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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

Quality Guidelines for Energy System Studies: Process Modeling Design Parameters

The National Energy Technology Laboratory (NETL) conducts systems analysis studies that require a large number of inputs, from ambient conditions to parameters for Aspen Plus ® (Aspen) process blocks. The sheer number of assumptions required makes it impractical to document all of them in each issued report. The purpose of the Quality Guidelines for Energy System Studies (QGESS) is to document the assumptions most commonly used in system analysis studies and the basis for those assumptions. In order to develop the systems analysis models presented in various NETL reports, significant vendor data have been obtained, and these data enhance the model outputs. Much of the vendor data obtained are considered proprietary and not suitable for public release or attribution to a specific vendor. As such, several sub-systems common in NETL reports and their process parameter data are not reported in this document to protect proprietary vendor information. The values and ranges of values presented in this report represent assumptions that have been made in previous studies.

97 MATHEMATICS AND COMPUTING

Quality Guidelines for Energy System Studies: Capital Cost Scaling Methodology: Revision 4b Report

The National Energy Technology Laboratory (NETL) regularly updates legacy analysis with new studies and cases as the Department of Energy objectives change, technology performance improves, costs are reduced, regulations change, market drivers are established, fuel prices fluctuate, and any number of other relevant factors vary in the market. As legacy studies are updated by NETL, the underlying performance and cost of the cases presented changes, and as such, the methods for interpreting and scaling the cost estimates change. Therefore, it is important that NETL maintain public guidance documents associated with different sets of cost estimates that delineate how a specific set, based on report vintage and/or year published, should be scaled. This Quality Guidelines for Energy System Studies report, providing guidance on capital cost scaling, should generally be applied to NETL case costs included in the report “Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity Revision 4b,” (NETL, 2025) or any cases derived from the cases presented in the referenced report.

29 ENERGY PLANNING, POLICY, AND ECONOMY

Evaluation and calibration of MERRA-2 and CAMS reanalysis for PM 2.5 in a semi-urbanized area in the south of the Amazon

Air pollution has significant implications for the climate and poses irreversible risks to human health. The Amazon region of Brazil is severely affected by biomass burning (BB) emissions, yet air quality monitoring remains highly inadequate. Given the scarcity of surface-based observations, reanalysis models have become essential tools for assessing air pollution. Although MERRA-2 and CAMS PM 2.5 products are widely utilized, their validation and comprehensive evaluation for the Amazon Basin remain limited. Here, this study assesses the performance of these products in a semi-urbanized region in the southern Amazon. The calibrated time series was employed to analyze PM 2.5 concentrations from 2003 to 2023. Our results showed satisfactory performance of both products for the 24-h averages of PM 2.5 , with linear correlations above 0.76. However, it was found that both products overestimate surface concentrations. MERRA-2 performed better, with approximately 30% lower bias than CAMS. Time series analysis showed that the study area is strongly impacted by emissions BB in the dry period, mainly in August and September. Furthermore, our findings indicate a positive trend in increasing PM 2.5 concentrations, with a notable rise observed since 2014. The average PM 2.5 levels frequently exceed the daily air quality guidelines established by the WHO in 2021. It has been estimated that the population of this region is exposed to concentrations above 15 μg.m -3 , on average, more than 30 days per year. Our results contribute to the evaluation of MERRA-2 and CAMS products for Amazon and provide a corrected estimate for surface PM 2.5 . Recent concerns about air quality and the implementation of new surface monitoring networks may improve the evaluation of reanalysis products. In the short term, the need for this information makes our assessments indispensable.

54 ENVIRONMENTAL SCIENCES

ORNL Package Testing Program Software Quality Assurance Plan

The Oak Ridge National Laboratory (ORNL) Package Testing Program (PTP) uses commercial off-the-shelf (COTS) software in performing data collection of thermal test results for package designs that contain radioactive materials. Specifically, this software is used to collect temperature data from the furnace, packages, and ambient air to prepare and execute the thermal test specified in 10 CFR 71.73, “Thermal Test.” This software quality assurance (SQA) plan sets forth the guidelines, standards, and procedures that shall be used to provide SQA for PTP software applications. This is a living document that will be maintained for the lifecycle of the PTP program. The SQA plan follows the requirements set forth in ORNL Standards Based Management System (SBMS): Information Technology; Subject Area: Software Quality Assurance. When applicable to the requirements as described in ORNL SBMS, Software Quality Assurance, the software shall be listed in the ORNL Software Registration System (SRS). Exemptions to this SBMS are COTS and firmware that are not modified; spreadsheet applications and personal productivity tools that do not have a utility or safety application, research applications, legacy software, system software, vendor-supplied software used to interface with the vendor’s services, software used within the organization to facilitate processing or management of information, and software developed for applications not specific to the US Department of Energy (DOE).

97 MATHEMATICS AND COMPUTING

DOE Zero Energy Ready Manufactured Housing: Subject Matter Expert Technical Assistance Summary

Manufactured homes offer American consumers an affordable option for decent single-family detached housing. For working-class American families in many U.S. markets, manufactured homes are the first step toward home ownership. They now make up 10% of all new homes constructed in the United States, with higher percentages in the south and in rural communities. To help encourage the production of homes that are more durable, healthy, efficient, and disaster resistant, the U.S. Department of Energy is bringing its building science research to the manufactured housing industry through DOE’s Zero Energy Ready Manufactured Home (ZER-MH) program, which provides technical assistance and voluntary guidelines to manufactured home builders. Homes built to these guidelines are better able to handle power outages and less likely to experience moisture issues, offering a better product option for American families. This higher quality is evidenced by energy modeling which shows homes manufactured to these voluntary guidelines will typically use half the energy of manufactured homes built to the current minimum requirements of the U.S. Department of Housing and Urban Development (HUD)’s Manufactured Housing and Construction Safety Standard (MHCSS). These homes can also reduce critical energy demand during the busiest hours of the day, typically late afternoon and early evening in the summer when air conditioning demand is highest and mornings in the winter when furnaces and heaters are heating up. Reducing electricity demand during these peak periods when electricity rates are at their highest reduces costs for American families while freeing up capacity on overburdened energy distribution networks. Builders participating in the DOE ZER-MH program are eligible for a tax incentive via the 45L tax credit, which helps to offset the costs of ZER-MH upgrades, enabling builders to offer these certified homes at no additional cost. Together these factors enable manufactured homes to offer home buyers a housing option that is both affordable to finance and affordable to operate, with lower monthly mortgage payments and lower monthly energy bills.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Guideline 36 Conformance Test v2.0

ASHRAE Guideline 36 provides guidance for how typical commercial building HVAC systems should be controlled to reduce energy costs and improve the indoor environmental quality for occupants. An industry-led effort is developing test scripts for how control manufacturers can test that the control logic in their control products follows Guideline 36. This software intends to support that effort in two ways. First, by providing a testbed for control manufacturers to run the test scripts against their own control products and compare their generated results to the expected results provided by the test scripts. Second, by providing a testbed that can be used during the development of test scripts to rapidly and repeatably verify they exercise Guideline 36 logic as desired and generate accurate expected results that control products can be compared to. An initial version of the software has already been developed and released open-source by a previous CEC-funded project that implemented the first use case (https://github.com/LBNL-ETA/guideline36_conformance_test/blob/master/LICENSE.txt), while this software disclosure will add the functionality of the second use case, as well as update the software where needed, all open-source. We intend to extend and contribute to the existing open-source software repository.

Blum, David [Lawrence Berkeley National Laboratory

Análisis de Tareas del Inspector de Control de Calidad [Quality Control Inspector Job Task Analysis (Spanish Translation)]

El Laboratorio Nacional de Energía Renovable (NREL) ha sido contratado por el Programa de Asistencia para la Climatización (WAP) del Departamento de Energía de EE.UU. (DOE) para desarrollar y mantener los recursos en el marco del proyecto de Directrices para Profesionales de la Energía Doméstica (GHEP). El objetivo del proyecto GHEP es aumentar la calidad del trabajo realizado para la remodelación energética residencial en Estados Unidos a través de WAP y otros programas de remodelación residencial. Para cumplir el objetivo de “Establecer certificaciones nacionales de la mano de obra y normas de formación”, el DOE encargó al NREL el desarrollo de recursos GHEP, incluido un conjunto de certificaciones avanzadas, basadas en aptitud, para el personal de los profesionales de la energía doméstica (HEP). Desde 2010, el NREL ha reclutado voluntarios expertos en la materia de WAP y de la industria del mantenimiento del hogar para que formen parte de comités que desarrollen y actualicen programas de certificación y sus análisis de tareas (JTA) necesarios como base de programas de certificación y formación estandarizados. Las certificaciones HEP apoyan al WAP y al sector del mantenimiento de viviendas residenciales en general mediante el proceso de acreditación y el desarrollo de JTA definidos para auditores energéticos (EA) e inspectores de control de calidad (QCI). Este informe es un resumen de las actualizaciones más recientes (2022) del JTA del QCI. [The National Renewable Energy Laboratory (NREL) is contracted by the U.S. Department of Energy (DOE) Weatherization Assistance Program (WAP) to develop and maintain the resources under the Guidelines for Home Energy Professionals (GHEP) project. The purpose of the GHEP project is to increase the quality of work conducted for residential energy retrofits in the United States through the WAP network and other residential retrofit programs. This is the Spanish translation of NREL/TP-7A40-85789.]

29 ENERGY PLANNING, POLICY, AND ECONOMY

A mechanistic study on environment gas in laser powder bed fusion

A variety of protective or reactive environmental gases have recently gained growing attention in laser-based metal additive manufacturing (AM) technologies due to their unique thermophysical properties and the potential improvements they can bring to the build processes. However, much remains unclear regarding the effects of different gas environments on critical phenomena in laser AM, such as rapid cooling, energy coupling, and defect generation. Through simultaneous high-speed synchrotron x-ray imaging and thermal imaging, we identify distinct effects of two environmental gases in laser AM and gained a deeper understanding of the underlying mechanisms. Compared to the commonly used protective gas, argon, it is found that helium has a negligible effect on cooling the part. However, helium can suppress unstable keyholes by decreasing effective energy absorption, thus mitigating keyhole porosity generation and reducing pore size under certain processing conditions. In conclusion, these observations provide guidelines for the strategic use of environmental gases in laser AM to produce parts with improved quality.

36 MATERIALS SCIENCE

Análisis de Tareas del Auditor Energético [Energy Auditor Job Task Analysis (Spanish Translation)]

El Laboratorio Nacional de Energía Renovable (NREL), bajo el contrato con el Programa de Asistencia para la Climatización (WAP) del Departamento de Energía de EE.UU. (DOE), desarrolla y mantiene los recursos en el marco del proyecto Directrices para Profesionales de la Energía Doméstica (GHEP). El objetivo del proyecto GHEP es aumentar la calidad del trabajo de remodelación energética residencial realizado por WAP y otros programas de remodelación residencial en Estados Unidos. Para cumplir el objetivo de “Establecer certificaciones nacionales de la mano de obra y normas de formación”, el DOE encargó al NREL el desarrollo de recursos GHEP, incluido un conjunto de certificaciones avanzadas, basadas en aptitud, para el personal de los profesionales de la energía doméstica (HEP). Desde 2010, el NREL ha reclutado voluntarios expertos en la materia de WAP y de la industria del mantenimiento del hogar para que formen parte de comités que desarrollen y actualicen programas de certificación y sus análisis de tareas (JTA) necesarios como base de programas de certificación y formación estandarizados. Las certificaciones HEP apoyan al WAP y al sector del mantenimiento de viviendas residenciales en general mediante el proceso de acreditación y el desarrollo de JTA definidos para auditores energéticos (EA) e inspectores de control de calidad (QCI). Este informe es un resumen de las actualizaciones más recientes (2022) del JTA del EA. [The National Renewable Energy Laboratory (NREL) is contracted by the U.S. Department of Energy (DOE) Weatherization Assistance Program (WAP) to develop and maintain the resources under the Guidelines for Home Energy Professionals (GHEP) project. The purpose of the GHEP project is to increase the quality of work conducted for residential energy retrofits in the United States through the WAP network and other residential retrofit programs. This is the Spanish translation of NREL/TP-7A40-85300.]

29 ENERGY PLANNING, POLICY, AND ECONOMY

Review of High‐Speed Digital Image Correlation: Advancements and Good Practices

This paper reviews the current state of the art in high‐speed (HS) and ultrahigh‐speed (UHS) digital image correlation (DIC) techniques, emphasizing their critical role in experimental research across various scientific domains. HS and UHS DIC have evolved significantly, driven by advancements in camera systems, image processing algorithms and experimental methodologies. These developments have opened new avenues for capturing and analysing dynamic events with unprecedented temporal and spatial detail, but not without introducing challenges such as optical distortions, motion blur and lighting issues that can affect measurement quality. This review advocates for standardized reporting practices in HS/UHS DIC methodologies to improve reproducibility and reliability across studies, drawing on guidelines from the International Digital Image Correlation Society (iDICs). Through a comprehensive analysis of over 150 articles, this review identifies key advancements in imaging technology and their application in six research domains: material characterization, test development, fracture mechanics, model validation, ballistic and explosive phenomena assessment and measurement uncertainties. Distinctions between two‐dimensional (2D) and stereo‐DIC applications are explored, offering insights into their practical implementation and trade‐offs. Good practices for HS/UHS DIC applications are proposed along with suggestions for future directions for this evolving field, highlighting the indispensable role of technological innovation in expanding the capabilities of optical metrology.

experimental mechanics

15-minute Parker River gap-filled tide height and salinity data, PIE LTER, Plum Island Sound, MA (2014–2023), for ELM PFLOTRAN modeling

This dataset contains 15-minute tide height and salinity data from the Typha site along the Parker River, part of the Plum Island Ecosystems Long Term Ecological Research (PIE LTER) site in Plum Island Sound, Massachusetts (MA) 2014-2023. Tide height (in NAVD88) was compiled from measurements conducted at the mouth of Plum Island Sound and corrected for time lags. Gap-filling of missing periods were done by fitting tidal constituents to the time series. Salinity was measured (and is stored on ESS DIVE ) in 2022 and 2023 using HOBO U24-002 conductivity loggers. River discharge is the most important control on tidal river water salinity at the location (Vallino & Hopkinson, 1998). An artificial neural network was trained to predict river water salinity at the location using Parker River discharge (USGS station 01101000, Parker River at Byfield, MA) and gap-filled salinity observations from a long-term monitoring station ca. 3km downstream from the Typha site (LTER station ‘Middle Road’) as input variables to create continuous time series information. The data set was used in the spin up and simulations of a land surface model coupled to a biogeochemical reaction network (ELM PFLOTRAN) assessing impacts of hydrology and salinity input on methane fluxes in 2022 and 2023 (Sulman et al., 2024). Metadata files ELMPFLOTRAN_tide_salinity_dd.csv and ELMPFLOTRAN_tide_salinity_flmd.csv provide details on site location, data variables, and QA/QC methods .

54 ENVIRONMENTAL SCIENCES

Data for Kim et al., "Variations in the optical and molecular composition of dissolved organic matter exported from coastal wetlands"

Knowledge about sources and composition of marsh-derived dissolved organic matter (DOM) is critical for understanding the role of marshes in coastal biogeochemical cycling and the fate of marsh-derived DOM in the ocean. To investigate tidal variability in composition of marsh-derived DOM, Kim et al. examined the optical and molecular characteristics of hourly surface water samples at three tidal creeks in the Chesapeake Bay. Groundwater samples along the terrestrial landscape gradient as well as estuarine water from the adjacent estuary at each site were also collected to help resolve sources of surface water DOM. Samples were collected in summer 2024 at three sites – SWH: Sweet Hall Marsh, GCW: Kirkpatrick Marsh, and GWI: Goodwin Islands – which are part of synoptic sites in the Chesapeake Bay region of the COMPASS-FME (Coastal Observations, Mechanisms, and Predictions Across Systems and Scales - Field, Measurements, and Experiments) project. Surface water samples were collected hourly over a 48-hour period at each site. Groundwater and estuarine water samples were collected once. This dataset includes- Surface water depth and salinity- Dissolved organic carbon (DOC) and total dissolved nitrogen (TDN) concentrations- Optical indices and relative composition of parallel factor analysis (PARAFAC) components- High resolution mass spectrometry data.

54 ENVIRONMENTAL SCIENCES

Genome collection processing for “Conserved upper thermal limits and small safety margins in soil copiotrophic bacteria”

We extracted the genomic DNA of 400 randomly selected isolates using a Quick-DNA Microprep Kit (Zymo Research D3020) according to the manufacturer’s protocol. We then submitted the extracted gDNA samples for short-read Illumina sequencing (200 Mbp) at SeqCoast Genomics (Portsmouth, NH, USA). After preprocessing the sequences using Trimmommatic (Bolger et al. 2014), we assembled the genomes using SPADES (Bankevich et al. 2012) and checked the quality of each assembly using QUAST (Gurevich et al. 2013). We processed the genome assemblies using a KBase (v1.4.0) pipeline (Allen et al. 2017; Arkin et al. 2018). Briefly, we used DRAM (v0.1.2) with default settings to annotate the genome assemblies. We then evaluated genome quality and possible contamination levels using CheckM (v1.0.18) (Parks et al. 2015) and retained genomes with completeness above 98% and contamination below 5% (n = 354), following the authors' guidelines. We then obtained taxonomic assignments for all remaining isolates using the Genome Taxonomy Database tool GTDB-Tk (v2.3.2, database version r214) (Chaumeil et al. 2019). We constructed a phylogenetic tree using the tool SpeciesTree (v2.2.0). We then trimmed the tree (using Trim SpeciesTree to GenomeSet- v1.4.0), retaining only tips within our collection with measured thermal performance.

59 BASIC BIOLOGICAL SCIENCES

A transfer learning approach to energy-efficient control of small and medium-sized commercial buildings

Model-free reinforcement learning (RL) provides a data-driven and adaptive approach to optimize building energy use while satisfying occupant comfort. This powerful tool does not need any prior knowledge about the environment and system it is optimizing and can adapt its policy based on the changes in captures. Like any other data-driven tool, it faces high training costs due to the extensive agent-environment interactions required to capture long-term building dynamics and user comfort. Transfer learning, particularly policy distillation, offers a promising way to accelerate training by leveraging pretrained RL agents in different building and system types. Here, this study investigates online student distillation, in which the student model updates its neural network weights using outputs from teacher models. The work introduces a student distillation strategy designed for efficient knowledge transfer, along with a teacher selection method that ensures high-quality guidance. The approach is validated using a highly calibrated whole building energy model for a small/medium commercial building test facility. Results show substantial reductions in training time and data requirements while surpassing the performance of ASHRAE Guideline 36, an advanced rule-based control strategy. The distilled RL model required 45% less data and achieved 20% higher cumulative rewards than a state-of-the-art RL model, with faster convergence and lower energy consumption. These outcomes demonstrate that effective transfer learning enables a scalable and data-efficient energy management solution for commercial buildings.

ASHRAE guideline 36

Opportunities and Challenges for Hydrotreating of Catalytic Fast Pyrolysis Oil to Fuels

Catalytic fast pyrolysis (CFP) provides a versatile platform for producing fuels to combat climate change and meet decarbonizing targets. In this contribution, we will discuss the hydroprocessing of CFP oils to a variety of fuels, including sustainable aviation fuel (SAF), diesel, and marine fuel. Both standalone and co-hydroprocessing with petroleum streams will be covered. Hydrotreating CFP oil at temperatures around 400 Degrees Celsius can produce a highly deoxygenated product with oxygen contents below the detection limit. However, the quality of fuel fractions produced has been a problem, manifesting as low octane numbers for the gasoline-range fraction and low cetane numbers for the diesel-range fraction. Incorporating an initial transition zone for hydrogenation during hydrotreating was shown to dramatically increase the diesel fraction cetane number from 24 to 45. A similar approach enabled the production of a cycloalkane-rich SAF fraction meeting key ASTM 4054 guidelines with respect to density, viscosity, heating value, volatility, freeze and flash point. Over 400 hours of hydrotreating for SAF was demonstrated with no signs of catalyst bed fouling, measured by pressure drop over the catalyst bed. Compared to other fuels, marine fuel is unique in that it does not require complete deoxygenation. We investigated the minimum hydrotreating requirements to produce fuel compatible with very low sulfur fuel oil, and the results suggested 30% reduction in hydrotreating costs for this approach. Co-hydroprocessing offers an opportunity to take advantage of refinery infrastructure and economies of scale although the operation is less flexible with respect to operating conditions. Co-hydroprocessing CFP oil with petroleum streams gave efficient deoxygenation at milder conditions (e.g. at temperatures of 320 Degrees Celsius) than required for standalone hydrotreating. Over 90% incorporation of biogenic carbon in the CFP oil was confirmed by carbon-14 analysis. Hydrotreating of CFP oil, whether by standalone or co-processing, can produce a variety of fuel cuts, whose quality can be tailored by changing process conditions. Challenges remain, including long-term catalyst performance and determining CFP oil quality requirements.

09 BIOMASS FUELS

Industrial Assessment Center Technical Field Manager

The work to be performed involves managing Industrial Assessment Centers through a portfolio of activities. The core activities to be performed are in the general areas of; quality assurance of IAC operations, enhancement of the student IAC experience, program development for improving assessments and implementing smart manufacturing projects, program outreach to carry assessment successes beyond the program, and program integration with other DOE/manufacturing assistance programs. The IAC Technical Field Management Organization (FMO) works in close collaboration with DOE and provides technical management for the IAC program working under policy guidelines established by DOE.

42 ENGINEERING