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At least 163 records · Page 9

Techno-Economic Case Study: Fermentation Cost Impacts from Selected Critical Material Attributes

This report summarizes analysis conducted to support a case study under the Feedstock-Conversion Interface Consortium (FCIC) focused on techno-economic analysis (TEA) modeling to quantify the economic implications of biomass hydrolysate substrate variability on fermentation performance and resultant biorefinery fuel yields. It is known that fermentation inhibitors or byproducts, as may either come from constituents in the biomass feedstock or imparted through biorefinery processing operations, can detrimentally impact fermentation rates and yields. However, it is often difficult to isolate fermentation impacts to individual components given the complex nature of biomass varying simultaneously in multiple attributes from one lot to another. For this study, we worked with FCIC researchers to obtain data on key fermentation performance metrics, namely productivity rates and conversion yields, across a number of material attribute species previously selected by the researchers as "critical" attributes which may be found in hydrolysate used as microbial carbon sources during fermentation. These data were run through TEA models to estimate resultant impacts on biorefinery economics, reported as minimum fuel selling price (MFSP). Overall, the trends in MFSP closely followed fuel yields, in turn tied to fermentation process yields and selectivity, with minimal economic impact from variations in fermentation productivity.

09 BIOMASS FUELS↗

Quality Guidelines for Energy System Studies: Cost Estimation Methodology for NETL Techno-economic Assessments

This Quality Guidelines for Energy System Studies (QGESS) summarizes the methodology employed by the National Energy Technology Laboratory (NETL) in calculating plant costs in its techno-economic studies, such as the Cost and Performance Baseline for Fossil Energy Systems series of reports. It also outlines the approach used to calculate the cost of electricity (COE) or cost of product (COP) metrics by which NETL estimates the impact of technology options. These metrics and a clear understanding of the methodology used are essential in allowing different plant technologies to be compared on a similar basis. These guidelines were initially developed for power producing plants, although they can be applied to a variety of different revenue generating plants (e.g., coal to liquids, syngas generation, hydrogen) by substituting the industrial product quantity for the electrical quantity in the equations. The tables contained in this QGESS have been expanded upon relative to previous versions to include values to assume for several industries.

20 FOSSIL-FUELED POWER PLANTS↗

Enhanced Weathering: Techno-Economic and Life Cycle Screening Analysis

This report presents a detailed, transparent, and independent screening level techno-economic analysis and lifecycle analysis of enhanced weathering of igneous rocks and industrial waste materials. The performance, costs, and CO 2 removal potential is reported for a process spanning material acquisition, preparation, transport, application and monitoring, reporting, and verification. The base cases examined serve as a reference for informative performance and cost sensitivity analyses. This approach aims to highlight promising scenarios for enhanced weathering application and potential avenues for cost reduction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Integrated Life Cycle and Techno-Economic Assessments of Central Appalachian Legacy Mine Sites for Biomass Development and Waste Coal Utilization

This project, funded by the U.S. Department of Energy – National Energy Technology Laboratory (DOE-NETL) under award DE-FE0032212, evaluated how legacy coal mine lands and coal refuse piles in Central Appalachia (West Virginia and Pennsylvania) can be reclaimed and repurposed to support biomass development and beneficial utilization of waste coal, with the long-term goal of supporting net-zero or net-negative greenhouse gas (GHG) pathways. The project had two primary objectives: 1. Characterize legacy mine sites (including site conditions, waste coal/refuse resources, and soil/ecosystem indicators) and develop reclamation and best management practices (BMPs) for biomass cultivation; and 2. Conduct integrated machine learning (ML)-assisted life cycle assessment (LCA) and techno-economic analysis (TEA) to quantify environmental and economic outcomes for multiple biomass and waste-coal utilization pathways. Across West Virginia, the team identified ~625 coal refuse sites covering ~19,705 acres, and developed methods to estimate refuse pile volume using digital elevation models (DEMs) and geospatial workflows. A large subset of sites received volume estimates totaling ~1.6 billion m³.

01 COAL, LIGNITE, AND PEAT↗

Techno-Economic Analysis of Geologically Connected Seawater Air Conditioning (GeoSWAC) Concept for District Cooling at the University of Puerto Rico at Rio Piedras

At the University of Puerto Rico at Rio Piedras, a central chilled water plant supplies cooling to several campus buildings, contributing significantly to electricity demand during daytime peak hours, particularly in the summer months. These operational challenges are exacerbated by Puerto Rico's tropical rainforest climate and a power grid vulnerable to frequent disruptions caused by hurricanes and tropical storms. This study presents a techno-economic analysis of the existing chilled water plant serving four representative campus buildings and introduces a conceptual alternative: the Geologically connected Seawater Air Conditioning (GeoSWAC) system. GeoSWAC leverages stable low temperatures of deep ocean water (~1 km depth), hydraulically connected to an inland well, to deliver cooling without the use of vapor-compression refrigeration. Using modeled annual cooling loads and chiller performance data, capital costs, energy consumption, and levelized cost of cooling (LCOC) were evaluated for both systems. While GeoSWAC showed higher capital costs than the chiller-based scenario, operational costs were significantly lower at $26k-$53k annually, resulting in a lower LCOC between $2.3/MWh and $8.2/MWh compared to $30.2/MWh-$33.6/MWh for the chiller scenario. These results suggest that the GeoSWAC system offers a promising, low-energy, and climate-resilient alternative for large-scale cooling in tropical coastal environments, with significant potential to reduce peak electricity demand and improve long-term system reliability.

15 GEOTHERMAL ENERGY↗

Agent-based Modeling for the Multi-objective Optimization of Energy Production Pathways: Integrated Techno-Economics and Life Cycle Assessment

This project developed an integrated modeling framework to evaluate how purpose-grown bioenergy feedstocks could support large-scale sustainable aviation fuel production in the United States. Led by Colorado State University with project partners, the work combined geographically resolved analysis, techno-economic assessment, life cycle assessment, multi-objective optimization, and agent-based modeling to examine feedstock performance, deployment potential, land-use implications, and adoption dynamics. The overall goal was to identify practical and sustainable pathways for producing aviation fuel from feedstocks such as energy crops, woody crops, oilseeds, and algae while helping inform policy, investment, and research needs tied to national SAF goals. In essence, the project provides a systems-level assessment of the opportunities and constraints associated with scaling bioenergy-based aviation fuels in the U.S.

09 BIOMASS FUELS↗

Techno-Economic Assessment of Regional Carbon Utilization Scenarios and Attendant Monitoring Technology

Presented at Mastering the Subsurface Through Technology Innovation, Partnerships and Collaboration: Carbon Storage and Oil and Natural Gas Technologies Review Meeting, Pittsburgh, Pennsylvania, August 13–16, 2018. A techno‑economic study was conducted to evaluate the carbon value chain in North Dakota. The project included collaboration with the U.S. Department of Energy to develop methods for assessing CO 2 storage resources in residual oil zones (ROZs). In addition, the seismic processing workflow was improved to enhance data quality and interpretation.

02 PETROLEUM↗

Preliminary Techno-Economic Assessment of Gas Switching Reforming (GSR) of Natural Gas for Pure Hydrogen Production and Power Generation with Integrated CO2 Capture

The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) is an advanced auto-thermal reforming technology that produces hydrogen or syngas from natural gas. It integrates inherent CO2 capture by utilizing a specialized oxygen carrier in a single fluidized bed reactor, eliminating the need for complex, energy-intensive post-combustion separation. GSR technology builds upon Chemical Looping Reforming (CLR), an experimentally proven technology with strong potential for scaling up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H₂) and a combined cycle (GSR-CC) in which high-purity H₂ is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H₂ production by ~30% and improved efficiency relative to prior studies. For GSR-H₂, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H₂, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ~75% of total global warming impacts (~2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗

Preliminary techno-economic assessment of gas switching reforming (GSR) of natural gas for pure hydrogen production and power generation with integrated CO2 capture

The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) with integrated CO2 capture, a technology based on Chemical Looping Reforming (CLR), has been experimentally proven and shows potential for scale-up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H2) and a combined cycle (GSR-CC) in which high-purity H2 is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H2 production by ∼ 30% and improved efficiency relative to prior studies. For GSR-H2, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H2, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ∼ 75% of total global warming impacts (∼2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗

Enabling Production of Algal Biofuels by Techno-Economic Optimization of Co-Product Suites

Recent techno-economic analysis (TEA) has underscored that for algal biofuels to be cost competitive with petroleum fuels, co-products are necessary to offset the cost of fuel production. The co-product suite must scale with fuel production while also maximizing value from the non-fuel precursor components. The co-product suite also depends on algal biomass composition, which is highly dynamic and depends on environmental conditions during cultivation. Intentional shifts in composition during cultivation are often associated with reduced biomass productivity, which can increase feedstock production costs for the algae-based biorefinery. The optimal algae-based biorefinery configuration is thus a function of many factors. We have found that comprehensive TEA, which requires the construction of process models with detailed mass and energy balances, along with a complete accounting of capital and operating expenditures for a commercial-scale production facility, provides invaluable insight into the viability of a proposed biorefinery configuration. This insight is reflected in improved viability for one biorefining approach that we have developed over the last 10 years, namely, the Combined Algal Processing (CAP) approach. This approach fractionates algal biomass into carbohydrate-, lipid-, and protein-rich fractions, and tailors upgrading chemistry to the composition of each fraction. In particular, transitioning from valorization of only the lipids to a co-product suite from multiple components of high-carbohydrate algal biomass can reduce the minimum fuel selling price (MFSP) from more than $8/gallon of gasoline equivalent (GGE) to $2.50/GGE. This paper summarizes that progress and discusses several surprising implications in this optimization approach.

09 BIOMASS FUELS↗

Adapting Technology Learning Curves for Prospective Techno-Economic and Life Cycle Assessments of Emerging Carbon Capture and Utilization Pathways

Comparisons of emerging carbon capture and utilization (CCU) technologies with equivalent incumbent technologies are necessary to support technology developers and to help policy-makers design appropriate long-term incentives to mitigate climate change through the deployment of CCU. In particular, early-stage CCU technologies must prove their economic viability and environmental reduction potential compared to already-deployed technologies. These comparisons can be misleading, as emerging technologies typically experience a drastic increase in performance and decrease in cost and greenhouse gas emissions as they develop from research to mass-market deployment due to various forms of learning. These changes complicate the interpretation of early techno-economic assessments (TEAs) and life cycle assessments (LCAs) of emerging CCU technologies. The effects of learning over time or cumulative production themselves can be quantitatively described using technology learning curves (TLCs). While learning curve approaches have been developed for various technologies, a harmonized methodology for using TLCs in TEA and LCA for CCU in particular is required. To address this, we describe a methodology that incorporates TLCs into TEA and LCA to forecast the environmental and economic performance of emerging CCU technologies. This methodology is based on both an evaluation of the state of the art of learning curve assessment and a literature review of TLC approaches developed in various manufacturing and energy generation sectors. Additionally, we demonstrate how to implement this methodology using a case study on a CO 2 mineralization pathway. Finally, commentary is provided on how researchers, technology developers, and LCA and TEA practitioners can advance the use of TLCs to allow for consistent, high-resolution modeling of technological learning for CCU going forward and enable holistic assessments and fairer comparisons with other climate technologies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Life-Cycle and Techno-Economic Assessment of Early-Stage Carbon Capture and Utilization Technologies—A Discussion of Current Challenges and Best Practices

The mitigation of climate change requires research, development, and deployment of new technologies that are not only economically viable but also environmentally benign. Systematic and continuous technology assessment from early technology maturity onwards allows assessment practitioners to identify economic and environmental characteristics. With this information, decision-makers can focus time and resources on the most promising technologies. A broad toolset for technology assessment exists—stretching from the well-established life cycle assessment (LCA) methodology to more loosely defined techno-economic analysis (TEA) methods and the increasingly popular principles of technology maturity assessment such as the concept of technology readiness levels (TRL). However, current technology assessment practice faces various challenges at early stages, resulting in a potential mismatch of study results and stakeholders' needs and an escalation of assessment effort. In this practice review, we outline current challenges in the interplay of LCA, TEA, and TRL and present best practices for assessing early-stage climate change mitigation technologies in the field of carbon capture and utilization (CCU). The findings help practitioners systematically identify the TRL of a technology and adapt technology assessment methodologies accordingly. We highlight the methodological challenges for practitioners when adapting the goal and scope, identifying benchmark technologies, creating a comprehensive inventory, comparing early stage to commercial stage, ensuring clarity of recommendations for decision-making under high uncertainty, and streamlining conventional LCA and TEA assessment approaches and provide actionable recommendations. Overall, this work contributes to identifying promising technologies faster and more systematically, accelerating the development of new technologies for climate change mitigation and beyond.

54 ENVIRONMENTAL SCIENCES↗

Techno-Economic Optimization of CSP Plants with Free-Falling Particle Receivers

Particle receivers are one of the candidates for the next generation of CSP plants, whose goal is to reduce the levelized cost of electricity (LCOE) to 0.05 $/kWh. This paper presents a techno-economic analysis to study if a CSP system with free-falling particle receiver can achieve this goal. The plant analyzed integrates two ground-based bins to store the excess energy and a supercritical CO2 cycle to generate electricity. The model used for the analysis presents several upgrades to previous particle systems models in order to increase its fidelity, accuracy, and representativeness of an actual system. The main upgrades are the addition of off-design conditions during the annual simulations in all the components and an improved receiver model validated against CFD simulations. The size of the main components is optimized to obtain the system configuration with minimum LCOE. The results show that particle CSP systems can reduce the LCOE to 0.056 $/kWh if the configuration is composed of 1.61 × 106 m2 of heliostats, a 250 m high tower with a 537 m2 falling particle curtain, and 16 h thermal energy storage.

54 ENVIRONMENTAL SCIENCES↗

Techno-Economic Analysis of a Thermally Integrated Solid Oxide Fuel Cell and Compressed Air Energy Storage Hybrid System

Natural-gas-fueled solid oxide fuel cell (SOFC) systems have the potential for high-efficiency conversion of carbon to power due to the underlying electrochemical conversion process while readily facilitating carbon capture through the separation of the fuel and oxidant sources. Compressed air energy storage (CAES) technology can potentially store significant quantities of energy for later use with a high round-trip efficiency and lower cost when compared with state-of-the-art battery technology. The base load generation capability of SOFC can be coupled with CAES technology to provide a potentially flexible, low-carbon solution to meet the fluctuating electricity demands imposed by the increasing share of intermittent variable renewable energy (VRE) production. SOFC and CAES can be hybridized through thermal integration to maximize power output during periods of high electrical demand and then store power when either demand is low or renewable generation reduces power prices. The techno-economics of a low-carbon hybrid SOFC and CAES system was developed and investigated in the present study. The proposed hybrid system was found to be cost-competitive with other power-generating base-load facilities when power availability was considered. The hybrid system shows increased resilience to changes in a high VRE grid market scenario.

25 ENERGY STORAGE↗

Techno-Economic Comparison of Molten-Salt Electrolysis and Carbothermic Reduction for the Production of Metallurgical-Grade Silicon

Metallurgical-grade silicon (MG-Si) is an important source material for many industrial applications, including the manufacture of alloys, solar photovoltaics, and electronics. The process to refine raw materials into MG-Si is energy-intensive, with the predominant method of submerged-arc furnaces requiring energy consumption of approximately 11–13 kWh/kg Si. Recent research has discussed promising methods for reducing the energy required for the silicon production process, including the use of molten-salt electrolysis (MSE), a technique that offers potential savings in energy consumption without requiring carbon inputs for the process. This paper presents a techno-economic study of a potential industrial-scale MSE plant for MG-Si production to evaluate the trade-offs between capital and operating costs of the system. Capital costs are sourced from recent MG-Si plants and an existing cost model developed for MSE processes that includes the size of the plant and the operating temperature among its inputs. The results show that MSE technology has the potential to be an economically cost-competitive option for MG-Si production if the technology successfully scales to industrial production and matures enough to allow for financing costs similar to that of a comparably sized submerged-arc furnace plant.

14 SOLAR ENERGY↗

Techno-Economic Analysis of High-Pressure Metal Hydride Compression Systems

Traditional high-pressure mechanical compressors account for over half of the car station’s cost, have insufficient reliability, and are not feasible for a large-scale fuel cell market. An alternative technology, employing a two-stage, hybrid system based on electrochemical and metal hydride compression technologies, represents an excellent alternative to conventional compressors. The high-pressure stage, operating at 100–875 bar, is based on a metal hydride thermal system. A techno-economic analysis of the metal hydride system is presented and discussed. A model of the metal hydride system was developed, integrating a lumped parameter mass and energy balance model with an economic model. A novel metal hydride heat exchanger configuration is also presented, based on minichannel heat transfer systems, allowing for effective high-pressure compression. Several metal hydrides were analyzed and screened, demonstrating that one selected material, namely (Ti0.97Zr0.03)1.1Cr1.6Mn0.4, is likely the best candidate material to be employed for high-pressure compressors under the specific conditions. System efficiency and costs were assessed based on the properties of currently available materials at industrial levels. Results show that the system can reach pressures on the order of 875 bar with thermal power provided at approximately 150 °C. The system cost is comparable with the current mechanical compressors and can be reduced in several ways as discussed in the paper.

42 ENGINEERING↗

A Techno-Economic Look at SiC WBG from Wafer to Motor Drive

Techno-economic analysis helps benchmark and deliver supply chain and manufacturing insights that can be leveraged by decision-makers to inform investment strategies, policy, and other decisions to promote economic growth and competitiveness. Silicon Carbide (SiC) wide-band gap (WBG) technologies is poised to be an integral contributor to the clean energy economy. We use bottoms-up regional manufacturing cost models to show SiC power electronics, manufactured in volume, could result in final product cost parity with those manufactured with silicon. The models are further leveraged to show innovation pathways to lower cost and potentially expanded technology adoption.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗