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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Techno-economic and life cycle analysis of bio-hydrogen production using bio-based waste streams through the integration of dark fermentation and microbial electrolysis

Hydrogen derived from bio-based sources, or biohydrogen (bioH 2 ), has the potential to reduce GHG emissions from industrial and transportation sectors, owing to the low carbon footprint and myriad applications like refinery operation, ammonia production, steel production, fuel cell, etc. To evaluate the commercialization potential of bioH 2 production, we modeled bioH 2 production and conducted techno-economic analysis (TEA) and life cycle analysis (LCA) of two facilities producing 50 metric tonnes of bioH 2 per day from cheese whey (CW) and solid food waste (SFW) through the integration of dark fermentation (DF) and microbial electrolysis cell (MEC) technologies. LCA results showed that CW and SFW can produce carbon-negative bioH 2 , with emissions of −8.6 and −8.0 kg GHG kg −1 bioH 2 with carbon sequestration and renewable electricity resources, respectively, making bioH 2 potentially eligible for a tax credit of $\$3$ kg −1 H 2 based on provision 45 V of the U.S. Inflation Reduction Act (IRA). In this study, bioH 2 production treats waste streams to generate fresh water, thus, potentially can receive waste water treatment fee that varies with regions. The MEC capital cost dominates the bioH 2 cost, which is mainly determined by current density. With a current density of 20 A m −2 , the production cost for CW input varied between $\$17$ and $\$24$ kg −1 bioH 2 , while that for SFW input ranged from $\$29$ to $\$30$ kg −1 bioH 2 under different operating conditions, considering the 45 V tax credit, waste water treatment fee and production revenue. If the current density increases to 100 A m −2 , the bioH 2 cost decreases to a range of $\$4.0$–$\$6.9$ for CW and $\$5$–$\$6$ for SFW scenarios. This study also shows that low-cost bioH 2 can be produced using CW waste stream as feedstock.

Ganguly, Arna [Argonne National Laboratory (ANL), ↗
DOE OSTI2020

Algae-Based Beneficial Re-use of Carbon Emissions Using a Novel Photobioreactor: a Techno-Economic and Life Cycle Analysis

Despite the many advantages of microalgae, the feasibility of large-scale cultivation requires significant amounts of carbon dioxide (CO 2 ) to enable high growth rates. A synergistic union typically proposed for the supply of CO 2 is the coupling of algal cultivation with emissions from power plants. This study investigates the sustainability of a novel microalgae platform coupled with coal-based flue gas. The proposed system consists of a novel photobioreactor (PBR) for the production of biomass followed by a two-stage dewatering process. Here, a systems model, which quantifies the CO 2 and energy consumption of the proposed system, was developed and the minimum biomass selling price (MBSP) was determined by a techno-economic analysis (TEA). TEA results indicate that a facility with the capacity to capture 30% of the emissions from a 1 MW power plant requires a biomass production of 1280 metric tonnes per year, which when scaled to a nth of kind facility, can produce biomass at a MBSP of $2322 per tonne. The environmental impact of the proposed facility was determined by a life cycle assessment methodology and results indicate a carbon capture potential of 1.16 x 10 4 metric tons of CO 2 equivalent. In addition, an energy analysis indicates a desirable net energy ratio of 0.1, which is lower than conventional PBRs. Discussion focuses on the requirements to reduce biomass production cost, including research investment areas for increasing productivity while decreasing energy requirements.

09 BIOMASS FUELS↗
DOE OSTI2022

Analyzing the Multiscale Impacts of Implementing Energy-Efficient HVAC Improvements Through Energy Audits and Economic Input–Output Analysis

Abstract Heating, ventilation, and air-conditioning (HVAC) systems are usually an industry’s highest consumer of energy, most of which goes toward space cooling in buildings. Industrial energy-efficiency audits not only benefit manufacturers but also generate significant economic and environmental benefits to localities, states, and the nation. This article analyzes the micro- and macro scale impacts of implementing energy-efficient HVAC systems by integrating the industrial building energy data with the macroeconomic regional economic flow model. Micro-scale data include 10 years of historical energy, cost, and carbon dioxide savings achieved from energy-efficient HVAC implementation offered to manufacturers through industrial energy audits. The data were integrated into the macroeconomic modeling framework to illuminate the cascading regional economic impacts of implementing energy-efficient HVAC recommendations in manufacturing facilities. Results show that if recommendations had been implemented throughout all manufacturers in the region, $656 M energy costs would have been directly saved, 7.8 million metric tons of carbon dioxide emissions would have been avoided, and 4387 jobs could have been created, resulting in a total annual economic impact of $899 M stemming from direct, indirect, and induced impacts. The results offer insight into how industrial energy systems can be designed and provide models for how communities can accomplish a net-zero society.

Energy & Fuels↗
DOE OSTI2024

Techno-economic and life cycle analysis of synthetic natural gas production from low-carbon H 2 and point-source or atmospheric CO 2 in the United States

Synthetic natural gas (SNG) is of great interest in reducing fossil energy consumption while maintaining compatibility with existing NG infrastructure and end-use applications equipment. SNG can be produced using clean H 2 generated from renewable or nuclear energy and CO 2 captured from stationary sources or the atmosphere. In this study, we develop an engineering process model of SNG production using Aspen Plus® and production scales reported by the industry. We examine the levelized cost and life cycle greenhouse gas (GHG) emissions of SNG production under various CO 2 supply scenarios. Considering the higher cost of H 2 transportation compared with CO 2 transportation, we assume that CO 2 feedstock is transported via pipeline to the H 2 production location, which is collocated with the SNG plant. We also evaluate the cost of CO 2 captured from the atmosphere, assuming the direct air capture process can occur near the SNG facility. Depending on the CO 2 supply chain, the levelized cost of SNG is estimated to be in the range of $\$45–76$ per million British thermal units (MMBtu) on a higher heating value (HHV) basis. The SNG production cost may be reduced to $\$27–57$/MMBtu-HHV by applying a tax credit available in the United States for low-carbon H 2 production (45V). With a lower electricity price of 3¢/kWh for water electrolysis and accounting for a 45V tax credit, the SNG cost reaches parity with the cost of fossil NG. Depending on the CO 2 supply chain, SNG can reduce life cycle GHG emissions by 52–88% compared with fossil NG.

03 NATURAL GAS↗
DOE OSTI2020

Energy, economic, and environmental analysis of integration of thermal energy storage into district heating systems using waste heat from data centres

Data centres produce waste heat, which can be utilized in district heating systems. However, the mismatch between data centres’ heat supply and district heating systems’ heat demands limits its utilization. Further, high peak loads increase the operation cost of district heating systems. This study aimed to solve these problems by introducing thermal energy storages. A water tank and a borehole thermal energy storage system were selected as the short-term and long-term thermal energy storage, respectively. Energy, economic, and environmental indicators were introduced to evaluate different solutions. The case study was a campus district heating system in Norway. Results showed that the water tank could shave the peak load by 31% and save the annual energy cost by 5%. The payback period was lower than 15 years when the storage efficiency remained higher than 80%. However, it had no obvious benefits in terms of mismatch relieving and CO emissions reduction. In contrast, the borehole thermal energy storage increased the waste heat utilization rate to 96% and reduced the annual CO emissions by 8%. However, the payback period was more than 17 years. These results provide guidelines for the retrofit of district heating systems, where data centres’ waste heat is available.

25 ENERGY STORAGE↗
DOE OSTI2023

Techno-Economic and Deployment Analysis of Fossil Fuel-Based Power Generation with Integrated Energy Storage

Most existing coal-fired power plants were designed for sustained operation at full load to maximize efficiency, reliability, and revenues. Depending on plant type and design, these plants can adjust output within a fixed range in response to plant or market conditions. The need for flexibility driven by increased penetration of variable and non-dispatchable power generation such as wind and solar is shifting traditional mission profile of thermoelectric power plants in three ways: more frequent shutdowns when market or grid conditions warrant, more aggressive load ramp rates (rate of output change), and lower minimum sustainable load, which provides a wider operating range and helps avoid costly plant shutdowns. The recent studies have shown that flexibility of a coal-fired power plant can be improved by the energy storage. The objective of this project was to analyze a set of energy storage options (technologies) and determine their impact on flexibility and economics of a representative coal-fired power plant. The effect of five Energy Storage Systems (ESSs) integrated with a coal power plant on plant flexibility and economics was investigated in this study. The results obtained in this project and presented in this report showed that ESS integrated with a thermal power plant improves plant flexibility and participation in the Energy and Ancillary Services markets and also improves plant financial performance.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Multi-Timescale Optimal Operation Framework for Integrated Economic and Reliability Analysis of Hybrid Power Plants

This paper introduces a hierarchical modeling framework for hybrid power plants (HPP) to facilitate the operation of HPP in power systems similar to conventional generators (Congens) in the integrated multi-timescale optimal operation framework. To consider the uncertainties of HPP renewable power in the day-ahead scheduling, distributionally robust optimization (DRO) is used. To ensure that the state-of-charge (SOC) of energy storage systems in HPPs aligns closely with the planned value for long-term reliability, real-time SOC management is incorporated. In addition, an adjustable real-time control is designed for the robust delivery of HPP real-time services. Case studies performed on a revised IEEE 39-bus system demonstrate the effectiveness of the proposed framework for HPP operation. Simulation results highlight that the proposed framework not only can help operators schedule HPP similar to Congens in varying weather conditions but can also maintain the frequency reliability of the system.

frequency stability↗
DOE OSTI2025

Regional Analysis for an Economically and Environmentally Viable Transition to Heavy-Duty Vehicles with Alternative Powertrains

The transportation sector is responsible for a significant portion of greenhouse gas emissions. Within the sector, truck freight is responsible for a third of the associated emissions. Alternative powertrains are seen as a viable approach to significantly reduce these emissions. Prior to making a large-scale transition, it is important to consider the following questions: will the power grid support a transition to alternative powertrains?; will the transition truly reduce carbon emissions?; and will the transition impose an unnecessary economic burden on companies within the industry? The answer to these questions, however, can vary by geography, maturity/capacity of the energy distribution network or predicted vehicle load. We focus on the latter two questions, investigating the variation in estimated total cost of ownership and carbon emissions across the United States at the zip code level for both heavy-duty battery electric vehicles and heavy-duty fuel cell electric vehicles. As a benchmark, we compare estimated emissions and costs of alternative powertrain vehicles to that of conventional heavy-duty vehicles powered by diesel internal combustion engines. This work highlights areas with electric grids primed for a transition to alternative powertrain vehicles, such as the Pacific Northwest, and areas that require further infrastructure investment in renewables, such as many of the Mountain states, Missouri, and Florida. Additionally, this work illustrates the current advantages in carbon emissions of battery electric vehicles compared to fuel-cell electric vehicles, while providing insights into required regional investments for narrowing the gap.

Goulet, Nate [ORNL] (ORCID:0000000237314965)↗
DOE OSTI2023

Uncertainty analysis for techno-economic and life-cycle assessment of wet waste hydrothermal liquefaction with centralized upgrading to produce fuel blendstocks

Wet waste hydrothermal liquefaction is a promising technology for producing transportation fuels with much lower greenhouse gases emissions than petroleum-based fuels. However, its techno-economic and life cycle assessment are primarily based on laboratory scale testing data, subject to considerable uncertainties, and even bias, due to knowledge gaps. Here, a preliminary uncertainty analysis of key economic measures was conducted based on the 2019 state-of-technology model for biocrude production. Building on the preliminary analysis, this work presents a comprehensive uncertainty analysis in both economic and environmental measures of the entire supply chain of wet waste hydrothermal liquefaction to fuel blendstocks including biocrude upgrading based on the 2021 state-of-technology model. The analysis includes the most recent developments in hydrothermal liquefaction and biocrude upgrading technologies and Monte Carlo simulation based on an integrated model system including an improved reactor yield model, reduced-order process model, discounted cash flow economic model and simplified life-cycle assessment model. The estimated biocrude yield ranges from 42.2% to 52.4% with a median of 47.3%. The estimated fuel yield ranges from 34.7% to 42.7% with a median of 38.7%. The estimated minimum fuel selling price ranges from $\$ $2.28/gge to $\$ $3.45/gge with a median of $\$ $2.80/gge. Relative to petroleum-derived diesel, the estimated reduction in supply chain greenhouse gas emissions ranges from 73.4% to 81.8% with a median of 77.7%. Compared to the 2019 state-of-technology analysis, a significant improvement in biocrude selectivity and economic measures and reduction in uncertainties were achieved due to the incorporation of additional continuous experimental data sets, technology development and de-risking, and improvement in model accuracy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Development of high concentration photovoltaics (HCPV) power plants in the US Southwest: Economic assessment and sensitivity analysis

High concentration photovoltaic (HCPV) technologies offer several advantages over typical PV systems. In this study, a detailed economic assessment and sensitivity analysis of deploying HCPV plants in the US southwest is performed. To do this, a 20 MWdc HCPV power plant is designed using the System Advisor Model (SAM) and is evaluated from both technical and financial aspects. The sensitivity analysis shows that reducing the installed cost per capacity of the HCPV system can significantly improve the economics and reduce the levelized cost of electricity (LCOE) and levelized power purchase agreement (LPPA). Also, providing proper incentives including both investment tax credits (ITC) and production tax credit (PTC), loan debt ratio, and interest rate are among the most influential parameters. The analysis shows that with the 30% ITC, the LCOE, and LPPA of the designed HCPV projects are between $65.4/MWh and $69.3/MWh and between $71.0/MWh and $75.2/MWh, respectively. The estimated LCOE and LPPA values are almost 50% higher than the utility-scale PV projects. If proper funding is provided to continue the support of the HCPV system, they would become more economical and competitive with PV plants. Federal and state government policies must also be established to advocate HCPV systems.

14 SOLAR ENERGY↗
DOE OSTI2024

Technical and Economic Assessment and Gap Analysis of Advanced Nuclear Reactor Integration with a Reference Oil Refinery

Efforts to identify the most-economic methods to decarbonize several sectors of the U.S. economy are underway. Industrial processes such as crude-oil refining rely heavily on energy-dense and easily stored and transported fossil fuels for powering their operations. Refineries use large amounts of energy, primarily derived from fossil sources to separate crude-oil components, break down heavier hydrocarbons into lighter compounds, remove impurities, reform hydrocarbon molecules, and generate steam and electricity for pumps and compressors and other various auxiliary systems. Crude-oil refining operations such as distillation, cracking, desulfurization, reforming, utilities systems and some offsite facilities collectively account for most of the energy consumption. Other operations such as hydrocracking or hydrotreating also require hydrogen for developing hydrogenation reactions which involve substantial heating to keep the reactors at high-temperature and pressure levels. All heat and energy demands are typically provided by natural gas (NG), oil, or other fuels, which makes refinery industry one of the most-difficult sectors to decarbonize. Nuclear power is a viable and energy-dense source of clean electricity, heat, and hydrogen to provide the large, sustainable energy supply that the refining industry demands. The U.S. Department of Energy’s (DOE’s) Integrated Energy Systems (IES) program is working to perform research and development, design, economic siting, and risk analysis. This state-of-the-art work will enable the first on-site demonstrations and commercial deployments of advanced small modular nuclear reactors (SMNRs) integrated with industries such as chemical production, refining, iron and steel making, and more. IES seeks to demonstrate the ability of advanced nuclear reactors to meet the heat and power demands of these industries while reducing carbon emissions in a sustainable and cost-competitive way. The primary objective of this research effort is to analyze industrial-scale SMNR integration intended to decarbonize refining facilities. The foreseen outcome is the provision of reliable, cost-competitive, and sustainable clean energy, alongside a reduction of carbon emissions. Specifically, the focus of this work lies on meeting the reference facilities’ heat and electricity demands with nuclear power while also supplying clean hydrogen via integrated high-temperature steam electrolysis (HTSE). This report presents a comprehensive technical and economic assessment of the integration of advanced nuclear reactors into a reference refinery, leveraging financial incentives from the Inflation Reduction Act (IRA). The evaluation aims to explore the potential economic benefits and challenges associated with incorporating advanced nuclear reactors into refinery operations, particularly in terms of energy efficiency, economic implications and environmental impact. By examining both the technical feasibility and economic viability, this analysis seeks to identify existing gaps and propose solutions for successful nuclear integration implementation. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the refining sector. A refinery reference-plant was developed, using an open-source refinery model, Petroleum Refinery Lifecycle Inventory Model (PRELIM) and expert assessment, as a base case for comparison with various nuclear integration options. The capacity of 100 kbd/day (KBD) of heavy crude-oil feed was selected to represent a general coking-type refinery with deep conversion capabilities (incorporating heavy-oil upgrading with FCC, coking, and associated hydrotreating process units), using a heavy crude-oil feed, which represents about 70% of U.S. refineries configurations. A summary of all cases considered in this study is shown in Table 1.

13 HYDRO ENERGY↗
DOE OSTI2021

Comparative Techno-Economic and Life Cycle Analysis of Water Oxidation and Hydrogen Oxidation at the Anode in a CO 2 Electrolysis to Ethylene System

We compare the economic viability of employing hydrogen oxidation versus water oxidation at the anode of a commercial-scale electrolysis plant that converts CO 2 to ethylene. We vary the electrolyzer capital cost, membrane lifetime, and renewable electricity price to represent a current and future market scenario. We find that anodic hydrogen oxidation with membraneless reactor design can reduce the electrolyzer capital cost by up to 48% and reduce electricity demand by at least 50% with the current underdeveloped electrolyzer market. These capital and operating cost savings could further lead to a lower ethylene production cost from anodic hydrogen oxidation than the anodic water oxidation system with hydrogen supplied at less than $\$6$ kg. In the future scenario with a fully developed electrolyzer market and cheap renewable electricity, we find that the anodic hydrogen oxidation system requires hydrogen cheaper than $0.7/kg to compete with the anodic water oxidation system. Moreover, hydrogen oxidation at the anode enables extremely low cradle-to-gate emission ethylene by utilizing negative emission hydrogen such as biomass gasification with carbon capture and sequestration, ~240% lower than ethylene produced from the wind/solar electricity-driven water oxidation system. Furthermore, this low carbon footprint ethylene can further boost the economic competitiveness for anodic hydrogen oxidation with a future carbon credit market.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Techno-economic and life-cycle analysis of strategies for improving operability and biomass quality in catalytic fast pyrolysis of forest residues

Many of the challenges faced by the first commercial biorefineries were associated with feedstock handling, quality, and cost. Strategies are needed to enable further expansion of biorefineries and meet the growing demand for bio-based fuels and products. Here, we examine 2 key feedstock challenges and mitigation strategies in the context of a catalytic fast pyrolysis (CFP) biorefinery: (1) the operability of the feed system, which may be improved by modifying the minimum particle size fed to the reactor, and (2) the quality of the biomass, which may be improved by employing air classification to remove undesirable material and increase fuel yields. We conduct techno-economic analysis (TEA) and life-cycle analysis for these strategies, employing a discrete event simulation model for biomass preprocessing combined with a series of correlations developed from literature data and a rigorous CFP conversion model. Our results highlight the importance of balancing increased cost and material losses from preprocessing against improved operability and fuel yields. Economics and sustainability were optimized when operating at the lowest minimum particle size, emphasizing the importance of minimizing material losses while maintaining the operability of the process. Economically, additional costs and material losses from air classification could be acceptable due to improved biomass conversion, and an optimum air classification speed was identified; however, the fuel GHG emissions were minimized when air classification was not used. Valorizing material removed during preprocessing as a coproduct could improve economics and sustainability, decreasing the burden of material losses.

09 - BIOMASS FUELS↗