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DOE OSTI2021

Recycled Paper as a Source of Renewable Jet Fuel in the United States

Converting biomass into jet fuel involves more than the core chemical process. The overall process includes the logistics of harvesting and transporting the biomass, handling and preparing the material for processing, and processing and disposal of waste. All of these activities contribute to cost. Controlling cost involves more than developing efficient process chemistry. Choice of feedstock also has a significant impact on process economics. We consider chemical conversion of paper from municipal solid waste as a feedstock for the production of jet fuel and diesel. Paper has a significantly higher cellulose content than raw lignocellulosic biomass such as corn stover, so it requires less pretreatment to convert it into hydrocarbons than lignocellulosic biomass. Our techno-economic analysis showed that the cost of converting paper waste into jet fuel is about $1.00/gal less than jet fuel produced from corn stover. Although the cost of recycling paper into jet fuel is less than producing it from corn stover, the process is not competitive with petroleum. We estimated a minimum selling price of $3.97/gal for paper-derived jet fuel. Our sensitivity studies indicated that the biggest economic obstacle is the cost of cellulose hydrolysis. Direct hydrogenation of paper to sugar alcohols combined with increased economy of scale could make recycling paper jet fuel competitive.

09 BIOMASS FUELS↗

NASA NTRS2010

Launch Pad Flame Trench Refractory Materials

The launch complexes at NASA's John F. Kennedy Space Center (KSC) are critical support facilities for the successful launch of space-based vehicles. These facilities include a flame trench that bisects the pad at ground level. This trench includes a flame deflector system that consists of an inverted, V-shaped steel structure covered with a high temperature concrete material five inches thick that extends across the center of the flame trench. One side of the "V11 receives and deflects the flames from the orbiter main engines; the opposite side deflects the flames from the solid rocket boosters. There are also two movable deflectors at the top of the trench to provide additional protection to shuttle hardware from the solid rocket booster flames. These facilities are over 40 years old and are experiencing constant deterioration from launch heat/blast effects and environmental exposure. The refractory material currently used in launch pad flame deflectors has become susceptible to failure, resulting in large sections of the material breaking away from the steel base structure and creating high-speed projectiles during launch. These projectiles jeopardize the safety of the launch complex, crew, and vehicle. Post launch inspections have revealed that the number and frequency of repairs, as well as the area and size of the damage, is increasing with the number of launches. The Space Shuttle Program has accepted the extensive ground processing costs for post launch repair of damaged areas and investigations of future launch related failures for the remainder of the program. There currently are no long term solutions available for Constellation Program ground operations to address the poor performance and subsequent failures of the refractory materials. Over the last three years, significant liberation of refractory material in the flame trench and fire bricks along the adjacent trench walls following Space Shuttle launches have resulted in extensive investigations of failure mechanisms, load response, ejected material impact evaluation, and repair design analysis (environmental and structural assessment, induced environment from solid rocket booster plume, loads summary, and repair integrity), assessment of risk posture for flame trench debris, and justification of flight readiness rationale. Although the configuration of the launch pad, water and exhaust direction, and location of the Mobile Launcher Platform between the flame trench and the flight hardware should protect the Space Vehicle from debris exposure, loss of material could cause damage to a major element of the ground facility (resulting in temporary usage loss); and damage to other facility elements is possible. These are all significant risks that will impact ground operations for Constellation and development of new refractory material systems is necessary to reduce the likelihood of the foreign object debris hazard during launch. KSC is developing an alternate refractory material for the launch pad flame trench protection system, including flame deflector and flame trench walls, that will withstand launch conditions without the need for repair after every launch, as is currently the case. This paper will present a summary of the results from industry surveys, trade studies, life cycle cost analysis, and preliminary testing that have been performed to support and validate the development, testing, and qualification of new refractory materials.

Calle, Luz M.↗

DOE OSTI2025

OR-AGENT framework – Architecting electrified heavy-duty drayage applications

The widespread adoption of zero-emission vehicles in heavy-duty (HD) commercial freight transportation faces considerable technoeconomic challenges. For heavy-duty trucks, ensuring high uptime, cost parity with diesel, and safety standards is especially critical as these vehicles operate over long distances with heavy loads, where any downtime or off-nominal behaviors significantly impacts logistics, productivity, and the total cost of ownership. Unlike traditional diesel refueling, BEV charging infrastructure must be co-optimized with vehicle deployment, operational demands, and grid capacity to ensure cost-effective and reliable freight operations. However, the lack of a standardized ownership and service model has led to a fragmented approach—where commercial vehicle operators may invest in, own, and maintain both vehicle/batteries and charging/energy infrastructure. This disconnect may exclude energy service providers from the equation, forcing fleet operators to explore ‘behind-the-fence’ energy solutions that increase capital investment, operational downtime, overhead costs, and, in some cases, net carbon emissions. To address these issues, this study introduces OR-AGENT (Optimal Regional Architecture Generation for Efficient National Transport), a comprehensive modeling framework that integrates powertrain architectures, charging infrastructures, and energy backbone systems into a cohesive strategy. In this paper, OR-AGENT is applied to develop an interconnected systems architecture for energy efficiency and resiliency enhancement of heavy-duty drayage vehicles at the Port of Savannah, GA. This framework showcases an interconnected systems approach to electrifying heavy-duty drayage vehicles at the Port of Savannah, GA. The study assessed BEVs with 400–1200 kWh battery capacities, accounting for seasonal variations in weather and freight routing. A diverse charging mix (150 kW–1250 kW) was evaluated alongside grid capacity constraints, cost, and carbon intensity analysis, leading to the development of a strategic microgrid/Distributed Energy Resources (DER) deployment architecture to ensure a reliable and sustainable transition. However, the findings also highlight the need for alternative zero-emission solutions for remaining trips, such as larger batteries, electrified roadways, hydrogen powertrains, or net-zero emission fuels. In conclusion, the findings are incorporated into a Total Cost of Ownership (TCO) model to identify optimal architectures for an interconnected electrified ecosystem.

Commercial vehicles↗

DOE OSTI2022

Solid Oxide Cell and Stack Manufacturing Cost Tool

This is the user manual for the SOC Manufacturing Cost Tool spreadsheet. The manual details the use and meaning of each tab, color scheme, and spreadsheet operation. Also detailed are specific instructions for end-user modification and inputs to tailor the tool to their specific technology. To access the cost tool, please visit: <a href="https://netl.doe.gov/energy-analysis/details?id=d224ad08-6a38-402a-9cad-907db19e394f" rel="noopener noreferrer">Energy Analysis | netl.doe.gov</a>.

cost modeling↗

DOE OSTI2023

Feasibility Analysis for the Use of Retrofitted Air-Conditioners Using Thermal Energy Storage (TES) for High Ambient Temperature (HAT) Countries

In high ambient temperature (HAT) countries, summer temperatures exceed 35℃, degrading the performance of air-conditioning systems and straining power grids. In this paper, a feasibility analysis was conducted to investigate potential savings during the peak using latent Thermal Energy Storage (TES) at near room phase-change temperatures, replacing condensers, thus, minimizing temperature lifts. Weather data, building loads, and baseline air-conditioning systems data were gathered for Dubai. A transient vapor-compression model in Modelica was used to compare the COP, total power input and cooling capacity of the air-conditioner at peak hours when ambient temperatures range between 35 – 45 ⁰C versus the TES-Phase-Change Material (PCM) melting temperatures from 22 – 28⁰C. The results indicate that the TES-PCM can enhance the system COP at the peak by a factor 1.4 and 2 for during for outdoor temperatures of 35 – 40⁰C, and 40 – 45⁰C, respectively. Lower melting temperature PCMs were able to reduce the required power input by 30-50%, with more savings occurring at higher temperature days. On the other hand, higher temperature PCMs enhancements were minimal especially at outdoor ambient temperatures ranging between 35 – 40⁰C. Improvements to the cooling capacity range from 8 – 18 % for the outdoor temperature range of 35 – 45 ⁰C. An economic analysis was conducted to find the potential saving in utility costs for 30%, 60%, and 90% of the space cooling demands of Dubai, and find the trade-off points between utility savings and cost of PCM-TES implementation. If the peak loads are to be shifted by 6 hours daily, the percentage utility savings for the city is 18%. Using estimated costs of the PCM-TES, ranging from $200-500/kWh, the daily load shifting hours were estimated to range from 4 hours at the lowest cost systems to 2.5 hours at the highest costs.

25 ENERGY STORAGE↗

NASA NTRS1981

Silicon Ingot Casting - Heat Exchanger Method (HEM). Multi-Wire Slicing - Fixed Abrasive Slicing Technique (Fast). Phase 4 Silicon Sheet Growth Development for the Large Area Sheet Task of the Low-Cost Solar Array Project

The crystallinity of large HEM silicon ingots as a function of heat flow conditions is investigated. A balanced heat flow at the bottom of the ingot restricts spurious nucleation to the edge of the melted-back seed in contact with the crucible. Homogeneous resistivity distribution over all the ingot has been achieved. The positioning of diamonds electroplated on wirepacks used to slice silicon crystals is considered. The electroplating of diamonds on only the cutting edge is described and the improved slicing performance of these wires evaluated. An economic analysis of value added costs of HEM ingot casting and band saw sectioning indicates the projected add on cost of HEM is well below the 1986 allocation.

Schmid, F.↗

NASA NTRS1983

Ad Hoc modeling, expert problem solving, and R&T program evaluation

A simplified cost and time (SCAT) analysis program utilizing personal-computer technology is presented and demonstrated in the case of the NASA-Goddard end-to-end data system. The difficulties encountered in implementing complex program-selection and evaluation models in the research and technology field are outlined. The prototype SCAT system described here is designed to allow user-friendly ad hoc modeling in real time and at low cost. A worksheet constructed on the computer screen displays the critical parameters and shows how each is affected when one is altered experimentally. In the NASA case, satellite data-output and control requirements, ground-facility data-handling capabilities, and project priorities are intricately interrelated. Scenario studies of the effects of spacecraft phaseout or new spacecraft on throughput and delay parameters are shown. The use of a network of personal computers for higher-level coordination of decision-making processes is suggested, as a complement or alternative to complex large-scale modeling.

Silverman, B. G.↗

NASA NTRS1976

An analysis of the market potential of water hyacinth-based systems for municipal wastewater treatment

The potential U.S. market for tertiary municipal wastewater treatment facilities which make use of water hyacinths was investigated. A baseline design was developed which approximates the "typical" or "average" situation under which hyacinth-based systems can be used. The total market size for tertiary treatment was then estimated for those geographical regions in which hyacinths appear to be applicable. Market penetration of the baseline hyacinth system when competing with conventional chemical and physical processing systems was approximated, based primarily on cost differences. A limited analysis was made of the sensitivity of market penetration to individual changes in these assumptions.

Robinson, A. C.↗

NASA NTRS1979

Computerized systems analysis and optimization of aircraft engine performance, weight, and life cycle costs

The computational techniques utilized to determine the optimum propulsion systems for future aircraft applications and to identify system tradeoffs and technology requirements are described. The characteristics and use of the following computer codes are discussed: (1) NNEP - a very general cycle analysis code that can assemble an arbitrary matrix fans, turbines, ducts, shafts, etc., into a complete gas turbine engine and compute on- and off-design thermodynamic performance; (2) WATE - a preliminary design procedure for calculating engine weight using the component characteristics determined by NNEP; (3) POD DRG - a table look-up program to calculate wave and friction drag of nacelles; (4) LIFCYC - a computer code developed to calculate life cycle costs of engines based on the output from WATE; and (5) INSTAL - a computer code developed to calculate installation effects, inlet performance and inlet weight. Examples are given to illustrate how these computer techniques can be applied to analyze and optimize propulsion system fuel consumption, weight, and cost for representative types of aircraft and missions.

Fishbach, L. H.↗

DOE OSTI2020

Techno-Economic Analysis for GTI's Compact Hydrogen Generator

A technoeconomic analysis of the compact hydrogen generator compared to a traditional steam methane reformer (SMR) was performed for both processes with and without carbon capture. The project goal for the technoeconomic analysis was to demonstrate a minimum of 20% lower CAPEX and 15% lower levelized cost of hydrogen compared to SMR with and without carbon capture. GTI obtained baseline capital and costs for the SMR with and without and methodology to calculate the levelized cost of hydrogen from an IEAGHG Technical Report: 2017-02 Techno-Economic Evaluation of SMR Based Standalone (Merchant) Hydrogen Plant with CCS. This methodology was then applied to GTI’s compact hydrogen generator using direct material costs previously obtained from a reputable engineering procurement and construction company, CB&I Howe-Baker. The analysis was performed for plants producing 90MMSCFD (million standard cubic feed per day) of hydrogen. Direct material costs were converted to total installed costs and total capital requirements using the same multiplying factors for both processes. We have found that the direct materials cost of the compact hydrogen generator is less than half the direct materials cost required for SMR without capture, and about one quarter the direct materials cost of SMR with carbon capture. This low materials cost translates into a significant CAPEX savings and lower levelized cost of hydrogen that exceed the goals of the techno-economic assessment. We have found that the CHG has a 43% lower installed cost and capital requirement compared to SMR without capture, that results in a levelized cost of hydrogen that is 19% lower than SMR. When 90% CO2 capture is added to the plants, the advantages is even better. The CHG has a 51% lower installed and capital requirement compared to SMR with capture, resulting in a 28% lower levelized cost of hydrogen. A sensitivity analysis was performed and showed natural gas feedstock cost and discount rate to be the main contributors to hydrogen price sensitivity. Given these significant cost advantages, GTI is encouraged to continue to develop the technology and market the economic advantages as well as the efficiency gains and ability to inherently capture CO2.

08 HYDROGEN↗

DOE OSTI2026

Dual-loop Solvent-based CCS for Net Negative CO 2 Emissions with Lower Cost

This final technical report details the successful design, construction, and operational validation of an innovative dual-loop CO 2 capture technology designed to achieve deep decarbonization (>99%) from Natural Gas Combined Cycle (NGCC) power plants that results in the electricity with carbon intensity of approximate 42 kg CO 2 -eq/MWh, less than the electricity produced by solar PV. The integrated process couples a primary aqueous solvent (in this project, a water lean solvent – WLS) absorption loop for bulk CO 2 removal with a secondary potassium hydroxide (KOH) polishing loop featuring electrochemical regeneration. This architecture leverages the higher exergy efficiency of the primary loop while utilizing the fastest kinetic of the secondary loop to capture dilute residual CO 2 , achieving an overall capture rate of 99.9% and co-producing pure hydrogen after moisture being condensed and dehydrated. Technical feasibility was established through a comprehensive 2,000-hour experimental campaign on a bench-scale fully-integrated unit (using 4” absorber and 4” stripper) with the feeding flue gas flowrate in the range of 8-20 cfm, confirming the attainment of Technology Readiness Level (TRL) 4. The project executed extensive parametric testing followed by 1,000 hours of continuous steady-state testing, demonstrating exceptional process stability with the electrochemical regenerator exhibiting less than a 10% reduction in electrical conductivity over the duration of the campaign. Operational characterization gathering on the bench unit revealed distinct energy profiles for the hybrid system: the primary loop required approximately 280 kJ mol -1 for bulk removal, while the polishing loop required approximately 1,600 kJ mol -1 specifically when reducing dilute CO 2 concentrations from ~740 ppm down to <50 ppm. (Please note those energy values/numbers can only be viewed as relative relationship and should not be extrapolated as absolute values required for CO 2 capture). Furthermore, dynamic testing validated the system’s flexibility for utility applications, demonstrating a rapid process response time of <30 minutes to changes in flue gas flowrate. Emission monitoring confirmed that the dual-loop architecture effectively mitigates solvent losses, utilizing a water wash to remove entrained aerosols to <1 ppm. The Techno-Economic Analysis (TEA) indicates a cost of capture of $\$$59.3/tonne and a Levelized Cost of Electricity (LCOE) of 71.7 $\$$/MWh at the overall capture efficiency of 99.8% of total carbon in the flue gas stream, with sensitivity analysis identifying an economic optimum when the primary loop captures 97% of the total CO 2 . A Life Cycle Assessment (LCA) confirms the technology’s potential for net-negative emissions, determining a Global Warming Potential (GWP) of 52 kg CO 2 -eq/MWh—significantly lower than the baseline—which further decreases to 42 kg CO 2 -eq/MWh when crediting the displacement of conventional hydrogen production.

03 NATURAL GAS↗

NASA NTRS1975

A low cost LST pointing control system

Vigorous efforts to reduce costs, coupled with changes in LST guidelines, took place in the Fall of 1974. These events made a new design of the LST and its Pointing and Attitude Control System possible. The major design changes are summarized as: an annular Support Systems Module; removal of image motion compensation; reaction wheels instead of CMG's; a magnetic torquer system to also perform the emergency and backup functions, eliminating the previously required mass expulsion system. Preliminary analysis indicates the Low Cost LST concept can meet the newly defined requirements and results in a significantly reduced development cost.

Glaese, J. R.↗

NASA NTRS1981

Five-city economics of a solar hot-water-system

Report projects energy savings and system costs for five sites using analysis of actual solar energy installation performance in Togus, Maine. Maine system supplies 75 percent of hot water needed for single-family residence; economic payback period is 19 years. Benefits for all sites depend on maintenance or decrease of initial investment required and continuing increase in cost of conventional energy. Report includes analysis weighing potential changes in variables used to evaluate system profitability.

Source record↗

NASA NTRS2013

New Approaches in Reusable Booster System Life Cycle Cost Modeling

This paper presents the results of a 2012 life cycle cost (LCC) study of hybrid Reusable Booster Systems (RBS) conducted by NASA Kennedy Space Center (KSC) and the Air Force Research Laboratory (AFRL). The work included the creation of a new cost estimating model and an LCC analysis, building on past work where applicable, but emphasizing the integration of new approaches in life cycle cost estimation. Specifically, the inclusion of industry processes/practices and indirect costs were a new and significant part of the analysis. The focus of LCC estimation has traditionally been from the perspective of technology, design characteristics, and related factors such as reliability. Technology has informed the cost related support to decision makers interested in risk and budget insight. This traditional emphasis on technology occurs even though it is well established that complex aerospace systems costs are mostly about indirect costs, with likely only partial influence in these indirect costs being due to the more visible technology products. Organizational considerations, processes/practices, and indirect costs are traditionally derived ("wrapped") only by relationship to tangible product characteristics. This traditional approach works well as long as it is understood that no significant changes, and by relation no significant improvements, are being pursued in the area of either the government acquisition or industry?s indirect costs. In this sense then, most launch systems cost models ignore most costs. The alternative was implemented in this LCC study, whereby the approach considered technology and process/practices in balance, with as much detail for one as the other. This RBS LCC study has avoided point-designs, for now, instead emphasizing exploring the trade-space of potential technology advances joined with potential process/practice advances. Given the range of decisions, and all their combinations, it was necessary to create a model of the original model and use genetic algorithms to explore results. A strong business case occurs when viable paths are identified for an affordable up-front investment, and these paths can credibly achieve affordable, responsive operations, characterized by smaller direct touch labor efforts at the wing level from flight to flight. The results supporting this approach, its potential, and its conclusions are presented here.

Zapata, Edgar↗

NASA NTRS2013

New Approaches in Reuseable Booster System Life Cycle Cost Modeling

Zapata, Edgar↗

NASA NTRS1987

The economic payoff for a state-of-the-art high-efficiency flat-plate crystalline silicon solar cell technology

In 1986 during the flat-plate solar array project, silicon solar cells 4.0 sq cm in area were fabricated at the Jet Propulsion Laboratory (JPL) with a conversion efficiency of 20.1 percent (AM1.5-global). Sixteen cells were processed with efficiencies measuring 19.5 percent (AM1.5 global) or better. These cells were produced using refined versions of conventional processing methods, aside from certain advanced techniques that bring about a significant reduction in a major mechanism (surface recombination) that limits cell efficiency. Wacker Siltronic p-type float-zone 0.18-ohm-cm wafers were used. Conversion efficiencies in this range have previously been reported by other researchers, but generally on much smaller (0.5 vs. 4.0 cm) devices which have undergone sophisticated and costly processing steps. An economic analysis is presented of the potential payoffs for this approach, using the Solar Array Manufacturing Industry Costing Standards (SAMICS) methodology. The process sequence used and the assumptions made for capturing the economies of scale are presented.

Bickler, Donald B.↗

NASA NTRS2006

Simulation of Lunar Surface Communications Network Exploration Scenarios

Simulations and modeling of surface-based communications networks provides a rapid and cost effective means of requirement analysis, protocol assessments, and tradeoff studies. Robust testing in especially important for exploration systems, where the cost of deployment is high and systems cannot be easily replaced or repaired. However, simulation of the envisioned exploration networks cannot be achieved using commercial off the shelf network simulation software. Models for the nonstandard, non-COTS protocols used aboard space systems are not readily available. This paper will address the simulation of realistic scenarios representative of the activities which will take place on the surface of the Moon, including selection of candidate network architectures, and the development of an integrated simulation tool using OPNET modeler capable of faithfully modeling those communications scenarios in the variable delay, dynamic surface environments. Scenarios for exploration missions, OPNET development, limitations, and simulations results will be provided and discussed.

Linsky, Thomas W.↗

DOE OSTI2020

Fire Risk Investigation in 3D (FRI3D) Software and Process for Integrated Fire Modeling

Modeling and implementing fire safety for nuclear power plants is a costly activity. Because of the complexity of fire phenomena and multiple operational procedures, it is difficult to computationally provide assurance that mitigation methods are adequate for critical areas using current analysis methods in a cost-effective manner. The nuclear industry needs efficient methods to provide more accurate modeling and optimize mitigation methods to improve nuclear power plant understanding for fire scenarios. This report describes the work done over the last two year on the Fire Risk Investigation in 3D (FRI3D) software. This software simplifies the modeling process by importing existing plant models and data, incorporating a 3D modeling environment and coupling with the fire simulation software CFAST. This eliminates the manual labor and errors associated with much of the fire modeling process. The report lays out the status and path of FRID software for the Risk Informed Safety Analysis pathway of the Light Water Reactor Sustainability project at Idaho National Laboratory and industry collaborators to best help reduce costs and improve realism in fire probabilistic risk analysis.

97 MATHEMATICS AND COMPUTING↗