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DOE OSTI2025

Expansion of Carbon Calculator for Land Use and Land Management Change from Biofuels Production (CCLUB) to Address Induced Land Use Changes and Other Indirect Effects of Clean Fuel Production for R&D GREET ® 2024

Since the late 2000s, biofuel life-cycle analysis (LCA) has included induced land use change (ILUC) and other indirect effects (I-effects) of large-scale feedstock production for biofuels. In ILUC and I-effect emissions modeling, economic models are used to simulate the area of land conversion among different land types and other I-effects such as non-feedstock crop production and livestock production that are driven by the scenarios of biofuel production volume shocks. On the other hand, emission factors (EF) models estimate carbon stock changes and GHG emissions associated with these changes. Finally, the area and type of ILUC and I-effects are combined with the EFs to estimate the biofuel ILUC/I-effect GHG emissions in the unit of grams of CO 2 equivalent per MJ biofuel produced (g CO 2 e/MJ).

09 BIOMASS FUELS↗

DOE OSTI2025

Summary of Expansions and Updates in R&D GREET® 2024 Rev.1

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Decarbonizing Solvent Chemistry Through Microwave Processing [Abstract]

National Energy Technology Laboratory and Covestro LLC. will collaborate on a project titled, “Decarbonizing Solvent Chemistry Through Microwave Processing”, which was selected for funding by DOE’s Office of Energy Efficiency and Renewable Energy (EERE) Industrial Efficiency and Decarbonization Office (IEDO) FOA DE-EE0002997. The project aims to develop a microwave-based approach for low-heat aqueous-based industry-relevant reactions currently conducted using a conventional fossil-energy fueled hydrothermal reactor. The team has combined expertise in the areas of polymer production, microwave assisted reactions and scale-up, and life cycle analysis to perform the tasks proposed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Summary of Expansions and Updates in R&D GREET® 2025

The research and development (R&D) version of Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET®) model, or R&D GREET, is developed by Argonne National Laboratory (Argonne) with the support of the U.S. Department of Energy (DOE) and other federal agencies. R&D GREET is a life cycle analysis (LCA) model, structured to systematically examine the energy and environmental effects of a wide variety of transportation fuels and vehicle technologies in all transportation sub-sectors (i.e., road, air, marine, and rail) and other end-use sectors, and energy technology systems. Argonne has expanded and updated the model in many areas in R&D GREET 2025. This report provides a summary of the expansions and updates. R&D GREET is designed as an attributional LCA model, but specific consequential effects for certain pathways are included by default when they are scientifically important and/or highly policy relevant. For example, two major consequential elements – induced land use change (ILUC) for biofuels and avoided emissions for certain RNG-based pathways – are implemented by default in R&D GREET because they are highly relevant to our user base and crucial for a comprehensive evaluation of the environmental effects of these technologies. In a future version of R&D GREET, these consequential elements for biofuels and RNG could be more clearly distinguished from core attributional results. We will consider adding a highly visible toggle that would allow users to turn off or adjust these consequential impacts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Effects of Target Protium Content on SteadyState Isotope Rebalancing and Protium Removal Distillation Column Operation

• SRNL Fusion Fuel Cycle Research • SRNL Fuel Cycle Tritium Inventory Optimization Approaches • RHINO/Aspen • CODFISH • Direct Internal Recycling • IFE Fuel Cycle Overview • Direct Internal Recycling Applied to IFE • CODFISH Isotope Rebalancing and Protium Removal Column Optimization • RHINO Fuel Cycle Analysis • Conclusions and Future Work

Somers, Alex [Savannah River National Laboratory (↗

DOE OSTI2025

Renewable hydrogen horizon: Geospatial techno-economic feasibility and life cycle greenhouse gas analysis in the Middle East and North Africa

Renewable hydrogen is receiving increasing attention for its potential as a flexible energy carrier in sectors such as transportation and industry. Specific cost and carbon intensity (CI) of renewable hydrogen production vary largely based on the location, owing to differences in renewable energy resources, as well as the supply chain dynamics. This study maps the techno-economic and life cycle greenhouse gas emissions of renewable hydrogen production in the Middle East and North Africa region, leveraging abundant solar and wind resources. The work investigates the variability in hydrogen costs and CI, optimally sizing proton-exchange membrane (PEM) electrolyzers to account for partial and cyclic loading, and explores standalone versus grid-connected systems. PEM capacity ratios of 52 %–63 % for photovoltaic (PV) systems and 28 %–82 % for wind systems were identified as optimal, with hydrogen production costs ranging from $\$3.8$-$\$4.8$/kg for PV and $2.0-$7.0/kg for wind. CIs span from 1.9 to 3.7 kg CO 2 ,eq /kg H 2 for PV and 0.4–7.7 kg CO 2,eq /kg H 2 for wind systems. The study highlights significant cost and CI reductions achievable with technological advancements and co-product revenue from oxygen and excess electricity sales.

Carbon Intensity↗

DOE OSTI2026

Techno-economic analysis and life cycle assessment for the catalytic hydrogenolysis and hydrocracking of polyethylene

Catalytic hydrogenolysis and hydrocracking are promising technologies for the conversion of polyolefin waste into hydrocarbons. Here, to explore the economic and environmental viability of these approaches, we conducted techno-economic analysis and life cycle assessment of polyethylene hydrogenolysis and hydrocracking processes that produce fuel-range products or olefins, respectively. Relative to primary production, the minimum selling price (MSP) of alkanes for linear-chain naphtha was estimated to be 1.8-fold higher, whereas branched-chain naphtha and propylene were shown to be cost competitive. Environmental impacts showed similar trends across scenarios, with propylene production by hydrocracking exhibiting greenhouse gas emissions comparable with conventional propylene due to relatively low hydrogen demand and high yield. Together, these results suggest that innovations in catalysis and reaction engineering will be required to make viable products that are scale matched with today's plastics, such as light olefins for closed-loop recycling.

09 BIOMASS FUELS↗

DOE OSTI2025

Techno-Economic Analysis and Life Cycle Assessment of Alternative Fuels for Locomotives in the U.S. Freight Rail Sector

Freight rail is more energy-efficient than truck transport over long-haul distances, offering a low-energy and emissions-intensive option for transporting freight. This study evaluates techno-economic analysis and life cycle assessment of seven alternative unblended fuels for freight locomotive engines─biodiesel, renewable diesel (RD), bio-oils, methanol, dimethyl ether (DME), ethanol, and ammonia─across 16 fuel pathways utilizing soybean, corn, woody biomass, renewable hydrogen, and waste sources, e.g., sludge, manure, and industrial CO 2 , and compares these to conventional diesel. The minimum fuel selling price (MFSP) ranged from $\$2.05$ to $\$8.27$ per diesel gallon equivalent (2020 US dollars), with biocrude and RDs produced from hydrothermal liquefaction (HTL) of sludge having the lowest MFSPs due to coproduct credits and avoided waste treatment cost. Life cycle GHG emissions ranged from −41 to 53 g of CO 2 e/MJ. RD from waste via HTL achieves negative emissions by diverting sludge/manure from GHG-intensive conventional management. Few pathways such as biocrude, methanol, and DME require additional control for SO X emissions in the refinery, while ethanol, FT-diesel, and bio-oil require additional control for particulate matter emissions. Bio-oil and RD from sludge have lower marginal abatement cost or MAC (–$\$38$/tonne CO 2 lowest) while methanol and ammonia with renewable hydrogen have higher MAC ($\$490$/tonne CO 2 maximum).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Comprehensive techno-economic and life cycle greenhouse gases analysis of green ammonia production utilizing PV and wind energy: Jordan as a case study

Ammonia (NH 3 ) has emerged as a critical player in the global energy transition due to its potential as a low-carbon fuel. Conventional ammonia production methods, primarily through steam methane reforming, are significant contributors to global CO 2 emissions. This study investigates the potential of green ammonia production in Jordan by leveraging the country's abundant solar photovoltaic and wind energy resources. A comprehensive techno-economic and life cycle greenhouse gas analysis was conducted to compare green ammonia production with conventional grey and blue ammonia pathways. Here, the study utilized spatial mapping to assess renewable energy capacity factors across Jordan and optimized the integration of hybrid PV/wind systems with proton exchange membrane (PEM) electrolyzers. The results indicate that the levelized cost of green ammonia (LCOA) in Jordan varies between 900 USD/kg NH 3 and 2500 USD/kg NH 3 which is significantly higher than grey ammonia (similar to 360 USD/kg NH 3 ). Nevertheless, the carbon intensity of green ammonia production (between 0.1 kg CO 2eq /kg NH 3 and 0.5 kg CO 2eq /kg NH 3 ) is much lower than the grey ammonia (1.8 kg CO 2eq /kg NH 3 ). Finally, the results indicate that considering future reductions in capital costs and advancement in renewable energy systems and PEM electrolyzers as well as the ability to sell the co-product O 2 can reduce the LCOA by up to 92 % and make it competitive with grey ammonia.

Green Ammonia↗

DOE OSTI2026

Technoeconomic analysis and life cycle assessment of purification processes for captured CO 2 streams

Captured carbon dioxide (CO 2 ) streams contain impurities that must be removed to meet specifications for safe transport, storage, and utilization. Among these impurities, oxygen poses challenges due to its high reactivity and potential to cause corrosion, motivating stringent purity limits below 10 ppmv. Building on recent experimental demonstrations of catalytic oxygen removal using hydrogen (H 2 ), carbon monoxide (CO), methanol (CH 3 OH), and methane (CH 4 ) as reducing agents, this study presents a technoeconomic (TEA) and life cycle assessment (LCA) of these four catalytic purification pathways. Process flowsheets were developed and simulated in Aspen Plus for CO 2 streams representative of both low-temperature and high-temperature capture processes, with integrated heat recovery and energy optimization. Results showed that total purification costs were dominated by feedstock procurement and electricity consumption. Among the studied reducing agents, the CH 4 -assisted route achieved the lowest purification cost and highest CO 2 recovery. Sensitivity analyses showed that the H 2 route became competitive at H 2 prices below $\$$0.56/kg to $\$$0.84/kg, depending on the CO 2 feed temperature conditions. In conclusion, environmental impacts were primarily driven by indirect CO 2 emissions from raw material production and utility consumption.

CO2 pipeline specifications↗

DOE OSTI2024

Temperature–Pressure Swing Process for Reactive Carbon Capture and Conversion to Methanol: Techno-Economic Analysis and Life Cycle Assessment

Not Available

08 HYDROGEN↗

DOE OSTI2025

Techno-Economic Analysis and Life Cycle Assessment for the Separation of 2,3-Butanediol from Fermentation Broth Using Liquid–Liquid Extraction

It is energy-intensive to separate dilute 2,3-butanediol (2,3-BDO) (<10 wt %) from the aqueous phase of fermentation broth for sustainable aviation fuel (SAF) using conventional distillation. Liquid–liquid extraction (LLE) using oleyl alcohol as a solvent in a membrane extractor to extract BDO from water can significantly reduce the energy cost and minimize the potential emulsion. In an Aspen Plus model simulation, 95.2% BDO recovery and 97.1% BDO purity have been achieved using this LLE method with solvent recovery and heat integration. Here, the thermal energy cost was estimated to be 4.57 MJ/kg BDO, which is only about 16.8% of the lower heating value (LHV) of the BDO. This method consumes 81% less energy than the cascade distillation and reduces about $0.46/GGE (gasoline gallon equivalent) to the minimal fuel selling price. Meanwhile, the greenhouse gas (GHG) emission is 62% lower than petroleum-based jet fuel production and 34% less than using the cascade distillation.

09 BIOMASS FUELS↗

DOE OSTI2024

Techno-economic Analysis and Life Cycle Assessment of Biomass-Derived Polyhydroxyurethane and Nonisocyanate Polythiourethane Production and Reprocessing

Not Available

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Comparative Technoeconomic Analysis and Life Cycle Assessment of Emerging Reactive Carbon Capture-to-Methanol Pathways

Our group recently developed dual-function materials (DFMs) and reactive carbon capture (RCC) processes for the selective production of methanol (MeOH) or CO, offering two novel and unique pathways for MeOH production. This study conducted a comparative techno-economic analysis (TEA) of the two RCC pathways from exhaust CO 2 : 1) a “Direct RCC-to-MeOH” pathway and 2) an “Indirect RCC-to-CO” pathway followed by MeOH synthesis. The “Direct RCC-to-MeOH” pathway produced a lower levelized cost of MeOH (LCOM) at $\$$0.78/kg, compared to $\$$0.84/kg for the “Indirect RCC-to-CO” pathway. The key difference is the need to recompress the syngas from RCC before MeOH synthesis in “Indirect RCC-to-CO.” Nonetheless, with reduced catalyst costs and hydrogen requirements for “RCC-to-CO,” this pathway merits further study to produce syngas rather than MeOH. Both pathways are comparable in LCOM to baseline e-MeOH production from CO 2 hydrogenation ($\$$0.72/kg) while having lower carbon intensities (0.45 and 0.51 kg-CO 2 e/kg vs 0.54 kg-CO 2 e/kg).

08 HYDROGEN↗

DOE OSTI2024

Techno-Economic Analysis and Life Cycle Assessment of the Production of Biodegradable Polyaliphatic–Polyaromatic Polyesters

Poly(butylene-adipate terephthalate) (PBAT) is a polyaliphatic–polyaromatic polyester that is biodegradable and has found application in several markets, making it a widely produced biodegradable polymer worldwide. However, the production of PBAT is carbon-intensive, as it relies on the use of petroleum-based monomers. There is, thus, significant interest in identifying polyesters that are biodegradable and less carbon-intensive (e.g., use of biomass- derived monomers). In this work, we develop a detailed process model (and an associated database) for the production of polyaliphatic–polyaromatic polyesters including petroleum-based PBAT and biomass-derived alternatives including poly(pentylene- adipate terephthalate) and poly(pentylene-adipate furandicarboxy- late). Techno-economic analysis (TEA) reveals that the production costs of these polyesters strongly depend on monomer costs (accounting for over 90% of the total production cost) and identifies market conditions under which biomass-based polyesters can be cost-competitive to petroleum-based PBAT. Life cycle assessment (LCA) shows that biomass-derived polyesters can reduce the global warming impact of PBAT by half. Altogether, the proposed TEA/LCA model aims to provide guidance into polyesters that are most promising and help assess their overall economic and environmental performance.

42 ENGINEERING↗

DOE OSTI2024

Screening Analysis of Terrestrial Enhanced Rock Weathering of Igneous Rocks and Industrial Waste Materials

This poster, presented at the 17th Greenhouse Gas Control Technology Conference, reports on an NETL screening level techno-economic assessment of enhanced weathering (EW). EW is a promising emerging carbon dioxide removal approach that involves harnessing and accelerating the natural weathering process by which atmospheric CO2 passively reacts with exposed alkaline minerals and is removed from the atmosphere. Two primary cases utilizing different sources of alkaline material are considered: (1) utilizing naturally occurring mined igneous rocks, and (2) utilizing industrial waste materials. The analysis highlights that utilizing materials with high weathering potential in suitable locations may result in relatively low levelized cost of captured. NETL is publishing a detailed and transparent report titled “Enhanced Weathering: Techno-Economic and Life Cycle Screening Analysis” that includes more detail on the screening level techno-economic analysis and includes a life cycle analysis.

carbon dioxide removal↗

DOE OSTI2025

Screening analysis of enhanced weathering of igneous rocks and industrial waste materials

Enhanced weathering (EW) is a promising emerging carbon dioxide removal approach that involves harnessing and accelerating the natural weathering process by which atmospheric CO2 passively reacts with exposed alkaline minerals and is removed from the atmosphere. This manuscript reports on a screening level techno-economic analysis of EW. Two primary cases utilizing different sources of alkaline material are considered: (1) utilizing naturally occurring mined igneous rocks, and (2) utilizing industrial waste materials. The modeled EW process encompasses material purchase, comminution, transport, distribution of material on farmland, and measurement, reporting and verification of CO2 removal. Detailed sensitivities are performed to highlight promising scenarios for application. The analysis highlights that utilizing materials with high weathering potential in suitable locations may result in relatively low levelized cost of captured (less than $100 per total tonnes of CO2 captured from the atmosphere). NETL is publishing a detailed and transparent report titled “Enhanced Weathering: Techno-Economic and Life Cycle Screening Analysis” that includes more detail on the screening level techno-economic analysis and includes a life cycle analysis.

Leptinsky, Sarah [NETL Site Support Contractor, Na↗

DOE OSTI2024

Off-Design Load Analysis of sCO2 Bottoming Cycle for a Natural Gas Combined Cycle Power Plant with Carbon Capture

As an alternative to a steam cycle, a supercritical carbon dioxide (sCO2) power cycle can be considered. Able et. al performed an analysis of an sCO2 cycle in a 2x2-1 configuration; however, this study did not include carbon capture. Previous studies assumed an H-Frame turbine and added a solvent based 95% carbon capture system and performed a levelized cost of electricity (LCOE) optimization for the plant. Their results suggest a LCOE slightly better than when using a steam cycle. In the study, steam is still generated in the heat recovery sections for the solvent regeneration in the carbon capture stripper reboiler. H-Frame gas turbines are also assumed. This work starts with the optimal design from the mentioned work to analyze the off-design performance of the power plant from 100% down to 50% load. The main operational findings and plant-efficiency for off-load conditions while maintaining the target CO2 capture rate are presented. H-Frame gas turbine off-design performance and exhaust conditions to the heat recovery section are obtained from commercial software, Thermoflow®. The CO2 turbomachinery, heat exchangers and other unit operations are sized and implemented in an Aspen Plus® model. Using the gas turbine exhaust conditions as input, the sCO2 cycle is optimized by adjusting stream split ratios, sCO2 circulation flowrate and compressor speed for maximum efficiency. This is done while keeping the target 95% CO2 capture.

Chinen, Anderson Soares↗