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DOE OSTI2026

Comparative techno-economic and environmental analysis of using nuclear energy and fossil energy with carbon sequestration in U.S. Gulf Coast petroleum refineries

U.S. Gulf Coast refineries have processing capacity of approximately 9.4 million barrels of crude oil per day—about 50% of U.S. national capacity—while consuming natural gas, electricity, and hydrogen, resulting in approximately 100 million metric tonnes (MMT) of onsite CO₂ emissions in 2022. This study evaluates two alternative refinery energy supply pathways: nuclear energy (NE) and fossil energy-derived hydrogen with carbon capture and sequestration (FE-CCS; autothermal reforming), intermittent renewable sources are not considered as they cannot reliably meet continuous industrial heat and hydrogen demands. Using publicly available data for refineries, we conducted a bottom-up, facility-level assessment to estimate energy use by type, well-to-gate refinery emissions, and associated costs of integration. Compared to current refinery operations using natural gas energy supply and conventional hydrogen production (steam methane reforming without sequestration), NE and FE-CCS could produce, respectively, average emissions reductions of 37% and 42%, total abatement costs of $\$$52–$\$$221 and $\$$211–$\$$612/MT CO₂, and additional costs of about $\$$0.2–$\$$6 and $\$$3–$\$$11 per barrel of crude, respectively. Our analysis indicates that 25 out of 27 refineries have lower total additional cost ($\$$/bbl.) for the NE scenario than the FE-CCS scenario, making a strong case for NE integration with petroleum refineries. This work's main contribution is a detailed bottom-up refinery-level analysis method that can be utilized by the worldwide refining industry and stakeholders as they assess different technological options, along with their costs and environmental impacts for a specific refinery operation.

Carbon capture and sequestration↗

DOE OSTI2020

Special Issue from the Advances in Fossil Energy R&D topical sessions held at the 2019 American Institute of Chemical Engineers Annual Fall Meeting

This special issue entitled “Catalysis for Energy Related Activities” represents a collection of research works presented during the Advances in Fossil Energy R&D topical sessions at the 2019 American Institute of Chemical Engineers (AIChE) Annual Meeting in Orlando, Florida November 10–15, 2019.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2016

The NETL MFiX Suite of multiphase flow models: A brief review and recent applications of MFiX-TFM to fossil energy technologies

Here, the MFiX suite of multiphase computational fluid dynamics (CFD) codes is being developed at U.S. Department of Energy's National Energy Technology Laboratory (NETL). It includes several different approaches to multiphase simulation: MFiX-TFM, a two-fluid (Eulerian–Eulerian) model; MFiX-DEM, an Eulerian fluid model with a Lagrangian Discrete Element Model for the solids phase; and MFiX-PIC, Eulerian fluid model with Lagrangian particle ‘parcels’ representing particle groups. These models are undergoing continuous development and application, with verification, validation, and uncertainty quantification (VV&UQ) as integrated activities. After a brief summary of recent progress in the verification, validation and uncertainty quantification (VV&UQ), this article highlights two recent accomplishments in the application of MFiX-TFM to fossil energy technology development. First, recent application of MFiX to the pilot-scale KBR TRIG™ Transport Gasifier located at DOE's National Carbon Capture Center (NCCC) is described. Gasifier performance over a range of operating conditions was modeled and compared to NCCC operational data to validate the ability of the model to predict parametric behavior. Second, comparison of code predictions at a detailed fundamental scale is presented studying solid sorbents for the post-combustion capture of CO 2 from flue gas. Specifically designed NETL experiments are being used to validate hydrodynamics and chemical kinetics for the sorbent-based carbon capture process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2017

Enabling CCS via Low-temperature Geothermal Energy Integration for Fossil-fired Power Generation

Here, among the key barriers to commercial scale deployment is the cost associated with CO 2 capture. This is particularly true for existing large, fossil-fired assets that account for a large fraction of the electricity generation fleet in developed nations, including the U.S. Fitting conventional combustion technologies with CO 2 capture systems can carry an energy penalty of thirty percent or more, resulting in an increased price of power to the grid, as well as an overall decrease in net plant output. Taken together with the positive growth in demand for electricity, this implies a need for accelerated capital build-out in the power generation markets to accommodate both demand growth and decreased output at retrofitted plants. In this paper, the authors present the results of a study to assess the potential to use geothermal energy to provide boiler feedwater preheating, capturing efficiency improvements designed to offset the losses associated with CO 2 capture. Based on NETL benchmark cases and subsequent analysis of the application using site-specific data from the North Valmy power plant, several cases for CO 2 capture were evaluated. These included geothermally assisted MEA capture, CO2BOLs capture, and stand-alone hybrid power generation, compared with a baseline, no-geothermal case. Based on Case 10, and assuming 2.7 MMlb/h of geothermally sourced 150 ºC water, the parasitic power load associated with MEA capture could be offset by roughly seven percent, resulting in a small (~1 percent) overall loss to net power generation, but at levelized costs of electricity similar to the no-geothermal CCS case. For the CO 2 BOLs case, the availability of 150°C geothermal fluid could allow the facility to not only offset the net power decrease associated with CO 2 BOLs capture alone, but could increase nameplate capacity by two percent. The geothermally coupled CO 2 BOLs case also decreases LCOE by 0.75 ¢/kWh relative to the non-hybrid CO 2 BOLs case, with the improved performance over the MEA case driven by the lower regeneration temperature and associated duty for CO 2 BOLs relative to MEA.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2016

Nacre tablet thickness records formation temperature in modern and fossil shells

Nacre, the iridescent outer lining of pearls and inner lining of many mollusk shells, is made of periodic, parallel, organic sheets alternating with aragonite (CaCO 3 ) tablet layers. Nacre tablet thickness (TT) generates both nacre's iridescence and its remarkable resistance to fracture. Despite extensive studies on how nacre forms, the mechanisms controlling TT remain unknown, even though they determine the most conspicuous of nacre's characteristics, visible even to the naked eye.Thermodynamics predicts that temperature (T) will affect both physical and chemical components of biomineralized skeletons. The chemical composition of biominerals is well-established to record environmental parameters, and has therefore been extensively used in paleoclimate studies. The physical structure, however, has been hypothesized but never directly demonstrated to depend on the environment. Here we observe that the physical TT in nacre from modern and fossil shallow-water shells of the bivalves Pinna and Atrina correlates with T as measured by the carbonate clumped isotope thermometer. Based on the observed TT vs. T correlation, we anticipate that TT will be used as a paleothermometer, useful to estimate paleotemperature in shallow-water paleoenvironments. Here we successfully test the proposed new nacre TT thermometer on two Jurassic Pinna shells. The increase of TT with T is consistent with greater aragonite growth rate at higher T, and with greater metabolic rate at higher T. Thus, it reveals a complex, T-dependent biophysical mechanism for nacre formation.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Self-Repairing Polymer-Modified Cements for High Temperature Geothermal and Fossil Energy Applications

In this work five novel polymer-cement composite formulations were prepared and evaluated as potential cementitious material alternatives to conventional wellbore cement. These cement composites were cured at 200 °C and their mechanical properties, including compressive strength, Young modulus, shear bond strength to steel casing, and self-healing and re-adhering (to steel) capability. Thermal stability was also evaluated by curing these cement materials at 200 °C for up to one month followed by determining their mineralogy and chemical composition by X-ray diffraction spectroscopy, 13C NMR, and total organic carbon. Permeability analysis was performed before and after healing a longitudinal fracture on unmodified cements and polymer-cement composites with the later showing lower (2nd/1st) permeability ratios with respect to base cements. Furthermore, a reduction in permeability of up to 80X on average with respect to their unmodified (base) cement, was observed in two polymer-cement formulations suggesting that the introduction of these polymers bring about self-healing capability. Two of the best performing polymer-cement composites were exposed to 30-day curing period at 200 °C showing that their self-healing capability is maintained. The composite stability is associated to the fact that the polymer material is stable as demonstrated by total organic carbon and NMR spectroscopy. These advanced polymer-cement composites with higher ductility and self-healing capability could be used as alternative wellbore cement materials for geothermal and fossil energy applications.

Rod, Kenton A.↗

DOE OSTI2024

Insights from FEED studies for retrofitting existing fossil power plants with carbon capture technology

Recent United States Department of Energy (DOE) sponsored front-end engineering design (FEED) studies for retrofitting existing fossil-fueled power plants with state-of-the-art carbon capture technology contain previously overlooked real-world design considerations for near-term deployment of carbon capture. Insights from examining seven recently published FEED study reports are summarized in this paper. This includes a discussion of the design, performance, and cost implications associated with (1) location-specific considerations such as water availability, land availability, and accessibility; (2) host-plant-specific factors such as flue gas specifications, allowable degree of integration between the capture system and host plant, and operational mode; and (3) miscellaneous factors such as market conditions, permitting requirements, and business case incentives. In conclusion, this manuscript highlights (1) water availability as a key design and cost driver, with host plant steam extraction increasing capture system cooling water availability, (2) modularization and constructability impacts on the number of capture trains, (3) the impacts of host plant operational mode and capacity factor on the business case for installing capture, and (4) the merit of continued research, development, and demonstration efforts addressing steam extraction, host plant tie-in at the stack, solvent reclamation and air emissions control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2010

Hydrogen production from fossil and renewable sources using an oxygen transport membrane.

Oxygen transport membranes (OTMs) made of mixed ion-electron conductors can be used to increase the production of hydrogen from fossil and renewable sources. This study describes two methods for producing hydrogen with La{sub 0.7}Sr{sub 0.3}Cu{sub 0.2}Fe{sub 0.8}O{sub 3-{delta}} (LSCF7328), an OTM material that is easily prepared, exhibits good mechanical properties, and is stable in severe gas conditions. In tests with thin-film (thickness {approx}22 {micro}m) LSCF7328 membranes, hydrogen was produced by flowing simulated product streams from CO{sub 2} gasification of coal on one side of the OTM and steam on the other side. In this method, the so-called coal gas on the oxygen-permeate side drives the removal of oxygen from the other side of the OTM, where hydrogen and oxygen are produced by water splitting. With CO (99.5% purity) flowing on the oxygen-permeate side, the hydrogen production rate was measured to be {approx}4.7 cm{sup 3}/min-cm{sup 2} at 900 C, indicating that hydrogen can be produced at a significant rate by using product streams from coal gasification. This process also yields a CO{sub 2}-rich product stream that is ready for sequestration. In another test, a tubular LSCF7328 was found to increase the hydrogen production from ethanol reforming by supplying high-purity oxygen from air.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Fossil fuel CO 2 emissions over metropolitan areas from space: A multi-model analysis of OCO-2 data over Lahore, Pakistan

Urban areas, where gathering more than 55% of the global population, alone contributed to more than 70% of anthropogenic fossil fuel carbon dioxide (CO 2ff ) emissions. Accurate quantification of CO 2ff emissions from urban areas is of great importance to the formulation of global warming mitigation policies to achieve carbon neutrality by 2050. Satellite-based inversion techniques are unique among “top-down” approaches, potentially allowing us to track CO 2ff emission changes over cities globally. However, its accuracy is still limited by incomplete background information, cloud blockages, aerosol contaminations, and uncertainties in models and emission inventories used as prior. To evaluate the current potential of space-based quantification techniques, we present the first attempt to monitor long-term changes in CO 2ff emissions based on the OCO-2 satellite measurements of column-averaged dry-air mole fractions of CO 2 (X CO2 ) over a fast-growing Asian metropolitan area: Lahore, Pakistan. We first examined the OCO-2 data availability at global scale. About 17% of OCO-2 soundings are marked as high-quality soundings by quality flags over the global 70 most populated cities over the period 2014-2019. Cloud blockage and aerosol contamination are the two main causes of data loss. As an attempt to recover additional soundings, we evaluated the effectiveness of OCO-2 quality flags at the city level by comparing three flux quantification methods (WRF-Chem, X-STILT, and flux cross-sectional integration method), all based on the Open-Data Inventory for Anthropogenic Carbon dioxide (ODIAC) product. The satellite/bottom-up emissions (OCO-2/ODIAC) ratios of the high-quality tracks better converged across the three methods compared to the all-data tracks with reduced uncertainties in emissions. Thus, OCO-2 quality flags are useful filters of low-quality OCO-2 retrievals at local scales, although originally designed for global-scale studies. All three methods consistently suggested that the ratio medians are greater than 1, which implies that the ODIAC slightly underestimated the CO2ff emissions over Lahore. Additionally, our estimation of the a posteriori CO2ff emission trend was about 734 kt C/year (i.e., an annual 6.7% increase). 10,000 Monte Carlo simulations of the Mann-Kendall upward trend test showed that less than 10% prior uncertainty for 8 tracks (or less than 20% prior uncertainty for 25 tracks) is required to achieve a greater-than-50% trend significant possibility at a 95% confidence level. It implies that the trend is driven by the prior and not due to the assimilation of OCO-2 retrievals. The key to improving the role of satellite data in CO 2 emission trend detection lies in collecting more frequent high-quality tracks near metropolitan areas to achieve significant constraints from X CO2 retrievals.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Flexible cryogenic air separation unit—An application for low-carbon fossil-fuel plants

In this study, the rapid integration of intermittent renewable sources into the electricity grid is driving the need for a flexible cryogenic air separation unit (ASU) coupled with a low-carbon fossil-fuel plant. However, the state-of-the-art ASU process is highly integrated and nonlinear, which can significantly restrict its ramping rate. In this work, we study the fundamental dynamics of a state-of-the-art double-column ASU, focusing on the dynamic characteristics of the highly integrated and nonlinear heat and mass transfers, and we propose basic control methods for achieving high process ramping rates. We found that the vapor–liquid countercurrent flows in the low-pressure column are critical to the cryogenic rectification of air, which governs the ramp rate of the ASU. This countercurrent flow structure is created through a complex heat integration process in the ASU. Here, this process is simplified as a countercurrent heat transfer to reduce the complexity of studying the ASU dynamics. To preserve this flow structure, the heat integration is maintained so that its heat duty follows the ASU load, using several basic controllers on the critical stream flowrates. A flow-driven dynamic ASU model is built in Aspen Plus Dynamics to capture the basic ramping dynamics. This model revealed a fundamental mismatch in the dynamics in the ASU column that causes a significant loss of O 2 product purity when ramping down the ASU and slightly increases the purity when ramping up. Based on these findings, we propose a basic control method for rapidly ramping down/up the ASU while maintaining O 2 product purity. Simulation results show the ASU basic dynamic process successfully ramps at a rate up to 10 %/min (40–100 % load) while maintaining the O 2 product purity at 95.2–95.6 mol%.

42 ENGINEERING↗

DOE OSTI2017

Summary of the Snowmastodon Project Special Volume A high-elevation, multi-proxy biotic and environmental record of MIS 6–4 from the Ziegler Reservoir fossil site, Snowmass Village, Colorado, USA

Abstract In North America, terrestrial records of biodiversity and climate change that span Marine Oxygen Isotope Stage (MIS) 5 are rare. Where found, they provide insight into how the coupling of the ocean–atmosphere system is manifested in biotic and environmental records and how the biosphere responds to climate change. In 2010–2011, construction at Ziegler Reservoir near Snowmass Village, Colorado (USA) revealed a nearly continuous, lacustrine/wetland sedimentary sequence that preserved evidence of past plant communities between ~140 and 55 ka, including all of MIS 5. At an elevation of 2705 m, the Ziegler Reservoir fossil site also contained thousands of well-preserved bones of late Pleistocene megafauna, including mastodons, mammoths, ground sloths, horses, camels, deer, bison, black bear, coyotes, and bighorn sheep. In addition, the site contained more than 26,000 bones from at least 30 species of small animals including salamanders, otters, muskrats, minks, rabbits, beavers, frogs, lizards, snakes, fish, and birds. The combination of macro- and micro-vertebrates, invertebrates, terrestrial and aquatic plant macrofossils, a detailed pollen record, and a robust, directly dated stratigraphic framework shows that high-elevation ecosystems in the Rocky Mountains of Colorado are climatically sensitive and varied dramatically throughout MIS 5.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Climate, air quality, and equity benefits from hydrogen substitution for fossil fuels used in process heat

Fossil fuel combustion for process heat in heavy industry accounts for ~15% of all United States CO 2 emissions and emits PM 2.5 and its precursors, emissions that have a disproportionate impact on minority populations. Decarbonizing process heat in the U.S. via hydrogen substitution presents an opportunity to reduce emissions of CO 2 and PM 2.5 and mitigate resulting exposure disparity. Here, we show that hydrogen substitution in steelmaking provides a large reduction in CO 2 emissions and air quality-related premature mortality, while hydrogen substitution in petroleum refining substantially benefits disadvantaged communities. When reductions in CO 2 emissions and premature mortality are monetized using standard regulatory values, we find that the sum of air pollution and climate benefits outweighs the difference in private cost associated with hydrogen substitution in steelmaking, regardless of the method of hydrogen production. The approach developed here can support evaluations of equity-focused decarbonization strategies in other industries and for specific sites.

08 HYDROGEN↗

DOE OSTI2023

A UNIONS view of the brightest central galaxies of candidate fossil groups

The formation process of fossil groups (FGs) is still under debate, and, because of their relative rarity, large samples of such objects are still missing. The aim of the present paper is to increase the sample of known FGs, to analyse the properties of their brightest group galaxies (BGGs), and to compare them with a control sample of non-FG BGGs. We extracted a sample of 87 FG and 100 non-FG candidates from a large spectroscopic catalogue of haloes and galaxies. For all the objects with data available in UNIONS (initially the Canada France Imaging Survey, CFIS) in the u and r bands, and/or in an extra r-band processed to preserve all low-surface-brightness features (rLSB), we performed a 2D photometric fit of the BGG with GALFIT with one or two Sérsic components. We also analysed how the subtraction of the intracluster light (ICL) contribution modifies the BGG properties. From the SDSS spectra available for the BGGs of 65 FGs and 82 non-FGs, we extracted the properties of their stellar populations with Firefly. To complement our study, and in order to provide a detailed illustration of the possible origin of emission lines in the FG BGGs, involving the presence or absence of an AGN, we investigated the origin of the emission lines in a nearby FG that is dominated by the NGC 4104 galaxy. Morphologically, a single Sérsic profile can fit most objects in the u band, while two Sérsics are needed in the r and rLSB bands, both for FGs and non-FGs. Non-FG BGGs cover a larger range of Sérsic index n. FG BGGs follow the Kormendy relation (mean surface brightness versus effective radius) previously derived for almost 1000 brightest cluster galaxies (BCGs), while the majority of non-FGs BGGs are located below this relation, with fainter mean surface brightnesses. This suggests that FG BGGs have evolved similarly to BCGs, and non-FG BGGs have evolved differently from both FG BGGs and BCGs. All the above properties can be strongly modified by the subtraction of the ICL contribution. Based on spectral fitting, the stellar populations of FG and non-FG BGGs do not differ significantly. FG and non-FG BGGs differ from one another in terms of their morphological properties and Kormendy relation, suggesting they have had different formation histories. However, it is not possible to trace differences in their stellar populations or in their large-scale distributions.