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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Final Technical Report

The project goal is to demonstrate low-cost, interlocking, and carbon-storing insulation materials with thermal insulation of R5/inch, flexural modulus > 10 MPa, low material price < $ 0.5/ft2 wall area (materials cost for ½” thick panel), and net embodied carbon of 0.8t net CO2e/t (60% reduction compared to gypsum), respectively, which can meet the cost and performance targets of department of energy (DOE)’s 2050 climate target. To achieve this goal, the project plans three tasks, and each has a specific objective: 1) Modular design and engineering analysis of interlocking insulation panel blocks using biogenic materials (cellulose, straw, etc.): with the consideration of potential assembling and recycling. 2) Scalable manufacturing of biogenic-based interlocking insulation panels: scale up the modular panel production using ambient pressure drying and surface superhydrophobic modification at 1ft*1ft with the potential for further scalable mass production of 4ft*4ft. 3) Code-compliant testing, recycling and carbon footprint analysis of manufactured interlocking insulation panels examined using ASTM standards of thermal insulation (ASTM C518), mechanical properties (ASTM C1161), and water vapor transmission (ASTM E96).

Ren, Shenqiang↗
DOE OSTI2021

Decisions and coordination of retailer-led low-carbon supply chain under altruistic preference

A low-carbon supply chain formed by a dominant retailer and a small and medium-sized manufacturer (SMM) is considered. Because the SMM faces the high cost pressure of adopting carbon emission reduction (CER) technologies, the retailer may take an altruistic preference for the long-term sustainability of the chain. Three decision-making models, centralized, decentralized without altruistic preference, and decentralized with altruistic preference, are constructed to compare decisions and profits of both parties. Since neither decentrailized models can lead to a coordinated solution that is incentive compitable, a coordination contract, referred to as the cost sharing contract with altruistic preference, is proposed. Numerical study shows that the altruistic preference can help increase the SMM's profit and system efficiency but decrease the retailer's profit. The coordination contract requires the retailer to adjust the unit profit and share more than half of the CER cost. Finally, it is found that the wholesale price is the lowest in the coordination contract and the comparison of unit profit depends on the coefficient of CER cost.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

U.S. Solar Photovoltaic System and Energy Storage Cost Benchmarks: Q1 2021

Based on our bottom-up modeling, the Q1 2021 PV and energy storage cost benchmarks are: $\$2.65$ per watt DC (WDC) (or $\$3.05$/WAC) for residential PV systems, 1.56/WDC (or $\$1.79$/WAC) for commercial rooftop PV systems, $\$1.64$/WDC (or $\$1.88$/WAC) for commercial ground-mount PV systems, $\$0.83$/WDC (or $\$1.13$/WAC) for fixed-tilt utility-scale PV systems, $\$0.89$/WDC (or $\$1.20$/WAC) for one-axis-tracking utility-scale PV systems, $\$30,326$-$\$33,618$ for a 7.15-kWDC residential PV system with 5 kW/12.5 kWh nameplate of storage, $\$2.04$ - $\$2.10$ million for a 1-MWDC commercial ground-mount PV system colocated with 600 kW/2.4 MWhusable of storage, $\$166$ - $\$167$ million for a 100-MWDC one-axis tracker PV system colocated with 60 MW/240 MWhusable of storage. Between 2020 and 2021, there were 3.3% ($\$0.0$9/W), 10.7% ($\$0.19$/W), and 12.3% ($\$0.13$/W) reductions (in 2020 USD) in the residential, commercial rooftop, and utility-scale (one-axis) PV system cost benchmarks respectively. Balance of system (BOS) costs have either increased or remained flat across sectors, year-on-year, unlike in previous benchmark reports, which generally have reported declining BOS costs. The increase in BOS cost has been offset by a 17% reduction in module cost. Overall, modeled PV installed costs across the three sectors have declined compared to our Q1 2020 system costs.

14 SOLAR ENERGY↗
DOE OSTI2025

Quantifying Distribution System Resilience From Utility Data: Large Event Risk and Benefits of Investments

We focus on blackouts in electric distribution systems that have a large cost to customers. To quantify resilience to these events, we show how to calculate risk metrics from the historical outage data routinely collected by utilities' outage management systems. Risk is defined using a customer cost exceedance curve. The exceedance curve has a heavy tail that implies large fluctuations in large blackout costs, and this makes estimating the mean large cost in the usual way impractical. To avoid this problem, we use new resilience metrics describing the large event risk; these metrics are the probability of a large cost event, the annual log cost resilience index, and the average of the logarithm of the cost of large-cost events or the slope magnitude of the tail on a log–log exceedance curve. Resilience can be improved by planned investments to upgrade system components or speed up restoration. The benefits that these investments would have had if they had been made in the past can be quantified by “rerunning history” with the effects of the investment included, and then recalculating the large event risk to find the improvement in resilience. An example using utility data shows a 2% reduction in the probability of a large cost event due to 10% wind hardening and 6%–7% reduction due to 10% faster restoration in two different areas of a distribution utility. This new data-driven approach to quantify resilience and resilience investments is realistic and much easier to apply than complicated approaches based on modeling all the phases of resilience. Moreover, an appeal to improvements to past lived experience may well be persuasive to customers and regulators in making the case for resilience investments.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Storage Enabled Flexibility of Conventional Generation Assets (StorFlex)

The power systems have faced progressively more demanding operational requirements over the last two decades. Several factors contribute to these challenging operating conditions, including load growth, aging infrastructure, increasing penetrations of distributed energy resources (DERs), electrification of the economy, and policy initiatives such as decarbonization. The power system and its components must provide high operational flexibility to mitigate these challenges. For example, the proliferation of intermittent DERs such as wind and solar has increased the need for conventional generation assets like hydropower plants to respond to sudden load-generation imbalances. The higher flexibility requirements for hydropower plants cause more wear and tear, potentially shortening the useful lifespan of hydropower turbines. To reduce the need for hydropower plants to follow sudden changes in the dispatch signal, we investigate their combined operation with the energy storage systems (ESSs; “ESS-based hybridization”). Our analyses focuses on improving the lifespan of hydropower plants through ESS-based hybridization. Wear and tear on hydropower turbines (particularly Francis turbines) is modeled using a loss-of-life concept that is based on damage experienced by the turbine due to various cycles of operation. Then, we show that using ESSs to offset some of the high variation increases the remaining life of the hydropower plants. To demonstrate this, a few modeling tools were developed for this work: (1) a dynamic model for various components of the turbine and its governor; (2) a control strategy that assigns a slow-varying dispatch signal to a hydropower unit versus a fastmoving signal to ESS, such that the overall power request remains the same; and (3) models for the financial analysis to quantify the economic merits of such a framework. We used the models we developed to analyze the dispatch pattern of an actual hydropower plant with a power output of 50 MW and a head height of 152 m. This work showed that ESS-based hybridization could extend the life of the hydropower plant by 5% on average. This extension in life was then used to estimate the economic benefit in terms of cost deferrals associated with hydropower plant maintenance and replacement: on average, $3.6 million. Sensitivity analysis with respect to the size of ESS and cost of turbines was performed to show the variation in benefits over the range of turbine costs and ESS sizes. Crucially, stacking damage reduction and lifetime extension with other ESS value streams such as providing ancillary services could substantially increase the financial benefits of ESS-based hybridization. The higher costs associated with ESS of appropriate size would make more financial sense when multiple value streams are stacked and co-optimized to extract the maximum benefit. This dimension will be explored in future work.

13 HYDRO ENERGY↗
DOE OSTI2022

Electrochemical CO2 conversion to formic acid through the Andora Process

Electrochemical utilization or conversion of CO2 can be used to convert waste CO2 into targeted high-value and cost-effective commercial products. Conventional processes for CO2 conversion to fuel sources are challenging and expensive due to their requirement for high temperatures and pressures. Electrochemically, a catalyst can be used at a fixed applied potential to reduce CO2 to form a desired product with less competition at modest operating conditions. Formic acid (FA) has recently become a product of interest for CO2 conversion due to its potential for hydrogen storage and fuel cell applications. Electrochemically, FA is produced through a direct two-electron transfer process involving CO2 with a proton source, requiring less energy input and fewer reaction steps than traditional processes. However, there remain significant obstacles for the broader-scale implementation of CO2 on the market, including competition with unwanted CO and H, the presence of molecular oxygen, and stability of the electrocatalyst. In order to overcome some of these challenges, a new continuous flow Andora Process was developed consisting of two separate cells to decouple electrochemical reduction of the charge carrier with the FA production via an engineered catalyst. Recent experimental results show that with appropriate design changes and operating conditions to the flow system, FA production above 500 mM can be achieved along with efficiencies above 80%. TEA and LCA assessments of the Andora Process show a potential for the reduction in the GWP potential and cost saving compared to the current comparative formic acid production process.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2026

High-Speed Layup and Forming of Automotive Composite Components

This Project is focused on the design and manufacture of automotive components that meet functional and environmental requirements of an existing automotive application at a cost of ≤ $\$$11.00 per kilogram weight reduction. This project fosters the development of composite material technologies suitable for high volume automotive processes and run rates as well as industry workforce development with these technologies. Current automotive manufacturing involves utilizing steel or aluminum in sheet form which is rapidly stamped into components at rates up to 3600 per hour. The metallic sheets are available in many different thicknesses, strength levels, and manufacturing rates are reasonable independent of part size. While composite materials are available for use in automotive applications, the material cost, labor to manufacture and the processing of the waste far exceed the cost compared to metallic designs. Typical composite layer by layer layup procedures don’t meet the desired 60 second layup time that current automotive processes require and are also restricted by part size. Due to these factors, composites have not yet made advances into today’s high volume automotive applications. Industry partners DURA, BASF, Ford, and IACMI core innovation partner MSU collaborated to develop a manufacturing process technology that is capable of manufacturing composite blanks at high volume and independent of part size. IACMI core innovation partner Purdue provided FEA analysis and cost modelling. The objective of this project was to demonstrate a composite sheet layup and consolidation process that can be commercialized for high volume requirements, identify potential layup equipment suppliers, and develop a process of 60 second layup, forming, and trimming of a continuous fiber automotive component for the mainstream market.

42 ENGINEERING↗
DOE OSTI2025

Assessing fuel cycle design options for advanced microreactors

Microreactor (MR) technology have recently gained traction due to their reduced construction cost compared to traditional large reactors. Their small physical geometry results in increased neutron leakage and deteriorated neutron economy which limits the achievable burnup of MR fuel. Refueling strategy currently discussed in MR design community is the battery-like refueling which is involve replacing the entire reactor core at the end of their operational cycle. Here, this paper investigates partial core refueling as means to increase MR fuel burnup and improve fuel cycle economy as a result. Two fuel cycle design strategies have been successful. These are the partial core refueling and partial core refueling combined with assembly rotation. Both strategies have been tested to operate a heatpipe-cooled MR referred to as the eVinci-like core for 72 Effective Full Power Months (EFPMs). The partial core refueling showed to reduce the refueling requirements by 18% compared to the battery-like refueling strategy. This corresponds to 10.5% reduction in the Net Present Value (NPV) of fuel cost over the 72 EFPMs of operation. The partial core refueling combined with rotation case reduces the refueling requirements by 29% (corresponding to 14.5% reduction in NPV of fuel cost) compared to the battery-like refueling strategy.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Optimal environmental and economic performance trade-offs for fifth generation district heating and cooling network topologies with waste heat recovery

Network topology greatly influences both the economic and environmental performance of fifth generation district heating and cooling (5GDHC) systems. In this study the optimal trade-offs between the environmental and economic performance of 5GDHC network topologies for a five-building district with waste heat recovery were explored. A life cycle assessment method was used to calculate the total life cycle CO 2 emissions (LCCO2) associated with the installation and operation of various network topologies. Twelve months of empirical data from a data center cooling system were analyzed to assess its suitability for integration into a 5GDHC system. The most suitable method for utilizing this waste heat was selected based on the ambient loop warm pipe setpoint, waste heat temperature, and district energy system configuration. A multi-objective optimization algorithm was used to select the 5GDHC network topology that provided the optimal trade-off between LCCO2 and life cycle cost (LCC). A trade-off parameter was employed to weigh the importance of each objective in the selection process. The results showed waste heat from the data center was suitable for integration into the 5GDHC system due to its availability and consistent temperature profile. When return temperatures of 25 °C or higher were available from the liquid-cooled system, direct pre-heating of the ambient loop warm pipe was found to be the most effective waste heat integration method. The selection of the network topology that provided the optimal trade-off between LCCO2 and LCC (optimal trade-off topology) was highly dependent on factors such as fuel prices, CO 2 prices, electricity CO 2 emissions factors, availability of waste heat, embodied CO 2 emissions associated with network installation and network infrastructure costs. Optimal trade-off topologies produced substantial LCCO2 reductions relative to corresponding LCC increases. LCCO2 reduction to LCC increase ratios from 5.78 to 117.79 were identified with CO 2 offset costs ranging from 4.77 to 60.08 ($/tCO 2 e).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Proton Therapy for Breast Cancer: A Consensus Statement From the Particle Therapy Cooperative Group Breast Cancer Subcommittee

Radiation therapy plays an important role in the multidisciplinary management of breast cancer. Recent years have seen improvements in breast cancer survival and a greater appreciation of potential long-term morbidity associated with the dose and volume of irradiated organs. Proton therapy reduces the dose to nontarget structures while optimizing target coverage. However, there remain additional financial costs associated with proton therapy, despite reductions over time, and studies have yet to demonstrate that protons improve upon the treatment outcomes achieved with photon radiation therapy. There remains considerable heterogeneity in proton patient selection and techniques, and the rapid technological advances in the field have the potential to affect evidence evaluation, given the long latency period for breast cancer radiation therapy recurrence and late effects. In this consensus statement, we assess the data available to the radiation oncology community of proton therapy for breast cancer, provide expert consensus recommendations on indications and technique, and highlight ongoing trials’ cost-effectiveness analyses and key areas for future research.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2025

C-C Coupling Mechanism on Cu(100) A Molecular Dynamics Study at 298K

The electrochemical reduction of carbon dioxide (CO2) into valuable fuels such as C1 (syngas, methane) and C2 (ethylene, ethanol) products is a key strategy for achieving a carbon-neutral economy. Computational studies of C-C coupling, a critical step in CO2 reduction, are essential for designing more efficient catalysts. However, simulating these processes under realistic electrochemical conditions, including temperature and solvent effects, is computationally demanding. In this work, we develop a machine learning-based atomistic potential to study CO2 reduction on Cu(100) surfaces, accounting for temperature and explicit water solvent effects. We compute thermodynamic free energies of the possible C-C coupling pathways, CO*+CO*→OCCO*, CO*+CHO*→OCCHO*, CO*+COH*→OCCOH*, CHO*+COH*→OHCCOH*, COH*-COH*→HOCCOH*, and CHO*-CHO*→OHCCHO*. Our results quantify the thermodynamic tendencies of these reactions and reveal that, in addition to the well-established CO* + CO* → OCCO* pathway, CHO* is a critical intermediate in the formation of C2 products on Cu(100). Furthermore, we demonstrate that the machine learning approach offers a cost-efficient framework for studying CO2 reduction on diverse catalysts under realistic electrochemical conditions.

machine learning↗
DOE OSTI2026

Experimental Evaluation of a Microchannel Condenser for R600a Domestic Refrigerators

Domestic refrigerators are among the most common household appliances, accounting for approximately 4% of total household energy consumption, which is higher than that of clothes dryers, lighting, or cooking appliances. With nearly 13 million new domestic refrigerators sold annually, even marginal improvements in their energy performance can yield significant reductions in overall energy demand and cost. This study focuses on enhancing the performance of domestic refrigerators using R600a as the refrigerant. Most domestic refrigerators currently employ wire-and-tube condensers, which are bulky and require a larger refrigerant charge. Given that R600a is classified as an A3 flammable refrigerant under ASHRAE standards, minimizing the system charge while maintaining or improving performance is critical. To address this, a compact and light weight single-pass serpentine microchannel heat exchanger (made of aluminum) was adopted as a condenser, replacing the conventional wire-and-tube configuration. The modified system was experimentally tested according to AHAM test standards, and charge optimization was performed. The results demonstrated that the refrigerator equipped with the microchannel condenser achieved a 5.3% reduction in energy consumption compared to the baseline configuration with wire-and-tube condenser.

Murugan, Muneeshwaran [ORNL] (ORCID:00000003340352↗
DOE OSTI2025

On the optimal sizing of power take-off systems for wave energy converters

The power take-off (PTO) system in a wave energy converter (WEC) is the means by which the energy in an ocean wave is converted into useful energy. There has been a general lack of technology convergence in the wave energy industry and PTO design has been largely device-specific with the design process determined by the WEC developer. An optimized PTO design can significantly affect the efficiency, reliability, performance, and overall cost and viability of a device. There remains a need in the marine energy industry for best practices and efficient design processes to be identified as it could greatly benefit developers and researchers in designing an optimal WEC PTO. This research utilizes the open-source Matlab-Simulink based software, WEC-Sim, which was developed by the National Renewable Energy Laboratory, and the Eagle, a high-performance computing system, to model and optimize two WECs of different archetypes and then investigates if any trends exist that can be exploited for greater efficiency in optimal PTO design. The results from this research indicate that there may be an optimal sizing for WEC PTOs for both power and PTO force rating and that substantial reductions can be made in the cost of a device without significant loss in the energy produced. Furthermore this optimal sizing may be independent of WEC type and deployment location. With an optimal, or near optimal, approach to WEC PTO sizing demonstrated, a methodology is proposed to address the challenge of nameplate ratings in the wave energy industry.

13 HYDRO ENERGY↗
DOE OSTI2026

Comparative techno-economic and environmental analysis of using nuclear energy and fossil energy with carbon sequestration in U.S. Gulf Coast petroleum refineries

U.S. Gulf Coast refineries have processing capacity of approximately 9.4 million barrels of crude oil per day—about 50% of U.S. national capacity—while consuming natural gas, electricity, and hydrogen, resulting in approximately 100 million metric tonnes (MMT) of onsite CO₂ emissions in 2022. This study evaluates two alternative refinery energy supply pathways: nuclear energy (NE) and fossil energy-derived hydrogen with carbon capture and sequestration (FE-CCS; autothermal reforming), intermittent renewable sources are not considered as they cannot reliably meet continuous industrial heat and hydrogen demands. Using publicly available data for refineries, we conducted a bottom-up, facility-level assessment to estimate energy use by type, well-to-gate refinery emissions, and associated costs of integration. Compared to current refinery operations using natural gas energy supply and conventional hydrogen production (steam methane reforming without sequestration), NE and FE-CCS could produce, respectively, average emissions reductions of 37% and 42%, total abatement costs of $\$$52–$\$$221 and $\$$211–$\$$612/MT CO₂, and additional costs of about $\$$0.2–$\$$6 and $\$$3–$\$$11 per barrel of crude, respectively. Our analysis indicates that 25 out of 27 refineries have lower total additional cost ($\$$/bbl.) for the NE scenario than the FE-CCS scenario, making a strong case for NE integration with petroleum refineries. This work's main contribution is a detailed bottom-up refinery-level analysis method that can be utilized by the worldwide refining industry and stakeholders as they assess different technological options, along with their costs and environmental impacts for a specific refinery operation.

Carbon capture and sequestration↗
DOE OSTI2026

An Analysis of Future Wind Energy Resources and Cost Uncertainties Across the United States

Wind power is a growing source of energy generation that relies on complex global atmospheric and earth system processes. There has been evidence of reductions in average wind speeds over land in North America since the 1980s, and several models project that average wind speeds will continue to decrease. Concurrently, the cost of wind energy systems in the United States has been decreasing since around 2010, a trend also projected to continue. There is considerable uncertainty in these future projections, with quantitative estimates of future wind resource and system costs varying widely. To study this, we run wind energy models with possible future system costs, turbine designs, and meteorological inputs from multiple downscaled earth system models over the contiguous United States. Changes in mean annual energy production from 2000-2019 to 2040-2059 can be as high as +10% in South Texas or as low as -20% in Iowa. Larger turbines and moderate reductions in system costs can offset the largest projected decreases in wind resource, but much uncertainty remains in the extent to which wind resources will change and to what extent system costs can be reduced. An analysis of variance shows, in several states in the Midwest, uncertainty in future wind resources can influence the cost of wind energy nearly as much as uncertainty in future system costs.

17 WIND ENERGY↗
DOE OSTI2020

FINAL TECHNICAL AND ECONOMIC FEASIBILITY STUDY ON THE APPLICATION OF A HEAT INTEGRATED POST-COMBUSTION CO2 CAPTURE SYSTEM WITH HITACHI ADVANCED SOLVENT INTO EXISTING COAL-FIRED POWER PLANT

This report contains the results of a techno-economic assessment (TEA) conducted of a heat integrated post-combustion CO2 capture process with Hitachi advanced solvent for retrofit into an existing coal-fired power plant (but treated as greenfield plant on cost analysis). The process has been developed by the University of Kentucky Center for Applied Energy (UK CAER). EPRI was chiefly responsible for this analysis, with significant input from WorleyParsons, Hitachi Power Systems America (Hitachi) and UK CAER. The project also involves the design, fabrication, installation, testing, and analyses of a slipstream facility located at L&GE-KU’s E.W. Brown Generating Station to demonstrate the UK CAER carbon capture system that could utilize heat integration with the main power plant. The design, start-up, and baseline of the pilot system was performed with a generic 30 wt% MEA solvent to obtain data for direct comparison with the DOE/NETL Reference Case followed by testing Hitachi’s proprietary solvent H3-1. In this techno-economic analysis, two cases utilizing the UK CAER process are compared, using different approach temperatures and solvent, against the DOE/NETL Reference Case (Case 10). The results are shown comparing the energy demand for post-combustion CO2 capture and the net higher heating value (HHV) efficiency of the power plant integrated with the post-combustion capture (PCC) plant. A levelized cost of electricity (LCOE) assessment was performed showing the costs of the options presented in the study. The key factors contributing to the reduction of LCOE were identified as CO2 partial pressure increase at the flue gas inlet, thermal integration of the process, and performance of the Hitachi H3-1 solvent. Recent UK CAER process pilot-scale testing data and process simualtion data showed that the packing heights of absorber and stripper columns were significantly oversized in the prelimanary TEA (Task 2 of this project) and thus updated in this final TEA for the H3-1 case only. In addition, the solvent make-up cost for H3-1 was updated based on lattest test results. Finally, a heat integration with the main power plant was applied in this final TEA to increase overall energy effciency for both the MEA and H3-1 cases. Additonal reductions in capital and operational costs are expected but not taken into account here. Shorter columns result in reduced pressure drops, smaller blower head and pump hydraulic head requirements. An increase in overall energy efficiency resuls in a decreased size of the power plant, the CCS and a reduced parasitic steam requirement to the CCS. The net efficiency of the UK CAER integrated PC power plant with CO2 capture changes from 26.2% for the Reference Case 10 plant in 2010 revised DOE/NETL baseline report to 27.6% for the MEA options considered, and 29.1% for the options utilizing the Hitachi advanced solvent. The UK CAER Process + Hitachi case also produces an extra 30.9 MW of generation compared to the UK CAER Process + MEA case and total 60.9 MW more than DOE Case 10. LCOE ($/MWh) values are $172.08/MWh for the MEA option and $157.65/MWh for the Hitachi H3-1 solvent cases considered in comparison to $189.59/MWh in January 2012 dollar for the Reference Case 10. The UK CAER CCS process with MEA case lowers energy consumption for CO2 capture to 1340 Btu/lb-CO2 captured as compared to 1540 Btu/lb-CO2 in the Reference Case 10. The UK CAER CCS process with H3-1 case further lowers energy consumption for CO2 capture to 973 Btu/lb-CO2 captured, for an advantage of 36.8% less energy consumption than Case 10. The study also shows 38.1% less heat rejection associated with the carbon capture system from 3398 MBtu/hr (Case 10) to 2104 MBtu/hr for the UK CAER + MEA system. Heat rejection is reduced to 2464 MBtu/hr in the UK CAER + H3-1 case, for a 27.5 % decrease compared to Case 10. Modeling outputs show that in the UK CAER process, the cooling water that is 2-5°C cooler than conventional cooling tower water can be achieved for ambient conditions common to the midwest and other regions. The results from the techno-economic assessment show that the proposed technology can be investigated further as a viable alternative to conventional CO2 capture technology. The evaluation also shows the effect of the critical parameters on the LCOE, with the main variables being the approach temperature and CO2 partial pressure increase at the flue gas inlet. A summary of the key advantages of the UK CAER Process + H3-1 case for LCOE and other economic factors compared to the DOE Case 10 is as follows: • A lower variable operating cost by $1.56/MWh ($1.08MWh less than the UK CAER Process + MEA Case), a 11.7% reduction compared to the DOE Case 10 • A lower COE by $25.32MWh ($13.94/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower LCOE by $31.94/MWh ($17.51/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower cost of CO2 captured by $18.65/tonne CO2 ($9.44/tonne CO2 lower than the UK CAER Process + MEA Case), a 30.4% reduction compared to the DOE Case 10 • A lower cost of CO2 avoided by $34.95/tonne CO2 ($18.53 tonne CO2 lower than the UK CAER Process + MEA Case), a 38.7% reduction compared to the DOE Case 10

Bhown, Abhoyjit S.↗
DOE OSTI2023

Techno-economic analysis of the water, energy, and greenhouse gas emissions impacts from the adoption of water efficiency practices in the U.S. manufacturing sector

Water is a critical resource for all of manufacturing. As such, mitigating risks to the supply of water to manufacturing plants facilitates maintaining a vital manufacturing sector. Reductions in water use through water efficiency is one method for mitigating risk, however little is known about its potential in the United States (U.S.) manufacturing sector. Herein, we address this gap and calculate the water reduction potential in U.S. manufacturing from commercially available water efficiency opportunities specific to the manufacturing sector. A list of water efficiency measures specific to the manufacturing sector is compiled and applied to estimates of U.S. manufacturing water withdrawals. The energy and carbon dioxide equivalent (CO 2 e) emission impacts from implementation of these measures are also quantified to better inform the resource, environmental, and economic trade-offs from implementation of these measures. We find that the water savings potential from the evaluated measures is up to 60 percent of U.S. manufacturing water withdrawal for certain subsectors, with the energy and emissions impact dependent on the measure. Further, we calculate the levelized cost of conserved water for several water efficiency measures (-$\$4,000$ to $\$85$/thousand m 3 , where negative values indicate net cost savings and positive values indicate net cost expenditures) and compare them to the levelized cost of alternative water sources ($\$600$ to $\$3,400$/thousand m 3 ). The results show significant opportunities for water and energy use reductions at levelized costs at least one order of magnitude lower than alternative water supplies, with some being revenue-generating.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Storing Co 2 in Built Infrastructure: Co 2 Carbonation of Precast Concrete Products

The overall objective of the proposed study was to advance the technical understanding of CO 2 incorporation into novel cementitious materials for the development of high value products that provide a net reduction in carbon emissions. This project combined two primary phases of research that addressed technical barriers related to (i) optimizing CO 2 storage capability of cementitious materials, (ii) evaluating and enhancing physical properties of novel carbonated materials, and (iii) assessing the reductions in life cycle CO 2 emissions attributed to CO 2 carbonation of precast cementitious materials. Engineered cementitious composites (ECC) are a class of highly ductile concrete composites that have been shown to be very durable when used in the built environment. CO 2 carbonation of ECC was examined in this study and it was found that precast ECC specimens could sequester up to 35% CO 2 by cement mass after 24 hours of curing at a CO 2 pressure of 0.5 MPa and 23°C and had a strain capacity of 3%. Carbonation conditions were optimized at the bench-scale and then utilized to create full-scale CO 2 -cured ECC railroad ties that were field tested on a train track. Rail ties were selected for this initial assessment of CO 2 storage in precast concrete materials due to the large market for concrete ties in the railroad industry. Although the full-scale rail ties passed all of the required American Railway Engineering and Maintenance-of-Way Association qualifying mechanical tests, on-track testing of the CO 2 -cured ECC rail ties was unsuccessful due to fiber alignment in the ECC the during the rail tie casting process which prevented the material from achieving the expected level of strain capacity. This result highlights the challenge in scaling up bench-scale processes to full-scale product manufacturing and requires additional investigation into the casting process of large-scale infrastructure elements using ECC combined with carbonation curing. Life cycle assessment of a CO 2 -cured ECC rail tie versus a traditional concrete rail tie indicates that the ECC tie can have lifecycle carbon savings of between 11% and 51% depending on how much longer its useful lifetime is compared to traditional concrete rail ties. Both carbon and cost savings are driven by a reduction in the need to replace broken rail ties, so the key factor is the extent to which a CO 2 -cured ECC rail tie will have increased lifetime durability compared to alternative rail ties.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗