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At least 1,693 records · Page 94

System Advisor Model (SAM) Improvements for Emerging Solar Thermal Applications

The System Advisor Model (SAM) is an open-source tool developed by NREL to simulate the techno-economic performance of technologies like photovoltaics, solar thermal, wind, and geothermal. NREL has recently completed, active, and planned projects to improve the solar thermal models in SAM and its underlying code base to represent emerging component technologies, systems, and applications. This poster describes new capabilities in the SolarPILOT optical modeling tool, supercritical carbon dioxide (sCO2) power cycles, and solar industrial process heat.

14 SOLAR ENERGY↗

Assessment of Heavy-Duty Fueling Methods and Components-Modeling and Analysis

The goal of the Assessment of Heavy-Duty Fueling Methods and Components project was to comprehensively assess heavy-duty (HD) fuel cell electric vehicle fueling protocols and their effects on techno-economic assessments (TEA) and total cost of ownership (TCO). The project leveraged and built upon ongoing international HD fueling protocols and fueling component development activities to deliver component performance assessments, modeling tools and methods evaluations, TEA of industry-selected protocol structures, and experimental validations of the strategies at the station scale. The effects of the protocols on the fueling times, station costs, and TCO were explored. Fueling time, which was influenced by temperature and protocol selection, had a large impact on the station cost due to component sizing and satisfying hourly demand. As the fleet size increased, the station cost was shown to exponentially decrease by achieving economies of scale. Technology year and fuel economy were the largest contributors to the TCO; however, the choice of fueling protocol had a minor impact on the TCO.

33 ADVANCED PROPULSION SYSTEMS↗

Modular System for Direct Conversion of Methane into Methanol via Photocatalysis

In this project, the Recipient’s objective is to develop a liquid phase photocatalytic process for direct conversion of methane into methanol. The specific objectives are to: Develop a bifunctional catalyst using a semiconductor photocatalyst architecture to facilitate methane activation to directly convert methane into methanol. Develop a scalable reactor design to maximize mass transfer and methanol selectivity using an optimized photocatalyst. Develop a conceptual process design for a modular system for flare gas utilization. Conduct comprehensive techno-economic and commercial market assessments to position the technology for commercialization.

03 NATURAL GAS↗

Open-Source Tidal Energy Converter (OSTEC) Testbed: Design Basis Report

This report describes the design basis and design details for an instrumented marine turbine system intended to serve as the DOE’s marine tidal turbine test bed for foundational open-source R&D and data generation to advance our understanding and to identify knowledge gaps on the techno-economic performance of tidal energy converters (TEC) under real tidal flow conditions and at sufficiently large scale to enable upscaling of fluid-structure-interactions and component and material load responses

16 TIDAL AND WAVE POWER↗

RePED 250: A Revolutionary, High Drilling Rate, High-T Geothermal Drilling System and Companion Power Electronics

Geothermal drilling in the United States is drastically slower and more costly than Oil and Gas (O&G) drilling, primarily due to the additional challenges in geothermal wells: hard rock types and high temperatures. The Repetitive Pulsed Electric Drill (250°C) (RePED-250), developed by Tetra Corporation has the potential to change this with a novel electro-crushing technology. RePED-250 releases pulses of electricity through the rock, which causes it to break in tension, instead of compression like conventional rotary drilling. The tensile strength of hard rocks like granite is only ~5% of their compressive strength, requiring less energy, time, and wear on the bit compared to conventional drilling. The RePED drill bit has no moving parts, uses drilling mud to remove rock fragments, and uses standard drill pipe, enabling a direct transition from conventional drilling systems. The objective of this project is to move RePED technology towards commercial readiness for high-temperature geothermal applications. This involves: 1) Creating high-temperature, high power electronic components for the RePED drill capable of operating at the high temperatures of a geothermal well. The target is a 250°C ambient environment. Specifically, capacitors, high voltage switches, and a downhole generator capable of generating the necessary power. 2) Demonstrating RePED’s effectiveness drilling through hard rock (granite) and examining its pathway to commercialization and effect on the US geothermal market. Work on this project has led to significant improvement over the state-of-the-art for all the examined electronics, through design, modeling, and testing of these novel components, though some additional development is still needed to deploy these high-temperature parts in a geothermal well. Besides their use in RePED-250, each component has applications in other industries where the stability of electronics at high-temperature is needed. To address the second barrier to commercialization, a 9” hole was drilled through a sample block of granite, demonstrating the tool’s effectiveness in hard rock. The team investigated RePED-250’s effect on well cost and the geothermal industry, through various techno-economic models described in the report.

15 GEOTHERMAL ENERGY↗

Williston basin associated co 2 storage field laboratory

The Williston Basin Associated CO 2 Storage Field Laboratory (WBCFL), led by the Energy & Environmental Research Center (EERC) in partnership with Denbury (now ExxonMobil), was established to advance understanding of CO 2 enhanced oil recovery (EOR) and associated geologic CO 2 storage in the Williston Basin. The specific objective of the WBCFL was to conduct field and laboratory activities to inform decisionmakers regarding the 1) efficacy of associated storage in stacked geologic reservoirs during EOR operations; 2) CO 2 injectivity, oil production, and storage in residual oil zones (ROZs); 3) use of a novel CO 2 storage monitoring, verification, and accounting (MVA) technology (active seismoelectric [ASE] monitoring), and 4) life cycle and techno-economic factors for EOR development scenarios targeting ROZs. The project location was the Pennel Field in southeast Montana, which is part of the Cedar Creek Anticline (CCA) geologic structure within the Williston Basin.

02 PETROLEUM↗

Southern Company Services: Project 2: Tall Tower Wind Technical Potential for the Southeast (Modifications 4, 5), Project 4: Offshore Wind Potential for Southern Company Services (Modifications 7, 8)

Project 2: The National Laboratory of the Rockies (NLR) and Southern Company Services (SCS) seek to establish an agreement to assess the technical potential for wind energy in the Southeastern U.S. SCS has requested that NLR conduct a detailed assessment of system performance, available capacity, transmission distance, and levelized cost of electricity (LCOE) at turbine hub heights of 100m to 160m within the SCS service territory. NLR will also provide an assessment of utility photovoltaic (PV) technical potential within the SCS service territory. NLR has unique modeling capabilities to assist SCS with high spatial and temporal resolution assessment of wind and PV technical potential, considering geospatial constraints. Project 4: NLR and SCS seek to develop a spatially explicit techno-economic assessment for offshore wind energy in the Southeastern U.S. The analysis aims to characterize the regional sensitivities of offshore wind plant costs and performance, underwater cabling, potential siting constraints, and landfall spur transmission costs.

17 WIND ENERGY↗

Engineering B-ketoadipic Acid Production in Pseudomonas putida KT2440: Cooperative Research and Development (Final Report)

We propose a 2-year project to enable commercialization of an Agile Biofoundry (ABF) related, performance-advantaged bioproduct, B-ketoadipic acid (BKA), in an ABF-relevant, industrially-relevant host, Pseudomonas putida KT2440. Informed by techno-economic analysis (TEA), our BKA production goals are to enable a 40 g/L titer, 0.5 g/L/h productivity, and a 40% molar yield from hydrolysate sugars at the 1 kg scale. This material will be used to produce BKA-nylons.

09 BIOMASS FUELS↗

Bench-Scale Development of Promoted High-Capacity Structured Sorbents (Final Technical Report)

The project objective was to develop high-capacity structured sorbent capable of achieving low CO 2 removal from air. The sorbent framework consists of an amine-functionalized onto hydrophobic polymer backbone with an added promoter. The functionalized amine provides high CO 2 capacity and adsorption rates and the polymer backbone to reduce water uptake. For the sorbent development, multiple functionalized amines and promoters were assessed to select a candidate that achieved high CO 2 capacity, high adsorption rate, and high stability. A sorbent-coated filter design was selected as the structured sorbent, which provides high sorbent loading capacity and contains an electrically conductive nonwoven filter substrate that can be Joule-heated to provide efficient utilization of available electricity for sorbent regeneration. A commercial partner operated a pilot filter manufacturing line to produce the filter panels coated with the developed sorbent. A 1 kg CO 2 /day bench unit was designed and fabricated to test the structured filter sorbent. The key achievements from the structured sorbent development activity were demonstrating that existing filter industrial-scale processes can be used for manufacturing Susteon’s structured sorbent and completing a proof-of-concept demonstration of the commercially manufactured structured sorbent filters for CO 2 capture from air with direct, Joule-heated regeneration. A techno-economic assessment with sensitivity analysis was conducted on a 100,000 TPY facility with 85% operating capacity. Through sorbent optimization and process design improvements, it is estimated that the cost of capture was reduced from $\$$349/tCO 2 to $\$$241/tCO 2 . The TEA projects further reductions to $165/tCO 2 through enhancements in CO 2 adsorption rate and sorbent capacity and reducing manufacturing and scale up risks. A life cycle analysis was conducted on the same 100,000 TPY facility and confirmed that the facility’s electricity demand drives its greenhouse gas impact. It was determined that electricity supplied through the current grid mix would result in net-positive CO 2 emissions and that achieving net-negative emissions is only possible by powering the system with renewable electricity or fossil fuel sources equipped with carbon capture and sequestration.

36 MATERIALS SCIENCE↗

Final Report: Process Intensification of Hydrogen Production through Sorption-Enhanced Gasification of Biomass

The University of Utah, in partnership with Idaho National Laboratory (INL), evaluated Sorption-Enhanced Gasification (SEG) as a transformative pathway for producing hydrogen with the potential for negative CO 2 emissions. SEG integrates gasification, water-gas shift, and in-situ carbon capture within a dual fluidized bed reactor to enable efficient clean hydrogen production. Key challenges related to biomass variability and process complexity were addressed through feedstock engineering, reaction optimization, and process validation. A co-pelletized biomass–limestone feedstock was developed to simplify feeding and introduction of makeup limestone. Kinetic and sorbent studies identified optimal operating conditions and confirmed the suitability of low-cost limestone, while catalysts were developed to reduce tar formation. Reactor modeling and techno-economic analysis indicated that SEG can achieve competitive hydrogen production costs, particularly when combined with carbon incentives, supporting its potential for scale-up and carbon-negative operation.

08 HYDROGEN↗

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↗

King City Asbestos Corporation (KCAC) Mine Carbon Mineralization Field Test (Final Combined Report)

The overall objective of the KCAC carbon mineralization project is to determine the most successful approaches to CO 2 mineralization of asbestos-bearing serpentinite rocks and mine waste at the closed KCAC asbestos mine. The objectives of Budget Period 1 (BP1) are to characterize the site including, mineralogical and geochemical variability in site materials, baseline conditions including CO 2 flux and local climate, and to establish the designs for the second, experimental phase of the project. As described in Section 3 of this report, all tasks outlined in the Statement of Project Objective (SOPO) have been completed or are on schedule to be completed by the end of BP1. As described in Section 4, all success criteria and milestones have been met or will be met by the end of BP1. We conclude that the findings of BP1 strongly support moving to the second phase of the project to investigate methods to increase the rate of CO 2 mineralization. CO 2 flux monitoring during BP1 established an estimated baseline uptake of CO 2 over the 142,193 m 2 KCAC mine site of 147 and 179 metric tons CO 2 /yr using dynamic closed chamber and eddy covariance monitoring methods, respectively. Mineralogical analysis shows that the loose surficial waste material contains pyroaurite and minor hydromagnesite, indicating past carbon mineralization. Sediment samples at depths below 60 cm contained ~3 wt% brucite and localized high brucite contents of ~24 wt% were measured at depth, indicating significant unreacted material at relatively shallow depths. Together, these results demonstrate that despite prolonged exposure to the atmosphere, reactive material is still present and accessible and is naturally taking up atmospheric CO 2 . However, these natural rates are still well below rates that can be achieved by applying practices that can accelerate the CO 2 mineralization reaction. Designs for the Field-Testing Phase (BP2) of the project have been established, incorporating the findings of BP1. Based on results to date we have selected two methods to accelerate the rate of CO 2 mineralization, which we refer to as the Tilling Method and the Greenhouse Method. We hypothesize that these methods can increase the CO 2 mineralization rate by up to 5 times greater than the natural background rate measured in BP1. An Initial Lifecyle Assessment (LCA) and techno-economic analysis (TEA) were conducted for these two methods. The LCA concluded that the baseline version of the Greenhouse and Tilling methods at commercial scale are expected to achieve a CDR efficiency of 97% and 71%, respectively (cumulative, over 30 years of operation). Incorporating the net CO 2 removal rates calculated in the LCA, the TEA found the levelized, 30-year costs of the baseline Greenhouse and Tilling methods to be $\$$95/t-CO 2 and $\$$119/t-CO 2 , respectively, and that costs could be brought to well below $\$$100/t-CO 2 for either method by scaling up the volume of rock utilized. An initial EH&S Risk Assessment, evaluating the potential EH&S risks of the proposed carbon mineralization methods at commercial scale, was completed by LLNL EH&S professionals for these two methods.

58 GEOSCIENCES↗

Hydrogen Production Cost from Proton-Conducting Solid Oxide Electrolysis

Rigorous stakeholder-vetted techno-economic analysis (TEA) was conducted to estimate the cost of hydrogen (H 2 ) production using Proton-Conducting Solid Oxide (PSO) electrolysis. The analysis evaluates Current (2025) and Future (2035) technology cases at centralized plant scales of 50 and 500 metric tonnes per day (MTD), assuming electricity, water, and air as the only system inputs. Untaxed, unsubsidized levelized cost of hydrogen (LCOH) is projected to range from 2020 $\$$1.81 to $\$$2.47/kg H 2 at an electricity price of $\$$0.03/kWh and 97% capacity factor under Nth-of-a-kind (NOAK) deployment assumptions. Total installed capital cost was developed using bottom-up Design for Manufacture and Assembly (DFMA) stack cost modeling and detailed balance-of-plant estimates, including mechanical and electrical subsystems, installation, site preparation, engineering, and contingency. Stack performance assumptions include thermoneutral operation, degradation over time, and periodic replacement. LCOH was calculated using the Hydrogen Analysis (H2A) discounted cash flow model in constant 2020 dollars. Results indicate PSO electrolysis has potential for competitive hydrogen production costs under low-cost electricity and mature manufacturing conditions.

08 HYDROGEN↗

Roadmap to Advance Heliostat Technologies for High Temperature Solar-Thermal Systems

Since its establishment, the Heliostat Consortium (HelioCon) has made substantial progress toward closing many of the gaps in concentrating solar power (CSP) research. Numerous techno-economic studies have been performed, investigating topics ranging from the trade-off between size and temperature for industrial process heat applications to optimization of the heliostat design itself for various applications. Significant improvements have been made in optical metrology techniques, with first steps toward in situ measurement of heliostat fields. Several standards have been, and continue to be, developed with the coordination of an international group of CSP industry participants. Training programs have been developed, with universities including CSP in their engineering curricula, and many public webinars have been held to provide broad access to the latest CSP research. Improved CSP components such as mirror facets and wireless communication systems have been developed, and the solar tower at Sandia National Laboratories has been upgraded with a testbed for closed-loop controls research and development. Field deployment challenges involving heliostat foundations and sensitive wildlife habitats have been explored, with progress made toward methods for streamlining project development and permitting. Additional knowledge has been added to the body of work on wind behavior of heliostats and arrays of heliostats, with progress made toward a holistic understanding of wind design methods. Finally, techniques have been developed and demonstrated for assessing soiling conditions at a proposed project site, with predictive models for the soiling rate showing good results. Taking these results together, HelioCon has contributed greatly to the global CSP research and development effort over the past several years.

14 SOLAR ENERGY↗

Grid Resiliency using Hydro-based Microgrids During Wildfires

The primary objective of this project is to assess the techno-economic viability of hydropower resources with supplementary investments, including microgrid controllers, storage solutions, load banks, additional generation like diesel generators, communication links, and transmission infrastructure. The aim is to enable these systems to operate autonomously (in islanded mode) and ensure grid resiliency during and after wildfire events. The project seeks to establish a comprehensive framework for setting up hydropower-based microgrids, from risk estimation to final investment decisions. These microgrids can provide critical support during emergencies and offer additional grid stability and revenue opportunities during regular operations and other system contingencies.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Systems-To-Atoms (S2A): enabling hydrogen for climate security

The project addresses a critical gap in hydrogen infrastructure by integrating system-level energy models with atomic-scale material simulations in a unified Systems-to-Atoms (S2A) framework. The motivation stems from the need to develop efficient, cost-effective, and durable hydrogen transport and utilization technologies to support decarbonization of hard-to-electrify sectors such as heavy-duty transportation. Current system models lack awareness of material performance mechanisms, while material-scale models do not account for system-level usage and variability. To bridge this divide, the team developed a co-simulation capability linking techno-economic analyses, reactor/process-flow modeling, and molecular-scale catalysis simulations. Applied to hydrogen delivery in California, the framework enabled comparative evaluations of compressed, cryogenic, and liquid organic hydrogen carrier (LOHC) pathways, highlighting how catalyst operation and unit process efficiency influence overall performance. The results demonstrate that no single material or transport mode is universally optimal; instead, heterogeneous solutions tuned to specific operational contexts deliver better performance. The project delivers a new capability for cross-scale material co-design, advancing hydrogen infrastructure readiness and informing DOE and LLNL missions in climate and energy resilience.

organic↗

REopt: Energy Decision Analysis Overview for NCSP+ States Collaborative [Slides]

This presentation offers an overview of NREL's REopt(R) web tool for the National Community Solar Partnership+ States Collaborative. REopt is a techno-economic modeling tool for evaluating distributed energy resources toward a site's cost savings and resilience goals. The presentation includes an overview of the REopt platform, a REopt web tool demonstration, and resources to learn more about REopt.

14 SOLAR ENERGY↗

Evaluation of Additively Manufactured Monolithic SiC and SiC Ceramic Matrix Composites for CSP- Fabrication and Testing of Receiver Design Feature Specimens in a Simulating Lab Test via Laser Heating

Critical to the creation of a multi-component SiC receiver design concept capable of meeting the SETO CST cost goal objectives of <$150/kWth is the optimal utilization of material for solar absorption and heat transfer to transport fluid. This is to maximize the solar-thermal efficiency in the techno-economic analysis of derived use case. As a first step in preparation of sub-component design for on-sun test evaluations we use different proposed SiC absorber element in a customized laser heat flux test to assess an effective heat transfer coefficient characteristic of the design. The test results are analyzed to extract the effective heat transfer coefficient, thus enable optimization of the geometry of receiver components for heat transfer, efficiency attributes and the thermo-structural management of the components. High intensity CO2 laser is used in combination with air flow through the test specimen to assess the effective heat transfer coefficient under heat flux conditions corresponding to high solar concentrations in the range of 1000-2000 suns.

14 SOLAR ENERGY↗