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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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General atom theory for volume ion production cost and rate in tenuous plasma having Maxwellian distribution of electron energies - detailed results for argon, cesium and helium gases
Capacity expansion modeling tools are increasingly being utilized to investigate a wide range of potential future scenarios, particularly with high penetrations of variable and energy-constrained resources that may be operated differently than current dispatch paradigms. While capacity expansion models are particularly adept at making investment decisions for future years, they must make compromises in operational aspects to maintain computational tractability. However, it is of high interest to determine if such future systems would be able to maintain reliability during a variety of grid conditions, and to identify any potential operational challenges for these systems at finer temporal resolution than is typically captured in CEMs. As such, there is value in having an automated tool that can convert many CEM investment pathways into inputs for a more detailed production cost model, in this case the PLEXOS commercial software package. This paper describes the methodology used to make that translation for the NREL-developed ReEDS model, making use of two internally developed tools - PIDG and beetle - along with a set of processing scripts. We describe the current assumptions, data sets, and important operational characteristics of these translations along with an example of the extended analyses that may be done through this connection.
Abstract In this Technical Note, we present a simple and low-cost production method for fluorescent particles perfectly suitable for velocimetry applications. We leverage the unique ability of Nile Red (NR) fluorophores to adsorb on the polymer surface and/or embed itself in between polymeric chains. The laboratory procedure to dye polyamide particles with NR and monetary advantages over commercially available fluorescent particles is outlined. Subsequently, the fluorescence behavior of the dyed particles is tested under a laser illumination source in polar and non-polar liquids. The distinct advantage of the emission spectrum of NR-dyed particles is demonstrated with sample test results.
This report is a joint piece by PNNL and NREL describing two similar projects and complementary approaches to improving the representation of hydropower in production cost models.
The use of ensiled biomass sorghum enables implementation of relatively mild pretreatment conditions compared to non-ensiled sorghum and results in higher sugar yields, which reduces the biofuel production cost and associated carbon footprint.
The comparative costs entailed in producing hydrogen by major technologies that rely on petroleum, natural gas, coal, thermochemical cycles, and electrolysis are examined. Techniques were developed for comparing these processes by formulating the process data and economic assessments on a uniform and consistent basis. These data were normalized to permit a meaningful comparative analysis of product costs of these processes.
One of the challenges of a high-renewable, low-carbon system is that grid operators will no longer be able to count on fossil-fired generation should wind miss its forecast or modeling errors create shortage issues, and this change has operational and reliability implications that affect variable renewable energy integration. Hydropower can help in that it can provide many of the services that have been traditionally provided by fossil generation. However, getting the most from hydropower can be challenging in that its capabilities vary with time and are affected by other water users' needs, two complexities that are not well represented in most of today's production cost models (PCMs). This work is an early step in addressing these gaps and making the most of hydropower's capabilities.
For early design concepts, the conventional approach to cost is normally some kind of parametric weight-based cost model. There is now ample evidence that this approach can be misleading and inaccurate. By the nature of its development, a parametric cost model requires historical data and is valid only if the new design is analogous to those for which the model was derived. Advanced aerospace vehicles have no historical production data and are nowhere near the vehicles of the past. Using an existing weight-based cost model would only lead to errors and distortions of the true production cost. This paper outlines the development of a process-based cost model in which the physical elements of the vehicle are soared according to a first-order dynamics model. This theoretical cost model, first advocated by early work at MIT, has been expanded to cover the basic structures of an advanced aerospace vehicle. Elemental costs based on the geometry of the design can be summed up to provide an overall estimation of the total production cost for a design configuration. This capability to directly link any design configuration to realistic cost estimation is a key requirement for high payoff MDO problems. Another important consideration in this paper is the handling of part or product complexity. Here the concept of cost modulus is introduced to take into account variability due to different materials, sizes, shapes, precision of fabrication, and equipment requirements. The most important implication of the development of the proposed process-based cost model is that different design configurations can now be quickly related to their cost estimates in a seamless calculation process easily implemented on any spreadsheet tool.
As a low-carbon fuel, feedstock, and energy source, hydrogen is expected to play a vital role in the decarbonization of high-temperature process heat during the pyroprocessing steps of clinker production in cement manufacturing. However, to accurately assess its potential for reducing CO2 emissions and the associated costs in clinker production applications, a techno-economic analysis and a study of facility-level CO2 emissions are necessary. Assuming that up to 20% hydrogen can be blended in clinker fuel mix without significant changes in equipment configuration, this study evaluates the potential reduction in CO2 emissions (scopes 1 and 2) and cost implications when replacing current carbon-intensive fuels with hydrogen. Using the direct energy substitution method, we developed an Excel-based model of clinker production, considering different hydrogenblend scenarios. Hydrogen from steam methane reformer (gray) and renewable-based electrolysis (green) are considered as sources of hydrogen fuel for blend scenarios of 5%20%. Metrics such as the cost of cement production, facility-level CO2 emissions, and cost of CO2 avoided were computed. Results show that for hydrogen blends (gray or green) between 5% and 20%, the cost of cement increases by 0.6% to 16%, with only a 0.4% to 6% reduction in CO2 emissions. When the cost of CO2 avoided was computed, the extra cost required to reduce CO2 emissions is $229 to $358/ metric ton CO2. In summary, although green hydrogen shows promise as a low-carbon fuel, its adoption for decarbonizing clinker production is currently impeded by costs.
Rigorous stakeholder-vetted techno-economic analysis was performed to assess the cost of hydrogen (H 2 ) produced using state-of-the-art Anion Exchange Membrane (AEM) electrolysis. Projected high-volume, untaxed and unsubsidized levelized cost of hydrogen (LCOH)1 range from 2020 $\$$1.78 to $\$$3.68/kg H 2 depending on technology year, process design, and electrolyzer project scale, assuming an electricity price of $\$$0.03/kWh and a capacity factor of 97%. The total installed capital cost for an AEM electrolysis plant was estimated from bottom-up stack and process plant cost models. The stack cost model accounts for manufacturing equipment, equipment maintenance, material, tooling, cycle time, yield, labor, utilities and general overhead. The process plant cost model accounts for purchased equipment, installation costs, site preparation, and general overhead costs. For this study, the AEM electrolysis plant is assumed to be a stick-built, greenfield project developed by an engineering, procurement, and construction (EPC) firm with electrolysis stacks purchased directly from an electrolysis stack manufacturer. The price of the electrolysis stacks is based on a bottom-up cost assessment with business markup for the electrolysis company fabricator. Methods from the Hydrogen Analysis (H2A) production model, a peer-reviewed national laboratory-developed discounted cash flow (DCF) model, were used to calculate the production LCOH in 2020 $\$$/kg H 2 . The baseline electricity price case ($\$$0.03/kWh) corresponds to average wholesale electricity prices currently possible in U.S. markets with plentiful wind. Similar low-cost electricity pricing is possible from solar Power Purchase Agreements (PPA) although these prices are typically limited by renewable energy capacity factors.
Rigorous stakeholder-vetted techno-economic analysis was performed to assess the cost of hydrogen (H 2 ) produced using state-of-the-art Liquid Alkaline (LA) electrolysis. Projected high-volume, untaxed levelized cost of hydrogen (LCOH) range from 2020US $\$ 1.84$ to $\$ 2.88$/kg-H 2 depending on technology year, process design, and electrolyzer project scale, assuming an electricity price of $\$ 0.03$/kWh. The total installed capital cost for a LA electrolysis plant was estimated from bottom-up stack and installed cost models that account for purchased equipment, installation costs, site preparation, and general overhead costs. For this study, the LA electrolysis plant is assumed to be a stick-built, greenfield project developed by an EPC firm with electrolysis stacks purchased directly from an electrolysis stack manufacturer. The price of the electrolysis stacks is based on a bottom-up cost assessment with business markup for the electrolysis company fabricator. Methods from the Hydrogen Analysis (H 2 A) production model, a peer-reviewed national laboratory-developed discounted cash flow model, were used to calculate the LCOH production in 2020$/kg-H 2 . The baseline electricity price case ($\$ 0.03$/kWh) corresponds to average wholesale electricity prices currently possible in U.S. markets with plentiful wind. Similar low-cost electricity pricing is possible from solar Power Purchase Agreements (PPA) although these prices are typically limited by renewable energy capacity factors.
Residential photovoltaic (PV) costs have fallen consistently for over a decade (Ardani et al. 2018). DOE has subsequently developed a new residential PV cost target for 2030 of $0.05/kilowatt hour (SETO 2023). Ardani et al. (2018) conclude that integrated roofing and PV (RIPV) products may be key to achieving the residential target for both new construction and retrofit residential PV. In RIPV, the PV product is incorporated into or replaces the roofing material. RIPV systems can use conventional crystalline or thin-film technologies, may be aesthetically attractive alternatives to traditional racked and mounted PV systems, and may increase building property values (Cook et al. 2023). These products also have the potential to provide customer acquisition, labor, and equipment cost savings over traditional, racked and mounted residential rooftop PV and several companies have recently introduced integrated roofing and PV (RIPV) products (Cook et al. 2023). In 2022, Tesla was the market leader, representing 94% of RIPV capacity installed in 2022 through its Solar Roof offering, while GAF Energy and its Timberline Solar product was second capturing 3% (Feldman et al. 2023). In this project, NREL analyzed three research questions: (1) How do current RIPV products compare to racked and mounted PV in terms of costs, install times and processes? (2) How are RIPV products installed and are there opportunities for cost savings? (3) What are the key barriers to expanding market opportunities for integrating solar and roofing products? In this project, we explored residential RIPV cost reduction opportunities by analyzing installation processes. Our study documented residential RIPV installations at two reroofing sites (20.52 kilowatts) and the equivalent of nine new construction sites (71.75 kW) in California through a methodology known as time and motion study. We also conducted 15 interviews with subject-matter experts to identify barriers and solutions to maximize these products' market penetration.
Large-scale production model combines most modern manufacturing techniques to produce silicon-solar-cell panels of low costs by 1982. Model proposes facility capable of operating around the clock with annual production capacity of 20 W of solar cell panels.
The objectives of this research program were to reduce the manufacturing costs of variable stator vane bushings by 1) eliminating the expensive carbon fiber braiding operation, 2) replacing the batch mode impregnation, B-stage, and cutting operations with a continuous process, and 3) reducing the molding cycle and machining operations with injection molding to achieve near-net shapes. Braided bushings were successfully fabricated with both AMB-17XLD and AMB-TPD resin systems. The composite bushings achieved high glass transition temperature after post-cure (+300 C) and comparable weight loss to the PNM-15 bushings. ANM-17XLD bushings made with "batch-mode" molding compound (at 0.5 in. fiber length) achieved a +300 lb-force flange break strength which was superior to the continuous braided-fiber reinforced bushing. The non-MDA resin technology developed in this contract appears attractive for bushing applications that do not exceed a 300 C use temperature. Two thermoplastic polyimide resins were synthesized in order to generate injection molding compound powders. Excellent processing results were obtained at injection temperatures in excess of 300 C. Micro-tensile specimens were produced from each resin type and the Tg measurements (by TMA) for these samples were equivalent to AURUM(R). Thermal Gravimetric Analysis (TGA) conducted at 10 C/min showed that the non-MDA AMB-type polyimide thermoplastics had comparable weight loss to PMR-15 up to 500 C.
This project developed a novel neodymium (Nd) electrowinning reactor for energy-efficient electrowinning of Nd metal. Throughout this project we have developed an alternative chloride based molten salt electrolysis process. Our process lowers the specific electrical energy consumption compared to the state of the art, while producing reusable chlorine gas and eliminating direct CO2 and PFC emissions. Facilities required for implementing the project were setup and designs were finalized, and a standard operating procedure for safe operation of high temperature electrolysis cells was written. The electrowinning reactor was designed and constructed. Electrolysis experiments confirmed the ability to reproducibly electrowin Nd metal on a Mo cathode. The current efficiency for Nd electrowinning was measured as a function of applied current density in the presence of the separator. Successful electrowinning of Nd sponge at high current densities (200 mA/cm2 and above) at a current efficiency >80% was demonstrated using multiple techniques. Stable Nd electrowinning up to 10h at 250 mA/cm2 was demonstrated. All of these design advancements were used to develop a techno-economic and life cycle assessment model that demonstrated that our process could be operated at cost of less than $0.20/kg-Nd (~30% lower compared to state of the art when comparing electrolysis energy cost) with a >20% total reduction in global warming potential compared to the state of the art while generating no direct CO2 or perfluorocarbon emissions.
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