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DOE OSTI2025

Climate-focused Life Cycle Assessments of Biochar Production by an ARTi Pyrolysis Reactor and an Air Burners CharBoss® Air Curtain Incinerator

This report presents a limited, dynamic, consequential life cycle assessment (LCA) to compare the climate impacts of two biochar production methods using wood as a feedstock. The two methods are a pyrolysis reactor supplied by ARTi (Des Moines, IA, https://www.arti.com/) and a T26 CharBoss® air curtain incinerator supplied by Air Burners, Inc. (Palm City, FL, https://airburners.com/). The underlying LCA methodology is described in a chapter by Singh et al. (2024) and implemented in the form of a workbook freely available as online Supplementary Material for the chapter. For the convenience of the reader, a pre-print version of the relevant portions of Singh et al. (2024) is attached as Appendix A to this report. Specific assumptions and calculations to obtain the input parameters used in this LCA for each production method are described in the Methodology section below. This implementation of the LCA considers emissions associated with biomass loading, comminution and conversion, biochar decay in soil, and the production and use of bioenergy generated during the conversion process. The LCA is “limited” in that upstream emissions associated with biomass production, harvest, transportation, and land-use change, as well as embodied emissions in equipment and facilities are not considered. Similarly, downstream emissions from biochar transport and incorporation into soil (i.e., tillage), and the impact of biochar soil amendments on soil greenhouse gas (GHG) emissions (other than CO 2 from biochar decay in soil), soil organic carbon stocks, crop response, and surface albedo are not considered. As the intent is to compare different biochar production methods in a simple unbiased manner, the primary alternative biomass pathway for the LCA is immaculate combustion, which is the hypothetical instantaneous and complete conversion of carbon in the biomass to CO 2 at time zero without generation of any other greenhouse gases or aerosols (GHGAs) or any useful bioenergy. Use of this pathway provides relative values for the production methods and, when the embodied emissions are similar and the same feedstock is used, these relative values are reasonable approximations for those attained with a full LCA.

09 BIOMASS FUELS↗

DOE OSTI2022

Comparative Life Cycle Evaluation of the Global Warming Potential (GWP) Impacts of Renewable Natural Gas Production Pathways

Renewable Natural Gas (RNG) sources are being considered in future energy strategy discussions as potential replacements for fossil natural gas (FNG). While today’s supply of RNG resources is insufficient to meet U.S. demands, there is significant interest in its viability to supplement and decarbonize the natural gas supply. However, the resources that compare the life cycle global warming potential (GWP) of various RNG production pathways are lacking and focus mostly on a singular pathway. This effort is an attempt to close this gap and provide a comparison between the life cycle GWP of three major RNG pathways and the FNG pathway. The three RNG pathways evaluated are Anaerobic Digestion (AD), Thermal Gasification (TG), and Power-to-Gas (P2G) using various feedstocks. The functional unit is 1MJ of compressed RNG ready for injection into the natural gas transmission network. The results show that RNG production is not always carbon neutral or negative. Depending on the pathway the GWP impact of RNG production can range from -229 to 27 g CO 2 e/MJ compressed RNG, with AD of animal manure and AD of municipal solid waste being the least and the most impactful pathways, respectively, compared to the 10.1 g CO 2 e/MJ impact for compressed FNG.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Life cycle assessment of the wood pallet repair and remanufacturing sector in the United States

Wood pallets are ubiquitous products that can be recovered and reused to enhance their service life and environmental performance. Repair/remanufacturing has an important role in extending the service life of the wood pallet. To quantify environmental performances of wood pallet reuse, this study developed representative life cycle inventory data for pallet repair/remanufacturing in the United States based on comprehensive industry-wide production data for 2018. A gate-to-gate life cycle assessment covering raw material supply, raw material transportation and pallet repair/remanufacturing showed that repair/remanufacturing often had the highest impacts, including primary energy consumption at 5.09 MJ and global warming impact at 0.355 kg CO 2 eq per repaired/remanufactured pallet. Electricity consumed onsite followed by nail input and the fuel used by forklifts during the manufacturing drove much of the impacts on the environment. Finally, the results of this study provide valuable information on the repair/remanufacturing impacts, allowing quantification and evaluation of the recovery stage on the overall environmental performance of wood pallets.

09 BIOMASS FUELS↗

DOE OSTI2023

Evaluating the sustainability of the 2017 US biofuel industry with an integrated techno-economic analysis and life cycle assessment

The United States produced more than 66.2 billion Liters of biofuel, primarily in the form of corn ethanol (61 billion Liters) and soybean biodiesel (6 billion Liters), for the transportation industry in 2017. No work currently exists that evaluates both the economic and environmental outcomes of this industry with adequate geospatial resolution and national scope. In this study, a model framework is constructed to perform Techno-Economic Analysis and Life Cycle Assessment using high-resolution input datasets to provide a granular estimation of corn ethanol and soybean biodiesel sustainability performance in most counties in the United States in 2017 (the most recent year for which data is available). Results show a total life cycle, greenhouse gas emission volume of 99.5 million Mg CO 2-eq produced in 2017 by these two biofuels (94.8 million Mg from corn ethanol, and 4.7 million Mg from soybean biodiesel), excluding indirect land use change emissions. Further, this volume corresponds to a combined carbon intensity of 65.3 gCO 2-eq /MJ, which is a greenhouse gas improvement compared to petroleum-based gasoline (the carbon intensity of conventional gasoline is 93.0 gCO 2-eq /MJ). However, these biofuels are produced at an additional economic cost ($1.8 billion over the displaced gas/diesel). Additionally, these biofuels generate unfavorable impacts in other environmental categories when compared to petroleum-based fuels, particularly in areas of water, land, and nitrogen intensity. This work enables stakeholders to assess the specific value of biofuels as a means of emission reduction and determine if the attained improvements are worth the associated opportunity costs.

09 BIOMASS FUELS↗

DOE OSTI2020

Supply Cost and Life-Cycle Greenhouse Gas Footprint of Dry and Ensiled Biomass Sorghum for Biofuel Production

Here we discuss Biomass sorghum as a promising feedstock for cellulosic biorefineries because of its high yield and drought tolerance. However, the difficulty of effectively drying sorghum in some regions means that it may require different handling than previously studied grassy feedstocks. This study compares the delivered cost and life-cycle greenhouse gas (GHG) footprint of field drying and baling, module storage (wrapped, densely packed biomass), pelletizing, and ensiling. Ensiling has not been widely considered for use in bioenergy production. For farms within 66 km of the biorefinery, ensiled biomass is of the lowest cost and GHG strategy despite additional cost and energy demand for hauling wet biomass. Field drying and baling, if feasible, is the most cost-effective option for sorghum between 66 km and 104 km, beyond which pellets are preferable. A 2000 bone-dry-metric ton (bdt)/day biorefinery can source sorghum with 18 bdt/ha yield cultivated on 5% of surrounding land at costs ranging from $\$$122 (silage) to $\$$167 (pellets)/bdt and a life-cycle GHG footprint of 111 (silage) to 179 kg CO2e/bdt (pellets). With 28 bdt/ha biomass yield, 10% cultivation of surrounding land, and low fertilizer application, costs can range from $\$$66 (silage) to $\$$85 (pellets)/ bdt and GHG footprint of 43 (silage) to 96 kg CO2e (pellets)/bdt.

09 BIOMASS FUELS↗

DOE OSTI2025

Comparative life cycle assessment of various hydrogen pathways for cleaner methanol synthesis

This study evaluates the potential environmental impacts of e-methanol production using hydrogen from green, yellow, and blue sources, including Gas Switching Reforming for high purity hydrogen production with carbon capture (GSR-H 2 ), and compares their performance across current and renewable energy scenarios. Using a cradle-to-gate life cycle assessment (LCA), the study quantifies impacts across seven TRACI categories. Global warming potential (GWP) ranged from 0.28 kg CO 2 eq/kg MeOH for green hydrogen with renewables to 2.55 kg CO 2 eq/kg MeOH for SMR-CC under grid power. Among the scenarios, renewable electrolysis achieves the lowest GWP, while GSR-H 2 under renewable power offered the best balance of emissions reductions and resource efficiency among the fossil-based routes, offering a viable transitional solution in regions dependent on natural gas infrastructure. The study reveals GSR-H 2 's potential as an alternative to conventional steam methane reforming with carbon capture (SMR-CC), showing its advantages in carbon capture efficiency and reduced life cycle emissions as well as significantly lower water consumption. GSR-H 2 , when powered by renewables, consumed only 1.41 L of water per kg MeOH, an 82% reduction compared to grid-powered electrolysis, highlighting its potential in water-scarce regions. This study is the first to evaluate GSR-H 2 as a hydrogen source for e-methanol, providing new evidence for its role as a cleaner, scalable transitional solution aligned with cleaner production principles.

08 HYDROGEN↗

DOE OSTI2024

Life-cycle analysis of offshore macroalgae production systems in the United States

Offshore macroalgae production offers the potential to provide valuable biomass for food, energy, and higher value products without the use of land or freshwater while using excess nutrients and carbon dioxide. To realize this potential, the Macroalgae Research Inspiring Novel Energy Resources program of the Advanced Research Projects Agency-Energy has initiated projects to develop advanced cultivation technologies that enable the cost- and energy-efficient production of macroalgal biomass. Here, this study addresses the life-cycle greenhouse gas emissions and energy return on investment for five U.S. offshore macroalgae production systems designed for deployment at the thousand-hectare scale using a detailed module developed within the GREET life-cycle analysis model for this study. The carbon intensity of macroalgae production system designs, expressed as kg of carbon dioxide equivalent per dry metric ton of algae harvested, vary widely from 49 to 220 and confirm that biomass productivity has the highest degree of sensitivity across the model parameters tested. Regardless of the system designs, the upstream and combustion emissions from fuel use are the key contributor (over 45 %) to carbon intensity, indicating that the use of low-carbon fuels (e.g., renewable diesel) could further reduce greenhouse gas emissions. Further studies need to specify the market opportunity and specific product slates for macroalgae to provide a complete picture of the environmental impacts of macroalgal feedstock.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Battery asset management with cycle life prognosis

We report Battery Asset Management problem determines the minimum cost replacement schedules for each individual asset in a group of battery assets that operate in parallel. Battery cycle life varies under different operating conditions including temperature, depth of discharge (DOD), charge rate, etc., and a battery deteriorates due to usage, which cannot be handled by current asset management models. This paper presents a new battery asset management methodology where battery cycle life prognosis is integrated with parallel asset management to reduce lifecycle cost of the Battery Energy Storage Systems (BESS). For the battery failure time prognosis, a nonlinear physics-based battery capacity fade model is developed and incorporated in parallel asset management model to update battery capacity over time. Experiment results have shown that the developed battery asset management methodology can be conveniently used to facilitate BESS asset management decision making thereby decreasing asset lifecycle costs.

25 ENERGY STORAGE↗

DOE OSTI2023

A hybrid method to evaluate the life cycle climate performance of heat pumps

Heat pumps have a significant impact on the climate, and numerous studies exist discussing the environmental impact of heat pumps quantitatively. Life Cycle Climate Performance (LCCP) is a widely accepted metric and can evaluate the carbon footprint of heat pumps from cradle to grave. LCCP calculation typically requires inputs like annual energy consumption, the material used, refrigerant type, and charge level, which are usually the intermediate or final results from heat pump simulation tools. Thus, a platform linking the heat pump simulation software, local weather conditions, and LCCP evaluation tool can simplify the heat pump design process, especially for complicated systems. This paper presents an LCCP evaluation tool accessing the outputs from the DOE Heat Pump Design Model and the building loads and temperature bin data from AHRI standard 210/240. As for case studies, this paper investigates the LCCP values and life cycle electricity costs (LCEC) of a given cooling-based heat pump with R410A in five typical US cities. In conclusion, this cooling-based heat pump has the highest LCCP value at Chicago and lowest LCCP value at Seattle. In contrast, the heat pump has the highest LCEC at Seattle and the lowest LCEC at Miami. As a future work, a more comprehensive carbon emission and cost analysis of heat pump systems will be conducted through all major cities around the world.

Shen, Bo↗

DOE OSTI2025

Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing

Decarbonizing industrial manufacturing is a significant challenge in the effort to limit the impacts of global climate change. Additive manufacturing (AM) is one pathway for reducing the impacts of manufacturing as it creates parts layer-by-layer rather than by removing (i.e., subtracting) material from solid stock as with conventional techniques. This reduces material inputs and generates less waste, which can substantially lower life cycle energy consumption and greenhouse gas emissions. However, AM adoption in the manufacturing sector has been slow, partly due to challenges in making a strong business case compared with more traditional and widely available techniques. This paper highlights the need for the development of simple screening analysis tools to speed the adoption of AM in the manufacturing sector by providing decision-makers easy access to important production life cycle emissions, and cost information. Details on the development of two Microsoft Excel software tools are provided: upgrades to an existing tool on the energy and carbon impacts of AM and a new tool for analyzing the major cost components of AM. A case study applies these two tools to the production of a lightweight aerospace bracket, showing how the tools can be used to estimate the environmental benefits and production costs of AM.

GHG emissions↗

DOE OSTI2020

Fossil Power Plant Cyber Security Life-Cycle Risk Reduction, A Practical Framework for Implementation

Market conditions are forcing fossil electricity generation facility owners and operators to implement advanced digital technologies. These technologies enable efficiencies, operational flexibility, operations and maintenance efficiencies, and adapting to a transitioning workforce. These digital technologies, however, can increase the cybersecurity attack surface. The purpose of this research was to develop a holistic cybersecurity risk reduction framework for fossil generation facilities. The framework begins with assessing how cyber risk changes across facility life cycles, including plant, system, vendor, and business life cycles. The next phase performs consequence analysis to prioritize high consequence events. Focusing on high consequence events allows owners to use a graded, risk-informed approach to prioritize cybersecurity efforts. The final phase identifies the digital asset attack surface in sensors and instrumentation and control equipment. After the vulnerabilities are identified, the owner selects mitigating cybersecurity control measures (or countermeasures) based on the risk analysis from the previous phases. This report describes the current industry cybersecurity best practices in fossil generation that are based on the first principles for cybersecurity engineering. The report is divided into five sections that describe the implementation of the risk reduction framework and present identified research, methodological, and technology gaps that were identified through this course of research and development.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

Fossil Power Plant Cyber Security Life-Cycle Risk Reduction: A Practical Framework for Implementation

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2020

Fossil Power Plant Cyber Security Life-Cycle Risk Reduction: A Practical Framework for Implementation

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Environmental life cycle assessment methods applied to amine-ionic liquid hybrid CO 2 absorbents

A hybrid solvent mixture of triethyl(octyl)phosphonium cyanopyrrolide [P2228][2-CNPyr] and aqueous monoethanolamine (MEA) has the potential for absorbing CO 2 from post combustion flue gas. However, previous studies have found that the production of phosphonium based ionic liquids (IL) had significantly higher potential environmental impacts compared to MEA. Literature attributes these higher environmental impacts to the phosphine and phosgene-based intermediates required to produce the phosphonium ion of the ionic liquid. This study proposes a novel synthesis pathway that eliminates the need for phosphine and phosgene intermediates in the production of [P2228][2-CNPyr]. The environmental impacts of producing 1kg of the ionic liquid through this novel synthesis route was evaluated using the TRACI 2.1 methodology within the life cycle assessment (LCA) framework. Additionally, the environmental impacts for the production of 1kg of a hybrid solvent was also evaluated and compared against MEA. The life cycle inventory for the production of the IL and its hybrid solvent were calculated based on the stoichiometry and then scaled up. This study found that the IL and its hybrid solvents had higher environmental impacts among 9 of the 10 environmental impact categories calculated by the TRACI 2.1 methodology, except for the ecotoxicity potential. A sensitivity analysis indicated that these solvents were more sensitive to the assumptions of the material requirements of the phosphonium cation than the overall energy or transportation requirements. Despite this sensitivity, both the solvents demonstrated a lower Ecotoxicity Potential compared to MEA, the rest of the environmental impacts were still found to be higher than that of MEA, thereby underscoring the need to investigate novel synthesis routes for the production of phosphonium cation. The uncertainty analysis performed confirmed the findings that the IL has a higher environmental impact potentials across all categories except ecotoxicity potential. The uncertainty analysis also confirms that the phosphonium cation is a major hotspot in production route of these solvents and a source of uncertainty in the model compared to the anion. Altogether, this study underscores the need for investigating novel green chemistry pathway for the synthesis of phosphonium based ionic liquids, such as [P2228][2-CNPyr], to ensure that the these ILs can be a truly green alternative to MEA by not only offering superior CO₂ capture capacity compared to MEA but also being sustainably produced.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Environmental life-cycle analysis of hydrogen technology pathways in the United States

Hydrogen is a zero-carbon energy carrier with potential to decarbonize industrial and transportation sectors, but its life-cycle greenhouse gas (GHG) emissions depend on its energy supply chain and carbon management measures (e.g., carbon capture and storage). Global support for clean hydrogen production and use has recently intensified. In the United States, Congress passed several laws that incentivize the production and use of renewable and low-carbon hydrogen, such as the Bipartisan Infrastructure Law (BIL) in 2021 and the Inflation Reduction Act (IRA) in 2022, which provides tax credits of up to $3/kg depending on the carbon intensity of the produced hydrogen. A comprehensive life-cycle accounting of GHG emissions associated with hydrogen production is needed to determine the carbon intensity of hydrogen throughout its value chain. In the United States, Argonne’s R&D GREET ® (Greenhouse Gases, Regulated emissions, and Energy use in Technologies) model has been widely used for hydrogen carbon intensity calculations. This paper describes the major hydrogen technology pathways considered in the United States and provides data sources and carbon intensity results for each of the hydrogen production and delivery pathways using consistent system boundaries and most recent technology performance and supply chain data.

Elgowainy, Amgad↗

DOE OSTI2025

Life Cycle Cost Analysis of Prestressed Concrete Poles Subjected to Wind, Surges, and Waves

Prestressed concrete (PC) poles are becoming popular choices to support coastal power transmission systems. However, the existing literature does not offer a detailed analysis of the effectiveness of PC poles in terms of long-term vulnerabilities and the direct and indirect costs. This is due to (1) lack of fragility models for PC poles and (2) lack of probabilistic wind, storm surge, and wave models in coastal settings. In this study, we address these gaps through a series of Monte Carlo simulations to estimate fragility of PC poles as a function of age and hazard (wind, surges, and waves) intensity, and the development of a probabilistic hazard model based on 10,000 years of synthetic tropical cyclone data. The probabilistic hazard model is used in conjunction with high-resolution hydrodynamic models to generate realizations of coastal wind, storm surges, and waves for the Louisiana and Mississippi coasts. A comprehensive life cycle cost analysis for a service life of 70 years considering direct and indirect losses is conducted to compare the performance of a transmission line located in Pascagoula, Mississippi, when wood poles are replaced by PC poles. Results showed that aging has a minor effect on the reliability of PC poles, highlighting the advantages of replacing wood poles with PC poles, especially in coastal areas. In addition, PC poles are significantly more cost-effective compared with wood poles over their life cycle, leading to an estimated saving of $11.55 million (68.17% reduction). The results of this study provide key insight to inform decision-making processes to keep the coastal power grids resilient and cost-effective against future storm hazards.

natural disasters↗

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 OSTI2024

U.S. Average Corn Ethanol Production Baseline for 45Q Life Cycle Analysis Version 1.0 (2018-2022)

U.S. Average Benchmark life cycle inventory documentation for ethanol production for calendar years 2018 - 2022. The documentation includes a technical report describing data sources and statistical methods used and an Excel file showing calculations. The calculations performed are used in the 45Q benchmark json-ld dataset, compatible with the NETL CO2U LCA Guidance Toolkit. Summary impact results will be included in the NETL CO2U LCA Documentation Spreadsheet within the Toolkit. To access the model referenced in the report, please visit https://www.netl.doe.gov/energy-analysis/details?id=55ab21f1-9238-4b63-9a7a-ae1a4cfa7b05.

09 BIOMASS FUELS↗