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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 OSTI2022

Overview of Integrated Pathway Analyses to Meet the Hydrogen Energy Earthshot Goal

This presentation was given at the 2022 Bulk Storage of Gaseous Hydrogen Workshop sponsored by the U.S. Department of Energy's (DOE) Hydrogen and Fuel Cell Technology Office (HFTO). The presentation topics cover the current status of an upcoming NETL publication titled "Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies." The study will publicize plant performance, life cycle environmental performance, and the levelized cost of hydrogen (LCOH) production from six fossil-based pathways. The presentation provides preliminary results pending finalization of the study. In addition, the presentation provides an overview of NETL analysis efforts to support the DOE Hydrogen Shot targets.

Lewis, Eric↗
DOE OSTI2022

High Temperature Steam Electrolysis Process Performance and Cost Estimates - DOE Hydrogen Program AMR Presentation

Technology readiness levels (TRLs) of electrolysis systems have dramatically increased in recent years as the interest in clean hydrogen production and decarbonization of transportation, industrial and other sectors increases across the globe. This is especially true of high temperature steam electrolysis (HTSE) / solid oxide electrolysis cell (SOEC) systems which show promise of much higher system efficiencies than other more developed electrolysis technologies. This possibility of higher efficiencies of HTSE / SOEC systems has been previously assumed to be theoretically possible but in recent years it has become less theoretical and more realistic as an increasing amount of suppliers complete lab and pilot tests showing very promising results. Research in the areas of manufacturing techniques, material selection, electrode and electrolyte compositions, and balance of plant size and integration continues at a fast pace as an increasing number of suppliers both internationally and domestically become involved. The advantages of HTSE become more pronounced when HTSE is coupled with nuclear power plants (NPPs). This is because thermal energy produced by the nuclear reactor can be used in a series of heat transfer loops and heat exchangers to vaporize HTSE feedwater, which drastically improves the economics of the process. Idaho National Laboratory (INL) has been very involved in the research and modeling of HTSE systems for a number of years, in collaboration with other national laboratories, academia, and industry stakeholders both on the hydrogen production as well as the hydrogen demand side. The modeling completed over the years on a large variety of projects has led to a wealth of knowledge at INL including in the area of the technoeconomic assessment (TEA) of HTSE systems. TEAs include process modeling of the HTSE systems to calculate system energy requirements and equipment sizing, followed by estimation of capital and operating costs to enable calculation of the levelized cost of hydrogen (LCOH). The TEA work performed has produced incremental improvements and tuning of the methods, assumptions, models, and results of the analyses as well as providing some opportunities for validating these results. The purpose of this document is to record the current baseline HTSE analyses led by INL to show the current status of assumptions and costs of these systems. Given the rapid development of this technology, the variety of suppliers entering the space, and the increasing attention government and industry are giving to such systems, this document may be updated on a periodic basis with updated analysis and assumptions. This document compiles various analyses results and approaches completed over a period of years into a single document to be used as a baseline going forward. It represents what the INL HTSE analysis group assumes to be the internal best estimate of the current operation, costs, and landscape of the HTSE industry state of the art capability for current SOEC technology in an Nth-of-a-Kind (NOAK) plant, which in this study is defined as existence of the manufacturing capacity to support previous deployment of N = 100 count of 25 MWe modular HTSE blocks (with modular equipment component cost reductions specified as following a 95% learning curve). That said, this is a public document and as such so no proprietary data was used or included in this report. There may be HTSE suppliers that have performance specifications, and cost estimates, and test data that differ from the analysis presented in this document. This document is meant to be a best conservative estimate of the technology and not an absolute reference.

08 HYDROGEN↗
DOE OSTI2022

Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies

Presentation describing NETL's public report entitled "Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies" which features levelized cost of hydrogen (LCOH) and greenhouse gas emissions from six cases (3 reforming and 3 gasification technology cases) as well as CO2 capture. One case also features coal/biomass co-gasification that targeted net-zero emissions.

Stevens, Robert↗
DOE OSTI2023

Wind Turbine Design Optimization for Hydrogen Production

To help meet the need for inexpensive green fuels, we are working on wind turbine design optimization specifically for hydrogen production. We have thus far achieved a 1.53% decrease in LCOH as compared to a turbine optimized for LCOE using the same code, design variables, and models . We accomplished this by optimizing some components of the wind turbine tower, rotor, and drivetrain design with hydrogen production and costs in the design loop.

design↗
DOE OSTI2023

Estimating the Value of Nuclear Integrated Hydrogen Production and the Dependency of Electricity and Hydrogen Markets on Natural Gas

Producing low carbon Hydrogen at a competitive price is one of the challenges to hydrogen being part of the solution to reach net-zero emission targets set by the U.S. DOE by 2050. With projected near-term improvements in technology, hydrogen production via solid oxide electrolysis cell (SOEC) / high-temperature steam electrolysis (HTSE) integrated with existing light water reactor (LWR) Nuclear Power Plants (NPP-HTSE) can produce carbon-free hydrogen competitively. In the near term, a 10-year production tax credit (PTC) found in the Inflation Reduction Act (IRA) has been passed, which will catalyze the development and improvement of hydrogen production technology to be competitive. The “1-1-1” target set by the U.S. DOE is to reduce the cost of carbon-free hydrogen by 80% to $1 per kilogram in 1 decade. Several models are available to analyze the profitability, opportunity, and technical capability of NPP-HTSE systems. In order of complexity from most complex to least complex some of these models include: RAVEN/HERON, process models using Aspen HYSYS and capital expense estimations using Aspen Process Economic Analyzer (APEA) and levelized cost of hydrogen (LCOH) calculation using the H2A model (Hydrogen Analysis Model), and custom spread sheets built by the interested party. Though some of the more advanced existing models provide detailed analysis to complex grid integrated problems, they also can take considerable time to setup and run. These advanced models are well suited to complex grid integrated analysis and the consideration of flexibility and variability of regulated and de-regulated electricity price and advanced estimation of capital and operating expenses and heat and material balances.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Application of a Novel Heat Pump Model for Estimating Economic Viability and Barriers of Heat Pumps in Dairy Applications in the United States

Heat pumps represent an important opportunity for energy savings and decarbonization. This work investigates the techno-economic performance of high-temperature heat pumps (HTHPs) for use in the U.S. dairy industry. The studied heat pump performs a 50 °C temperature lift on a waste heat stream of cleaning water and applies the upgraded heat stream to a fluid milk pasteurization process. This work involved the creation of a HTHP model that estimated the coefficient of performance (COP), internal rate of return (IRR), net present value (NPV), and payback period (PBP), and emissions saved for a heat pump replacing a natural gas boiler. Capital costs, operations, and maintenance (O&M) cost, heat pump lifetime, electricity prices, natural gas prices, and a cost of carbon were varied to perform a parametric study on the factors affecting the break-even price of HTHPs. The results show that HTHP economics are highly sensitive to COP and energy price environment, and less sensitive to capital and O&M cost variance, leading to a large scatter of positive and negative NPVs based on U.S. location. PBPs demonstrate a defined threshold, based on energy price environment, below which favorable two-to-three-year PBPs predominate. This work is focused on the U.S. dairy industry, but international application in relation to fossil vs. electricity price regimes. Heat pumps have seen wider adoption in regions with a high ratio of fossil energy to electricity prices ($/MMBTU vs. $/kWh). The U.S. has plentiful natural gas resulting in lower fossil energy prices which has reduced heat pump adoption. This paper identifies potential first mover industries for HTHP adoption and their associated price regimes even in regions with lower ratios of fossil energy to electricity prices that exist many places globally.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION,↗
DOE OSTI2024

Techno-economic feasibility of geothermal energy production using inactive oil and gas wells for district heating and cooling systems in Tuttle, Oklahoma

Oil and gas wells have been drilled in the United States and often encounter hot co-produced water possibly suitable for geothermal direct-use applications. Here this study evaluated geothermal resources, heating and cooling demand, and techno-economic potential of four oil and gas wells repurposed for geothermal energy production to serve two public schools and 250 nearby houses in Tuttle, Oklahoma, USA. Subsurface geology in the study area primarily consists of Permian to Mississippian sandstone and limestone formations approximately from 2 km to 3.5 km depth. With a geothermal gradient of 25.3 °C/km, the temperature of geothermal energy production was estimated as 68.2 °C at 2.1 km. The potential of calcite scaling within boreholes and pipes was minimal. Using the characterized reservoir properties, techno-economic analyses were conducted for evaluating levelized costs of geothermal energy production for direct-use heating and cooling and district heating systems with five different production scenarios. Heating and cooling demand in two schools and 250 houses and additional 0.3 MW and 0.6 MW base heating loads for potential geothermal direct-use applications in the study area were also incorporated in the modeling. Results indicated that the levelized cost of heating of geothermal district heating systems utilizing existing wells were significantly lower than those of conventional geothermal energy systems that include well drillings. The geothermal energy production with doublet and quartet configurations was generally sufficient to supply total annual heating demand in the district, while a peaking boiler was used to supply peak loads. Doublet configurations showed higher production temperature with a lower thermal drawdown than the quartet configurations. The doublet system at 2.1 km production depth with 9.3 kg/s flow rate represented the optimal levelized cost of $71/MWh and 91.2% utilization factor. These results imply that the Tuttle geothermal district heating system is techno-economically feasible and comparable to geothermal district heating systems in the United States and the regional natural gas rate for residentials by recycling inactive oil and gas wells with no drillings.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Cost analysis of hydrogen production by high-temperature solid oxide electrolysis

In this study, we estimate construction and operation costs of gigawatt-scale solid oxide electrolysis (SOE) facilities for producing high purity hydrogen gas from water. Manufacturing and assembly costs for two types of SOE cell stacks are estimated using a detailed design for manufacture and assembly (DFMA®) analysis. Modular balance of plant (BOP) process equipment is designed and sized with Aspen®, and cost estimated using equipment vendor quotes. Factory and on-site assembly and installation costs for SOEC stack and BOP equipment integration into modular SOE process units are calculated using a simplified DFMA® method. Total stack costs on a stack input power (SIP) basis reduce to <$100/kW e DC SIP for >500 MW e DC SIP /year production rates with electrode cermet, interconnects, and high-temperature heat treatments dominating the total cost. Integration of stacks with larger BOP equipment operating at higher pressures offers ~36% cost reduction in total facility capital cost due to an economies of physical scale effect since BOP equipment comprises >50% of facility costs. Optimized H 2 prices decrease from ~$\$$4/kgH 2 to ~$\$$2/kgH 2 for 1 GWe DCSIP facilities using $\$$0.025/kWh electricity price. All costs are reported in 2021 US dollars.

08 HYDROGEN↗
DOE OSTI2025

Cost analysis of alternative large-scale high-temperature solid oxide electrolysis hydrogen production facilities

We extend our past cost analysis of gigawatt-scale solid oxide electrolysis (SOE) facilities that produce high purity hydrogen gas from water by estimating construction and operating costs for three new alternative design cases: (1) offsite feed steam generation; (2) near-atmospheric pressure (NAP) stack; and (3) onsite electric boiler feed steam generation. Pressure effects on hydrogen electrode-(cathode-)supported SOE cell (SOEC) stack performance are estimated for the same assumed cell and stack construction and used to determine facility-wide stack capital costs for achieving a fixed H2 production at different pressures. Modular balance of plant (BOP) process equipment capital costs are estimated for each new alternative design case using our past equipment sizing, design, and cost data and scaling relationships. Furthermore, we update BOP equipment sizing and design for the NAP case using Aspen®. Vendor quotes for electric boilers are used to estimate costs for the electric boiler design case. Factory and onsite assembly and installation costs for SOEC stacks and BOP equipment are calculated using our past simplified first-principles approach. First-of-a-kind (FOAK) and N th -of-a-kind (NOAK) production maturity cost estimates are included for all results. The case with NAP stacks offers the lowest facility total capital cost (TCC, ~23% lower than base) while use of small electric boilers requires the highest TCC (~3% higher than base). H 2 production prices decrease from the base of ~$\$2.17$ /kgH 2 to ~$\$1.92$/kgH 2 for 1 GW e DC SIP facilities utilizing NAP stacks supplied by offsites steam situated in large modules and blocks for $\$0.030$/kWh e and $0.009/kWh t prices for electricity and thermal energy, respectively. We report all costs in 2021 US dollars.

Balance of plant (BOP) process equipment↗
DOE OSTI2023

Closed Loop Geothermal Working Group: GeoCLUSTER App, Subsurface Simulation Results, and Publications

To better understand the heat production, electricity generation performance, and economic viability of closed-loop geothermal systems in hot-dry rock, the Closed-Loop Geothermal Working Group -- a consortium of several national labs and academic institutions has tabulated time-dependent numerical solutions and levelized cost results of two popular closed-loop heat exchanger designs (u-tube and co-axial). The heat exchanger designs were evaluated for two working fluids (water and supercritical CO2) while varying seven continuous independent parameters of interest (mass flow rate, vertical depth, horizontal extent, borehole diameter, formation gradient, formation conductivity, and injection temperature). The corresponding numerical solutions (approximately 1.2 million per heat exchanger design) are stored as multi-dimensional HDF5 datasets and can be queried at off-grid points using multi-dimensional linear interpolation. A Python script was developed to query this database and estimate time-dependent electricity generation using an organic Rankine cycle (for water) or direct turbine expansion cycle (for CO2) and perform a cost assessment. This document aims to give an overview of the HDF5 database file and highlights how to read, visualize, and query quantities of interest (e.g., levelized cost of electricity, levelized cost of heat) using the accompanying Python scripts. Details regarding the capital, operation, and maintenance and levelized cost calculation using the techno-economic analysis script are provided. This data submission will contain results from the Closed Loop Geothermal Working Group study that are within the public domain, including publications, simulation results, databases, and computer codes. GeoCLUSTER is a Python-based web application created using Dash, an open-source framework built on top of Flask that streamlines the building of data dashboards. GeoCLUSTER provides users with a collection of interactive methods for streamlining the exploration and visualization of an HDF5 dataset. The GeoCluster app and database are contained in the compressed file geocluster_vx.zip, where the "x" refers to the version number. For example, geocluster_v1.zip is Version 1 of the app. This zip file also contains installation instructions. **To use the GeoCLUSTER app in the cloud, click the link to "GeoCLUSTER on AWS" in the Resources section below. To use the GeoCLUSTER app locally, download the geocluster_vx.zip to your computer and uncompress this file. When uncompressed this file comprises two directories and the geocluster_installation.pdf file. The geo-data app contains the HDF5 database in condensed format, and the GeoCLUSTER directory contains the GeoCLUSTER app in the subdirectory dash_app, as app.py. The geocluster_installation.pdf file provides instructions on installing Python, the needed Python modules, and then executing the app.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Roadmap to Advance Heliostat Technologies for Concentrating Solar-Thermal Power

Heliostat-based concentrating solar-thermal power (CSP) systems can offer immense potential to provide low-cost, dispatchable renewable thermal and electrical energy to help achieve 100% decarbonized energy infrastructure in the United States. Heliostats are a major capital cost technology and a performance-dominating component of state-of-the-art commercial molten salt towers and Generation 3 CSP systems. In 2021, the U.S. Department of Energy (DOE) Solar Energy Technologies Office (SETO) launched the Heliostat Consortium (HelioCon), a five-year initiative to advance heliostat technologies. The HelioCon mission is threefold: (1) establish strategic core testing and modeling capabilities and infrastructure at national labs; (2) support heliostat technology development in relevant industries; and (3) serve as a central repository to integrate industry, academia, and other stakeholders for heliostat technology research, development, validation, and deployment. In this report, HelioCon presents a roadmapping study on advancing heliostat technologies, intended as a central reference for the whole CSP community.

14 SOLAR ENERGY↗
DOE OSTI2023

Tabulated Database of Closed-Loop Geothermal Systems Performance for Cloud-Based Technical and Economic Modeling of Heat Production and Electricity Generation: Preprint

To better understand the heat production, electricity generation performance and economic viability of closed loop geothermal systems in hot-dry-rock, the Closed Loop Geothermal Group, a consortium of several national labs and academic institutions has tabulated time-dependent numerical solutions and levelized cost results of two popular closed loop heat exchanger designs (u-tube and co-axial). The heat exchanger designs were evaluated for two working fluids (water and super-critical CO2) while varying seven continuous independent parameters of interest (i.e., mass flow rate, vertical depth, horizontal extent, borehole diameter, formation gradient, formation conductivity, and injection temperature). The corresponding numerical solutions (approximately 1.2 million per heat exchanger design) are stored as multi-dimensional HDF5 datasets and can be queried at off-grid points using multi-dimensional linear interpolation. A Python script was developed to query this database and estimate time-dependent electricity generation using an Organic Rankine cycle (for water) or direct turbine expansion cycle (for CO2) and perform a cost assessment. This document aims to give an overview of the HDF5 database file and highlights how to read, visualize, and query quantities of interest (e.g., levelized cost of electricity, levelized cost of heat) using the accompanying python scripts. Details regarding the capital, operation, and maintenance and levelized cost calculation using the TEA (techno-economic analysis) script are provided.

co-axial↗