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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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DOE OSTI2024

NX Fuels H2 Shot Incubator Phase I (CRADA Final Report)

NX Fuels will work with NREL to perform Life-Cycle Analysis (LCA) and Techno-Economic Analysis (TEA) for NX Fuels' solar H 2 system. TEA/LCA modeling developed early on will provide insight on the most critical parameters related to the green H 2 cost and environmental impacts and help us create the business case at scale. This project will advance the Nation’s decarbonization goals by demonstrating the economic feasibility of NX Fuels clean hydrogen production pathway and evaluate its impact on CO 2 emissions.

08 HYDROGEN↗
DOE OSTI2023

Production of bio-diesel blend stocks via acid-catalyzed dehydration of ethanol oligomerization products

Ethanol is the most widely produced biofuel in the world. Gasoline demand is projected to decrease in the next 20 years largely due to an increase in electric vehicles. Diesel fuel demand is projected to continue to increase. Long-chain mono C10+ ethers have high cetane numbers and appropriate physical properties to be blended at high levels into petroleum diesel fuel. A techno-economic analysis shows that the ethers can be produced at prices similar to biodiesel. In our presentation we will show the catalytic chemistry involved in our ethanol to diesel approach, the engine and physical measurements of the produced diesel-range ethers, and a summary of the techno-economic analysis.

Canales, Emmanuel↗
DOE OSTI2022

Front-End Engineering Design for Piperazine with the Advanced Stripper

This Department of Energy (DOE) funded project was executed with the goal of preparing a Front-End Engineering Design (FEED) for the capture and compression of 90% of the CO2 that would normally be emitted from an existing natural gas combined cycle (NGCC) plant. The FEED focused on the application of the piperazine advanced stripper (PZAS) process at Mustang Station of the Golden Spread Electric Cooperative (GSEC), which consists of two gas turbines with common heat recovery steam generator (HRSG). The University of Texas at Austin (UT) served as the prime contractor, and subcontracted AECOM Technical Services and Trimeric Corporation to support FEED development. This project team has worked together to advance PZAS for more than a decade. ExxonMobil, Chevron, and Total provided project co-funding. The objectives of this work included: 1. To advance engineering design such that a comprehensive estimate for the total installed cost of a full-scale PZAS CO2 Capture Plant with CO2 compression can be developed on an existing NGCC power plant. a. These detailed costs can also be used to qualify PZAS and other related second generation (2G) amine scrubbing processes for use on cogeneration facilities in refineries and chemical plants that use gas turbines with HRSGs to produce steam. b. These detailed costs will help qualify 2G amine scrubbing for use on NGCC power plants and establish a more accurate baseline cost to be used as a target by other capture technologies. 2. To provide cost details to be used in the economic optimization of the process features of PZAS and other 2G amine scrubbing processes. 3. To provide DOE with a more detailed understanding of carbon capture costs in a commercial application, enabling DOE to better design its R&D program to improve the economics for carbon capture. 4. To provide the host site and cost share partners with the information necessary to determine whether a commercial project to capture and use CO2 for enhanced oil recovery (EOR) or for sequestration can be justified (when accounting for the 45Q tax credit). A key component of the FEED is the estimated total installed cost, which provides a basis for the likely capital investment necessary to implement the PZAS carbon capture process at this location and scale. In combination with the included economic analysis, which accounts for potential revenue from the produced CO2, potential avenues to profitability are explored. The major findings of the FEED are as follows: The Mustang Station PZAS CO2 Capture Plant estimated total project cost of $698 MM of which $384 MM was direct costs. The annual operating costs were $32.6 MM. The total investment for a PZAS facility at Mustang Station is $725 MM. This estimate includes owner’s cost of $25 million and a contingency of $110 MM. • The study estimated the CO2 capture plant at Mustang Station would generate CO2 at $110/tonne for EOR, assuming a 12% IRR (internal rate of return) and an 85% capacity factor. For CO2 storage, the same case would achieve a 12% IRR at about $114/tonne. At a capacity factor of 52%, the storage and EOR cases would break even when carbon is priced ~$150/tonne. The economic analysis determined that the capacity factor and utility pricing, among other variable factors, had a significant effect on the economics and will need additional studied. • The energy penalty of the PZAS plant would be about 46 MW in connected power and 35 MW in operating load. The natural gas requirement (for the Gas Boiler package) would be about 354 MMBTU/hr. • The FEED revealed no major risks in process maturity. However, some areas were outlined for further engineering during detailed design, which included the Gas Boiler system, general arrangement and site layout, air coolers, schedule development, and optimization of the process for higher CO2 removal. • If PZAS were to be implemented at another host site, additional opportunities for cost reduction for would include cost reduction through use of cooling water and steam extraction.

03 NATURAL GAS↗
DOE OSTI2022

Hydrogen Energy Storage Integrated with a Combined Cycle Plant

A project is being developed that will build upon the existing infrastructure and resources at the Intermountain Power Project (IPP) site to provide reliable, dispatchable energy and to support the transmission of renewable energy resources while transitioning to an economical green energy future. The concept study depicted in this report outlines a techno-economic optimization to fulfill the demand for 30% vol hydrogen co-firing in the IPP 840 MW advanced class combined cycle power plant. In an initial step, a site assessment concluded the site has sufficient land available to co-locate a hydrogen production and storage facility. The team evaluated and defined a scalable concept that considered technology characteristics, including input and output models to be used for optimization purposes. The concept for the hydrogen production and storage system integrates multiple technologies, to determine system size and scalable approach, for each of the technologies evaluated, the team defined component and subcomponent sizes, minimum and maximum capacity, modularity, component utility consumption (electric, water), component flexibility and servicing, layout, and technology status, as well as technology alternatives. For hydrogen generation, the project considers Siemens Energy’s Silyzer-300 (S300) technology, a 17.5 MW modular Proton Exchange Membrane (PEM) electrolyzer. For the S300 configuration, the team determined that three S300 arrays, or approximately 1,000 kg/hr, per block would yield a compact block design. This configuration results in a fairly wide and flexible arrangement that fits well into the spaces available at the site. Therefore, the overall design approach is based on multiple identical blocks of 3 arrays to minimize engineering cost and optimize constructability. In parallel, a transmission screening study was conducted to determine any potential transmission constraints from the energy sources that could feed the hydrogen production equipment. The study results show that minimum transmission constraints would be encountered to deliver 400 MW renewable generation from southern California, or south-central Wyoming. At last, the techno-economic analysis concluded that a scenario that uses solar and wind power yields the lowest levelized cost of hydrogen (LCOH 2 ) production and the lowest cost per tonne of CO 2 reduced. In this optimized scenario, the hydrogen production plant was determined as 6,201 kg/hr and the hydrogen storage (underground cavern) was determined as 4,600 tonnes. The resulting capacity factor for the hydrogen production plant was 66.33% with 8,745 operating hours in one year. This techno-economic analysis provided various options for integrating hydrogen storage at the Intermountain Power Plant site to co-fire the CCPP units. The results provide insightful data about the magnitude of capacity needed and the economics of producing hydrogen and reducing CO 2 emissions.

08 HYDROGEN↗
DOE OSTI2021

Pilot-Scale Testing of an Integrated Circuit for the Extraction of Rare Earth Minerals and Elements from Coal and Coal Byproducts Using Advanced Separation Technologies

The primary objective of this project was to develop and demonstrate an integrated pilot-scale circuitry for recovering high-value rare earth elements (REEs) from coal and coal byproducts. The target performance was to produce a mixed REE product with content of at least two percent by weight on a dry mass basis in a cost-effective and environmentally benign manner. During the first nine months of the project period (Phase 2 Budget Period 2), pilot plant construction was completed including all field site startup activities such as permitting, engineering design, procurement/bidding, unit fabrication, site construction, equipment installation, module assembly, safety training, and circuit shakedown. During the remaining 21 months of project period (Phase 2 Budget Period 3), detailed field-testing activities were performed including feedstock sample collection and preparation, exploratory testing, circuit modification, detailed parametric study, and performance optimization. A detailed techno-economic analysis was performed based on the pilot plant testing findings which provided various scenarios for REE production. The project successfully accomplished the proposed target performance by producing mixed rare earth oxide (REO) with greater than 90% purity by weight in a continuous pilot scale operation from two distinctly different coarse refuse materials (i.e., West Kentucky No. 13 and Fire Clay coal seams), and at least three secondary sources (i.e., heap leach process and naturally formed acid mine drainage system). Project partners included the University of Kentucky, Virginia Tech, West Virginia University, Alliance Coal, Blackhawk Mining, Mineral Refining Company, and Mineral Separation Technologies. The pilot scale test facility was constructed at a former mining complex owned by Alliance Natural Resource Partners (Alliance Coal). The site was rehabilitated to accommodate the equipment installation, construction and fabrication, electrical power requirement, water line management and containment. The process units constructed and installed included X-ray sorting unit, crushing and grinding unit, physical separation unit, acid leaching unit, solvent extraction unit, and wastewater management unit. A rare earth mineral concentration unit was constructed as a standalone unit for flexible operation. A detailed environmental assessment and control plan was carried out to identify and quantify any potential impacts of the pilot-scale processing circuitry on the human and eco-system health and well-being. Corresponding mitigation strategies and control measures were provided. A conceptual flowsheet was developed to effectively remove thorium and uranium from high purity rare earth oxide mix or any potential radionuclide enriched stream. The two distinct feedstock materials were secured from the Blackhawk Mining Complex in eastern Kentucky where the Fire Clay (Hazard No. 4) seam is processed. The West Kentucky No. 13 (Baker) coarse refuse material was collected from an active process stream at an Alliance coal preparation plant located in western Kentucky. Characterization analysis indicated that both of feed materials generated from the two sources contained >300 ppm of TREEs on a dry whole mass basis which met the requirements for a qualified feed stock. The two feedstocks were further upgraded using a dual x-ray sorter to prepare the feed material for hydrometallurgical circuit. Thermal treatment on feed material prior to leaching was found to: 1) improve the leaching recovery of REEs, 2) increase the leaching kinetics, and 3) allow the leaching reaction to occur at lower acidity. Roasting at 600°C was selected as the pre-treatment condition for both West Kentucky No. 13 and Fire Clay coarse refuse material. Over 40% of leaching recovery was achieved by roasting West Kentucky No. 13 material having a top particle size of 3 mm in the pilot scale operation using 1.2M sulfuric acid leaching at 75OC. Initial pilot scale testing involved continuous operation of the pilot plant for 94 hours. The leaching unit was operated at solid-to-liquid ratio of 1 to 10 (w/v) using 0.5M sulfuric acid solution at a temperature of 75°C. The continuous solvent extraction circuit utilized rougher and cleaner units with DEHPA and TBP as the extractants. An innovative stripping circuit was developed to accumulate the REE concentration in the stripping solution to a level above 600 ppm. A bleed stream from the recycled strip solution was treated using oxalic acid precipitation which produced a high grade rare earth oxalate. The oxalate product was roasted to remove the oxalate which produced a rare earth oxide product having a purity greater 90%. Due to high concentrations of contaminant ions in the pregnant leach solution (PLS), a modified flowsheet was developed that involved pre-concentration of the REEs using multiple stages of precipitation and redissolution. The advantage of this process was improved removal of contamination before the downstream purification process and a significant cost reduction relative to the circuit that utilized the solvent extraction process. The modified circuitry included processes involving leaching, multistage precipitation, redissolution, and oxalate precipitation followed by roasting of the oxalate product. The circuit produced a mixed REO that was 92.96% pure from the initial test. A detailed parametric test plan was carried out which involved varying key parameters including solids feed rate, acid flowrate, acid concentration, multistage precipitation pH, redissolution pH, oxalate precipitation dosage and pH. The response variables included REE recovery, contaminant recovery, REO product grade and overall chemical consumption. Test results indicated that the acid-to-solid ratio is the key parameter to leaching efficiency as performance deteriorated with an increase in solids concentration. The optimal pH determined for REE precipitation and redissolution was 6.5 and 2.5, respectively. Additional tests were conducted to further improve the flowsheet. Recirculating a portion of the PLS to the feed of the leach tanks improved the leaching performance by lowering the pH of the leaching system and reducing the contamination recovery by shortening the residence time. Moreover, the removal of Al prior to REE precipitation significantly reduced the oxalic acid consumption in the oxalate precipitation circuit. The modified circuit produced over 90% grade REO by weight from both West Kentucky No. 13 and Fire Clay coarse refuse material in pilot scale continuous test programs. A case analysis model was developed to project the REE and major contaminants concentration in each PLS stream based on the leaching condition, pH cut point, and oxalic acid dosage. A correlation was established using empirical and semi-empirical models. Using the models, chemical consumption required for each stage was predicted based on the projected performance of the hydrometallurgy circuit. After identifying the optimum conditions, validation tests were carried out for the treatment of both West Kentucky No. 13 and Fire Clay coarse refuse materials in the pilot plant. The actual circuit performance and chemical consumptions were very close to the model predictions. Other than the two coarse refuse sources, several secondary feedstocks were also tested in the pilot plant facility. A “heap leach” system was constructed using the coarse refuse material generated from cleaning the West Kentucky No. 13 seam coal. Using the two stage SX rougher and cleaner circuit, a concentrate with a grade >90% REO was produced while recovering >97% of the REEs from the heap leach PLS. Naturally generated acid mine drainage (AMD) from West Kentucky No.13 mine was processed using the multistage precipitation circuit in the pilot plant in a test conducted for a period of 32 hours. The final grade of the mix RE oxide produced from the AMD was 90.84% with an overall circuit recovery of 64%. The primary source of REE was the selective precipitation steps involving iron and aluminum rejection. The hydrophobic-hydrophilic separation (HHS) process was proven to effectively recover coal from fine waste materials. For REM recovery, the HHS process was able to produce concentrates at grades of approximately 1.8% REE on an ash basis; however, recovery values were typically low, <10%, under the optimal conditions determined in the laboratory-scale testing. Staged testing of the pilot-scale HHS process for coal recovery and semi-continuous laboratory testing for REM testing showed that a total concentration ratio of more than 15x was observed for the REM recovery process. A circuit simulation package was developed for REE extraction and purification using a spreadsheet-based platform (Microsoft Excel). The REESim circuit simulation package is configured to track the mass and volume flows of components passing through a series of unit operations specified and configured by the user. The mass rates can then be utilized by the user to determine important performance indicators such as product mass yields, concentrate purity levels, element-by-element recoveries, and so forth. The techno-economic analysis showed that the roasting and leaching operations were the most expensive capital items, each contributing approximately 30% to the total capital cost. One notable contributor to the high production costs was the low REE recovery observed in the pilot scale trials. The product basket price was shown to have a strong influence on the economic viability of the scenarios, with the scandium price being the most significant influencer. Operating cost was shown to be extremely sensitive to REE recovery, REE feed grade, and leaching acid consumption. An analysis of ten different scenarios for a 500 t/h commercial operation revealed that three were economically favorable, producing internal rates of return varying from 27.7% to 33.1% and payback periods of 4 to 5 years. The project successfully developed and demonstrated a process to recover REEs from coal and coal byproducts in a pilot-plant operation which consistently produced over 90% grade REO mix from varies types of feedstocks. Commercialization analysis showed that the technology readiness level successfully achieved TRL 6 at the end of the project and demonstrated the need and the potential for scaling the process to further advance the technologies toward the goal of providing a domestic supply of REEs at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

A comparative TEA of a two-step process using chemical solvents for producing an ultra-sweet natural gas

Here, a comprehensive Techno-Economic Analysis (TEA) was performed to evaluate the economic feasibility of a novel two-step process (TSP) developed in Aspen Plus V12.1 to desulfurize and decarbonize a raw natural gas containing (2 mol% H 2 S and 5 mol% CO 2 ) into an ultra-sweet natural gas containing (1.72 ppmv H 2 S and 4.19 ppmv CO 2 ). The raw natural gas flow rate used in the TSP was 117.74 kg/s at 60 °C and 50 bar. The TSP combines an H 2 S desulfurization step using potassium carbonate (K 2 CO 3 ) and a CO 2 capture step using 3 different chemical solvents, monoethanolamine (MEA), sodium glycinate (SGS), and potassium glycinate (PGS). Both steps employ fixed-bed absorbers packed with Mellapak 250Y structured packing. The hydraulics and mass transfer characteristics for the TSP were calculated, indicating normal operation with higher gas-side (k G ) than liquid-side (k L ) mass transfer coefficients. The TEA of TSP indicated that PGS had the most promising economic feasibility among the 3 solvents as it exhibited the lowest Levelized Cost of CO 2 capture (LCOC) of $\$$47.54/ton.CO 2 at a Capital Expenditure (CAPEX) of $\$$24.98 million, and an Operating Expenditure (OPEX) of $\$$12.20 million/year. Also, the TSP could produce one MMSCF of ultra-sweet natural gas at a total cost of $\$$339.55.

03 NATURAL GAS↗
DOE OSTI2022

Techno-economic assessment for the production of algal fuels and value-added products: opportunities for high-protein microalgae conversion

Abstract Background Microalgae possess numerous advantages for use as a feedstock in producing renewable fuels and products, with techno-economic analysis (TEA) frequently used to highlight the economic potential and technical challenges of utilizing this biomass in a biorefinery context. However, many historical TEA studies have focused on the conversion of biomass with elevated levels of carbohydrates and lipids and lower levels of protein, incurring substantial burdens on the ability to achieve high cultivation productivity rates relative to nutrient-replete, high-protein biomass. Given a strong dependence of algal biomass production costs on cultivation productivity, further TEA assessment is needed to understand the economic potential for utilizing potentially lower-cost but lower-quality, high-protein microalgae for biorefinery conversion. Results In this work, we conduct rigorous TEA modeling to assess the economic viability of two conceptual technology pathways for processing proteinaceous algae into a suite of fuels and products. One approach, termed mild oxidative treatment and upgrading (MOTU), makes use of a series of thermo-catalytic operations to upgrade solubilized proteins and carbohydrates to hydrocarbon fuels, while another alternative focuses on the biological conversion of those substrates to oxygenated fuels in the form of mixed alcohols (MA). Both pathways rely on the production of polyurethanes from unsaturated fatty acids and valorization of unconverted solids for use as a material for synthesizing bioplastics. The assessment found similar, albeit slightly higher fuel yields and lower costs for the MA pathway, translating to a residual solids selling price of $899/ton for MA versus $1033/ton for MOTU as would be required to support a $2.50/gallon gasoline equivalent (GGE) fuel selling price. A variation of the MA pathway including subsequent upgrading of the mixed alcohols to hydrocarbon fuels (MAU) reflected a required solids selling price of $975/ton. Conclusion The slight advantages observed for the MA pathway are partially attributed to a boundary that stops at oxygenated fuels versus fungible drop-in hydrocarbon fuels through a more complex MOTU configuration, with more comparable results obtained for the MAU scenario. In either case, it was shown that an integrated algal biorefinery can be economical through optimal strategies to utilize and valorize all fractions of the biomass.

09 BIOMASS FUELS↗
DOE OSTI2022

EERC Final Topical Report – Findings on Subtask 3.2 – Produced Water Management Through Geologic Homogenization, Conditions, and Reuse

The Energy & Environmental Research Center (EERC) was awarded a contract by the North Dakota Industrial Commission (NDIC) Oil and Gas Research Program (NDIC No. G-051-101) to conduct a study on the recycling of water used in oil and gas operations, also known as produced water, from oil- and gas-producing regions of North Dakota as directed by Section 19 of North Dakota House Bill 1014. This final report provides a compilation of results of the study, which include regulatory, scientific, technological, and feasibility methods and considerations associated with North Dakota produced water management. The report provides a synopsis of this project’s previously submitted produced water assessment report entitled “Produced Water Management and Recycling Options in North Dakota” (Energy & Environmental Research Center, 2020), with updated values provided as appropriate. The report provides the results from the investigation of a novel produced water management strategy, referred to as geologic homogenization, conditioning, and reuse (GHCR), which aims to use a subsurface geologic formation as a natural medium for managing produced water recycling and reuse. Water management is a significant technical and economic challenge for sustainable oil and gas production, and water volumes are intrinsically linked to oil production volumes. North Dakota oil production rose to over 1.5 million barrels (MMbbl)/day in 2019, and despite a downturn in oil price in early 2020, North Dakota oil production has recovered to 1.1 MMbbl/day as of August 2021. Bakken petroleum system development between 2008 and 2020 has resulted in a nearly fourfold increase in produced water volumes to 642 MMbbl/yr in 2020 after peaking at 740 MMbbl/yr in 2019 and a fivefold increase in saltwater disposal (SWD) volumes to 565 MMbbl/yr in 2020 after a peak of 682 MMbbl/yr in 2019. Produced water and SWD volumes are forecasted to double by 2030. SWD is the primary method of produced water management used in North Dakota, with approximately 95% of the SWD volume occurring through subsurface injection into sandstones of the Dakota Group (Dakota). Localized pressurization of the Dakota resulting from SWD and projected increases in produced water volumes could impact the economics of North Dakota oil production. As a result, there is an emerging need to pursue alternative produced water management approaches, including recycling and reuse. While produced water recycling is not yet widespread, commercial operators are making strides in overcoming the technical challenges of using high salinity produced water in completion operations (Marathon Oil, 2020). As water management continues to be a key focal point in companies’ environmental, social, and governance (ESG) initiatives, focus on water management, including recycling, will likely continue to increase. Laboratory column testing, field sample collection, geologic modeling and numerical simulation, and techno-economic analysis all indicate that GHCR could feasibly be implemented as a potential water management option. Laboratory column testing and field sample collection indicate that the Inyan Kara sandstone and native formation fluid are capable of homogenizing with the Bakken produced water to a point where the fluid composition appears to stabilize. Extracting that stabilized fluid could be considered homogeneous and capable of providing individual batches of hydraulic fracturing fluid. Numerical simulation results indicate that extraction of fluids from the Inyan Kara in a GHCR implementation scenario is capable of reducing formation pressure, which would help ease localized pressurization of the Inyan Kara and extend the available capacity for nearby existing SWD wells. Economic analysis indicates that there are scenarios where GHCR implementation can be a competitive or even lower-cost option than a conventional water management approach. Site-specific conditions will dictate the economic potential of GHCR, but potentially attractive sites for GHCR implementation will be those that are located above a pressurized zone of the Inyan Kara, need six or more Bakken infill wells, and face high costs for conventional SWD and/or freshwater. Based on the regulatory review, drilling into the Inyan Kara for SWD and to harness as a source water for industrial use have precedent in North Dakota, and a workable regulatory solution for GHCR seems likely. However, restrictions in the state regarding surface storage and transport of produced fluids may limit some activities, which will affect how GHCR could ultimately be implemented. In summary, this study reveals pursuing GHCR can be a viable approach to water management in North Dakota. The GHCR concept addresses some of the challenges that hinder the more traditional approaches to recycling in the industry. Furthermore, an assessment of the current landscape of water management within the state reveals the ongoing trend of increasing volumes of produced water and SWD. Projections reveal that the volumes of produced water that need to be managed are expected to double over the next decade (Energy & Environmental Research Center, 2020). With the continued development of the Bakken and continuing driving factors related to ESG initiatives, implementing a practice such as GHCR is a feasible approach to adding recycling of produced water to industry within the state. This subtask was cofunded through the EERC–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission Oil and Gas Research Program. References Energy & Environmental Research Center, 2020, Produced water management and recycling options in North Dakota: Final Report for North Dakota Legislative Management Energy Development and Transmission Committee and North Dakota Industrial Commission. Marathon Oil, 2020, Sustainability report: https://cdn.sanity.io/files/ghcnw9z2/website/ 91744eb6ef8fbe59505a911c6b8d2e8dd9a537fa.pdf?dl (accessed November 2021).

02 PETROLEUM↗
DOE OSTI2021

Pumped-Storage Hydropower using Abandoned Underground Mines (PSH-AUM) as an Innovative Energy Storage Technology for Fossil-Integrated Systems

Pumped-storage hydropower (PSH) provides around 95% of all utility-scale energy storage in the U.S. and globally. Additional deployment of PSH is hampered by excessively long permitting and commissioning requirements and is constrained to locations for which natural topography provides suitable elevation relief between the upper and lower reservoirs (the ΔH challenge). The purpose of this research was to evaluate Pumped-Storage Hydropower using Abandoned Underground Mines (PSH-AUM) as a means to solve the ΔH challenge and initiate the commercialization pathway for a promising new energy storage technology. Four primary tasks were conducted: Screening and ranking of candidate sites for project development; multiphase reservoir modeling to evaluate mine performance; techno-economic analysis and preliminary designs for PSH-AUM systems integrated with fossil-fuel power units; and stakeholder engagement to identify pathways to commercialization of this new technology. Key results were achieved in each of the four primary tasks. Candidate site screening determined that nearly 10,000 underground mines were spatially locatable, of which more than 100 sites appear suitable for integration with existing fossil power plants that are expected to remain in longer-term operation. Mine reservoir models were developed using PNNL’s STOMP simulator and parameterized using candidate site data to evaluate interactions with the surrounding groundwater system and confirm the potential for some mines to accommodate inflows and outflows on the order of 100 m3/s over 8-hour durations (1.6 GWh system) without excessive aqueous pressures. Techno-economic analysis resulted in a project cost optimization scheme to identify key sensitivities and the development of preliminary designs that can minimize overall costs of deployment. Finally, stakeholder engagement with industry, state government, and local economic development leaders confirmed the viability of PSH-AUM as a promising new technology. Our Phase I project results suggest that PSH-AUM technology has a domestic market potential on the order of $100+ Billion with ample space for technology development to commercialization within the next decade.

13 HYDRO ENERGY↗
DOE OSTI2021

A Minimal Information Set To Enable Verifiable Theoretical Battery Research

Batteries are an enabling technology for addressing sustainability through the electrification of various forms of transportation (1) and grid storage. (2) Batteries are truly multi-scale, multi-physics devices, and accordingly various theoretical descriptions exist to understand their behavior (3-5) ranging from atomistic details to techno-economic trends. As we explore advanced battery chemistries (6,7) or previously inaccessible aspects of existing ones, (8-10) new theories are required to drive decisions. (11-13) The decisions are influenced by the limitations of the underlying theory. Advanced theories used to understand battery phenomena are complicated and require substantial effort to reproduce. However, such constraints should not limit the insights from these theories. We can strive to make the theoretical research verifiable such that any battery stakeholder can assess the veracity of new theories, sophisticated simulations or elaborate analyses. We distinguish verifiability, which amounts to “Can I trust the results, conclusions and insights and identify the context where they are relevant?”, from reproducibility, which ensures “Would I get the same results if I followed the same steps?” With this motivation, we propose a checklist to guide future reports of theoretical battery research in Table 1. We hereafter discuss our thoughts leading to this and how it helps to consistently document necessary details while allowing complete freedom for creativity of individual researchers. Given the differences between experimental and theoretical studies, the proposed checklist differs from its experimental counterparts. (14,15) This checklist covers all flavors of theoretical battery research, ranging from atomic/molecular calculations (16-19) to mesoscale (20,21) and continuum-scale interactions, (9,22) and techno-economic analysis. (23,24) Finally, as more and more experimental studies analyze raw data, (25) we feel this checklist would be broadly relevant.

25 ENERGY STORAGE↗
DOE OSTI2020

Distributed Photovoltaic Economic Impact Analysis in Indonesia

Like other countries in the region, the Government of Indonesia aims to increase its use renewable energy in the near term from various technologies, including grid-connected distributed photovoltaics (DPV). While little DPV has been installed to date, the policy landscape has been shifting over the past few years with recent pronouncements from the state-run utility Perusahaan Listrik Negara (PLN) and the Ministry of Energy and Mines (MEMR) that have begun to provide a more supportive policy framework for the deployment of DPV. Nonetheless, many questions remain as to how DPV impacts customers, the utility, and the economy as a whole. This report presents a holistic view of DPV economic impacts in the Java-Bali region of Indonesia by assessing customer economic impacts, utility revenue impacts, and jobs and economic development impacts.

14 SOLAR ENERGY↗
DOE OSTI2026

Data for High Yield Production of 3-Hydroxypropionic Acid Using Issatchenkia orientalis

Biomanufacturing provides a more sustainable alternative to fossil-based chemical manufacturing. 3-Hydroxypropionic acid (3HP) is a top Department of Energy value-added chemical and precursor to bioplastics, yet cost-effective microbial production remains elusive. Here, we establish the acid-tolerant yeast Issatchenkia orientalis as a robust host for low-pH 3HP biosynthesis. Genome-scale modeling identifies the β-alanine pathway as optimal, offering the highest theoretical yield and lowest oxygen requirement. Thermodynamic analysis confirms its favorability under acidic conditions. Using sequence similarity network analysis, we discover highly active aspartate 1-decarboxylase (PAND), β-alanine-pyruvate aminotransferase (BAPAT), and 3HP dehydrogenase (YDFG), which significantly improve the pathway efficiency. Next, to further elevate the production, pathway optimization through multi-copy PAND integration, byproduct elimination (knockouts of pyruvate decarboxylase and glycerol-3-phosphate dehydrogenase), and reinforcement of aspartate flux by overexpression of pyruvate carboxylase and aspartate amino transferase improves the titer to 29 g/L in shake flasks. Fed-batch fermentation at pH 4 with low-cost corn steep liquor medium further increases the production to 92 g/L with 0.7 g/g yield and 0.55 g/L/h productivity. Techno-economic analysis indicates that such performance could potentially enable a financially viable process for sustainable acrylic acid production. This work establishes I. orientalis as a next-generation platform for cost-effective 3HP production and paves the way toward industrial commercialization.

Bioproducts↗
DOE OSTI2023

Biomass Gasification for Chemicals Production Using Chemical Looping Techniques (Final Report)

The Ohio State University (OSU) is investigating the Biomass to Syngas (BTS) chemical looping technology to produce syngas for chemical production applications from biomass under US Department of Energy (DOE) Award #DE-EE0007530. The BTS process aligns with the programmatic area of interest of “Conversion, via biological, thermal, catalytic or chemical means, of acceptable feedstocks into advanced biofuels and/or biobased products including intermediate and end-use products”. Compared to conventional biomass gasification processes, the BTS process eliminates the need for air separation units and tar reforming reactors, which leads to energy efficiency improvement and capital cost reduction. The overall objective is to ascertain the potential of biomass gasification based on the chemical looping technique through mitigation of the possible techno-economic challenges in the steps of scale up for commercialization. The scope of work consists of 1) designing, constructing and operating a 10 kWth commercially scalable sub-pilot BTS system and; 2) completing a comprehensive techno-economic analysis (TEA) of the BTS process using methanol production as an example. Over the course of the project, the project team completed the design, fabrication, and operation of a 10 kWth sub-pilot scale test unit for the BTS process. Corn cob and wood pellets were successfully tested in the unit for high purity syngas generation in extended test campaigns that totals over 200 hours. Syngas purity (H2 and CO) of >70% was achieved with a CH 4 concentration of <6%. The H 2 /CO ratio was greater than 1.8. A comprehensive techno-economic analysis was performed to compare the BTS process and a reference indirectly heated gasification process for methanol synthesis. The result, updated with experimental results for BTS process performance, shows a methanol required selling price (MSP) of $\$ $1.15/gal, compared to $1.28/gal for the reference case.

08 HYDROGEN↗
DOE OSTI2020

Simulating the Trajectory and Biomass Growth of Free-Floating Macroalgal Cultivation Platforms along the U.S. West Coast

Trajectory tracking and macroalgal growth models were coupled to support a novel macroalgae-harvesting concept known as the Nautical Off-shore Macroalgal Autonomous Device (NOMAD). The NOMAD consists of 5 km long carbon-fiber longlines that are seeded and free float southward along the U.S. West Coast for approximately 3 months before harvesting off the California coast, taking advantage of favorable environmental conditions. The trajectory and macroalgal growth models were applied to answer planning questions pertinent to the techno-economic analysis such as identifying the preferred release location, approximate pathway, timing until harvest, and estimated growth. Trajectories were determined with the General NOAA Operational Modeling Environment (GNOME) model, using 11 years of current and wind data, determining probabilities by running nearly 40,000 Monte Carlo simulations varying the start time and location. An accompanying macroalgal growth model was used to estimate the growth of macroalgae based on the trajectory tracks and environmental forcing products, including light, temperature and nutrients. Model results show that NOMAD lines transit south in the months of April to September due to seasonal currents, taking approximately 3 months to reach Southern California. During transit, NOMAD lines are dispersed but typically avoid beaching or passing through marine sanctuaries. NOMAD lines can yield up to 30 kg wet weight per meter of cultivation line.

09 BIOMASS FUELS↗
NASA NTRS1982

A study of dirigibles for use in the Peruvian Selva Central region

The potential for dirigibles as transports in the Selva Central region of Peru was evaluated by means of a mission and economic analysis. A total requirement to transport over 19 million tons (t) of agricultural produce, lumber and meat was projected by the year 2004. A primary route involving zones for loading and delivering this carbo was identified. Although dirigibles are capable of short field operation, all existing airfields must be enlarged in width to allow for all conditions of wind and weather and to provide space for overnight mooring. A maintenance base and operations headquarters, complete with hangar and other service facilities would be required. The quantities of cargo capacities of 5 to 100 tons were identified. Fleet sizes up to 106 dirigibles (in 20 t capacities) would be required. Dirigibles were assumed to be of the nonrigid type except in the 100 t category for which rigid characteristics were assumed. A method of determining dirigible costs was developed. The values derived were then applied to an economic analysis to determine initial investment and operating costs. It was found that larger dirigibles of approximately 20 t capacities or higher could offer significant cost benefits over airplanes, provided cruise speeds were higher than 100km/hr.

Mayer, N. J.↗
DOE OSTI2023

Cost and life cycle analysis for deep CO 2 emissions reduction of steelmaking: Blast furnace-basic oxygen furnace and electric arc furnace technologies

Iron and steel manufacturing is the largest contributor to CO 2 emissions among heavy industries worldwide. This is mostly due to the use of coal in blast furnace-basic oxygen furnace (BF-BOF) process for virgin (primary) steel production. The electricity generation mix used in the electric arc furnace (EAF) process to recycle scrap steel also contributes to the CO 2 emission associated with secondary steel production. To decarbonize iron and steel sector, we investigated decarbonization options for BF-BOF and EAF processes, including energy efficiency, carbon capture and storage, and the use of clean energy sources, in various BF-BOF and EAF process configurations. Additionally, for each decarbonization approach, we evaluated the CO 2 reduction potential via life cycle analysis (LCA) and estimated the associated cost through techno-economic analysis (TEA). A typical U.S. BF-BOF for virgin steel production has a cradle-to-gate (CTG) CO 2 emissions of 1,990 kg/MT steel with a levelized cost of steel (LCOS) of $\$439$/MT steel, while a typical U.S. EAF process for secondary steel production in the United States has a CTG CO 2 emissions of 270 kg/MT steel with a LCOS of $\$365$/MT steel. Combining renewable energy sources and carbon capture, BF-BOF CTG CO 2 emissions can be reduced to 16 kg/MT steel, and EAF configurations can achieve similar deep reductions to reach 25 kg/MT steel. The corresponding LCOS with these decarbonization levels is estimated to increase to $\$542$/MT steel and $\$348$/MT steel, respectively. The estimated CO 2 avoidance costs vary from -$\$90$/MT CO 2 to $\$646$/MT CO 2 , depending on the various decarbonization technologies and energy prices.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1982

A study of dirigibles for use in the Peruvian Selva Central Region

The potential for dirigibles as transports in the Selva Central region of Peru was evaluated by means of a mission and economic analysis. A total requirement to transport over 19 million tons (t) of agricultural produce, lumber, and meat was projected by the year 2004. A primary route involving zones for loading and delivering this cargo was identified. Although dirigibles are capable of short field operation, all existing airfields must be enlarged in width to allow for all conditions of wind and weather and to provide space for overnight mooring. A maintenance base and operations headquarters, complete with hangar and other service facilities would be required. The quantities of cargo to be carried establish requirements for fleets of dirigibles of various sizes and capacities. Cargo capacities of 5 to 100 tons were identified. Fleet sizes up to 106 dirigibles (in 20 t capacities) would be required. Dirigibles were assumed to be of the nonrigid type except in the 100 t category for which rigid characteristics were assumed. A method of determining dirigible costs was developed. The values derived were then applied to an economic analysis to determine initial investment and operating costs. It was found that larger dirigibles of approximately 20 t capacities or higher could offer significant cost benefits over airplanes, provided cruise speeds were higher than 100 km/hr.

Mayer, N. J.↗