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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

In planta production of the nylon precursor beta-ketoadipate

Beta-ketoadipate (βKA) is an intermediate of the βKA pathway involved in the degradation of aromatic compounds in several bacteria and fungi. Beta-ketoadipate also represents a promising chemical for the manufacturing of performance-advantaged nylons. We established a strategy for the in planta synthesis of βKA via manipulation of the shikimate pathway and the expression of bacterial enzymes from the βKA pathway. Using Nicotiana benthamiana as a transient expression system, we demonstrated the efficient conversion of protocatechuate (PCA) to βKA when plastid-targeted bacterial-derived PCA 3,4-dioxygenase (PcaHG) and 3-carboxy-cis,cis-muconate cycloisomerase (PcaB) were co-expressed with 3-deoxy-D-arabinoheptulosonate 7-phosphate synthase (AroG) and 3-dehydroshikimate dehydratase (QsuB). This metabolic pathway was reconstituted in Arabidopsis by introducing a construct (pAtβKA) with stacked pcaG, pcaH, and pcaB genes into a PCA-overproducing genetic background that expresses AroG and QsuB (referred as QsuB-2). The resulting QsuB-2 x pAtβKA stable lines displayed βKA titers as high as 0.25 % on a dry weight basis in stems, along with a drastic reduction in lignin content and improvement of biomass saccharification efficiency compared to wild-type controls, and without any significant reduction in biomass yields. Using biomass sorghum as a potential crop for large-scale βKA production, techno-economic analysis indicated that βKA accumulated at titers of 0.25 % and 4 % on a dry weight basis could be competitively priced in the range of $2.04-34.49/kg and $0.47-2.12/kg, respectively, depending on the selling price of the residual biomass recovered after βKA extraction. This study lays the foundation for a more environmentally-friendly synthesis of βKA using plants as production hosts.

Kazaz, Sami↗
DOE OSTI2026

Evaluating CO 2 mitigation strategies in SAF biorefineries: Techno-economic and life cycle analysis

The aviation sector requires scalable decarbonization strategies, and lignocellulosic sustainable aviation fuel (SAF) represents a promising pathway. This study comparatively evaluates the techno-economic analysis and life cycle assessment (LCA) of three CO 2 management strategies integrated within a U.S.-based gasification–Fischer–Tropsch SAF biorefinery: (i) catalytic hydrogenation of captured CO 2 to methanol, (ii) geological CO 2 sequestration, and (iii) mineralization to sodium bicarbonate (NaHCO 3 ). Techno-economic analysis indicates that methanol synthesis requires approximately 26% higher capital investment and 33% higher operating costs than mineralization. Although methanol co-production generates the highest gross revenue, NaHCO 3 production reduces the SAF minimum selling price by approximately 38% relative to both methanol synthesis and geological sequestration pathways, reflecting a more balanced cost allocation through mineral co-product valorization. Geological sequestration lowers operating costs by nearly 50% compared with methanol synthesis but remains highly dependent on carbon credit mechanisms. LCA reveals substantial divergence in climate performance. Relative to methanol synthesis, sequestration improves net greenhouse gas performance by approximately 163%, transitioning the system from net-positive to net-negative emissions. Mineralization further enhances carbon mitigation, achieving roughly 85% greater carbon reduction than sequestration and over sixfold improvement relative to methanol synthesis within the defined system boundary. Sensitivity analysis identified hydrogen price, co-product market value, and process emissions as dominant drivers. Under baseline assumptions, CO 2 mineralization is found to offer the most balanced pathway.

Carbon capture and storage↗
DOE OSTI2025

Upcycling of post-consumer mixed polyolefin feedstock: An economic and technical evaluation

Here, this study reports techno-economic and life cycle analyses to evaluate the economic and environmental impacts of mechanically recycled PE/PP blends in the presence of rheology modifiers. Additionally, fiber-reinforced composites derived from the compatibilized blends were prepared and evaluated for their performance compared with virgin plastics. Results suggest that compatibilized PE/PP blends exhibit a 70% lower selling price compared to virgin PE. Furthermore, these blends achieved a 74% reduction in greenhouse gas emissions or climate change impact compared to the virgin counterpart. Fiber-reinforced composites from compatibilized PE/PP blends demonstrated improved or comparable mechanical properties relative to composites made from virgin PE/PP blends. Based on their favorable cost and environmental impact, along with performance comparable to virgin composites, compatibilized PP/PE composites made from post-consumer plastics can find applications in large-scale composite manufacturing.

Fiber reinforced plastics (FRP)↗
DOE OSTI2026

Transforming E-Waste Into Strategic Resources: Techno-Economic Analysis of Gallium and By-products Recovery from LEDs via Bioleaching

The growing demand for gallium in optoelectronics and renewable energy applications raises concerns about supply security and production sustainability. This study evaluates the techno-economic feasibility of recovering gallium and by-products (copper and nickel) from waste GaN-based LEDs via bioleaching. A process flowsheet encompassing transportation, robotic disassembly, ball milling, bioleaching, solvent extraction/electrowinning, and refining was modeled. Based on mass balance analysis, more than 53 tons of LED waste are required annually to yield 1 kg of gallium alongside substantial copper and nickel co-products. Preliminary techno-economic analysis (TEA) shows an average total cost (ATC) of 6.84 USD/kg metal when costs are allocated by mass-weighted economic value (market price) fraction, corresponding to 6.75 USD/kg for copper, 15.91 USD/kg for nickel, and 470.95 USD/kg for gallium. For gallium, direct operational costs account for more than 70% of the cost. Monte Carlo simulations further quantify cost uncertainties under market price fluctuations. This work represents the first TEA of gallium recovery from GaN-based LEDs and highlights potential pathways for future cost reduction.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Techno-economic analysis and network design for CO 2 conversion to jet fuels in the United States

The conversion of carbon dioxide (CO 2 ) into jet fuel holds significant potential for reducing CO 2 emissions, providing an alternative to carbon-based resources, and offering a renewable means of energy storage. The objective of this study is to conduct a techno-economic analysis and optimize the supply chain network for converting CO 2 to jet fuel in the United States, aiming to minimize total costs while assessing the environmental and economic feasibility of two CO 2 conversion pathways. This first pathway is based on Fischer-Tropsch synthesis (FTS), and the other one is based on the valorization and upgrading of light methanol (MeOH). Incorporating spatial and techno-economic data, a mixed-integer linear programming model was developed to select source plants and conversion pathways, locations of conversion refinery sites, and the amount of captured CO 2 across the United States. The optimal results indicate that the FTS pathway is adopted at all selected refineries when the hydrogen price is 1000 dollars/t and the operating cost, mainly electricity used in conversion, is reduced to 5 % of its current level. Under this scenario, the total annual profit is 8 billion dollars, and the net carbon emissions are -88,783,284 tons. The sensitivity analyses reveal that the prices of electricity and hydrogen significantly contribute to total production costs. The CO 2 recycle percentage of the FTS pathway influences the choice of applied pathways at refineries. Additionally, a higher conversion rate holds a substantial promise for reducing the total production cost and can make the MeOH pathway a viable choice.

10 SYNTHETIC FUELS↗
DOE OSTI2025

Accelerating room air conditioner efficiency in India: Grid, economic, and policy implications through 2035

India is poised for a rapid surge in space cooling demand, driven by rising incomes, urbanization, and intensifying heat. Between 2025 and 2035, the country is expected to add 130–150 million new room air conditioners (ACs). If Minimum Energy Performance Standards (MEPS) continue to improve at the historical rate of 2–3 % annually, room ACs alone could contribute over 180 GW to peak electricity demand by 2035-nearly 30 % of the projected national total. This study evaluates the impact of an accelerated MEPS trajectory, proposing to raise the 1-star threshold to ISEER 5.0 by 2027, ISEER 6.3 by 2030, and ISEER 7.4 by 2033. Drawing on engineering cost analysis, stock turnover modeling, and retail pricing data, we find that this pathway could reduce peak demand by over 60 GW, save 118 TWh of electricity annually, avoid 49 MtCO₂ of electricity-related emissions per year, avert ₹7.5 trillion (∼US$85 billion) in power system investments, and yield ₹0.7–2.3 trillion (∼US$8–26 billion) in net consumer savings by 2035. Contrary to affordability concerns, empirical trends show that higher efficiency does not increase AC prices. These results highlight the value of ambitious MEPS as a cost-effective strategy for improving grid reliability, reducing emissions, and advancing consumer welfare in emerging economies.

Abhyankar, Nikit↗
DOE OSTI2024

Coupled management of electric vehicle workplace charging and office building loads

Significant building energy savings are realized through heating, ventilation, and air conditioning (HVAC) setpoint adjustment and daylighting control. Workplace charging (WPC) enables colocation of electric vehicles (EVs) with office building loads. We proposed managing energy use of workplace EV charging and the office building and determined the number of EVs that building energy savings can facilitate charging. We simulated building energy savings in typical medium offices in Chicago IL, Baltimore MD, and Houston TX, spanning three US climate regions. Considering the EV hosting capacity of the saved building energy and travel patterns of roundtrip commuting, we minimized EV charging costs under time-of-use electricity pricing. Managed WPC can reduce charging electricity bills compared to first-come, first-served charging. The ratio of EVs to chargers, the coincident period of commuters’ dwell time and lower electricity prices, and the number of EVs in the office impacted the economic benefits achieved through charging management.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Smart Charging of Fleet and Personal Electric Vehicles through Joint Vehicle-to-Grid Optimization

As electric vehicle (EV) adoption accelerates, vehicle-to-grid (V2G) strategies offer advantages over unmanaged charging (V0G) by enhancing grid stability, reducing fleet operation costs, and supporting integration of variable generation resources. This research develops a day-ahead optimization framework linked with agent-based simulations to evaluate coordinated V2G participation by fleet and personal EVs under 5 energy-pricing settings in Austin, Texas. Three scenarios (V0G, fleet-only V2G, and joint-V2G) are examined, considering real-time price and grid profiles, health-damage costs, and operational constraints for both fleet and personal EVs. Results show how V2G scenarios shift fleet EV charging to mid-day while enabling strategic battery-discharge during evening peaks, mitigating grid stress and lowering EV energy costs. V2G delivers close to 80% energy-cost savings for a 2000-EV fleet in Austin on grid-stressed days, with 55% lower charging pollutant outputs. Joint-V2G amplifies system-level benefits by complementing fleet discharge, but smart-charging equipment costs can offset those benefits.

Electric vehicle↗
DOE OSTI2026

Production of high-quality polyethylene (PE) films from post-consumer shrink wrap with solvent targeted recovery and precipitation (STRAP)

The solvent-targeted recovery and precipitation (STRAP™) process separates polymers from contaminants present in the feedstock. In this work, we demonstrate the recyclability of a post-consumer waste (PCW) shrink wrap that contains inks, adhesives, and paper using STRAP. We produced a clear rPE cast film from the PCR shrink wrap with no visual contamination from paper or inks. STRAP decreased the ash content from 0.96 wt% to 0.24 wt%. A techno-economic analysis (TEA) shows that a STRAP plant processing 50,000 metric tons annually of shrink wrap waste (purchased at $\$0.25$/kg) containing 85 wt% PE can achieve an IRR of 16.2% when selling rPE at $\$1.30$/kg, an IRR of 10.7% with an rPE price of $\$1.00$/kg, or an IRR of 3.79% with an rPE price of $\$0.70$/kg. Furthermore, the life cycle assessment (LCA) shows a 64% reduction in global warming potential (kg CO 2 equivalent) when compared to the production of virgin LDPE. As a result, this work shows how feedstocks with insoluble impurities can be recycled using STRAP on a large scale.

Radkevich, Elizaveta [University of Wisconsin-Madi↗
DOE OSTI2026

Superstructure Optimization of Waste Plastic Pyrolysis, Integrating Thermal, Catalytic, and Plasma Technologies with Machine Learning

Global plastic waste generation exceeds 430 million tonnes per year, yet fewer than 9% are recycled in the United States. Pyrolysis offers a chemical recycling route at scale, but existing techno-economic and life cycle assessments fix product yields to single pure polymers, producing economic and environmental outputs that break down when the feed composition changes. Here, we present a superstructure optimization framework that addresses this by embedding a composition-aware random forest yield predictor, trained on 566 pyrolysis experiments, within a full-scale process simulation. Product distributions update automatically as feed allocation shifts across four reactor chemistries: conventional thermal, catalytic (HZSM-5), thermal oxo-degradation, and nonequilibrium CO2 plasma. The optimal superstructure achieves minimum selling prices of −0.56 to −0.76/kg feed and global warming potentials of −0.276 to −0.322 kg CO2-eq/kg feed across four commodity price scenarios, confirming profitable, carbon-negative operation without tipping fees. Carbon abatement costs of $\$$0.46 to $\$$1.25/kg CO2-eq are competitive with direct air capture. Sensitivity analysis shows that the catalytic-plasma split fraction is the single largest driver of both economic and climate performance, while hydrocracking allocation in the wax upgrading stage is emission-neutral across the full variable range. Mixed plastic waste streams, evaluated as composition-variable feedstocks rather than pure resins, are profitable and carbon-negative across realistic market conditions. These results give a quantitative basis for reactor selection, circular economy investment, and policy design targeting chemical recycling on a large scale.

Life cycle assessment↗
DOE OSTI2025

Characterizing the Potential for Sustainable Azelaic Acid Production from High-Oleic Vegetable Oil Using Two-Step Oxidative Cleavage

Azelaic acid is a renewable monomer conventionally produced via the energy-intensive ozonolysis of oleic acid. Recent advancements have enabled the use of high-oleic vegetable oils (rather than tallow-derived oleic acid) and replaced ozonolysis with two-step oxidative cleavage using hydrogen and oxygen. Although this shift would improve process safety, the financial viability and environmental implications remain uncertain. In this study, we characterized the sustainability of azelaic acid production from high-oleic vegetable oil using two-step oxidative cleavage. Process design, simulation, technoeconomic analysis (TEA), and life cycle assessment (LCA) were executed under uncertainty using BioSTEAM. The modeled system produces azelaic acid at a market-competitive minimum selling price (MSP) of 8.32 [4.93−13.34] $\$kg$ −1 (median 5th−95th percentiles), below the minimum estimated market price of 9.93 $\$kg$ −1 . Further, it has the potential to approach carbon neutrality (0.0 [−5.5 to 5.6] kg of CO 2 -eq kg −1 ) under displacement allocation. Improvements to dihydroxylation (86 to 99%) and oxidative cleavage conversions (93 to 99%) would reduce MSP to $\$5.24$ kg −1 and carbon intensity to −1.90 kg of CO 2 -eq kg −1 (displacement). Additionally, increasing the feedstock triolein content (75 to 85%) lowers MSP by $\$0.82$ kg −1 . Overall, this research demonstrates the potential for financially viable production of azelaic acid from vegetable oils and the utility of agile TEA/LCA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

E3SM‐GCAM: A Synchronously Coupled Human Component in the E3SM Earth System Model Enables Novel Human‐Earth Feedback Research

Abstract Modeling human‐environment feedbacks is critical for assessing the effectiveness of climate change mitigation and adaptation strategies under a changing climate. The Energy Exascale Earth System Model (E3SM) now includes a human component, with the Global Change Analysis Model (GCAM) at its core, that is synchronously coupled with the land and atmosphere components through the E3SM coupling software. Terrestrial productivity is passed from E3SM to GCAM to make climate‐responsive land use and CO 2 emission projections for the next 5‐year period, which are interpolated and passed to E3SM annually. Key variables affected by the incorporation of these feedbacks include land use/cover change, crop prices, terrestrial carbon, local surface temperature, and climate extremes. Regional differences are more pronounced than global differences because the effects are driven primarily by differences in land use. This novel system enables a new type of scenario development and provides a powerful modeling framework that facilitates the addition of other feedbacks between these models. This system has the potential to explore how human responses to climate change impacts in a variety of sectors, including heating/cooling energy demand, water management, and energy production, may alter emissions trajectories and Earth system changes. Plain Language Summary Earth system models help us understand how humans are changing the climate. Currently, these models do not include human systems, so predetermined greenhouse gas, aerosol, and land use change data are input to these models. These data do not reflect human responses to changes projected by Earth system models. We have added a human component to an Earth system model to represent human responses to environmental change and calculate corresponding greenhouse gas and land use change data instead of using predetermined data. Including this human component changes projections of land use, land carbon storage, and regional climate. Key Points We have incorporated a novel, advanceable human component in an Earth system model to simulate human‐Earth feedbacks Including terrestrial productivity feedbacks from the Earth to the human systems affects land change, crop prices, carbon, and climate Regional effects of including terrestrial productivity feedbacks are greater than global effects because land change is the main driver

E3SM↗
DOE OSTI2024

Non-linear relationships between daily temperature extremes and US agricultural yields uncovered by global gridded meteorological datasets

Global agricultural commodity markets are highly integrated among major producers. Prices are driven by aggregate supply rather than what happens in individual countries in isolation. Furthermore, estimating the effects of weather-induced shocks on production, trade patterns and prices hence requires a globally representative weather data set. Recently, two data sets that provide daily or hourly records, GMFD and ERA5-Land, became available. Starting with the US, a data rich region, we formally test whether these global data sets are as good as more fine-scaled country-specific data in explaining yields and whether they estimate similar response functions. While GMFD and ERA5-Land have lower predictive skill for US corn and soybeans yields than the fine-scaled PRISM data, they still correctly uncover the underlying non-linear temperature relationship. All specifications using daily temperature extremes under any of the weather data sets outperform models that use a quadratic in average temperature. Correctly capturing the effect of daily extremes has a larger effect than the choice of weather data. In a second step, focusing on Sub Saharan Africa, a data sparse region, we confirm that GMFD and ERA5-Land have superior predictive power to CRU, a global weather data set previously employed for modeling climate effects in the region.

54 ENVIRONMENTAL SCIENCES↗
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 OSTI2026

Pathways to cost competitive and viable lithium production from Salton Sea geothermal brines

Lithium supply chains remain heavily concentrated in hard rock and brine resources, creating significant supply risks. Geothermal brines represent an underutilized alternative, yet commercial progress is hindered by the absence of facility-scale cost assessments. Here, we present a techno-economic analysis of large-scale lithium extraction from Salton Sea geothermal brines, drawing on primary company disclosures, process patents, and brine resource modeling. Caused by varying lithium and impurity concentrations, brine dilution over time, and process configurations (e.g., production via carbonation and conversion vs. electrolysis), we find that large-scale production costs may reach ~10,000 United States dollars per ton, but increase up to 22,000 United States dollars per ton with higher certainty of brine modeling, raising concerns about economic competitiveness to conventional low-cost sources. Finally, a project feasibility-focused scenario analyses shows that leveraging brine pre-treatment by-product sales could lower long-term lithium break-even prices by ~5,000 United States dollars per ton, whereas capital cost optimization of 20% could further reduce lithium break-even prices by 10%.

Wesselkaemper, Jannis↗
DOE OSTI2025

Spatially explicit terrestrial carbon densities for calibrating the carbon cycle in human-Earth system Models

Soil and vegetation carbon stocks play a critical role in human-Earth system models. These stocks (denominated as densities in MgC/ha) affect variables such as land use change emissions and also influence land use change pathways under climate forcing scenarios where terrestrial carbon is assigned a carbon price. Here we present reharmonized soil and vegetation carbon densities both at the 5-arcmin resolution grid cell level and also aggregated to 235 water sheds for 4 land use types (Cropland, Grazed land, Urban land and unmanaged vegetation) and 15 unmanaged land cover types. Moreover, we use the distribution of carbon within and across pixels to define statistical "states" of carbon, once again differentiated by land type. These statistical states are used to define a range of possible carbon values that can be used for defining initial conditions of soil and vegetation carbon in human-Earth system models. We implement these data in a state-of-the-art multi sector dynamics model, namely the Global Change Analysis Model (GCAM), and show that these new data improve several land use responses, especially when terrestrial carbon is assigned a carbon price.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Valorization of consolidated bioprocessing residues for bioplastics

This study demonstrates an organic solvent-free processing strategy to valorize consolidated bioprocessing (CBP) residues, from switchgrass and poplar biomass, into functional poly(butylene succinate) (PBS)-based biocomposites using high-shear homogenization (HSH). HSH transformed the switchgrass and poplar CBP residues (CBP-R) into fine, uniformly distributed particles and microfibers. The composites of PBS with homogenized switchgrass residues (H-CBP-R-SG) or homogenized poplar residues (H-CBP-R-P) at a 70/30 weight ratio exhibited improved processability and mechanical integrity, with the Young's modulus for the PBS/H-CBP-R-SG and PBS/H-CBP-R-P nearly doubling to 0.66 ± 0.07 GPa and 0.65 ± 0.04 GPa, respectively, compared to neat PBS (0.36 ± 0.02 GPa). Dynamic Mechanical Analysis (DMA) reveals a significant suppression of the tan δ peak magnitude, indicating that HSH-mediated physical activation facilitates stress transfer in composites typical of covalent chemical grafting systems. While the transition to a stiffness-dominated profile reduces ductility, the resulting composites exhibit the dimensional stability and resistance to thermal warping required for high-fidelity FDM 3D printing and injection molding. Beyond material performance, comprehensive techno-economic analysis (TEA) and life cycle assessment (LCA) confirmed that diverting CBP residues into composite products can improve the economic viability of the biorefinery without substantially increasing biorefinery global warming potential (GWP). At a 30 wt% blend ratio, incorporating residuals into PBS yielded a minimum selling price for the composite of $\$4.07$ per kg compared to the conventional bioplastic price of $\$5.00$ per kg. This approach aligns with circular bioeconomy principles by converting waste streams into value-added products. Furthermore, this innovative strategy addresses key challenges in bioplastic development, including cost, compatibility, and performance, while simultaneously advancing waste minimization strategies for sustainable manufacturing systems.

09 BIOMASS FUELS↗