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TEA and LCA Assessments of H2 Production from Coal, Coal/Biomass, and Biomass

This presentation was made at the "Gasification Technology Status and Pathways for Net-Zero Carbon Economy Workshop" held on November 30, 2022. The presentation primarily focuses on TEA/LCA results that NETL has developed for coal gasification w/ & w/o CCS as well as net-zero greenhouse gas coal/biomass gasification. Full reporting of these cases is publicly available in the NETL report titled "Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies," April 2022. Additionally, the presentation describes current NETL work in support of the U.S. Department of Energy (DOE) Office of Fossil Energy and Carbon Management (FECM) Gasification Program in the areas of TEA/LCA/Markets analysis of biomass/MSW/waste plastics gasification to achieve cost reductions for net-zero H2 production.

Lewis, Eric↗

Reactivity of radiolytically and photochemically generated tertiary amine radicals towards a CO 2 reduction catalyst

Homogeneous solar fuels photocatalytic systems often require several additives in solution with the catalyst to operate, such as a photosensitizer (PS), Brønsted acid/base, and a sacrificial electron donor (SED). Tertiary amines, in particular triethylamine (TEA) and triethanolamine (TEOA), are ubiquitously deployed in photocatalysis applications as SEDs and are capable of reductively quenching the PS’s excited state. Upon oxidation, TEA and TEOA form TEA •+ and TEOA •+ radical cations, respectively, which decay by proton transfer to generate redox non-innocent transient radicals, TEA • and TEOA • , respectively, with redox potentials that allow them to participate in an additional electron transfer step, thus resulting in net one-photon/two-electron donation. However, the properties of the TEA • and TEOA • radicals are not well understood, including their reducing powers and kinetics of electron transfer to catalysts. Herein, we have used both pulse radiolysis and laser flash photolysis to generate TEA • and TEOA • radicals in CH 3 CN, and combined with UV/Vis transient absorption and time-resolved mid-infrared spectroscopies, we have probed the kinetics of reduction of the well-established CO 2 reduction photocatalyst, fac-ReCl(bpy)(CO) 3 (bpy = 2,2'-bipyridine), by these radicals [k TEA• = (4.4 ± 0.3) × 10 9 M –1 s –1 and k TEOA• = (9.3 ± 0.6) × 10 7 M –1 s –1 ]. The ~50× smaller rate constant for TEOA • indicates, that in contrast to a previous assumption, TEA • is a more potent reductant than TEOA • (by ~0.2 V, as estimated using the Marcus cross relation). This knowledge will aid in the design of photocatalytic systems involving SEDs. Furthermore, we also show that TEA can be a useful radiolytic solvent radical scavenger for pulse radiolysis experiments in CH 3 CN, effectively converting unwanted oxidizing radicals into useful reducing equivalents in the form of TEA • radicals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

A dynamic price model based on supply and demand with application to techno-economic assessments of rare earth element recovery technologies

Rare Earth Elements (REEs) are essential for sustainable energy technologies. Techno-economic Assessments (TEAs) have been conducted to evaluate innovative approaches to recover REEs from waste streams. However, most TEA studies do not consider the price volatility of REEs, which raises concern over the reliability of the analysis in an unpredictable dynamic market. To address this shortcoming, a dynamic price model is proposed that adjusts REE price based upon supply-demand conditions. The dynamic market behavior is simulated and its effect on a TEA is examined via a case study. The results of the dynamic simulation indicate a growing trend of the market price for REE materials/products. Compared to a conventional TEA that does not consider price dynamics, a significant difference in economic performance metrics is identified from the dynamic TEA results. Finally, the proposed dynamic TEA method is not limited to a specific application and can provide insights for evaluating a broad range of technologies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Electron Transfer Theory Elucidates the Hidden Role Played by Triethylamine and Triethanolamine during Photocatalysis

Triethylamine (TEA) and triethanolamine (TEOA) are renowned, in part, for their ability to reductively quench excited states by outer-sphere electron transfer with vast and still growing applications as sacrificial electron donors for photocatalytic systems. Upon amine oxidation, the resulting TEA •+ and TEOA •+ radical cations undergo proton transfer (or hydrogen atom transfer), resulting in the formation of a chemical reductant that has an α-carbon centered radical adjacent to the nitrogen center (TEA • and TEOA • ). In this contribution, we have electrochemically and spectroscopically characterized a set of electron acceptors which, upon accepting an electron, are a series of photocatalysts, [ReCl(R 1 R 2 -bpy)(CO) 3 ] •– , where R 1 and R 2 are electron-donating and electron-withdrawing groups in the 4,4′- and 5,5′-positions on the bipyridyl ligand. Here, we substantiated the formation of the electron donors, TE(O)A • , by spin trapping electron paramagnetic resonance spectroscopy, where TE(O)A • reacts with 2,4,6-tri-tert-butylnitrosobenzene to generate N-centered and O-centered radical adducts. Having established the chemical behaviors of the electron acceptors and donors individually, the electron transfer rate constants were determined across a 1.43 V range in driving force. The redox potential of TEA • was benchmarked to within ±80 mV on an absolute scale in V vs Fc + /Fc in CH 3 CN by using an empirical rate vs free-energy correlation, electron transfer theory, and density functional theory calculations. The equilibrium potentials for TEA • and TEOA • were determined to be −1.98 V and −1.76 V, respectively. Based on the kinetic and thermochemical analysis presented for TEA • and TEOA • , these transient radicals can be broadly considered strong homogeneous chemical reductants within the wider context of photoredox potentials. Thus, this work clarifies a frequently unnoticed secondary function for these sacrificial electron donors during photocatalysis and rationalizes the possibility of a one-photon/two-electron conversion process that is dependent on the free-energy exchange between TE(O)A • and photocatalysts.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Techno-Economic Analysis: Best Practices and Assessment Tools

A team at Sandia National Laboratories (SNL) recognized the growing need to maintain and organize the internal community of Techno - Economic Assessment analysts at the lab . To meet this need, an internal core team identified a working group of experienced, new, and future analysts to: 1) document TEA best practices; 2) identify existing resources at Sandia and elsewhere; and 3) identify gaps in our existing capabilities . Sandia has a long history of using techno - economic analyses to evaluate various technologies , including consideration of system resilience . Expanding our TEA capabilities will provide a rigorous basis for evaluating science, engineering and technology - oriented projects, allowing Sandia programs to quantify the impact of targeted research and development (R&D), and improving Sandia's competitiveness for external funding options . Developing this working group reaffirms the successful use of TEA and related techniques when evaluating the impact of R&D investments, proposed work, and internal approaches to leverage deep technical and robust, business - oriented insights . The main findings of this effort demonstrated the high - impact TEA has on future cost, adoption for applications and impact metric forecasting insights via key past exemplar applied techniques in a broad technology application space . Recommendations from this effort include maintaining and growing the best practices approaches when applying TEA, appreciating the tools (and their limits) from other national laboratories and the academic community, and finally a recognition that more proposals and R&D investment decision s locally at Sandia , and more broadly in the research community from funding agencies , require TEA approaches to justify and support well thought - out project planning.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Microchannel-based Membrane-less Extraction of Li from Unconventional Lithium Sources & the Separation of REE

This final report provides an overview of the Project's entire duration, covering July 1, 2021 to December 31, 2023. It primarily focuses on the achievements, technological developments, and unique challenges the team faced while working on separating and extracting Lithium from produced waters. The project's primary aim was to create an integrated, high-throughput, membrane-less, and modular microfluidic platform that could extract Lithium from unconventional sources. We have successfully met all goals and milestones envisioned in the SOPO document. The most critical primary milestones, including the Go-No-Go milestone (refer to the Gantt chart in the Appendices), were successfully accomplished. We demonstrated phase separation (>90%) and extraction (>85%) performance in the MPSE using synthetic, and representative produced water composition feed at 50 ml/min total flow through MPSE 36. We have also performed a parametric study of the MPSE operations, beyond the scope of SOPO, exploring operating conditions of current and broader interest. The extended investigation of operational parameters is concurrent with our efforts to seek further development of the MPSE technology beyond the scope of the Project. Along these lines of development, we have made efforts to be responsive to DOE calls for technological developments of other types of resources (beyond PW) for the recovery of Critical Materials and higher TRL development (beyond TRL 4). During the work on this Project, we developed and implemented three innovative technical approaches that emerged from our efforts to successfully meet the Project milestones. The innovative & original technical approaches developed and implemented in this Project are now the contributions to process engineering that could be clearly credited to the Project. First, Convergent Design Approach is a comprehensive feedforward & feedback loop of four design phases: i) design for functionality, ii) design for manufacturing, iii) design for sustainability, and iv) design for market. Next was Process Intensification. A major aim of this Project was to create an innovative phase separation & extraction microscale-based technology for Li separation – thus the words microchannel-based in the Project title. A microscale-based technology is intrinsically in the center of the Process Intensification domain as defined by its unique principles. Therefore, Process Intensification was implicitly envisioned in the Project’s SOPO. Lastly, Time Scale Analysis is a novel tool for discovering the needs and directions of Process Intensification implementations in any process technology. This Project is fully credited for developing and implementing the three novel technical approaches mentioned above. These are general contributions to process engineering that emerged from this Project. Beyond the original SOPO scope, the OSU-U.Pitt research group utilized a Convergent Design methodology, integrating first-principles mathematical modeling with experimental validation on the Minimum Development Vehicle. By creating these Digital Twins, the team rapidly assessed manufacturing iterations to support TEA analysis. This framework further enabled the development of advanced Surface Modification Techniques, where hydrophobic and oleophobic coating strategies were optimized via Digital Twin tools and validated through rigorous 100-hour longevity testing. TEA Analysis: The closing efforts of this Project were focused on the TEA analysis. TEA analysis had two primary functions: i) enabling critical assessments of design variations withing 10 the Concurrent Design Approach, thus enabling evolution of the MPSE design to reach faster- better-cheaper alternatives; and ii) to create a bridge between the accomplishments of this Project and future projects of higher TRL, beyond TRL 6 level. It is important to note that the TEA model created in the Project stirred the technological solutions for the recovery of critical materials toward a vision of a very profitable modular plant that has unique zero-waste water discharge signature. More importantly, thanks to our experimental performance data and conservative assumptions, the TEA model predicts minimal technological and investment risks. Low cost of a modular unit of a nominal capacity of [1000 tons of Li 2 CO 3 /year] positions the MPSE based technology within the reach of community investors, thus offering a paradigm shift in the development of critical technologies. The project successfully navigated two primary challenges: solvent selection and manufacturing adaptation. Restricted by the SOPO to existing literature for lithium recovery, the team identified a critical need for a "material excellence program" to develop next-generation solvents, eventually concluding with a preliminary investigation into promising Ionic Liquids (ILs). Simultaneously, COVID-19 supply chain disruptions forced a pivot from traditional manufacturing to advanced additive methods at ATAMI-OSU. By transitioning from stainless steel to 3D-printed polymer substrates, the team achieved a transformative three-order-of- magnitude reduction in manufacturing costs and compressed prototyping timelines from several months to just two days. The MPSE technology offers significant energy, environmental, and economic advantages by overcoming the traditional bottlenecks of phase-separation hardware and contactor size. Unlike conventional mixer-settlers or membrane-based systems, MPSE operates without moving parts or fouling-prone membranes, achieving robust performance even with challenging, viscous, or particulate-heavy feeds. Key performance metrics include an energy intensity reduction of 5–50x (3–40 kJ/m 3 ) compared to incumbent technologies and a dramatic reduction of processing time to under 60 seconds, which drastically reduces the physical plant footprint. These technical efficiencies translate into superior economic outcomes; for a 100 t/year Li 2 CO 3 facility, implementing MPSE is projected to nearly halve contactor CAPEX (from $\$$6.08M to $\$$3.01M) and significantly increase the project's Net Present Value (NPV), derisking new investment and enabling distributed critical-mineral processing configurations. The commercialization of MPSE technology is being spearheaded by Vigsur Dynamics Inc., which has adopted a structured, parallel approach to technical and business development since its formation in January 2026. Following extensive customer discovery and engagement with the Oregon State University accelerator, Vigsur Dynamics is working to establish a business model that transitions from pilot demonstrations to modular hardware sales, ultimately aiming for a "build-own-operate" service strategy. Current technical milestones—including 100 hours of continuous operation, superior energy efficiency, and successful 6-unit modular scale-up— provide a foundation for this transition. Backed by ongoing IP licensing and a growing network of industrial and venture advisors, the company is actively de-risking the platform to replace conventional mixer-settler systems in the critical minerals market.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Beyond Price-Taker: Multiscale Optimization of Wind and Battery Integrated Energy Systems

Integrating renewable energy into the electric grid is challenging due to the intermittency and variability of wind and other non-dispatchable resources. Integrated energy systems (IESs) combine multiple energy technologies (e.g., fossil, nuclear, renewables, storage) to reduce costs and improve flexibility and reliability. However, standard techno-economic analysis (TEA) methods often overestimate the benefits of IESs because they fail to account for energy market adjustments. This paper systematically studies the limitations of the prevailing price-taker assumption for TEA and optimization of hybrid energy systems. As an illustrative case study, we retrofit an existing wind farm in the RTS-GMLC test system (which loosely mimics the Southwest U.S.) with battery energy storage to form an IES. We show that the standard price-taker model overestimates the electricity revenue and the net present value (NPV) of the IES up to 178% and 30.4%, respectively, compared to our more rigorous multiscale optimization. These differences arise because introducing storage creates a more flexible resource that impacts the larger wholesale electricity market. Moreover, this work highlights the impact of the IES has on the market via various strategic bidding, and underscores the importance of moving beyond price-taker for optimal storage sizing and TEA of IESs. We conclude by discussing opportunities to generalize the proposed framework to other IESs, and highlight emerging research questions regarding the complex interactions between IESs and markets.

25 ENERGY STORAGE↗

Analysis of Gaps in Techno-Economic Analysis to Advance Heliostat Technologies for Concentrating Solar-Thermal Power

The Heliostat Consortium (HelioCon) was launched in 2021 to advance heliostat technology. One of its first efforts was to do a detailed analysis of gaps in technology and capabilities in the heliostat industry and complete a roadmap study describing high-priority gaps. HelioCon gathered gaps through a series of outreach activities with representatives and experts from industries and research institutes. Here, this paper discusses the gap analysis for the techno-economic analysis (TEA) topic. One of the main objectives of the TEA topic is to relate the cost and performance of heliostats and heliostat components to the overall system performance. In this study, we limit the scope of this topic to the heliostat field, tower, and receiver and do not consider downstream applications or uses of thermal energy. We conducted a thorough review of existing models and compiled a list of the state of the art in open-source tools currently available to researchers. We collected an initial list of gaps for the TEA of heliostats from industry developers and experts. Each gap is briefly described, and the heliostat development cycle stages that the gap impacts are indicated. We ranked the initial list of TEA gaps into tiers depending on their potential impact. For TEA, most of the gaps identified are related to developing models or data. Strictly speaking, none of these gaps are essential for heliostat development, but all would aid in the heliostat development process.

14 SOLAR ENERGY↗

Techno-Economic Analysis of Product Diversification Options for Sustainability of the Monticello and Prairie Island Nuclear Power Plants

The objective of this work was to perform techno-economic analysis (TEA) of hybrid options that could be integrated with light water reactor (LWR) nuclear power plants (NPPs) in order to improve the viability and sustainability of existing LWRs through product diversification by utilizing nuclear energy not only to produce grid electricity but to also produce carbon free products such as hydrogen, ammonia or synthetic fuels. Much of the analysis herein could be generally applied to any LWR (high temperature steam electrolysis- HTSE design), but hydrogen demand and the optimization of the HTSE was completed with specific collaboration and data from Xcel Energy’s Prairie Island and Monticello nuclear generating stations and the surrounding market and logistics potential in the greater Minneapolis region. Xcel Energy has set aggressive goals with regards to decarbonization, including an 80% reduction in CO 2 emissions from 2005 levels, by 2030 and 100% carbon free by 2050. Other TEAs regarding hydrogen production with nuclear energy have been completed in collaboration with other utility companies previously. Besides being the first TEA in this regard specific to Xcel Energy and the surrounding markets and logistics, this TEA adds to the previously completed TEAs by providing the most up to date and state of the art analysis and optimization of the hydrogen production plant integrated with nuclear power (NPP-HTSE).

08 HYDROGEN↗

Supply Chain Sustainability Analysis of Renewable Hydrocarbon Fuels via Hydrothermal Liquefaction, Combined Algal Processing, and Biochemical Conversion: Update of the 2022 State-of-Technology Cases

The Department of Energy's (DOE) Bioenergy Technologies Office (BETO) aims to develop and deploy technologies to transform renewable biomass resources into commercially viable, high-performance biofuels, bioproducts, and biopower through public and private partnerships. BETO and its national laboratory teams conduct in-depth techno-economic assessments (TEA) of biomass feedstock supply and logistics and conversion technologies to produce biofuels. There are two general types of TEAs: A design case outlines a target case (future projection) for a particular biofuel pathway. It informs R&D priorities by identifying areas in need of improvement, tracks sustainability impact of R&D, and provides goals and benchmarks against which technology progress is assessed. A state of technology (SOT) analysis assesses progress within and across relevant technology areas based on actual results at current experimental scales relative to technical targets and cost goals from design cases, and includes technical, economic, and environmental criteria as available. In addition to developing a TEA for a pathway of interest, BETO also performs a supply chain sustainability analysis (SCSA). The SCSA takes the life-cycle analysis approach that BETO has been supporting for over 20 years. It enables BETO to identify energy consumption, environmental, and sustainability issues that may be associated with biofuel production. Approaches to mitigating these issues can then be developed. Additionally, the SCSA allows for comparison of energy and environmental impacts across biofuel pathways in BETO's research and development portfolio. This technical report describes the SCSAs for the production of renewable hydrocarbon transportation fuels via a range of conversion technologies in the 2022 SOTs: (1) renewable hydrocarbon fuels via hydrothermal liquefaction (HTL) of wet sludge from a wastewater treatment plant; (2) renewable hydrocarbon fuels via biochemical conversion of herbaceous lignocellulosic biomass; (3) renewable hydrocarbon fuels via HTL of an algae/woody biomass blend; and (4) renewable hydrocarbon fuels via combined algae processing (CAP).

09 BIOMASS FUELS↗

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↗

BETO 2021 Peer Review: 2.1.0.100 - Biochemical Platform Analysis

The objective of this project is to perform techno-economic analysis (TEA) to guide Biochemical Platform efforts, utilizing models for purposes of setting future R&D targets and tracking performance progress against those targets. Outcomes of our work are leveraged by BETO to guide program plans, as well as by other NREL/partner projects to quantify the impact of research on key technology barriers and to prioritize future efforts. This project provides high impact and relevance through establishing “bottom-up” TEA models as a basis for understanding the technical feasibility to meet “top-down” BETO cost targets. By providing a framework to translate technical performance to cost reductions in a biorefinery, our TEA models may be leveraged to maximize the efficiency of research funding towards the most economically impactful priorities, ultimately in support of BETO’s 2030 fuel cost targets below $2.5/GGE. In order to mitigate a key risk/challenge to this project in overly-constraining our analyses to a singular technology focus or TEA metric, our approach continuously re-assesses opportunities for better optimization and alternative technology pathway options, while maintaining close interaction with other BETO analysis partners. We have made numerous recent accomplishments rooted around identifying and working with the researchers to solve key technical and TEA/LCA challenges, reflected through notable improvements in State-of-Technology (SOT) updates over prior benchmarks.

biochemical↗

ABF Past Accomplishments - TEA/LCA

The Integrated Analysis task in the Agile BioFoundry (ABF) conducts techno-economic analysis (TEA) and life cycle assessment (LCA) to quantify the economics and environmental impacts of bioprocesses under development. The team from Argonne National Laboratory (ANL) and the National Renewable Energy Laboratory (NREL) develops TEA and LCA models of selected compound targets and hosts of interest to the ABF in an effort to provide an analysis-based foundation to the R&D. To date, the Integrated Analysis task has performed process modeling and analyses on multiple pairings of bioproducts and hosts, centered around major metabolic "beachheads" and "exemplar" molecules chosen for each of the metabolic pathways of interest. This presentation provides an overview of the approach used for TEA and LCA in the ABF and of the progress, outcomes, and impacts of TEA and LCA to support ABF goals, with a focus towards developing bio-based products that are both environmentally and economically viable.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗