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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Lessons Learned From Techno-Economic Analysis of Solar Photovoltaics and Battery Energy Storage at a Vietnam Industrial Park

Through the Clean Energy Investment Accelerator (CEIA), engineers from the United States (U.S.) National Renewable Energy Laboratory (NREL) conducted a case study analysis evaluating the techno-economic feasibility of battery energy storage systems (BESS) at an industrial park in Vietnam. The analysis uses NREL's REopt platform, a distributed energy modeling and optimization tool, to identify the cost-optimal system sizing for BESS, in conjunction with onsite renewables such as solar photovoltaics (PV), to reduce electricity costs, increase onsite renewable energy generation utilization, and improve resilience to grid outages.

batteries↗
DOE OSTI2025

Economic Analysis of the NIF Optics Recycle Loop Systems Investment Options: SAE 560 - Economic Considerations for Systems Engineering at University of Southern California

The National Ignition Facility (NIF) relies on large-scale precision optics to deliver high-energy laser pulses for fusion and high-energy-density physics research; however, the NIF routinely operates above the damage threshold for those optics, decreasing their effectiveness with every experiment. A production line composed of several dozen highly specialized processing systems, collectively referred to as the ‘optics recycle loop’, was established to support refurbishment and re-use of these critical components to reduce reliance on high-cost and high-risk optic replacement strategies. This analysis aims to identify the most cost-effective investment options for improving recycle loop throughput by maximizing availability and production flexibility while minimizing the engineering and infrastructure efforts and cost.

42 ENGINEERING↗
DOE OSTI2026

Techno-Economic Analysis of Repurposing Natural Gas Transmission Pipeline Networks to Accommodate Hydrogen Blends

Blending hydrogen into natural gas infrastructure could supplement natural gas supply and increase resilience for applications such as ammonia production, peaking and load-following power plants, and heating. The United States has an extensive network of natural gas pipelines, but the feasibility of employing this infrastructure to transport hydrogen is unclear. We analyze the costs associated with repurposing three distinct natural gas transmission pipelines in different locations within the United States to carry blends of hydrogen up to 100% via three different pipeline network modification methods and compare against the cost of building a new dedicated hydrogen pipeline. We conduct a sensitivity analysis on the hoop stress limit of the existing pipe, techno-economic parameters, emissions, and relative capacity. The results show that the capital costs required to upgrade a pipeline can vary from tens of millions to billions of dollars depending on the length and capacity of the existing pipeline section, whether the existing pipeline already operates at or below its maximum allowable operating pressure, whether future demand is expected to increase or decrease, the network modification method selected, and pipe material costs. The delivered cost of energy to end users is impacted less by the levelized cost of transporting hydrogen blends than by the cost of the natural gas and hydrogen fuels being transported. The emissions impact of blending hydrogen into natural gas transmission networks scales proportionally with the amount of energy displaced with low-emission hydrogen (such as from natural gas with carbon capture and sequestration or electrolysis powered by nuclear, renewable, or geothermal electricity), therefore low blend ratios (e.g., < 20% vol. hydrogen) will result in low emissions impacts. Factors such as permitting and right-of-way costs, the proximity of the pipeline to hydrogen demand and production, and the compatibility of and/or retrofitting costs of end-use gas-fueled technologies will likely be greater drivers in determining whether converting a particular natural gas pipeline to carry hydrogen makes economic sense.

08 HYDROGEN↗
DOE OSTI2023

Chapter 6: Recycling Plastic Waste to Produce Chemicals - A Techno-Economic Analysis and Life-Cycle Assessment

This study presents the results of a preliminary assessment on the technology, economics, and sustainability of using waste plastics as a feedstock to produce low molecular weight olefins via pyrolysis and gasification pathways. We also studied the formation of formaldehyde - an important polymer precursor - via the gasification of waste plastics. Process pathways for recovery of ethylene and propylene and production of formaldehyde from a simulated mixed plastic waste were constructed based on literature data. They included direct and indirect pathways based on either gasification or pyrolysis as the primary conversion step. Results of these studies have shown that significant economic challenges exist of producing olefins via pyrolysis and gasification, with the latter pathway especially difficult. Base costs of pyrolysis naphtha from waste plastics are higher when compared to the same material produced from fossil feedstocks. Base olefin costs for one direct route are two times higher than comparable costs from steam cracking of fossil naphtha. These costs are driven primarily by feedstock costs; some pyrolysis scenarios become more economically feasible when very low feedstock costs are used. Similarly, for gasification, the cost of methanol - the central intermediate - was found to be noticeable higher when produced by gasification of waste plastics compared to current selling prices, which negatively impacts all pathways that go through methanol as the central intermediate. Life-cycle assessment indicates that the production of pyrolysis naphtha from plastics is a carbon intensive operation; no major advantages were found in terms of greenhouse gas emissions for any of the pathways producing C2 and C3 olefins. The results of this study can serve as the baseline for future comparison to other plastic waste valorization processes.

BIOMASS FUELS,ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Transforming E-Waste Into Strategic Resources: Techno-Economic Analysis of Gallium and By-products Recovery from LEDs via Bioleaching

The growing demand for gallium in optoelectronics and renewable energy applications raises concerns about supply security and production sustainability. This study evaluates the techno-economic feasibility of recovering gallium and by-products (copper and nickel) from waste GaN-based LEDs via bioleaching. A process flowsheet encompassing transportation, robotic disassembly, ball milling, bioleaching, solvent extraction/electrowinning, and refining was modeled. Based on mass balance analysis, more than 53 tons of LED waste are required annually to yield 1 kg of gallium alongside substantial copper and nickel co-products. Preliminary techno-economic analysis (TEA) shows an average total cost (ATC) of 6.84 USD/kg metal when costs are allocated by mass-weighted economic value (market price) fraction, corresponding to 6.75 USD/kg for copper, 15.91 USD/kg for nickel, and 470.95 USD/kg for gallium. For gallium, direct operational costs account for more than 70% of the cost. Monte Carlo simulations further quantify cost uncertainties under market price fluctuations. This work represents the first TEA of gallium recovery from GaN-based LEDs and highlights potential pathways for future cost reduction.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Techno-Economic Analysis of Chemical Precipitation Followed by Low Hydraulic Residence Time Biological Treatment, Including Ultrafiltration

This National Energy Technology Laboratory (NETL) analysis is a techno-economic evaluation of chemical precipitation followed by low hydraulic residence time biological treatment, which was identified as Best Available Technology for treatment and control of selenium emissions from wet flue gas desulfurization wastewater streams.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Techno-economic analysis of cellulosic ethanol conversion to fuel and chemicals

In this paper, we describe multiple scenarios investigated to assess the techno-economic results of producing fuels from corn stover-derived ethanol and the impact of co-producing higher-value, ethanol-derived n-butanol and 1,3-butadiene to improve economic feasibility. An alternative approach that produces only chemicals from the lignocellulosic-derived ethanol while producing fuels from the residual cell mass, unconverted sugars and lignin using hydrothermal liquefaction and hydrotreating also is described. Our results indicate that the hydrothermal liquefaction pathway has cost advantages relative to pathways that burn lignin from the corn stover conversion process to make ethanol when the associated ethanol stream is used to make only chemicals.

09 BIOMASS FUELS↗
DOE OSTI2020

Gallium Oxide Techno-Economic Analysis for the Wide Bandgap Semiconductor Market

More than 30% of electrical energy passes through power electronics today with speculation that in the next decade this could grow to 80%. The wide bandgap semiconductor market is already approaching $1 billon USD in 2019 and is projected to be almost $7 billion USD in 2028. Even with its high cost, SiC, is starting to dislodge the incumbent Si technology in some applications, such as hybrid and electric vehicles, due to smaller size, and higher efficiency. We review and report the IHS Markit’s market predictions for wide bandgap semiconductor technologies, and highlight the technoeconomic analysis results for the manufacturing cost of Ga2O3 wafers. Specifically, we focus on the potential for Ga2O3 to be more economically advantageous than SiC using current manufacturing methods and then identify opportunities where research can further reduce the volume cost of Ga2O3 wafers.

28 EE - Advanced Manufacturing Office (EE-5A)↗
DOE OSTI2022

Techno-Economic Analysis for Shear Assisted Processing and Extrusion (ShAPE) of High Strength Aluminum Alloys

Aluminum alloy 7075 (AA7075) is a high strength aluminum alloy (HSAL), attractive for applications such as automotive, aviation, aerospace, defense, and marine applications. However, AA7075 has not yet been widely adopted due slow extrusion speed, high energy use, narrow process window, and sensitivity to incipient melting common in conventional extrusion methods. Alternative extrusion methods may overcome these limitations. New research funded by the U.S. Department of Energy (DOE) Advanced Manufacturing Office (AMO) is exploring the use of a new SPP approach called Shear Assisted Processing and Extrusion (ShAPE) for the manufacture of AA7075 extrusions. Pacific Northwest National Laboratory (PNNL) are leading the development, testing and characterization of ShAPE, which is showing that high speed ShAPE extrusions (e.g., above 12 meters/min) which is significantly faster than the 1-2 meters/min possible with conventional AA7075 extrusions. Initial findings from the economic and energy analysis indicate that AA7075 tubes created with ShAPE use less energy than tubes that are conventionally heated and extruded. The reduction in energy use is primarily a result of using direct chill cast (non-homogenized) billets, eliminating the pre-heating step, and faster extrusion speeds. The TEA model translates CAPEX and O&M costs to a manufacturing cost, and then a minimum sustainable price (MSP) per ton of extruded product for multiple facility capacities. A sample output figure of the TEA model is presented below. It presents results of the preliminary version of the TEA model.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Techno-Economic Analysis of decentralized preprocessing systems for fast pyrolysis biorefineries with blended feedstocks in the southeastern United States

This study evaluated the economic feasibility of fast pyrolysis biorefineries fed with blended pine residues and switchgrass in the Southeastern U.S. with different supply chain design. Previous techno-economic analyses (TEA) have focused on either blended biomass or decentralized preprocessing without investigating the impacts of varied process parameters, technology options, and real-world biomass distribution. This study fills the literature gap by modeling scenarios for different biomass blending ratios, biorefinery and preprocessing site (so-called depot) capacities, and alternative preprocessing technologies. High-resolution, real-world geospatial data were analyzed using Geographic Information Systems to facilitate supply chain design and TEA. For a decentralized system, the minimum fuel selling price (MFSP) of biofuel was 3.92–4.33 per gallon gasoline equivalent (GGE), while the MFSP for the centralized biorefinery at the same capacities ranged between 3.75–4.02/GGE. Implementing a high moisture pelleting process depot rather than a conventional pelleting process lowered the MFSP by 0.03–0.17/GGE. Scenario analysis indicated decreased MFSP with increasing biorefinery capacities but not necessarily with increasing depot size. Medium-size depots (500 OMDT/day) achieved the lowest MFSP. Here, this analysis identified the optimal blending ratios for two preprocessing technologies at varied depot sizes. Counterintuitively, increasing the proportion of higher cost switchgrass reduced the MFSP for large biorefineries (>5000 ODMT/day), but increased the MFSP for small biorefineries (1000–2500 ODMT/day). Although the decentralized systems have a higher MFSP based on current analysis, it has other potential benefits such as mitigated supply chain risks and improved feedstock quality that are difficult to be quantified in this TEA.

09 BIOMASS FUELS↗
DOE OSTI2025

Techno-economic analysis and life cycle analysis of renewable natural gas production from brewery wastewater via ex-situ methanation processes

As sustainability becomes increasingly critical, the brewing industry encounters challenges in managing high-organic-content wastewater, a promising renewable energy source. This study evaluates the economic feasibility and environmental impacts of converting brewery wastewater into renewable natural gas (RNG) through anaerobic digestion and biogas upgrading, with an emphasis on different hydrogen sources for biomethanation. Four scenarios were analyzed: Scenario 1 uses purchased hydrogen, while Scenarios 2–4 use renewable hydrogen from microbial electrolysis cells and water electrolyzers. Results show that capital investments for processing 139 MT/h of wastewater, yielding 208 m 3 /h of RNG, range from 10.6 M to 31.9M USD, with estimated minimum selling prices of RNG between 2.25 and 4.37 USD/m 3 . Life cycle greenhouse gas (GHG) emissions span from -21 to 32g CO 2 -equivalent per MJ of RNG. Further, this study presents key economic and environmental metrics for RNG production from brewery wastewater, offering insights to enhance sustainability in brewery wastewater management.

03 NATURAL GAS↗
DOE OSTI2026

Model-based economic analysis under uncertainty for PFAS treatment by granular activated carbon and ion exchange technologies

Recent drinking water regulations have imposed the need for per- and polyfluoroalkyl substances (PFAS) remediation. In response, treatment facilities may be required to retrofit existing treatment schemes to treat PFAS below maximum contaminant levels (MCLs). Adsorption technologies such as granular activated carbon (GAC) and ion exchange (IX) have been demonstrated to be effective; however, there are limited techno-economic metrics available which provide guidance on technology selection and design for diverse PFAS-containing source water conditions. Process systems engineering (PSE) tools which can traditionally perform these analyses are hindered by the data availability, model validity, and understanding of treatment phenomena for emerging contaminants. This work employs published data regressions, statistical models, process models, techno-economic analyses, and other process systems tools in a model-based uncertainty framework to consider the limitations of emerging contaminant research. Through this analysis framework, economic results are provided as probabilistic distributions based on the uncertainty of the models and diverse conditions that treatment facilities experience.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Facilitated transport membranes for H 2 purification from coal-derived syngas: A techno-economic analysis

A single-stage membrane process has been designed for using facilitated transport membranes (FTMs) to decarbonize the coal-derived syngas from an integrated gasification combined cycle (IGCC) power plant. The necessary process model and costing method have also been developed to assess the technical feasibility and process economics. In order to account for the carrier saturation phenomenon associated with FTMs, a homogeneous reactive diffusion model is integrated into the process model. The techno-economic study reveals that the mitigated carrier saturation upon bulk CO 2 removal can lead to appreciable increases in the CO 2 permeance and CO 2 /H 2 selectivity, which can be utilized to achieve 95% CO 2 purity and 95% H 2 recovery with a CO 2 /H 2 selectivity of 50 at the complete carrier saturation. FTMs with different facilitated transport characteristics can also be arranged in a hybrid membrane configuration to render a H 2 recovery of 99% and a cost of electricity of $\$118.5$ /MWh, which is 12.5% lower than that of the benchmark Selexol process.

42 ENGINEERING↗
DOE OSTI2021

Techno-economic analysis of long-duration energy storage and flexible power generation technologies to support high-variable renewable energy grids

As variable renewable energy penetration increases beyond 80%, clean power systems will require long-duration energy storage or flexible, low-carbon generation. Here, we provide a detailed techno-economic evaluation and uncertainty analysis of applicable technologies and identify challenges and opportunities to support electric grid planning. We show that for a 120-h storage duration rating, hydrogen systems with geologic storage and natural gas with carbon capture are the least-cost low-carbon technologies for both current and future capital costs. These results are robust to uncertainty for the future capital cost scenario, but adiabatic compressed air and pumped thermal storage could be the least-cost technologies in the current capital cost scenario under uncertainty. Finally, we present a new storage system using heavy-duty vehicle fuel cells that could reduce the levelized cost of energy by 13%–20% compared with the best previously considered storage technology and, thus, could help enable very high (>80%) renewable energy grids.

25 ENERGY STORAGE↗
DOE OSTI2023

Techno-Economic Analysis of a Microgrid System for Rural Communities in the United States

Access to running water has been a pressing issue in many developing countries across the globe, and also continues to be a problem in some rural areas in the United States. Today, more than two million Americans living in rural areas lack access to basic water supply and infrastructure. Rural communities tend to be located in environmentally fragile areas with poor economic conditions, making access to appropriate, low-cost technology for clean water supply and sanitation more challenging. In addition, many of the water resources located in these areas are being jeopardized by climate change in recent years. This research proposes a photovoltaic (PV)-battery microgrid system for powering water pumps in off-grid areas in an effort to identify economically and technologically feasible solution to the problems. Utilizing the HOMER Pro software, developed by the U.S. National Renewable Energy Laboratory (NREL), the case of the Navajo Nation is examined by analyzing the effects of this region's air temperature on the life and performance of battery storage and the economics of the proposed microgrid system.

battery↗
DOE OSTI2023

Summary: Techno-Economic Analysis of Solar Photovoltaics and Battery Energy Storage at a Vietnam Industrial Park

The Clean Energy Investment Accelerator conducted a case study analysis of battery energy storage system (BESS) feasibility for an industrial park in Vietnam using the National Renewable Energy Laboratory's (NREL's) REopt platform (a distributed energy modeling and optimization tool) to evaluate how BESS may reduce electricity costs, increase utilization of onsite renewable energy generation, and improve resilience to utility grid outages. This presentation summarizes the analysis and key takeaways.

batteries↗