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DOE OSTI2026

Data for 3-Hydroxypropionic Acid Recovery from Fermentation Broth through Novel Downstream Processing: Technoeconomic Analysis

This study develops and validates a simplified, fully solvent-free downstream processing (DSP) strategy for high-purity recovery of 3-hydroxypropionic acid (3-HP) from real fermentation broth containing 62.3 g/L of 3-HP. Optimized activated carbon treatment achieved 98% color removal, while Amberlite IRA-67 was operated at pH 4.5 and 30 °C to minimize product loss. This is the first integrated demonstration of a fully solvent-free DSP enabling recovery of bio-based 3-HP as both a solid sodium salt and a concentrated aqueous solution, supported by techno-economic analysis. At lab scale, the process achieved 77.3% recovery of sodium 3-HP with 83.2% (w/w) purity and produced a 30% (w/v) aqueous solution. Techno-economic analysis yielded minimum selling prices of $0.551/kg for the solution and $0.892/kg for the salt, both below target thresholds for cost-competitive bio-acrylic acid production. Overall, these results demonstrate an efficient, scalable, and economically viable industrial pathway for 3-HP recovery.

Bioproducts↗

DOE OSTI2026

3-Hydroxypropionic acid recovery from fermentation broth through novel downstream processing: Technoeconomic analysis

09 BIOMASS FUELS↗

DOE OSTI2026

Technoeconomic Analysis of the Miba Segmented Journal Bearing

This presentation describes a technoeconomic analysis using NLR's Windfarm Operations & Maintenance cost-Benefit Analysis Tool (WOMBAT) to compare operational expenses and levelized cost of energy for wind turbines using standard spherical roller bearings with a novel segmented journal bearing developed by Miba.

17 WIND ENERGY↗

DOE OSTI2026

Technoeconomic Analysis Round Robin of a Retrofit of the Ivanpah Concentrating Solar Plant with a Molten-Salt System with Thermal Energy Storage

While the fidelity of technoeconomic analysis (TEA) models for concentrating solar thermal systems has improved in recent years, there is a lack of consensus on the specific inputs used to forecast performance of a newly built tower system due to a lack of validations and post-mortems available to the public. This effort is a joint initiative between multiple international organizations to validate and compare their TEA models. The specific case study is a proposed retrofit of one unit of the Ivanpah Solar Energy Generating System to include molten-salt storage, replacing the steam generation system with a molten-salt receiver, salt-to-steam heat exchanger train, and new balance of plant while keeping the existing steam turbine, solar field, and interconnection in place, using plant data for calibration. This manuscript discusses several of the agreed-upon assumptions for this study as well as a preliminary analysis from prior work that motivates the study.

14 SOLAR ENERGY↗

DOE OSTI2026

Technoeconomic Analysis of Steel Production with Electric Thermal Energy Storage

The iron and steel industry is an important manufacturing sector and one of the largest energy consumers in the United States and globally. Hydrogen direct reduction of iron ore (H2DRI) is considered a promising process that could enhance domestic steel production. This process requires hydrogen inlet temperatures up to 950 degrees C to drive the endothermic reduction of the iron ore pellets. In this work we investigate the technoeconomic performance of an H2DRI plant using electric thermal energy storage (ETES) technologies for the hydrogen heating, compared to conventional natural gas fired heaters, hydrogen fired heaters, and electric hydrogen heaters. A technoeconomic analysis framework for the plant is developed and used in multiple case studies, covering different hydrogen prices, grid electricity profiles, and financing scenarios. The levelized cost of steel production is found out to be in the range of $775-950/mt, which is mostly inside the benchmarked steel price of $941/mt. ETES-based hydrogen heating is found to be in par with conventional natural gas fired heaters, and cheaper than hydrogen fired heaters and electric hydrogen heaters. The major cost drivers are the iron ore and hydrogen feedstock, followed by the hydrogen compression and heating capital. Several insights and suggested future directions are identified.

08 HYDROGEN↗

DOE OSTI2025

Technoeconomic Analysis of a Microwave-Assisted Novel Process That Converts Polypropylene Plastic Waste to Propylene

Propylene is an important petrochemical that is used in various industries, including the automobile and polymer sectors. Conventionally, propylene has been produced through fluid catalytic cracking, steam cracking, and propane dehydrogenation. In this project, a novel process to produce propylene from polypropylene plastic waste using a microwave reactor is introduced. Propylene production is simulated in Aspen Plus for both the conventional propane dehydrogenation process and the novel design, with heat integration applied to minimize utility demands and the conventional process serving as the base case for comparison. Finally, a tailored technoeconomic analysis is carried out for both simulated cases to estimate important economic indicators. Analysis of the results shows that the novel microwave-assisted process outperforms the conventional route for propylene production, achieving a single-pass conversion of almost 100%, compared with only 33.8% in the conventional plant. The Net Present Value of the novel plant is $\$1720.3$ MM, which is 3.5 times higher than the conventional process, while the Levelized Cost of Propylene is reduced by 40%. Capital and operating expenditure are also improved in the proposed scheme, with reductions of approximately $\$29$ MM and $\$222$ MM/yr, respectively. In addition to cost savings, this novel process also provides a convenient means to recycle waste polypropylene.

42 ENGINEERING↗

DOE OSTI2026

Technoeconomic Analysis of a Novel Microwave Process to Produce Ethylene from Methane

Ethylene is a critical feedstock in industrial processes, serving as a raw material in the petrochemical industry to produce plastics and commodity chemicals. Conventional ethylene production routes are energy-intensive and contribute substantially to the carbon footprint of chemical manufacturing. In this study, an industrial-scale novel microwave process was simulated using ASPEN Plus to assess its economic viability. Technoeconomic analysis confirmed the economic competitiveness of the novel microwave process, with a levelized cost of ethylene of USD 0.51/kg compared to USD 0.56/kg for the conventional base case. Key economic drivers of the process were identified, and sensitivity analyses were conducted to evaluate their impact on project economics. Furthermore, 87.7% of the total utility consumption in the novel microwave process is electricity, highlighting its potential to contribute to the electrification of the chemical industry. The findings of this study confirm the economic feasibility of both industrial-scale microwave reactors and modular plant configurations for the production of ethylene from methane, offering a promising alternative to conventional processes.

electromagnetic radiation↗

DOE OSTI2026

Technoeconomic analysis and life cycle assessment of purification processes for captured CO 2 streams

Captured carbon dioxide (CO 2 ) streams contain impurities that must be removed to meet specifications for safe transport, storage, and utilization. Among these impurities, oxygen poses challenges due to its high reactivity and potential to cause corrosion, motivating stringent purity limits below 10 ppmv. Building on recent experimental demonstrations of catalytic oxygen removal using hydrogen (H 2 ), carbon monoxide (CO), methanol (CH 3 OH), and methane (CH 4 ) as reducing agents, this study presents a technoeconomic (TEA) and life cycle assessment (LCA) of these four catalytic purification pathways. Process flowsheets were developed and simulated in Aspen Plus for CO 2 streams representative of both low-temperature and high-temperature capture processes, with integrated heat recovery and energy optimization. Results showed that total purification costs were dominated by feedstock procurement and electricity consumption. Among the studied reducing agents, the CH 4 -assisted route achieved the lowest purification cost and highest CO 2 recovery. Sensitivity analyses showed that the H 2 route became competitive at H 2 prices below $\$$0.56/kg to $\$$0.84/kg, depending on the CO 2 feed temperature conditions. In conclusion, environmental impacts were primarily driven by indirect CO 2 emissions from raw material production and utility consumption.

CO2 pipeline specifications↗

DOE OSTI2026

Technoeconomic analysis of hydrogen storage using 1,4-butanediol (BDO)/γ-butyrolactone (GBL) as a stationary backup power system

Liquid organic hydrogen carriers (LOHCs) are compounds that store and release hydrogen in stable forms at high density. While one-way carriers such as methanol and ammonia have gained attention, their economic advantages are often realized from their use as an export product and direct use as a fuel. Liquid carrier materials that can instead be cycled for energy storage have promise for stationary power applications. In particular, the reversible LOHC system 1,4-butanediol (BDO, H 2 -rich) and gamma-butyrolactone (GBL, H 2 -lean) has a lower enthalpy of dehydrogenation compared to conventional cyclic hydrocarbons and can utilize non-precious metal copper-based catalysts. Here, in this study, BDO/GBL system capital and operating expenses are characterized for vapor phase versus liquid phase hydrogenation and dehydrogenation in a 10 MW backup power application corresponding to sizing of Tier 2 datacenters as well as other critical infrastructure such as hospitals. Costs are benchmarked against two incumbent technologies: a well-established methylcyclohexane/toluene carrier system and compressed gas storage. BDO/GBL storage costs are found to differ substantially between operating modes, with liquid phase hydrogenation coupled with liquid phase dehydrogenation leading to the lowest LCOS of $\$$4.58/kg H 2 in the absence of byproduct formation. In this bounding case, LCOS for the BDO/GBL system is lower than for MCH/TOL ($\$$6.97/kg H 2 ) and compressed gas ($\$$8.48/kg H 2 at 170 bara and $\$$12.05/kg H 2 at 350 bara). However, escalating costs of carrier replacement due to byproduct formation (ranging from an added $\$$6–11/kg H 2 ) illustrate the need for highly selective catalysts to ensure BDO/GBL carrier viability.

BDO/GBL↗

DOE OSTI2025

Technoeconomic analysis for near-term scale-up of bioprocesses

Growing the bioeconomy requires products and pathways that are cost-competitive. Technoeconomic analyses (TEAs) aim to predict the long-term economic viability and often use what are known as n th plant cost and performance parameters. However, as TEA is more widely adopted to inform everything from early-stage research to company and investor decision-making, the n th plant approach is inadequate and risks being misused to inform the early stages of scale-up. Some methods exist for conducting first-of-a-kind/pioneer plant cost analyses, but these receive less attention and have not been critically evaluated. This article explores TEA methods for early-stage scale-up, critically evaluates their applicability to biofuels and bioproducts, and recommends strategies for producing TEA results better suited to guiding prioritization and successful scale-up of bioprocesses.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Technoeconomic Analysis of Microwave-Assisted Dry Reforming Integrated with Chemical Looping for Production of Methanol

Methanol is a key component in producing formaldehyde, acetic acid, and methyl tert -butyl ether (MTBE) and supports a wide array of industries, including plastics, textiles, and automotive. It also plays a growing role in renewable energy solutions. However, the conventional production of methanol involves steam reforming of methane, which is very energy-intensive and produces significant quantities of the greenhouse gas carbon dioxide. In this research, a chemical looping scheme is combined with dry reforming of natural gas in a novel microwave reactor to produce an industrial quantity of methanol. A heat exchanger network is developed to substantially reduce hot and cold utility usage. The effect of the cost of purchasing carbon dioxide from an external source for dry reforming, the capital cost of the microwave reactor, and the cost of electricity on the net present value is analyzed. Technoeconomic comparison with the conventional industrial process that produces methanol via steam reforming of methane indicates that the chemical looping generates a significant positive net present value along with a substantial reduction in carbon dioxide emissions while producing methanol significantly below the U.S. Department of Energy’s goal of $800/ton.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Novel artificial neural network model for instantaneous power losses and operational efficiency mapping of MW-scale vanadium redox flow battery for improved technoeconomic analysis

A novel data-driven, machine-learning-based method for modeling the instantaneous power losses of a distribution-sited 2 MW/8MWh vanadium redox flow battery (VRFB), a grid-scale electrochemical storage technology, is introduced and compared against benchmark empirical modeling approaches, including symmetric and asymmetric models, as well as a recent convex hull modeling approach. The novel loss modeling method introduces several advantages over the benchmark models and over simplistic efficiency estimates, the most significant of which is that the model can accurately reflect the stepwise and non-linear parasitic losses associated with the duty cycles of mechanical auxiliary systems like pump motor drives and blower fans. Residuals of the models are compared; the proposed data driven model features significantly improved accuracy over the benchmark models. The model's coefficient of determination is also improved relative to that of the benchmark models. Furthermore, a novel method for visualization of operational efficiency of the grid-scale storage technology is introduced. To demonstrate the benefits of the novel data-driven method for modeling the VRFB, the benchmark models and the proposed models are embedded into an Open DSS distribution network model to study two applications of the grid-scale electrical storage system: load leveling for grid support and energy arbitrage. This article demonstrates that the accuracy of the instantaneous power loss model significantly impacts the understanding of the state of charge of the VRFB. In turn, the accuracy of the efficiency modeling of the VRFB impacts the understanding of the potential economic value and technical benefits to the distribution network operators. In conclusion, the presented power loss modeling approach is, therefore, highly relevant for utility-stakeholders, battery asset owners, system engineers, system designers, and financial planners interested in evaluating or optimizing the operation of grid-scale VRFBs.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

A technoeconomic analysis of poly- and single-crystalline NMCxyz from material synthesis to battery pack design

A process model was developed for estimating the cost of manufacturing lithium nickel manganese cobalt oxide (LiNi x Mn y Co z O 2 , NMCxyz), the main cathode active material in lithium-ion batteries used for electric vehicles in the United States. The model was used to estimate the prices of NMC622, NMC811, and NMC955 with poly- and single-crystalline morphologies. The Battery Performance and Cost Model (BatPaC) was used to translate the NMC prices into battery pack prices. A decrease in cobalt content from NMC622 (20% Co) to NMC955 (5% Ni) decreases the material price by $\$$0.85/kg (−3%) due to a decrease in the cost of battery materials, which account for >60% of the total price. NMC622 only produce cheaper packs if the nickel sulfate cost is > 4 × its baseline, indicating higher nickel materials will lower pack cost under normal market conditions. Single-crystalline materials are $\$$2/kg (+8%) more expensive than their polycrystalline counterparts due to higher manufacturing costs from longer, hotter calcinations in less densely packed saggars. This increases the pack price by ∼$\$$3/kWh, assuming identical electrochemical properties. In conclusion, the single-crystalline materials could yield cheaper packs if cycled to higher upper cutoff voltages (i.e., 4.35 to 4.43 V for the single-crystalline material vs. 4.25 V for their polycrystalline counterparts).

Cost modeling↗

DOE OSTI2025

Demonstration and technoeconomic analysis of dodecanol production from acetate using metabolically engineered Escherichia coli

In a circular bioeconomy, the one-way conversion of petroleum to chemicals and CO 2 is replaced with processes that reduce CO 2 to energy carriers and useful materials that are returned to CO 2 upon combustion. A circular bioeconomy that relies on photosynthesis to generate sugars as the chief energy carrier and precursor to chemical building blocks has yet to overcome many recalcitrant aspects of plant-based photosynthesis, namely, high feedstock costs, arable land scarcity, food competition, and fertilizer overuse. Acetate is a potential sustainable energy carrier because it can be produced from CO 2 either electrocatalytically or by acetogens via the Wood-Ljungdahl pathway. Here, in this work, we conducted a metabolic engineering study of Escherichia coli 's ability to convert acetate into dodecanol as a model oleochemical product. We performed techno-economic and life cycle analyses to determine break-even points with alternative fossil fuel-based strategies and identified critical process performance parameters for supporting an industrial acetate-based bioprocess. These analyses showed that oleochemical yield is the primary driver of minimum oleochemical selling price and carbon intensity. Therefore, to increase yield on acetate, we deleted the aceBAK operon, which facilitates funneling of acetate into biomass instead of product. We performed additional strain engineering to increase flux towards dodecanol and increase acetate uptake. Finally, we demonstrated increased yield in controlled bioreactors, improving from 13% of the maximum theoretical yield to 37%. Rigorous uncertainty analyses assuming a range of market conditions and future technological performances resulted in 88% and 37% of simulated scenarios having lower carbon intensities than fossil fuel-based routes and lower minimum selling prices than the market price.

Acetate↗

DOE OSTI2025

Comparative Technoeconomic Analysis and Life Cycle Assessment of Emerging Reactive Carbon Capture-to-Methanol Pathways

Our group recently developed dual-function materials (DFMs) and reactive carbon capture (RCC) processes for the selective production of methanol (MeOH) or CO, offering two novel and unique pathways for MeOH production. This study conducted a comparative techno-economic analysis (TEA) of the two RCC pathways from exhaust CO 2 : 1) a “Direct RCC-to-MeOH” pathway and 2) an “Indirect RCC-to-CO” pathway followed by MeOH synthesis. The “Direct RCC-to-MeOH” pathway produced a lower levelized cost of MeOH (LCOM) at $\$$0.78/kg, compared to $\$$0.84/kg for the “Indirect RCC-to-CO” pathway. The key difference is the need to recompress the syngas from RCC before MeOH synthesis in “Indirect RCC-to-CO.” Nonetheless, with reduced catalyst costs and hydrogen requirements for “RCC-to-CO,” this pathway merits further study to produce syngas rather than MeOH. Both pathways are comparable in LCOM to baseline e-MeOH production from CO 2 hydrogenation ($\$$0.72/kg) while having lower carbon intensities (0.45 and 0.51 kg-CO 2 e/kg vs 0.54 kg-CO 2 e/kg).

08 HYDROGEN↗

DOE OSTI2026

Defining Electrode-Level Metrics for Enabling Earth-Abundant, Mn-Rich Cathodes: A Technoeconomic Analysis of Experimental Materials

Manganese-rich oxides are attractive options as next-generation, earth-abundant cathodes and significant efforts are being directed toward commercial implementation. We report here an updated techno-economic analysis of the lithium- and manganese-rich (LMR) class of earth-abundant cathodes for electric vehicle applications. BatPaC modeling was used to define the cell-level metrics that must be met for these materials to be cost and energy competitive with the current commercial earth-abundant benchmark, LiFePO 4 , as well as anticipated variations such as LiMn 0.8 Fe 0.2 PO 4 . The model was used to evaluate a high-performance material from the literature and subsequently define R&D targets as the likely limits of practical performance for similar LMR systems. Experimental validation and BatPaC evaluation of an advanced, cobalt-free LMR cell system was also conducted. Results show that the advanced LMR cells come within ∼5% of the defined limits and exceed the energy of LiFe(Mn)PO 4 cells at a similar cost. Excellent cycle-life, low impedance, and low impedance rise were also achieved under the conditions tested and reveal that cobalt is not necessary to achieve high-performance LMR oxides. Although the analysis conducted herein reports on LMR cell systems, the methodology and target values defined for performance metrics easily extend to the evaluation of other systems under consideration as earth-abundant options.

Chen, Jiajun [Argonne National Laboratory (ANL), A↗

DOE OSTI2025

Brazilian CBP - Technoeconomic analysis data

This data is related to the paper entitled "Techno-economic analysis of sugarcane bagasse and straw conversion into cellulosic ethanol via consolidated bioprocessing". That features the evaluation of sugarcane bagasse and straw conversion to ethanol at stand-alone facilities generating electricity from residues. The following scenarios were evaluated: Conventional, featuring hydrothermal pretreatment, fungal cellulase, and yeast fermentation (current commercial standard); Mid-term consolidated bioprocessing (CBP), relying on bagasse solubilization without pretreatment or cotreatment; and Mature CBP, incorporating cotreatment but no pretreatment and considering significant technological advance of the CBP. Available here are the spreadsheets used for Material and Energy balance calculation, Capital and Operational costs estimation and Cash flow analysis. Also available are the description and python code used for Monte Carlo analysis of the ethanol and capital investment variations. This data can be used as a source to implement other techno-economic analysis in the biorefinary context.

09 BIOMASS FUELS↗

DOE OSTI2025

Technoeconomic Analysis (TEA)

Techno-economic analysis (TEA) for the DuraMAT Consortium includes the following areas: linking solar photovoltaic (PV) technology trends to reliability implications; providing a framework to calculate technology costs, yielding insights useful for research decision-making, proposals, technology selection, and publications; and examining technology tradeoffs considering lifecycle project economics. This poster highlights results from the first and second iterations of the DuraMAT Technology Scouting reports as well as the updated Simplified PV Levelized Cost of Energy (LCOE) Calculator.

14 SOLAR ENERGY↗