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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Techno-Economic Impact of a Smart Battery Sorting System

Create analytical framework to capture costs and benefits of the automated sorting into battery recycling including the development and deployment of various types of battery recycling technologies such as pyrometallurgical, hydrometallurgical, and direct recycling. Li Industries, Inc. is a Virginia startup company focused on reinventing how lithium-ion batteries (LIBs) are recycled. Li Industries is focused on developing direct LIB recycling and automated battery sorting technologies in order to reduce the environmental impact of the LIB lifecycle. This work is to be conducted in support of the American-Made Challenges Lithium-Ion Battery Recycling Prize. Li Industries and NREL will work together to understand how novel technologies, such as those being developed by Li Industries, can impact the development and economics of the battery recycling industry. This voucher is being used to evaluate the profitability of an automated sorting system developed by Li Industries and the potential effect this increased value could have on the domestic lithium-ion battery (LIB) recycling industries in the United States. NREL has developed the Lithium-Ion Battery Resources Assessment (LIBRA) system dynamics model to project the future viability of the US LIB manufacturing and recycling industries under varying technoeconomic conditions and battery adoption scenarios over the coming decades. Additional logic was added to LIBRA to analyze the role automated sorting of recycling feedstock could play in the buildout of the industry and the impacts it has on the recovery of end-of-life (EOL) battery materials. This report summarizes the outcomes of this modeling analysis in the US context through a series of sensitivity analyses run for a range of values of a given input dimension and compared across the unsorted or automated sorting cases for LIB recycling feedstock. For greater detail on the process and analysis, the researchers are publishing a forthcoming journal article titled Techno-Economic Impact of a Smart Battery Sorting System for Lithium-Ion Battery Recycling and Mineral Recovery in the United States by Weigl, et al. In the event the article is not accepted by any currently seeking publication in academic or industry journal, it may be published by NREL. CRADA benefit to DOE, Participant, and US Taxpayer: assists laboratory in achieving programmatic scope competencies, uses the laboratory's core competencies.

25 ENERGY STORAGE↗
DOE OSTI2020

Correlation approach for quality assurance of additive manufactured parts based on optical metrology

Surface topography and surface finish are two significant factors for evaluating the quality of products in additive manufacturing (AM). AM parts are fabricated layer by layer, which is quite different from traditional formative or subtractive methods. Despite rapid progress in additive manufacturing and associated optical metrology for quality control and in-situ monitoring, limited research has been conducted to investigate the reliability of 3D surface measurement data. The surface topologies scanned by multiple optical systems demonstrated significant differences due to varying sampling mechanisms, resolutions, system noises, etc. The 3D datasets should be trustworthy in order to extract parameters for quality assurance or feedback control from 3D surface measurements. In this paper, we set up new standards to evaluate the reliability of 3D surface measurement data and analyze the variation in the topographical profile. In this study, two non-contact optical methods based on Focus Variation Microscopy (FVM) and Structured Light System (SLS) were adopted to measure the surface topography of the target components. The two optical metrology systems generated two entirely different point cloud datasets. Statistical methods were applied to test the difference between the data obtained from the two systems. By using a data analytics approach for comparison, it was found that the surface roughness estimated from the point cloud data sets of FVM and SLS has no significant difference, though the point cloud data sets were completely different. This paper provides standard validation approach to evaluate the plausibility of metrology data from in-situ real-time surface analysis for process planning of AM.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Technoeconomic analysis and life cycle assessment of purification processes for captured CO 2 streams

Captured carbon dioxide (CO 2 ) streams contain impurities that must be removed to meet specifications for safe transport, storage, and utilization. Among these impurities, oxygen poses challenges due to its high reactivity and potential to cause corrosion, motivating stringent purity limits below 10 ppmv. Building on recent experimental demonstrations of catalytic oxygen removal using hydrogen (H 2 ), carbon monoxide (CO), methanol (CH 3 OH), and methane (CH 4 ) as reducing agents, this study presents a technoeconomic (TEA) and life cycle assessment (LCA) of these four catalytic purification pathways. Process flowsheets were developed and simulated in Aspen Plus for CO 2 streams representative of both low-temperature and high-temperature capture processes, with integrated heat recovery and energy optimization. Results showed that total purification costs were dominated by feedstock procurement and electricity consumption. Among the studied reducing agents, the CH 4 -assisted route achieved the lowest purification cost and highest CO 2 recovery. Sensitivity analyses showed that the H 2 route became competitive at H 2 prices below $\$$0.56/kg to $\$$0.84/kg, depending on the CO 2 feed temperature conditions. In conclusion, environmental impacts were primarily driven by indirect CO 2 emissions from raw material production and utility consumption.

CO2 pipeline specifications↗
DOE OSTI2026

Raman spectroscopic investigation of ianthinite [U$_2^{4+}$(UO$_2$)$_4$O$_6$(OH)$_4$(H$_2$O)$_4$]·$5$H$_2$O, a rare mixed-valence uranium oxide hydrate

Ianthinite ([[U$_2^{4+}$(UO$_2$)$_4$O$_6$(OH)$_4$(H$_2$O)$_4$]·$5$H$_2$O) is an exotic mineral that possesses U in both tetravalent and hexavalent oxidation states and is structurally related to the U 3 O 8 polymorphs, which are commonly encountered technogenic materials in the nuclear fuel cycle. Despite the similarities between U 3 O 8 and ianthinite, and the importance of ianthinite in U paragenesis, no Raman spectra have been reported for this mineral. Here, to gain a more complete understanding of how structural attributes of ianthinite give rise to observable spectroscopic features and how these may relate to important materials in the nuclear fuel cycle, we provide, for the first time, Raman spectra of ianthinite. Ianthinite readily oxidizes at ambient conditions, complicating analysis of phase-pure material. Several analytical methods are employed herein to decouple the Raman features of ianthinite from its alteration product(s). First, a simple difference spectrum is presented, then results of Raman spectroscopic mapping are employed, and finally, we use a novel processing and analysis method. Each analysis method provides different insight into structural features that are unique to ianthinite, in particular, features that are attributable to U(IV) in distorted octahedral coordination in both ianthinite and U 3 O 8 phases.

Spano, Tyler L. [Oak Ridge National Laboratory (OR↗
DOE OSTI2021

BETO 2021 Peer Review - Algal Biofuels Techno-Economic Analysis 1.3.5.200

The objective of NREL's Algal Biofuel Techno-Economic Analysis (TEA) project is to provide process modeling and analysis to support Algae Program activities, utilizing TEA models to relate key process parameters with overall economics for cultivation, processing, and conversion of algal biomass to fuels and coproducts. By quantifying economic implications of key process metrics, TEA models highlight the technical requirements to achieve future program cost goals as well as enabling a means to track progress towards these goals. This project provides high impact and relevance though generation of critical cost data tied to funded research, with our analyses subsequently exercised by BETO to guide program plans, FOA priorities, and other directives. This includes costs for both algal biomass production and downstream conversion, most notably to support BETO's fuel cost targets below $2.5/GGE by 2030. To mitigate a key risk/challenge in constraining our work to academic analyses rooted only in future projections, our work also seeks to provide near-term value to today's algae industry through frequent industry engagement, while maintaining close ties with other BETO collaborators. This project has made numerous accomplishments since the 2019 peer review, including a continued focus on opportunities for value-added products, with related analyses for new pathway opportunities to achieve BETO cost goals and notable State-of-Technology (SOT) improvements over prior cost benchmarks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Summertime ozone pollution in China affected by stratospheric quasi-biennial oscillation

In recent years, the near-surface ozone (O 3 ) level has been rising fast in China, with increasing damage to human health and ecosystems. In this study, the impact of stratospheric quasi-biennial oscillation (QBO) on interannual variations in summertime tropospheric O 3 over China is investigated based on GEOS-Chem model simulations and satellite retrievals. QBO has a significant positive correlation with near-surface O 3 concentrations over central China (92.5–112.5° E, 26–38° N) when the sea surface temperature (SST) over the eastern tropical Pacific is warmer than normal, with a correlation coefficient of 0.53, but QBO has no significant effect on O 3 under the cold SST anomaly. Compared to the easterly phase of QBO, the near-surface O 3 concentrations have an increase of up to 3 ppb (5% relative to the average) over central China during its westerly phase under the warm SST anomaly. O 3 also increases above the surface and up to the upper troposphere, with a maximum increase of 2–3 ppb (3%–5%) in 850–500 hPa over central China when comparing westerly phase to easterly phase. Process-based analysis and sensitivity simulations suggest that the O 3 increase over central China is mainly attributed to the anomalous downward transport of O 3 during the westerly phase of QBO when a warm SST anomaly occurs in the eastern tropical Pacific, while the local chemical reactions and horizontal transport processes partly offset the O 3 increase. This work suggests a potentially important role of QBO and the related vertical transport process in affecting near-surface O 3 air quality, with an indication for O 3 pollution prediction and prevention.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

TEAMER: Twin Ocean Power Wave Energy Converter Comprehensive Overview

These files collectively provide a comprehensive overview of the testing process, data analysis, and validation for the Twin Ocean Power device tested at the O.H. Hinsdale Wave Research Laboratory, supported by TEAMER funding. This resource includes an overview of power results for a series of 7 trials. The files included in this comprehensive overview include a comprehensive log sheet for each trial, a summary of all trials, and processing scripts for the raw data. It includes all raw data in .tsv and MATLAB compatible formats, an average power chart, angular velocity charts for each trial, trial metrics, and power output files. This resource includes images of the Twin Ocean Power Wave Energy Converter device components and movement during testing and video recordings of each trial.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Analysis of furnace contamination on superconducting radio frequency niobium using secondary-ion mass spectrometry

Detection of surface contamination on niobium materials used in superconducting radio frequency (SRF) applications is difficult due to quantitative sensitivity and near-atomic depth resolution needed. Inspection of samples known to have experienced surface contamination was found to have inconsistent nitride coverage after high-temperature nitrogen gas exposure (“doping”). Here we compare contaminating species found on samples treated in several different vacuum furnaces, both “exposed” directly in the chamber and “protected” by containment shielding from evaporative sources with “furnace caps.” Typically, furnace caps are used to impede contamination from reaching the interior surface of cavities during the high-temperature vacuum bake that immediately precedes exposure to nitrogen gas. Although, to date, little is known about the effectiveness of these caps, SIMS results showed that they were effective in limiting contamination arising from the furnace environment. Inspection of sample surfaces by SEM showed a lack of nitrides present on contaminated specimens. TEM with energy dispersive spectroscopy performed on these samples revealed that a carbon-rich layer now existed, indicating that a relatively high contaminant load prevents the nucleation and growth of surface nitrides, while thus inhibiting interstitial nitrogen uptake. Except in extreme cases, subsequent removal of the top several micrometers of the surface via electropolishing appears to effectively eliminate any strong influence on the subsequent SRF cavity performance. With the absence of furnace cleaning, carbon contamination was found to be nearly 10× higher for protected nitrogen-doped and electropolished samples, with minimal metallic contamination detected for both processes. SIMS analysis was also performed to compare the cleanliness of samples fully prepared by such nitrogen “doping” with those prepared by a related process, involving the dissolution of niobium surface oxide and diffusion of oxygen into the surface. This oxygen doping or alloying process offers attractive advantages.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗
DOE OSTI2022

Software Development for Data Visualization and Analysis of PN-Diodes & MOSFET Devices

The U.S. Department of Energy has a broad mission to ensure the nation’s security by addressing ongoing environmental challenges, developing novel energy production technologies, and mitigating nuclear security concerns. These efforts benefit from developing more effective semiconductor materials and devices. The research discussed in this report aims to further the development of these new electronics by improving implementations of vertical device structures, which offer theoretically better performance compared to lateral structures. Specifically, it reviews the background and development of a new and easy-to-use program for data processing and analysis from experiments run on vertical gallium nitride power devices. Current vertical structures fall short in critical performance metrics, such as On-Resistance and Breakdown Voltage, due to poor management of the device’s electric field. Junction termination extensions, or JTEs, are a field management technique that increases a device’s resilience to expected failure modes by controlling its surface electric fields. Each JTE design requires significant experimental validation, consisting of hundreds of tested devices, each outputting an enormous set of data points. The new software includes multiple methods of filtering large sets of device testing data to identify and remove flawed devices, automate device analyses, and provide statistical breakdowns for four metrics used to define the effectiveness of the JTE and the current carrying capacity of the device. These results can then be related back to fabrication techniques and device design, and in the future, be combined with processing simulations to further improve our understanding of the JTE mechanisms.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

The prevalence of precipitation from polar supercooled clouds

Abstract. Supercooled clouds substantially impact polar surface energy budgets, but large-scale models often underestimate their occurrence, which motivates accurately establishing metrics of basic processes. An analysis of long-term measurements at Utqiaġvik, Alaska, and McMurdo Station, Antarctica, combines lidar-validated use of soundings to identify supercooled cloud layers and colocated ground-based profiling radar measurements to quantify cloud base precipitation. We find that more than 85 % (75 %) of sampled supercooled layers are precipitating over the Arctic (Antarctic) site, with more than 75 % (50 %) precipitating continuously to the surface. Such high frequencies can be reconciled with substantially lesser spaceborne estimates by considering differences in radar hydrometeor detection sensitivity. While ice precipitation into supercooled clouds from aloft is common, we also find that the great majority of supercooled cloud layers without ice falling into them are themselves continuously generating precipitation. Such sustained primary ice formation is consistent with continuous activation of immersion-mode ice-nucleating particles (INPs), suggesting that supercooled cloud formation is a principal gateway to ice formation at temperatures greater than ∼-38 ∘C over polar regions. The prevalence of weak precipitation fluxes is also consistent with supercooled cloud longevity and with well-observed and widely simulated case studies. An analysis of colocated microwave radiometer retrievals suggests that weak precipitation fluxes can be nonetheless consequential to moisture budgets for supercooled clouds owing to small liquid water paths. The results here also demonstrate that the observed abundance of mixed-phase clouds can vary substantially with instrument sensitivity and methodology. Finally, we suggest that these ground-based precipitation rate statistics offer valuable guidance for improving the representation of polar cloud processes in large-scale models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

DeepAdversaries: examining the robustness of deep learning models for galaxy morphology classification

With increased adoption of supervised deep learning methods for work with cosmological survey data, the assessment of data perturbation effects (that can naturally occur in the data processing and analysis pipelines) and the development of methods that increase model robustness are increasingly important. In the context of morphological classification of galaxies, we study the effects of perturbations in imaging data. In particular, we examine the consequences of using neural networks when training on baseline data and testing on perturbed data. We consider perturbations associated with two primary sources: (a) increased observational noise as represented by higher levels of Poisson noise and (b) data processing noise incurred by steps such as image compression or telescope errors as represented by one-pixel adversarial attacks. We also test the efficacy of domain adaptation techniques in mitigating the perturbation-driven errors. We use classification accuracy, latent space visualizations, and latent space distance to assess model robustness in the face of these perturbations. For deep learning models without domain adaptation, we find that processing pixel-level errors easily flip the classification into an incorrect class and that higher observational noise makes the model trained on low-noise data unable to classify galaxy morphologies. On the other hand, we show that training with domain adaptation improves model robustness and mitigates the effects of these perturbations, improving the classification accuracy up to 23% on data with higher observational noise. Domain adaptation also increases up to a factor of ${\approx}2.3$ the latent space distance between the baseline and the incorrectly classified one-pixel perturbed image, making the model more robust to inadvertent perturbations. Successful development and implementation of methods that increase model robustness in astronomical survey pipelines will help pave the way for many more uses of deep learning for astronomy.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Towards the Quantum Internet: Entanglement Rate Analysis of High-Efficiency Electro-Optic Transducer

Coherent microwave-optical photon conversion is a key enabling technology for the Quantum Internet, since it allows entanglement distribution among superconducting-based network nodes. A high-efficiency electro-optic transducer based on three-dimensional superconducting radio-frequency (SRF) technology has recently been proposed at Fermilab. In this paper, we evaluate the impact of Fermilab's transduction hardware on the entanglement generation probability and the entanglement rate, which are two critical metrics from a communication engineering perspective. Furthermore, we provide some guidelines to increase the direct entanglement rate, i.e., the rate before any entanglement purification process. Our analysis shows that, through high-efficiency transduction, it is possible to reduce the network overhead. This preliminary work paves the way toward distantly interconnected superconducting quantum processors.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Measuring Hydroxylammonium, Nitrate, and Nitrite Concentration with Raman Spectroscopy for 238 Pu Supply Program

Optical spectroscopy has great potential to improve the timeliness of important analytical measurements for the 238 Pu Supply Program by enabling real-time analysis of process solutions within radiochemical hot cells. Hydroxylammonium (H 3 NOH + ]), nitrate (NO 3 - ), and nitrite (NO 2 - ) are three important molecular species present in multiple aqueous streams throughout the program’s flow sheet. The concentration of each species normally goes uncharacterized during processing. However, rapid quantification may benefit the program because uncertainties in kinetic redox expressions describing hydroxylammonium (HA) and nitrite reactions with Np and Pu leads to uncertainty in process model predictions for solvent extraction runs. HA concentration is normally quantified using ion chromatography, a technique that requires diluted grab samples taken out of the hot cell and analyzed off-line. Here we evaluate Raman spectroscopy for determining the concentration of H 3 NOH + , NO 3 - , and NO 2 - in benchtop tests to determine limits of detection. We also consider the possibility of using Raman spectroscopy in both glove box and hot cell environments for rapid analysis and pinpoint additional development opportunities needed to make this application successful.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2020

Policy Considerations When Federating Facilities for Experimental and Observational Data Analysis

Today’s computational, experimental, and observational facilities afford us tremendous opportunities to couple theory and experiment at increasingly large scales. Empirical sensing capabilities are growing dramatically with beam line and detector improvements, and with advances in our ability to deploy large-scale data gathering observations of the natural world. The coupling of computational simulations and analysis to process the data from experimental and observational facilities is giving rise to cross-facility workflows. Such federations of facilities are in fact becoming an explicit requirement for large-scale scientific discovery. As we scale up these pipelines of scientific discovery, each participating facility needs to establish and align policies so that the federation can work seamlessly in an end-to-end manner. This chapter outlines specific policy considerations in enabling the federation of facilities for data analysis. Design choices and vital policy decisions cover the areas of data acquisition and storage, data transfer, computational resource allocation and co-scheduling, seamless federated user access, and cross-cutting governance. By highlighting the explicit and implicit interdependencies between facilities, we aim to provide facility designers and policymakers the information on policy issues to address early in a facility’s operations, thus enabling successful cross-facility federation and improved experimental and observational data analysis outcomes.

Shankar, Mallikarjun (Arjun)↗
DOE OSTI2022

Evaluation of Joint Cyber/Safety Risk in Nuclear Power Systems

This report presents an analysis of the Emergency Core Cooling System (ECCS) for a generic Boiling Water Reactor (BWR)-4 NPP. The Electric Power Research Institute (EPRI) developed Hazards and Consequences Analysis for Digital Systems (HAZCADS) process is applied to the ECCS and its subsystems to identify unsafe control actions (UCAs) which act as possible cyber events of concern. The analysis is performed for two design basis events: Small-break Loss of Coolant Accident (SLOCA) and general transients (TRANS), such as unintended reactor trip. In previous work, HAZCADS UCAs were combined with other cyber-attack analysis to develop a risk-informed approach; however, this was for a single system. This report explores advanced systems engineering modeling approaches to model the interactions between digital assets across multiple systems which may be targeted by cyber adversaries. The complex and interdependent design of digital systems has the potential to introduce emergent cyber properties that are generally not covered by hazard analyses nor formal nuclear Probabilistic Risk Assessment (PRA). The R&D and supporting analysis presented here explores approaches to predict and manage how interdependent system properties effect risk. To show the potential impact of a successful cyber-attack to formal PRA event tree probabilities, HAZCADS analysis was also used. HAZCADS was also used to model the automatic depressurization system (ADS) automatic actuation. This analysis extended to an integrated system analysis for common-cause failure (CCF). In this aspect, the HAZCADS analysis continued by analyzing plant design details for system connectivity in support of critical plant functions. A dependency matrix was developed to depict the integrated functionality of the interconnected systems. Areas of potential CCF are indicated. Future work could include adversary attack development to show how CCF could be caused, resulting in PRA events. Across the multiple systems that comprise the ECCS, the analysis shows that the change in such probabilities was very different between systems. This indicates that some systems have a larger potential risk impact from successful cyber-attack or digital failure, which indicates a need for these systems to have a higher priority for design and defensive measures. Furthermore, we were able to establish that a risk analysis using any arbitrary threat model establishes an ordering of components with regard to cyber-risk. This ordering can be used to influence the overall system design with an eye to lowering risk, or as a way to understand real-time risk to operational systems based on a current threat landscape. Expert knowledge of both the analysis process and the system being analyzed is required to perform a HAZCADS analysis. The need for a tiered risk analysis is demonstrated by the results of this report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Measurement of J/psi Production near Threshold in J/psi -> µ+µ-

This dissertation presents a detailed analysis of J/psi photoproduction near the kinematic threshold in the J/psi -> µ+µ- decay channel, based on data collected by the GlueX experiment at Jefferson Lab. The study aims to probe the structure of the proton and the underlying mechanisms of heavy vector quarkonium photoproduction, contributing to a deeper understanding of Quantum Chromodynamics (QCD) in the non-perturbative regime. The measurement focuses on the total and differential cross-sections of J/psi photoproduction and explores various theoretical models, including two-gluon and three-gluon exchange, open-charm contributions, and potential exotic states like pentaquarks. The experimental setup, featuring a high-precision tagged photon beam and advanced particle identification techniques, allowed for the separation of J/psi events from background processes. The analysis of the J/psi -> µ+µ- channel yields cross-sections that complement previous measurements in the J/psi -> e+e- decay mode, providing new insights into gluon dynamics at low momentum transfer. This work also examines the systematic uncertainties and provides a comprehensive comparison of results with theoretical predictions, highlighting the role of gluon exchange mechanisms in the photoproduction process. The results presented in this dissertation help refine our understanding of proton structure and QCD dynamics, offering a robust dataset for future theoretical and experimental studies in hadronic physics.

Ebersole, Donavan [Florida State Univ., Tallahasse↗
DOE OSTI2026

A Kinetic Model-Driven Techno-Economic Analysis of Plastic Pyrolysis: Linking Process Dynamics to Economic Viability

This study employs a kinetic model integrated into Aspen Plus to predict pyrolysis product distribution under various conditions. A techno-economic assessment calculated the minimum selling price (MSP) of pyrolysis oil under different operating conditions for the baseline capacity of 100 kta, and across eight processing capacities ranging from 30 to 150 kta. The lowest MSP under the baseline capacity is estimated at $\$$420/ton, which is 33% lower than the 2023 average US crude oil price ($\$$74.6/bbl, equivalent to $\$$634/ton based on the density of pyrolysis oil). Under Monte Carlo simulation, accounting for variability in key economic and technical parameters, the mean MSP is estimated at $\$$1137/ton. The economic viability depends on feedstock price remaining below $\$$320/ton, defining the break-even feedstock price threshold. Sensitivity analysis further identifies capital investment and transportation cost as key economic drivers. Capacities beyond 90 kta show limited economies of scale benefits. Reducing product storage time cuts capital costs by 7% but raises operational risk. Uncertainty analysis suggests the economic feasibility of pyrolysis oil is unlikely to compete with crude oil without policy incentives.

petrochemicals↗