (PUCs) lead the development of state-level energy policy and utility regulation, respectively, and each has interests in encouraging appropriate public and private investments in resilience. To this end, the National Association of State Energy Officials (NASEO) and National Association of Regulatory Utility Commissioners (NARUC), with the support of the U.S. Department of Energy (DOE) Office of Electricity (OE), formed a joint Microgrids State Working Group to explore the costs and benefits of microgrids, barriers to broader deployment of microgrids to meet resilience and other objectives, and policy and regulatory strategies to optimize investments in resilience, including but not limited to microgrids. Although no universally accepted valuation tool for resilience exists, National Laboratories, utilities, researchers, and state and federal agencies have collaborated to develop, apply, and improve a number of approaches to quantify resilience, several of which are still in progress at the time this report is published. This report seeks to share these important advances by discussing current definitions of resilience (Section 1), how microgrids are defined and used to meet resilience objectives (Section 2), new approaches to valuing resilience (Section 3), steps State Energy Offices and PUCs have taken to further resilience valuation efforts (Section 4), and finally, considerations and suggested next steps for State Energy Offices and PUCs (Section 5). Relevant examples of specific microgrid projects and resilience valuation efforts are included throughout the report. While this report is written specifically for NASEO and NARUC members, it may be useful for utilities, local governments, and individual customers interested in improving the way public and private dollars are spent to achieve resilience outcomes.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

A Framework for Evaluating the Implementation Cost of Attacks on Large Language Models

Large Language Models (LLMs) have been increasingly proposed as a method to enhance productivity in tasks that involve language and code. However, these models are large, complex, and their capabilities are not easily understood and controlled, meaning that their adoption opens many possibilities for new cyberattacks and misuse. Numerous attacks on LLMs have been reported and summarized in literature reviews, but we found existing reviews lacking in understanding the implementation cost of the attacks - i.e., how much effort would an attacker need in terms of coding, expertise, and resources to adopt attacks presented in the literature. Therefore, we divide existing attacks on LLMs into a taxonomy, and define a cost evaluation framework to determine the cost of the attack. An attack’s cost can be 1) estimated from reading the publication about the attack or 2) determined by implementing the attack from that publication. We provide an example evaluation of a couple jailbreaking frameworks based on experiments, and then apply the more lightweight cost estimate to a representative selection of attacks across the taxonomy we define. We discuss the relative difficulty of the attacks and also highlight defenses that have attempted to mitigate these attacks and assess their effectiveness.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Expanding market opportunities: cogeneration strategies for integrated PWR and thermal energy storage systems

We assess the economic viability of nuclear cogeneration by investigating three different modes—fixed dispatch, fully flexible dispatch, and flexible dispatch with minimum heat supply requirements. The analysis focuses on an existing pressurized water reactor (PWR) integrated with thermal energy storage (TES). Heat production costs are estimated under these modes for two U.S. electricity markets: the Electric Reliability Council of Texas (ERCOT) and the Pennsylvania–New Jersey–Maryland Interconnection (PJM). A sensitivity analysis examines profitability at varying heat market prices. Results indicate that fixed heat dispatch inflates heat production costs, often rendering projects economically feasible only at higher heat price levels. Fully-flexible dispatch lowers heat production costs by an average of 43 % compared to fixed dispatch. However, the current 30 % thermal dispatch limit may be insufficient to serve high baseline industrial demands cost‐effectively; higher maximum dispatch rates could enhance project economics. Markets with higher and more volatile electricity prices (e.g., ERCOT) offer greater total energy sales potential (i.e., heat and electricity), but also increase opportunity costs when heat production scheduling restrictions are imposed. In contrast, lower-price, less volatile markets (e.g., PJM) experience smaller impacts from such constraints and provide greater flexibility in accommodating varying cogeneration modes. In conclusion, these findings provide a framework to guide nuclear plant operators in aligning cogeneration strategies with industrial process requirements and electricity market conditions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

CO2 Storage Economic Analysis: CarbonSAFE Use Case

Poster on “CO2 Storage Economic Analysis: CarbonSAFE Use Case” for the CCUS 2025 conference held in Houston, Texas March 3-5, 2025. The cost of designing, permitting, constructing, operating, and closing a CO2 storage project is of vital importance to project developers. The National Energy Technology Laboratory has developed the NRAP/SMART Technoeconomic and Liability Evaluation for Storage (TALES) Model to provide quantitative cost-based insights to support developers planning CO2 injection and storage projects. This study presents a collaborative economic analysis applying TALES with data from the San Juan Basin CarbonSAFE Phase III project led by the New Mexico Institute of Mining and Technology to estimate potential costs incurred during the implementation of a real-world commercial-scale carbon storage project. Scenario analysis was implemented in which different operational and cost attributes were varied and the associated cost implications observed. Key results data and project cost summary metrics, first-year breakeven price of CO2 ($/tonne) and net present value (NPV), are presented for base and alternative cases. Output provides a unique perspective for project stakeholders towards evaluating the influence of different operational strategies and financing approaches on overall project cost and financial viability.

carbon storage↗
DOE OSTI2023

Cost of Fish Exclusion and Passage Technologies for Hydropower

Hydropower represents a reliable source of renewable energy and accounts for approximately 7% of the total electrical generation in the United States. Future expansion of hydropower is likely to be in the form of either smaller new stream development projects or powering existing non-powered dams. For these new projects to be successful, careful analysis of risks, costs, and uncertainty to offset reduced power production as well as ensuring the protection and safe passage of migratory fish to gain public support, will be required. Exclusion and passage are two common approaches to protect fish from entrainment and impingement at hydropower facilities. The thresholds for entrainment risk and requirements for exclusion and passage often differ depending on the species involved, the characteristics of the facility, and the goals of stakeholders. While the costs associated with environmental mitigations represent a large proportion of the total costs required for the licensing of hydropower facilities, little quantitative information is present within the literature regarding the specific costs of fish exclusion and passage. Working with FOA awardee Natel Energy, scientists at Oak Ridge National Laboratory were tasked with assessing the capital construction costs for downstream fish exclusion and passage infrastructure. This report used keyword searches of an existing environmental mitigation cost data set and manual extraction of additional cost data associated with protection, mitigation, and enhancement (PM&E) measures related to positive barrier screening and passage from regulatory licensing documents available in the Federal Energy Regulatory Commission (FERC) eLibrary. This approach yielded a total of 50 PM&E mitigation measures with estimated capital construction costs pertaining to positive barrier screens, 142 pertaining to passage studies, and 26 pertaining to passage-related studies. PM&E measures associated with positive barrier screens represented <10% of the 171 total FERC project dockets available in the data set. These data were highly skewed toward conventional relicensing projects, as <7% were associated with new stream development (NSD) projects. Results from these data indicate highly variable costs associated with fish screening, with flow-normalized costs one to two orders of magnitude higher for screening with the highest exclusion capability (≤0.09 in. spacing) compared with coarser screening (1 to 2 in.). Furthermore, estimated capital costs of passage infrastructure were positively related to the scale of the project based on installed capacity for some, but not all, types of passage. These data provide an initial baseline for estimating exclusion and passage costs for hydropower development and may help developers consider options for more fish-friendly generation technologies, though gaps remain relating to a lack of data, particularly for NSD projects. More data may still be available within the FERC eLibrary, but significant effort will be required to manually identify and extract the data for future analyses.

13 HYDRO ENERGY↗
DOE OSTI2026

Design and demonstration of a direct air capture system with moisture-driven CO 2 delivery into aqueous medium

Two direct air capture (DAC) systems were designed and demonstrated to passively capture CO 2 from ambient air and use moisture to release the CO2 into an alkaline medium. A bench-scale system delivering ∼1 g CO 2 d –1 was demonstrated in a laminar flow hood, and a small pilot-scale system that could deliver ∼100 g CO 2 d –1 was operated outdoors in a 4.2 m 2 raceway pond. Novel elongated mesh-tube packets containing anion-exchange resin (AER) beads were found to reduce drying and CO 2 loading time 4.3-fold compared to larger mesh bags. Technoeconomic analysis (TEA) estimates the cost of capturing CO 2 into an alkaline solution, suitable for cultivating photosynthetic microorganisms, to be $\$229$ per tonne for a practical scenario based on current results and $\$72$ per tonne for an aspirational scenario considering improvements to sorbent capacity, hydrophobicity, and sorbent lifetime. TEA further estimates an additional $\$110$ per tonne to extract CO 2 from solution, purify it, and compress it to 15 MPa, suitable for sequestration. Furthermore, moisture-driven processes have the potential to use up to 87% less energy than thermal and/or vacuum swing DAC by using energy from water evaporation.

09 BIOMASS FUELS↗
DOE OSTI2021

Cost Efficiency of Environmental DNA as Compared to Conventional Methods for Biodiversity Monitoring Purposes at Marine Energy Sites

The installation of marine energy systems may affect marine environments, and by extension, marine fish communities. Therefore, biomonitoring is an integral part of assessing impacts on species. Environmental DNA (eDNA) provides a noninvasive alternative to conventional monitoring surveys and the possibility of a more accurate assessment of species richness. Yet, its cost efficiency compared to traditional methods of monitoring is relatively unknown, especially when applied to monitoring around tidal, wave, and offshore wind energy installations. For this study, 202 peer-reviewed journal articles were dissected to inventory the diversity of supplies used for collecting and processing eDNA samples and to compile the average cost of eDNA surveys. Information collected included the type, volume, and brand of containers used in sampling; material, size, and brand of filters; and extraction methods. Cost information was gathered for the most common supplies, and a total cost was estimated for a hypothetical eDNA survey in Sequim Bay, WA, to compare with traditional methods of surveying such as beach seining and scuba surveys. The results showed a higher-than-expected diversity of supplies to collect and process eDNA samples. The most common supplies were 1 L Nalgene bottles at an average cost of 7.96 USD for collecting samples, 0.45 µm glass fiber Merck Millipore filters at an average cost of 1.51 USD for filtering samples, and the Qiagen DNeasy Blood and Tissue kit at 3.54 USD per sample for extracting DNA. When compared to beach seine and scuba surveys, eDNA surveys undertaken by senior researchers are less expensive for both initial surveys with all new materials as well as for follow-up surveys reusing some of the supplies. However, when surveys are done solely by students, eDNA surveys are more expensive than scuba surveys when no prior supplies are available and more than both beach seine and scuba surveys for follow-up surveys reusing supplies. In a professional sphere, where surveys are less often conducted by teams of students only, eDNA surveys are an effective and less-costly alternative to conventional methods. We anticipate that the development and refinement of eDNA methodology will continue to decrease surveying costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Applying Improved Optical Recognition with Machine Learning on Sorting Cu Impurities in Steel Scrap

Annually, 20–55 million tons of electronic waste (e-waste) is produced worldwide (5% of all municipal solid waste). Although e-waste embodies only 2% of America’s municipal waste, it accounts for a significantly larger proportion of the heavy metals and flame retardants present in the waste stream. Currently, less than 20% of all e-waste is recycled in the United States because the heterogeneity of the feedstock limits the opportunity for reuse in high value products and processing of the waste itself is often too costly to justify handling. To address this concern, the aims of this study are: 1) to identify the major plastic and metal compositions within electronic shredder residue (ESR), 2) to formulate solvents and processing conditions to separate 90% of the plastics targeted from consumer shred ESR, and 3) to develop a process design model to estimate the cost and energy efficiency of the proposed solvent-based processing. In this study, a pre-sorted heterogeneous ESR feedstock (one where aluminum, magnetic components, and hazardous battery materials removed by an e-waste recycling facility) was used, with the major compositions of the ESR characterized. It was found that 25 wt.% of the feedstock was composed of plastics, 6 wt.% rubber, 27 wt.% printed circuit boards, 23% wire, and the remainder metals and capacitors. Within the plastic portion, polystyrene (PS, 40 wt.%), acrylonitrile butadiene styrene (ABS, 25 wt.%), and styrene-acrylonitrile (SAN, 9wt.%) were identified to compose the majority of the screened plastics using Fourier transform infrared spectroscopy (FTIR). Next, selective solvents were screened using Hansen Solubility Parameter Theory (HSP) for dissolving PS and ABS. The pre-screening results show that methylene chloride (dichloromethane, DCM) and tetrahydrofuran (THF) are capable of dissolving the most PS and ABS, while methanol (MeOH) and ethylene glycol (EG) are capable of precipitating the most PS and ABS. These solvents were subsequently used to recover polymers and remove. flame retardants within the ESR feedstock. By optimizing the dissolution time and the solvents used, the highest polymer dissolution yield (99 wt.%%) was achieved using DCM for 48 hr. Both pre-screened anti-solvents (MeOH and EG) showed the highest polymer precipitation yield (71 wt.%). In terms of flame retardant removal rate, EG was found to have a high phosphorus-containing flame retardant removal rate (up to 98%). Characterization shows that the proposed solvent-based processing can preserve a high molecular weight fraction of the polymers and effectively remove flame retardants. Cost analysis indicates that the amount of the solvent/anti-solvent recovered after the reaction would play a critical role in reducing the operating costs. The energy analysis shows that the proposed solvent-based processes can save up to 60% of the embodied energy used to manufacture plastics used in electronics (PS and ABS were used for calculations). The results from this project prove the potential of solvent-based processing to produce secondary materials (plastics and metals) from e-waste for cross-industry reuse.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Chemical Recycling of Mixed Plastics and Valuable Metals in the Electronic Waste Using Solvent-Based Processing

Annually, 20-55 million tons of electronic waste (e-waste) is produced worldwide (5% of all municipal solid waste). Although e-waste embodies only 2% of America’s municipal waste, it accounts for a significantly larger proportion of the heavy metals and flame retardants present in the waste stream. Currently, less than 20% of all e-waste is recycled in the United States because the heterogeneity of the feedstock limits the opportunity for reuse in high value products and processing of the waste itself is often too costly to justify handling. To address this concern, the aims of this study are: 1) to identify the major plastic and metal compositions within electronic shredder residue (ESR), 2) to formulate solvents and processing conditions to separate 90% of the plastics targeted from consumer shred ESR, and 3) to develop a process design model to estimate the cost and energy efficiency of the proposed solvent-based processing. In this study, a pre-sorted heterogeneous ESR feedstock (one where aluminum, magnetic components, and hazardous battery materials removed by an e-waste recycling facility) was used, with the major compositions of the ESR characterized. It was found that 25 wt.% of the feedstock was composed of plastics, 6 wt.% rubber, 27 wt.% printed circuit boards, 23% wire, and the remainder metals and capacitors. Within the plastic portion, polystyrene (PS, 40 wt.%), acrylonitrile butadiene styrene (ABS, 25 wt.%), and styrene-acrylonitrile (SAN, 9wt.%) were identified to compose the majority of the screened plastics using Fourier transform infrared spectroscopy (FTIR). Next, selective solvents were screened using Hansen Solubility Parameter Theory (HSP) for dissolving PS and ABS. The pre-screening results show that methylene chloride (dichloromethane, DCM) and tetrahydrofuran (THF) are capable of dissolving the most PS and ABS, while methanol (MeOH) and ethylene glycol (EG) are capable of precipitating the most PS and ABS. These solvents were subsequently used to recover polymers and remove. flame retardants within the ESR feedstock. By optimizing the dissolution time and the solvents used, the highest polymer dissolution yield (99 wt.%%) was achieved using DCM for 48 hr. Both pre-screened anti-solvents (MeOH and EG) showed the highest polymer precipitation yield (71 wt.%). In terms of flame retardant removal rate, EG was found to have a high phosphorus-containing flame retardant removal rate (up to 98%). Characterization shows that the proposed solvent-based processing can preserve a high molecular weight fraction of the polymers and effectively remove flame retardants. Cost analysis indicates that the amount of the solvent/anti-solvent recovered after the reaction would play a critical role in reducing the operating costs. The energy analysis shows that the proposed solvent-based processes can save up to 60% of the embodied energy used to manufacture plastics used in electronics (PS and ABS were used for calculations). The results from this project prove the potential of solvent-based processing to produce secondary materials (plastics and metals) from e-waste for cross-industry reuse.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

NETL's Cost of Capturing CO2 from Industrial Sources and Industrial Carbon Capture Retrofit Database

This presentation was given on behalf of NETL's Strategic Systems Analysis and Engineering Directorate, Energy Process Analysis Team at a United States Energy Association webinar on January 24, 2023. The presentation summarizes techno economic analysis results of nine industrial CO2 capture cases, and also gave an overview and brief demonstration of the industrial sources Carbon Capture Retrofit Database, which is a publicly available tool that estimates capture costs for a subset of the industrial sources appearing in the companion systems analysis report.

Hughes, Sydney↗
DOE OSTI2023

Renewable electricity capacity planning with uncertainty at multiple scales

Abstract We formulate and compare optimization models of investment in renewable generation using a suite of social planning models that compute optimal generation capacity investments for a hydro-dominated electricity system where inflow uncertainty results in a risk of energy shortage. The models optimize the expected cost of capacity expansion and operation allowing for investments in hydro, geothermal, solar, wind, and thermal plant, as well as battery storage for smoothing load profiles. A novel feature is the integration of uncertain seasonal hydroelectric energy supply and short-term variability in renewable supply in a two-stage stochastic programming framework. The models are applied to data from the New Zealand electricity system and used to estimate the costs of moving to a 100% renewable electricity system by 2035. We also explore the outcomes obtained when applying different forms of CO 2 constraint that limit respectively non-renewable capacity, non-renewable generation, and CO 2 emissions on average, almost surely, or in a chance-constrained setting, and show how our models can be used to investigate the merits of a proposed pumped-hydro scheme in New Zealand’s South Island.

Ferris, Michael C.↗