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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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NASA NTRS1979

Application of parametric weight and cost estimating relationships to future transport aircraft

A model comprised of system level weight and cost estimating relationships for transport aircraft is presented. In order to determine the production cost of future aircraft its weight is first estimated based on performance parameters, and then the cost is estimated as a function of weight. For initial evaluation CERs were applied to actual system weights of six aircraft (3 military and 3 commercial) with mean empty weights ranging from 30,000 to 300,000 lb. The resulting cost estimates were compared with actual costs. The average absolute error was only 4.3%. Then the model was applied to five aircraft still in the design phase (Boeing 757, 767 and 777, and BAC HS146-100 and HS146-200). While the estimates for the 757 and 767 are within 2 to 3 percent of their assumed break-even costs, it is recognized that these are very sensitive to the validity of the estimated weights, inflation factor, the amount assumed for nonrecurring costs, etc., and it is suggested that the model may be used in conjunction with other information such as RDT&E cost estimates and market forecasts. The model will help NASA evaluate new technologies and production costs of future aircraft.

Beltramo, M. N.↗

DOE OSTI2021

WISDEM® v3.4.1(Wind Plant Integrated System Design and Engineering Model) [SWR-14-05]

The Wind Plant Integrated System Design and Engineering Model (WISDEM®) is a set of models for assessing overall wind plant cost of energy (COE). The models use wind turbine and plant cost and energy production as well as financial models to estimate COE and other wind plant system attributes. WISDEM® is accessed through Python, is built using OpenMDAO, and uses several sub-models that are also implemented within OpenMDAO. These sub-models can be used independently but they are required to use the overall WISDEM® turbine design capability. Please install all of the pre-requisites prior to installing WISDEM® by following the directions below. For additional information about the NWTC effort in systems engineering that supports WISDEM® development, please visit the official NREL systems engineering for wind energy website. https://www.nlr.gov/wind/systems-engineering

Dykes, Katherine↗

DOE OSTI2024

WISDEM® v3.15.2 2024 (Wind-Plant Integrated System Design and Engineering Model) [SWR-14-05]

The Wind-Plant Integrated System Design and Engineering Model (WISDEM®) is a set of models for assessing overall wind plant cost of energy (COE). The models use wind turbine and plant cost and energy production as well as financial models to estimate COE and other wind plant system attributes. WISDEM® is accessed through Python, is built using OpenMDAO, and uses several sub-models that are also implemented within OpenMDAO. These sub-models can be used independently but they are required to use the overall WISDEM® turbine design capability. Please install all of the pre-requisites prior to installing WISDEM® by following the directions below. For additional information about the NWTC effort in systems engineering that supports WISDEM® development, please visit the official NREL systems engineering for wind energy website. https://www.nrel.gov/wind/systems-engineering.html

Dykes, Katherine↗

DOE OSTI2022

FECM/NETL Unconventional Shale Well Economic Model (UShWEM)

FECM/NETL Unconventional Shale Well Economic Model (UShWEM) is an Excel-based model that evaluates the economics of an unconventional shale well on a per-well and per-pad basis. The model calculates the net cash flow, internal rate of return (IRR), net present value (NPV), earnings before interest, taxes, depreciation, and amortization (EBITDA), payout month and year, and breakeven price (for either oil- or gas-wells). The model can be used to estimate the economics of a well or pad over its lifetime (development through site reclamation) based on (1) the capital and operating costs associated with well/pad development and operations, (2) the revenue associated with oil, gas, and condensate production streams, and (3) accounting for relevant tax policies and asset depreciation applicable for oil and gas operations. The main input for the model is the completion design and production data. Key financial considerations in the model include oil, gas, and condensate market prices, tax-related settings, royalty rates, the discount rate, minimum economic hurdle (IRR) [if performing break-even analysis], and project contingency. The financial consideration can be adjusted to reflect the level of granularity the user requires as input when calculating the economics for a well or pad development. In addition, the model affords users the option to provide their user inputs for all cost categories considered. As a result, the model can be used to generate a multitude of scenario cases for sensitivity analysis of the various financial considerations, as well as production and cost profiles. To make this seamless, the model has the capability for key economic outputs to be exported in large batches through macros-enabled functions on its “Model Output Summary” and “Multi-Well Cost Analysis. The spreadsheet model includes macros and user-defined functions, so the user must enable Excel’s macro capability for the model to function correctly.

Sheriff, Alana↗

DOE OSTI2022

Revenue prediction for integrated renewable energy and energy storage system using machine learning techniques

Revenue estimation for integrated renewable energy and energy storage systems is important to support plant owners or operators’ decisions in battery sizing selection that leads to maximized financial performances. A common approach to optimizing revenues of a hybrid hydro and energy storage system is using mixed-integer linear programming (MILP). Although MILP models can provide accurate production cost estimations, they are typically very computationally expensive. To provide a fast yet accurate first-step information to hydropower plant owners or operators who consider integrating energy storage systems, we propose an innovative approach to predicting optimal revenues of an integrated energy generation and storage system. In this study, we examined the performance of two prediction techniques: Generalized Additive Models (GAMs) and machine learning (ML) models developed based on artificial neural networks (ANN). Predictive equations and models are generated based on optimized solutions from a market participation optimization model, the Conventional Hydropower Energy and Environmental Resource System (CHEERS) model. The two predicting techniques reduce the computational time to evaluate annual revenue for one set of battery configurations from 3 h to 1 to 4 min per run while also being implementable with significantly less data. The model validation prediction errors of developed GAMs and ML models are generally below 5%; for model testing predictions, the ML models consistently outperform the regression equations in terms of root mean square errors. This new approach allows plant owners, operators, or potential investors to quickly access multiple battery configurations under different energy generation and market scenarios. This new revenue prediction method will therefore help reduce the barriers, and thereby promoting the deployment of battery hybridization with existing renewable energy sources.

13 HYDRO ENERGY↗

NASA NTRS2008

Distributed Aviation Concepts and Technologies

Aviation has experienced one hundred years of evolution, resulting in the current air transportation system dominated by commercial airliners in a hub and spoke infrastructure. While the first fifty years involved disruptive technologies that required frequent vehicle adaptation, the second fifty years produced a stable evolutionary optimization of decreasing costs with increasing safety. This optimization has resulted in traits favoring a centralized service model with high vehicle productivity and cost efficiency. However, it may also have resulted in a system that is not sufficiently robust to withstand significant system disturbances. Aviation is currently facing rapid change from issues such as environmental damage, terrorism threat, congestion and capacity limitations, and cost of energy. Currently, these issues are leading to a loss of service for weaker spoke markets. These catalysts and a lack of robustness could result in a loss of service for much larger portions of the aviation market. The impact of other competing transportation services may be equally important as casual factors of change. Highway system forecasts indicate a dramatic slow down as congestion reaches a point of non-linearly increasing delay. In the next twenty-five years, there is the potential for aviation to transform itself into a more robust, scalable, adaptive, secure, safe, affordable, convenient, efficient and environmentally friendly system. To achieve these characteristics, the new system will likely be based on a distributed model that enables more direct services. Short range travel is already demonstrating itself to be inefficient with a centralized model, providing opportunities for emergent distributed services through air-taxi models. Technologies from the on-demand revolution in computers and communications are now available as major drivers for aviation on-demand adaptation. Other technologies such as electric propulsion are currently transforming the automobile industry, and will also significantly alter the functionality of future distributed aviation concepts. Many hurdles exist, including technology, regulation, and perception. Aviation has an inherent governmental role not present in other recent on-demand transformations, which may pose a risk of curtailing aviation democratization .

Moore, Mark D.↗

NASA NTRS1977

A prediction model to forecast the cost impact from a break in the production schedule

The losses which are experienced after a break or stoppage in sequence of a production cycle portends an extremely complex situation and involves numerous variables, some of uncertain quantity and quality. There are no discrete formulas to define the losses during a gap in production. The techniques which are employed are therefore related to a prediction or forecast of the losses that take place, based on the conditions which exist in the production environment. Such parameters as learning curve slope, number of predecessor units, and length of time the production sequence is halted are utilized in formulating a prediction model. The pertinent current publications related to this subject are few in number, but are reviewed to provide an understanding of the problem. Example problems are illustrated together with appropriate trend curves to show the approach. Solved problems are also given to show the application of the models to actual cases or production breaks in the real world.

Delionback, L. M.↗

DOE OSTI2026

Arctic shipping under global change: A case study of offshore oil exports

We explore impacts of sea ice thinning and evolutions in the energy sector on future use of the Northern Sea Route (NSR) versus the Suez Canal Route (SCR), using a case study of shipping oil extracted from the offshore Russian Arctic to China. We combine an integrated human-Earth system model with a shipping cost model to incorporate impacts on both oil production and shipping costs under internally consistent scenarios. We find that the NSR could become cost-competitive with the SCR as sea ice thickness declines, especially in an RCP8.5 scenario, due to decreasing fuel and icebreaker escort costs. In a global energy evolution scenario consistent with RCP2.6, high emissions costs on the longer SCR may outweigh the costs associated with thicker sea ice on the NSR. Our novel framework provides integrated projections of NSR shipping traffic driven by a specific commodity likely to be shipped through the Arctic.

Arctic↗

DOE OSTI2023

Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing

Oak Ridge National Lab (ORNL) and Ford Motor Company used an AddUp FormUp 350 to print a turbo wheel geometry to show feasibility of laser powder bed fusion (L-PBF) additive manufacturing (AM) in producing cost-effective components for automotive industries. L-PBF AM has potential to disrupt traditional manufacturing techniques by introducing novel materials and geometries that cannot otherwise be produced. Fundamental challenges associated with L-PBF include limitations on printing overhang geometries and resulting surface finish. In this collaboration, ORNL and Ford partnered with AddUp to show the viability of using L-PBF for an AM design turbine wheel while reducing as-fabricated surface roughness. A cost model associated with mass production was produced to analyze benefits of pursing LPBF AM compared to investment casting.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Floating Wind Array Ontology and Modeling Framework

While there are many tools for designing and modeling a single floating turbine, array level design and modeling has much more to consider. Designing floating wind arrays requires a coupled approach considering many variables, from bathymetry to installation and maintenance to failure and risk analysis. With all of these considerations, an array-level modeling tool is needed to quickly evaluate array designs. The Floating Array Model (FAModel) tool developed at the National Renewable Energy Laboratory was created to fill this gap in low-fidelity array modeling. FAModel is a python framework created to streamline holistic low-fidelity floating wind modeling for array-level analysis. FAModel integrates site data and models with a variety of open-source modeling tools developed by NREL, including FLORIS, RAFT, MoorPy, and anchor capacity models. The integration of these tools allows users to quickly and holistically design an array by considering forces, area analysis, visualization, annual energy production, failure modeling, and component costs.

17 WIND ENERGY↗

NASA NTRS1976

Space-based solar power conversion and delivery systems study. Volume 3: Economic analysis of space-based solar power systems

A variety of economic and programmatic issues are discussed concerning the development and deployment of a fleet of space-based solar power satellites (SSPS). The costs, uncertainties and risks associated with the current photovoltaic SSPS configuration, and with issues affecting the development of an economically viable SSPS development program are analyzed. The desirability of a low earth orbit (LEO) demonstration satellite and a geosynchronous (GEO) pilot satellite is examined and critical technology areas are identified. In addition, a preliminary examination of utility interface issues is reported. The main focus of the effort reported is the development of SSPS unit production, and operation and maintenance cost models suitable for incorporation into a risk assessment (Monte Carlo) model (RAM). It is shown that the key technology area deals with the productivity of man in space, not, as might be expected, with some hardware component technology.

Hazelrigg, G. A., Jr.↗

NASA NTRS2006

The Application of Architecture Frameworks to Modelling Exploration Operations Costs

Developments in architectural frameworks and system-of-systems thinking have provided useful constructs for systems engineering. DoDAF concepts, language, and formalisms, in particular, provide a natural way of conceptualizing an operations cost model applicable to NASA's space exploration vision. Not all DoDAF products have meaning or apply to a DoDAF inspired operations cost model, but this paper describes how such DoDAF concepts as nodes, systems, and operational activities relate to the development of a model to estimate exploration operations costs. The paper discusses the specific implementation to the Mission Operations Directorate (MOD) operational functions/activities currently being developed and presents an overview of how this powerful representation can apply to robotic space missions as well.

Department of Defense Architecture Framework (DoDA↗

DOE OSTI2024

Wind plant wake losses: Disconnect between turbine actuation and control of plant wakes with engineering wake models

Wake losses from neighboring plants may become a major factor in wind plant design and control as additional plants are constructed in areas with high wind resource availability. Because plant wakes span a large range of physical scales, from turbine rotor diameter to tens of kilometers, it is unclear whether conventional wake models or turbine control strategies are effective at the plant scale. Wake steering and axial induction control are evaluated in the current work as means of reducing the impact of neighboring wind plants on power and levelized cost of electricity. FLOw Redirection and Induction in Steady State (FLORIS) simulations were performed with the Gauss–Curl Hybrid and TurbOPark wake models as well as two operation and maintenance models to investigate control setpoint sensitivity to wake representation and economic factors. Both wake models estimate losses across a range of atmospheric conditions, although the wake loss magnitude is dependent on the wake model. Annual energy production and levelized cost of electricity are driven by wind direction frequency, with frequently aligned plants experiencing the greatest losses. However, both wake steering and axial induction are unable to mitigate the impact of upstream plants. Wake steering is constrained by plant geometry, since wake displacement is much less than the plant wake width, while axial induction requires curtailing the majority of turbines in upstream plants. Individual turbine strategies are limited by their effective scale and model representation. New wake models that include plant-scale physics are needed to facilitate the design of effective plant wake control strategies.

Scott, Ryan (ORCID:0000000328107574)↗

DOE OSTI2025

Primary material supply configurations and domestic recycling for cost-effective battery material production in the US

Battery cathode active material costs hinge on regionally concentrated, price-volatile metal supply. Here. we construct a regional facility-level cost model based on over 80 global lithium, cobalt, and nickel mines, refineries, and battery-grade material plants. Our model yields aggregated lithium, nickel, manganese, and cobalt production material costs from 392 region-based supply configurations for five different cathode active materials. Focusing on the United States, all-domestic supply is 9–34% costlier than global average, increasing by cobalt content, while these shortfalls can be overcome by selective low-cost material imports. Furthermore, we analyze costs of two U.S.-based recycling facilities from primary data and techno-economic modelling and compare resulting cathode active material-level costs to primary supply. Although it is still significantly higher on cathode active material cost-level, rising end-of-life flows and lowered black-mass prices will, however, make secondary supply cost-competitive to domestic and foreign primary supply cost floors. Facility-level benchmarks reveal targeted import, scaling, and production cost optimization as levers for a resilient, cost-effective U.S. battery-material supply chain.

Energy↗

DOE OSTI2021

Sustainable production of 5-hydroxymethyl furfural from glucose for process integration with high fructose corn syrup infrastructure

5-Hydroxymethyl furfural (HMF) is a platform chemical, which can be derived from lignocellulosic biomass, and used for production of liquid fuels and polymers. We demonstrate a process for production of HMF using sequential enzymatic and catalytic reactions of glucose to synthesize HMF, and simulated-moving-bed (SMB) separation to purify HMF. The adsorption thermodynamic parameters of glucose, fructose, and HMF on a commercial chromatography resin are experimentally determined for modeling the SMB-based HMF production process. The experimental data are used to develop a rigorous process model and then estimate the cost of production. Chromatographic separation of HMF has 16% lower operating costs compared to an extraction-based process and has a minimum selling price of approximately $1478 per ton. We demonstrate that the HMF process can be integrated with the high fructose corn syrup (HFCS) process, and we performed analyses considering two systems including construction of a new integrated facility and retrofitting an existing HFCS facility to produce HMF. Our analyses suggest that the latter approach is a promising short-term low-risk strategy to advance the HMF production technology to commercial scale.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Wind Turbine Maintenance Costs: Assessing the Potential of Gear Oil Improvements

Wind turbine operations & maintenance (O&M) costs constitute a sizable portion of total energy cost for wind power. There are many components in a utility-scale wind turbine that need to be lubricated with either oil or grease. This study uses gearbox oil as an example and assesses how lubricant technology improvements may impact wind turbine power production and levelized cost of energy. Using the modeling tools (i.e., WOMBAT, reV, and SAM) developed at National Renewable Energy Laboratory and lubrication oil technology scenarios defined based on inputs provided by ExxonMobil and industry stakeholders, we quantify the potential for increasing energy production and reducing maintenance costs across the current and future U.S. fleet of wind turbines as a result of improvements in lubrication technologies. The modeled improvements reduce the median levelized cost of energy by 1-2% across the U.S. fleet. Cumulative saving from gear oil technology improvements in 2050 for U.S. fleet is estimated to be approximately $6 billion. Extending the lubricant replacement interval has a larger impact on total cost and energy production than reducing lubricant cost.

costs↗

DOE OSTI2020

Economic Analysis of Integrated Solar Power, Hydrogen Production, and Electricity Markets

Hydrogen is a versatile energy carrier that is used in a wide variety of chemical and industrial processes. Producing hydrogen using electrolysis can enable integration of multiple sectors including electricity, heating, and industrial sectors; however, the cost of producing hydrogen from electrolysis remains a challenge for encouraging greater adoption. To help improve the economics for both solar PV and hydrogen production using electrolyzers, we explore the benefit of combining PV and electrolysis systems. Using the Revenue Operation and Device Optimization Model (RODeO) model, the optimal breakeven hydrogen production cost for six unique market participation configurations is calculated at six candidate locations in California where PV is already installed. Costs include production, storage, and compression in preparation for gaseous delivery trucks. Revenue streams included in the optimization are the sale of hydrogen, Low Carbon Fuel Standard (LCFS) credits, renewable electricity sold to the grid, and Renewable Energy Credits (REC). The costs included are the electricity costs, capital and fixed operation and maintenance cost (FOM) for the electrolyzer, PV, and storage and compression systems as well as taxes and financing costs. In addition, cost reductions are achieved through retail and wholesale electricity use optimization, by which electricity is purchased at the lowest price and sold, if possible, at the highest price. For all locations analyzed, the breakeven hydrogen production cost results show that, in order of decreasing cost, the system configurations are islanded (highest), separated, NEM, retail, hybrid retail/wholesale, and wholesale (lowest). This report also explores other aspects of hydrogen systems including optimal renewable sizing and resulting energy mixture to the electrolyzer, value of renewable premiums, competition with incumbent technologies, cost sensitivity to a variety of parameters.

decarbonized economy↗

DOE OSTI2025

STREAM: A technology planning and capacity expansion model for the industrial sector

The Strategic Technology Roadmapping and Energy, Environmental, and Economic Analysis Model—STREAM—is an optimization-based modeling tool and analysis framework to assist with strategic planning and technology investments of the industrial sector. This open-source framework is written in Julia using the JuMP package, which enables users to model future “pathways” for incumbent and future production technologies, costs, fuels and energy carriers, and energy and non-energy environmental impacts from industries as they transform in pursuit of a robust and competitive manufacturing sector. The model starts with an initial stock of industrial production technologies and assets at a facility level and then determines pathways that minimize cost, subject to an array of possible constraints on demand, market shares, environmental flows, and other exogenously specified operational considerations such as capacity utilization rates or regional energy costs. Key features of the framework include flexibility to model a wide range of industries and industrial technologies/processes at varying levels of granularity, ability to perform parametric sensitivity analyses, and ability to visualize model results using visualization objects.

capacity expansion↗