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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Potential Cost Reduction in New Nuclear Deployments Based on Recent AP1000 Experience

The completion of Vogtle Units 3 and 4, despite significant cost and schedule overruns, a major bankruptcy, and a pandemic, demonstrates that the U.S. nuclear industry can still develop new supply chains, train a highly skilled workforce, and build large nuclear power plants. Vogtle, being a first-of-a-kind (FOAK) plant, faced overruns, but FOAK overruns can decrease with more deployments through a combination of design standardization and modularization, transferring and implementing lessons learned between consecutive projects, and innovation. This report quantifies the potential cost and schedule reductions in future AP1000 plants in the US and identifies the barriers in achieving those reductions. It starts with a summary and analysis of the cost and construction timeline data for AP1000 plants that started construction in the United States (Vogtle) and China. Motivated by the steep schedule reductions from the first to second series of AP1000 plants in China, a cost reduction model was developed to quantify potential reductions for future AP1000 builds in the US. Results show that within about 3 more builds, AP1000s can become economically attractive in large markets in the U.S., without leveraging the Investment Tax Credit (ITC) or Production Tax Credit (PTC), and much sooner if these tax credits are available. Importantly the financial risks for future AP1000 builds in the US might be much smaller than observed in the FOAK plants. The study also identifies various barriers for future builds including the availability of a supply chain and a skilled workforce, and emphasizes the importance of making investments to gather and implement lessons learned between consecutive projects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1977

Cost reduction potential of the DSN data base

The cost of the DSN data base can be reduced by computerizing and unifying the current multiplicity of separate manual, computer, and hybrid data bases. Savings would accrue from eliminating all manual system costs, increasing efficiency in data base implementation and maintenance-and-operation, and increasing data accuracy. By applying a simple mathematical savings model to current data base costs, this study estimates the probable range of net ten-year savings. The minimum net savings, under the assumptions of the study, are calculated as $7.5 million.

Mckenzie, M.↗
DOE OSTI2021

Methods identifying cost reduction potential for water electrolysis systems

The electrochemical reduction of water to form hydrogen is an emerging alternative for energy storage, where hydrogen can be used as a transportation fuel, combusted to generate electricity, utilized in a fuel cell, or used as a feedstock for chemical synthesis. Techno-economic analysis (TEA) is a valuable tool for understanding how to inform research directions that could make hydrogen from electrolysis cost competitive with that produced by conventional means like steam methane reforming. The current state of knowledge on TEA of electrolysis systems suggests cost reductions are likely to result from advances in system design and materials, scale-up of manufacturing processes, and learning by doing effects as electrolysis deployment increases. Future directions and opportunities for TEA of electrolysis systems include dispatchable operation in wholesale power markets, optimization of capital cost and system durability, and analysis of pathways for hydrogen to support economy-wide decarbonization.

08 HYDROGEN↗
DOE OSTI2022

2.2.1.410 - Significant Cost Reduction Potential for Wave Energy Conversion Devices with Variable-Geometry Modules

The Technology Commercialization Fund (TCF) award is built upon NREL's previous research exploring a bottom-fixed variable-geometry oscillating surge wave energy converter (VGOSWEC); however, unlike previous investigations, the VGOSWEC will be raised off the sea floor. Researchers believe that advances in offshore pilings and foundations, such as 3D printing, will provide low cost and easily deployable structures. There are several benefits to designing a raised VGOSWEC such as 1) reducing issues with sediment transport and environmental impacts near shore, 2) less expensive deployment and installation as work boats will not risk grounding in shallow water, and 3) deeper water deployments improve the wave resource.

oscillating surge wave energy converter↗
DOE OSTI2022

A Comprehensive Simulation Study to Evaluate Future Vehicle Energy and Cost Reduction Potential

Under the umbrella of EERE’s Office of Sustainable Transportation, the U.S. Department of Energy’s (DOE) Vehicle Technologies Office (VTO) and Hydrogen and Fuel Cell Technologies Office (HFTO) seek to develop sustainable, affordable, and efficient technologies for transportation of goods and people. Translating investments in advanced transportation component technologies and powertrains to estimate the potential for vehicle-level fuel savings is critical to understanding DOE’s impact and success in this mission For this study, Argonne National Laboratory (Argonne) simulated technologies funded by VTO and HFTO for light-duty vehicles across the following: Powertrain configurations (conventional, power-split hybrid electric vehicle, extended-range electric vehicle, battery electric drive, and fuel-cell vehicles); Vehicle classes (compact car, mid-size car, small sport utility vehicle [SUV], mid-size SUV, and pickup truck); Fuels (gasoline, diesel, natural gas, hydrogen, and battery electricity). We assessed each technology for five different timeframes: laboratory years 2015 (reference), 2020, 2025, 2030, and 2045. We assumed a delay of 5 years between laboratory year and model year (i.e., the year the technology is introduced into production). Finally, we included uncertainties for both technology performance and cost by considering two cases (note that these cases are not intended as predictions of future performance): Low case , aligned with DOE technology manager estimates of expected original equipment manufacturer (OEM) improvements based on business as usual regulatory and market environments; High case , aligned with aggressive technology advancements based on research and development (R&D) targets developed through support by VTO and HFTO. We estimated the energy and cost impact of different technologies using Autonomie (Argonne undated), a state-of-the-art vehicle system simulation tool developed by Argonne and used to assess the energy consumption, performance, and cost of multiple advanced vehicle technologies. The tool comprises a complete set of vehicle models to assess impacts across a wide range of classes (from light- to heavy-duty), powertrain configurations (from conventional to hybrid electric vehicles [HEVs], fuel cell electric vehicles [FCEVs], plug-in hybrid electric vehicles [PHEVs], and battery electric vehicles [BEVs]), components, and control strategies, including vehicle-level and component-level controls developed and calibrated using dynamometer test data. Autonomie has been used to support a wide range of studies: analyzing various component technologies, sizing powertrain components to meet different vehicle requirements, comparing the benefits of powertrain configurations, optimizing both heuristic and route-based vehicle energy control, and predicting transportation energy use when paired with a traffic modeling tool such as POLARIS. This report documents the assumptions made and the vehicle-level energy consumption benefits and associated technology costs estimated for various types of light-duty vehicles. Details regarding vehicle assumptions and simulation results are available in the spreadsheets accompanying this report.

08 HYDROGEN↗
DOE OSTI2023

Direct Air Capture Using Novel Structured Adsorbents (DE-FE0031959 Final Technical Report)

The objective of this project was to advance direct air capture (DAC) technology through a novel combination of a vacuum-temperature swing CO 2 adsorption process and structured adsorbent beds (SABs). The technical approach was to construct and operate an Integrated DAC System (IDS) at a test facility in Orange County, California. A 30 kilogram per day (kg/day) integrated field test unit was deployed into the field for testing, producing a concentrated CO 2 stream of at least 95% purity. A novel combination of DAC process and hardware with a transformational structured adsorbent laminate filter was fielded and tested at this site. The field testing also captured operational data on the novel process and material combination under real conditions. Data from this were used to advise techno-economic and life cycle analyses (TEA/LCA) of the technology. Despite the early development status and IDS aiming at field validation at TRL 5 rather than commercial scale operations, these analyses give valuable indications of this new technology route’s potential for cost reductions in DAC-based carbon dioxide removal. Climeworks and Svante are committed to further development of the technology route, including the realization of existing further cost reduction potential.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Potential Fuel Cycle Cost Reductions of Once Through HALEU Reactors

This report looks to identify potential cost reduction opportunities for SFR and HTGR reactors using HALEU fuel. This analysis focuses on how learning rates and experience from other industries could translate to future HALEU fueled reactor fuel cycles. Various fuel loading and residence scenarios are evaluated to estimate areas of potential cost savings. Cost savings from location optimization is explored for both fresh and spent nuclear fuel. Additional analysis was completed to estimate cost savings through improved labor productivity.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Technology Innovation Pathways for Distributed Wind Balance-of-System Cost Reduction

This exploratory analysis characterizes the balance-of-system (BOS) cost reduction opportunity for small, commercial, medium, and large distributed wind systems. To do this, we used the National Renewable Energy Laboratory’s (NREL’s) Land-based Balance of System Systems Engineering (LandBOSSE) model (Eberle et al. 2019). This model calculates the capital expenditures (CapEx) associated with installation and the system components (e.g., foundation and electrical infrastructure) other than the rotor nacelle assembly and tower. Then, building on the cost reduction potential assessment, we provide a more qualitative evaluation of prospective technology innovation concepts that may enable realization of those cost reductions for distributed wind systems.

17 WIND ENERGY↗
NASA NTRS1981

Advanced materials and fabrication processes for supersonic cruise aircraft

Research and development programs to develop high-strength aluminum alloys and low-cost materials and fabrication techniques for titanium alloys are being conducted. Thirteen aluminum alloy compositions are being evaluated. A section of a production component was fabricated using superplastic forming and diffusion bonding (SPF/DB) and fabrication studies are being conducted on three low temperature forming beta titanium alloys. Cost studies indicate substantial structural cost reduction potentials resulting from the use of both aluminum alloys and low-cost titanium fabrication techniques. Lowest overall costs are indicated for a composite/aluminum or composite titanium structure.

Guess, M. K.↗
NASA NTRS2007

Imaginable Technologies for Human Missions to Mars

The thesis of the present discussion is that the simultaneous cost and inherent safety issues of human on-site exploration of Mars will require advanced-to-revolutionary technologies. The major crew safety issues as currently identified include reduced gravity, radiation, potentially extremely toxic dust and the requisite reliability for years-long missions. Additionally, this discussion examines various technological areas which could significantly impact Human-Mars cost and safety. Cost reductions for space access is a major metric, including approaches to significantly reduce the overall up-mass. Besides fuel, propulsion and power systems, the up-mass consists of the infrastructure and supplies required to keep humans healthy and the equipment for executing exploration mission tasks. Hence, the major technological areas of interest for potential cost reductions include propulsion, in-space and on-planet power, life support systems, materials and overall architecture, systems, and systems-of-systems approaches. This discussion is specifically offered in response to and as a contribution to goal 3 of the Presidential Exploration Vision: "Develop the Innovative Technologies Knowledge and Infrastructures both to explore and to support decisions about the destinations for human exploration".

Bushnell, Dennis M.↗
DOE OSTI2023

Analysis of Crystalline Defects Caused by Growth on Partially Planarized Spalled (100) GaAs Substrates

We analyze the effect of growth on non-(100) surfaces resulting from incomplete planarization of spalled GaAs wafers on the defect structure of GaAs solar cell layers grown by hydride vapor phase epitaxy (HVPE). Controlled spalling of (100)-oriented GaAs has the potential to reduce substrate costs for III-V epitaxy; however, it creates regularly faceted surfaces that may complicate the growth of high-quality III-V optoelectronic devices. We leverage the anisotropic growth rate of HVPE to planarize these faceted GaAs substrates, reducing the surface roughness and degree of faceting. We observe degraded solar cell performance and material quality in sample areas where facets are not completely removed. We used dark lock-in thermography and photoluminescence to identify recombination in areas that were not fully planarized. We used cathodoluminescence to identify the presence of extended defects in these regions, which are correlated with bandgap fluctuations in the material. We hypothesize that these defects were created by strain from compositional fluctuations in ternary alloys grown on the faceted surfaces. This work elucidates the potential issues of solar cells grown on faceted surfaces and builds understanding toward realizing high performance III-V photovoltaics with the cost-reduction potential of controlled spalling.

14 SOLAR ENERGY↗
DOE OSTI2025

Manufacturing Cost Analysis for PEM Electrolyzers and Perspectives for Future Cost Reduction

Electrolyzer capital costs strongly influence the total levelized cost of hydrogen production and have implications for hydrogen deployment. Current electrolyzer costs are high, and large cost reductions may be needed to achieve competitive hydrogen costs and targets. Understanding pathways for cost reduction via R&D and deployment is a critical research area for informed energy planning and enabling hydrogen use. This work presents bottom-up cost estimates of polymer electrolyte membrane (PEM) electrolyzer systems tied to design specifications and discusses perspectives for cost reduction opportunities based on ongoing research. We use a detailed manufacturing and process model for a 1 MW PEM electrolyzer stack and balance of plant (BOP) for rigorous cost estimation. This allows for robust estimates of component and manufacturing costs and examination of key cost contributors. Stack costs are dominated by material costs such as iridium and platinum catalysts, especially at high manufacturing rates; power electronics and hydrogen purification equipment are the largest contributors to BOP cost. At higher manufacturing rates, better equipment utilization could reduce stack costs significantly, and we estimate that experience and bulk purchasing will allow for cost reductions to some BOP components. Still, many well-established BOP technologies and stack material costs are less likely to see significant cost reductions at high manufacturing rates. As such, manufacturing scale is limited in how much it can reduce electrolyzer costs, and additional advances for cost reduction may be needed to achieve cost targets. It will likely take many combined strategies to achieve significant cost reductions for electrolyzers and enable low-cost hydrogen production. We can use our manufacturing cost model to quantify potential cost reductions from the considerations described above and demonstrate pathways to lower cost electrolyzers. This allows for better understanding of cost reduction strategies and enables more informed research, development, and deployment for electrolyzers.

cost↗
DOE OSTI2024

Reducing the cost of home energy upgrades in the US: An industry survey

Decarbonizing the US residential building stock requires a substantial acceleration in home energy upgrades. Numerous barriers exist to accelerating adoption of efficient and electric building technologies, but foremost among these is high upfront costs. This study uses an industry survey delivered to a sample of home energy professionals to examine promising cost reduction strategies across a range of project types, including HVAC, water heating, and envelope/insulation projects. The survey included quantitative and qualitative questions to collect evidence on the estimated cost reduction potential of these strategies and their likelihood of use in the construction industry. The 167 survey respondents included contractors, energy consultants, architects, manufacturers, and others with experience in delivering energy upgrades in single-family and multifamily buildings in the US. Results show that significant cost reductions are achievable by minimizing additional infrastructure costs (such as replacing electric panels), streamlining project planning/management, and deploying innovations that simplify installation. We find that for a typical deep retrofit project, including heat pumps for space and water heating in addition to envelope upgrades, the strategies could result in a total installed cost reduction of nearly 50%, dramatically improving the customer economics of such a project. This research makes a novel contribution to the literature on strategies to reduce the costs of residential retrofits. We discuss how our study's insights on the highest-value cost reduction strategies for home energy upgrades can further accelerate their uptake in the US housing stock.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2001

A Study of the Economic Benefit Potential of Intermodal Transports

A conceptual study was conducted to determine the benefit potential of an Intermodal Transport in which quick change payload modules are used to reduce the cost of air travel by increasing daily utilization. Three basic concepts varying the degree of modularity were investigated for a 122,000 pounds payload 3,000 NM range regional wide body transport. The profit potential for operating as a passenger transport during the day and as a freighter at night was assessed. Assuming current levels of profitability, Intermodal operations could offer an operating cost reduction potential up to 20%. Enabling technology needs are identified as very quiet aircraft for expanded night operations, distributed load carrying quick disconnect latching, and configuration dependent safety issues. Recommendations are made to explore if additional benefits are possible from alternative mission and usage modules.

Nelson, J. M.↗
DOE OSTI2024

Options for Achieving Cost Reduction in Advanced Reactors through Open Architecture

A key contributor to high capital costs and schedule overruns for new nuclear power plants is lack of standardization, driven by site-specific customization and construction of multiple designs by competing vendors rather than commitment to a single standardized program. While advanced reactor vendors typically individually target repeat construction of standardized units, the many competing designs could exacerbate the problem. “Open Architecture”, the open specification of requirements and interfaces for structures, systems and components (SSCs), has been proposed as a means of promoting standardization, by facilitating existing non-nuclear suppliers to enter the industry and/or allowing SSCs to be configured for more than one reactor within the same technology type. Contracting mechanisms that facilitate information sharing and alignment of incentives between stakeholders may complement such an approach. A preliminary scheme is presented for selection of SSCs for which such strategies could be adopted, based on a vendor make/buy decision model and stakeholder interviews. SSCs are categorized according to number of suppliers and their contribution to the reactor’s competitive edge. SSCs with many potential suppliers and a high contribution to competitive edge may be attractive for widening the supply chain via open specification of system requirements and interfaces, e.g., SSCs in the power island. SSCs with few suppliers and low contribution to competitive edge may be potential avenues for common system specification between vendors, e.g., some of the auxiliary SSCs. Potential cost reductions from such strategies will depend upon the size of the build program and the reactor type.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Investigation of precooling unit design options in hydrogen refueling station for heavy-duty fuel-cell electric vehicles

Precooling gaseous hydrogen fuel to a cold temperature before refueling a heavy-duty (HD) hydrogen fuel cell electric vehicle (HFCEV) is essential to avoid overheating the vehicle tank, as well as achieving a high state of charge (SOC). Because a large volume of hydrogen is dispensed during each fill, the need for a shorter fill time amplifies the need to precool each load for refueling a HFCEV. Thus, the design and operation of a precooling unit (PCU), as well as the associated capital and operating costs, plays a pivotal role in any plans for heavy-duty hydrogen refueling stations. Here, in this paper, we present a thermodynamic and technoeconomic analysis of a PCU in a gaseous hydrogen refueling station (HRS) for HD HFCEVs. By employing Argonne National Laboratory's hydrogen station cost optimization and performance evaluation (H2SCOPE) model, the refueling of 50 kg of hydrogen on-board type IV tank at ambient temperatures of 15–45 °C and varying fill rates is simulated. The required degree of precooling temperature to obtain either 100% or the maximum possible SOC is obtained from the simulation. Additionally, the simulation results demonstrate that the average flow rate of hydrogen is approximately 40% lower than the maximum flow rate during a typical fill; which motivates further evaluation of the instantaneous hydrogen mass flow rate profile and suggests the scope of improving precooling unit design. Accordingly, a hybrid strategy of precooling hydrogen has been proposed to address the cooling load by sizing the refrigeration unit for the average flow rate of hydrogen, while supplementing the above average peak hydrogen flow cooling load through thermal buffering. The combined technique enables the downsizing of the original PCU capacity by 25–40% and demonstrates a potential cost reduction of the PCU by approximately 30%, which translates to an installed cost reduction of ∼$125,000 per dispenser.

25 ENERGY STORAGE↗
DOE OSTI2024

Assessment of Technoeconomic Opportunities in Automation for Nuclear Microreactors

Achieving full decarbonization of all economic sectors remains a challenge, especially in niche markets. For example, remote communities and industrial or mining activities detached from the main electric grid heavily rely on fossil fuels, similar to urban and industrial microgrids with combined heat and power needs. A combination of renewables and energy storage is often not suitable due to cost, reliability, intermittency, and large storage requirements. Small nuclear reactors with a flexible purpose could serve these applications. Microreactors (MR) are a class of reactors that are compact, factory manufactured, transportable, and self-regulating. Typically, they generate much less power than their large reactor counterparts. The main advantages of microreactors include the versatile nature of the energy produced, the reliability of supply, and freedom from having to transport and store large quantities of fuels on-site, coupled with the absence of dependence on an electrical grid. A strong business case is needed to move from the microreactor prototype to the commercialization phase. In fact, fossil fuels are still relatively inexpensive, and in the near term, carbon credits will be available to virtually compensate for emissions. For microreactors, one of the main costs in operation and maintenance (O&M) is their staffing levels. In this study, we investigate how to optimize the number (and thus the cost) of workers, moving from a traditional, fully manned, on-site personnel approach to an unmanned, remote personnel approach. We examine four different staffing models that can be implemented as the technology matures and evolves. We estimate the staffing needs of each model and build a business case to justify the substitution of on-site personnel with adequate technologies. To do so, we propose a cost model to quantify potential cost reductions from automating O&M activities. The model accounts for both the reduction in cost derived from the reduced number of full-time-equivalent (FTE) employees and the increase in cost derived from the need to buy new control hardware as needed. Applying the cost model that we created to different scenarios, an on-site O&M cost reduction exceeding 80% can be expected. Additionally, we found that it is more impactful to focus on automating routine O&M tasks rather than attempting to automate transient management (shutdowns, restarts, monitoring condition deviations). In fact, transients typically account for less than 1% of the total FTE time spent on the reactors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗