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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.
This report presents an independent assessment of the cost and performance of select fossil energy power systems—pulverized coal (PC), circulating fluidized bed (CFB), and natural gas combined cycle (NGCC) plants—using a systematic, transparent technical and economic approach. This is Volume 3 of a five-volume series, which comprise the following reports: Volume 1: Bituminous Coal and Natural Gas to Electricity; Volume 2: Coal to Synthetic Natural Gas and Ammonia (Various Coal Ranks); Volume 3: Low Rank Coal and Natural Gas to Electricity; Volume 4: Bituminous Coal to Liquid Fuels; and Volume 5: Natural Gas Electricity Generating Units for Flexible Operation. The cost and performance of fossil fuel-based generation technologies represented in this report (and the series at large) are important inputs to assessments and determinations of technology combinations to be utilized to meet the projected demands of future power markets. In addition to informing technology comparisons, the reference plant configurations found in this report provide perspective for regulators and policy makers. From a research and development perspective, this report is used to assess goals and metrics and to provide a consistent basis for comparing developing technologies.
This report presents an independent assessment of the cost and performance of select fossil energy power systems—pulverized coal (PC) and natural gas combined cycle (NGCC) plants—using a systematic, transparent, technical, and economic approach. This is Volume 1 of the baseline series: Bituminous Coal and Natural Gas to Electricity. The cost and performance of fossil fuel‐based generation technologies represented in this report are important inputs to assessments and determinations of technology combinations to be utilized to meet the projected demands of future power markets. From a research and development perspective, this report is used to assess goals and metrics and to provide a consistent basis for comparing developing technologies. The main report consists of fifteen power plant configurations, six PC cases (with and without carbon capture) nine NGCC cases (with and without carbon capture) and few additional cases of higher capture rate, for both PC and NGCC plants in the appendix. In addition to the report, an interactive tool was developed that allows users to manipulate six key study parameters simultaneously for each case and visualize the impact on three metrics: 1) levelized cost of electricity (LCOE), 2) cost of CO 2 capture (CCC), and 3) cost of CO 2 avoided (CCA). Following is the link to the interactive tool: https://netl.doe.gov/NETLVol1BaselineTool
The main goals of this project are to utilize real-time quantum dynamics simulations and quantum optimal control algorithms to (1) harness near-surface nitrogen vacancy (NV) centers to detect chemical analytes in harsh fossil energy environments, and (2) design optimally constructed electromagnetic fields for initializing these near-surface NV center spins for efficient sensor performance and detectivity.
This final report highlights the comprehensive achievements of the project focused on developing and validating a 5G-Time Sensitive Networking (TSN) architecture tailored for real-time operational awareness in fossil energy systems. The initiative successfully advanced through a series of technical milestones, including the integration of EMI-aware network models, deployment of advanced simulation frameworks, and real-world performance characterization at key sites such as UTEP and Fabens. Through the strategic use of NetSim® software, the team created and validated network configurations for wired and wireless environments, tested under varying congestion conditions, and verified network slicing implementations for URLLC-specific applications. Major accomplishments include the migration of simulation tools to the latest NetSim® version to support accurate modeling of TSN and network slicing, extensive EMI measurement campaigns, and the development of a robust simulation model for end-to-end SCADA system integration. Simulations compared both TDD and FDD duplexing modes, revealing insights into their performance under congested conditions. The wireless network was benchmarked for throughput, jitter, and delay metrics, aligning with 3GPP Release 15/16 and IEEE 802.1-TSN standards. A peer-reviewed conference paper was accepted and published, contributing to the broader academic and industrial discourse on 5G-TSN integration in energy systems, in addition to a journal article. Despite minor delays due to software limitations, the project achieved its objectives and delivered validated architecture ready for deployment in advanced energy network environments.
This presentation at EPRI's annual Generation Sector Meeting during the Advanced Generation and Carbon Capture and Storage session provides an overview of the recently published Cost and Performance Baseline for Fossil Energy Plants – Volume 1: Bituminous Coal and Natural Gas to Electricity dated May 2025. It further connects viewers with the recently released tool/dashboard, an interactive tool that allows users to manipulate six key study parameters simultaneously for each case and visualize the impact on three metrics: 1) levelized cost of electricity (LCOE), 2) cost of CO2 captured (CCC), and 3) cost of CO2 avoided (CCA).
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.
Hydrogen storage in subsurface caverns is known as perhaps largest and longest-term energy storage system. While few such systems are currently in service (e.g., Texas; Teesside, UK), they are envisioned as being a pillar of the current energy transition that will allow intermittent power production from renewable sources (e.g., wind, solar) to be balanced with demand at grid-scale. In addition, hydrogen energy storage can allow existing fossil power plants to run more economically either by minimizing startups/shutdowns or by allowing them to take advantage of arbitrage. Finally, stored hydrogen can feed a variety of non-power users such as pipeline gas, heating, transportation, and manufacturing. The H-2-SALT paper study assessed the feasibility of a power-to-hydrogen system utilizing salt cavern storage of hydrogen in bedded salt in central Kansas, where over 750 such caverns have been constructed to date, of which approximately 350 are still in service. Legacy well and salt cavern data were collected to develop a regional geological database for two sites in Central Kansas and adjacent areas for use in more detailed geological and geomechanical site characterization efforts. This study found commercial viability and competitiveness of large-scale, electrolytic H 2 production and storage ($1.78 per kg H 2 ) that can be used for both electrical power supply to the grid during high-priced electricity periods (including co-firing with NG and fuel cell power production) and sale of H 2 for various industries, such as petrochemicals or transportation. The commercial potential of the H-2-SALT system is also relatively high because each of its components operate commercially today. It is recommended that a stratigraphic test well be drilled to collect log data and core samples that can reduce uncertainty surrounding geological and geomechanical properties of the salt beds that will be required for further cavern and energy storage system design studies.
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Air pollution resulting from the use of fossil fuels is discussed. Phenomena relating to the emission of CO2 such as the greenhouse effect and multiplier effect are explored. Particulate release is also discussed. The following recommendations are made for the elimination of fossil fuel combustion products in the United States: development of nuclear breeder reactors, use of solar energy systems, exploration of energy alternatives such as geothermal and fusion, and the substitution of coal for gas and oil use.
To address the data needs of energy system designers and to serve as a baseline for research and development, NETL has carried out a study to characterize the flexibility attributes - both performance and cost - of nine common commercial natural gas-fueled electricity generating units. The intermittent output of low-carbon, renewable power generation sources such as wind and solar create challenges to grid stability and reliability. Fossil-fueled power generation technologies are currently used to provide reliable, on-demand power during periods of reduced renewable output. Dispatchable generators must be able to accommodate increasing renewable generation as the nation pursues the Administration’s target of a decarbonized energy sector by 2035. As energy system experts seek to identify least-cost approaches to decarbonization, accurate cost and performance data characterizing dispatchable fossil generators that operate flexibly, at capacity factors that have been declining over time, and are needed to inform models for capacity expansion. Furthermore, these technologies continue to be a significant source of carbon dioxide emissions, providing the impetus for research and development, including the advancement and potential incorporation of carbon capture technologies. This study characterizes the cost and performance of select state-of-the-art natural gas-fueled power generation technologies: reciprocating internal combustion engines (RICE), simple cycle combustion turbines, and natural gas combined cycles (NGCC). An emphasis is placed on flexibility characteristics, such as part-load heat rate, ramp rates, start up times, and start up costs.
Precise timing and data transmission within stringent time constraints are critical for numerous applications, such as robotics, virtual and augmented reality, industrial automation, energy and medical business, and various other sectors. Time-sensitive networks (TSN) and fifth-generation wireless communications (5G) are crucial for industrial communications, enabling convergent communication for various services using a common network core. Applications that are time-sensitive and require deterministic communications with low latency fall into this category, such as generation plant systems. This paper presents a simulated model of 5G-TSN for a fossil power plant based on the wired network parameters implemented in situ. Metrics analysis, comparison and future work are presented. © 2024 IEEE.
The aim of this work was to develop further understanding of the corrosion mechanisms found on the heat exchanger surfaces present in oxy-combustion and coal/biomass co-fired combustion systems, and to develop a modeling capability to predict the effect of the different fuels on the lifetime of plant components.
This document presents the final report of the research activity completed during the four years of the project and includes the major challenges and accomplishments. The report presents specific details of the engineering processes and methodologies used to develop the robotic crawler and complete the project milestones. In particular, the report includes sections that address the problem statement, background, development of crawler modules, bench scale testing, simulation development and full scale testing. The report concludes with a discussion on potential paths forward and concluding remarks.
The overarching goal of the proposed project is to demonstrate the feasibility of creating ultralow local disorder graphene quantum dots (GQDs)-based high-speed, high-fidelity spin quantum bits (qubits) for extremely cyber-secure coal energy plants of the future. Despite their inherent benefits, the coherence times in the state-of-the-art GQD qubits are still low primarily due to the local disorder in GQD devices generated during lithographic fabrication of GQDs. Hence, the focus of this research is to prepare ultralow disorder GQDs (e.g., edge roughness ~0.5nm) and evaluate the low temperature (~mK) charge/spin transport characteristics of the engineered GQD qubit platform. To achieve minimal disorder in GQD qubits, we employ a novel approach that combines nanotomy (novel GQD fabrication technique developed by the PI) and scanning probe microscopy-atomic oxidation lithography (SPM-AOL).
The research objective of this study is to develop an accelerated creep testing (ACT) program for advanced creep resistant alloys for high temperature FE applications. This research produced a new ACT for metallic materials based on Time-Temperature-Stress Superposition (TTSSP). In TTSSP, there exists a fundamental relationship between creep resistance, time, temperature, and stress that can be manipulated to reduce test durations. In our study, the stepped isostress method was employed where step increases of load during creep testing accelerated the time-to-rupture. Well-posed constitutive models including sin-hyperbolic and Wilshire-Cano-Stewart where calibrated using the SSM data and employed to predict the conventional creep response of the material. In our best experiments, <100-hour tests on lnconel 718 at 750 deg C produced over a 64x acceleration of data when compared to conventional data from Japan's National Institute of Materials Science. The ACTs enable the rapid screening of candidate materials, where a small test matrix of short duration tests can be employed to determine the creep resistance (minimum-creep-strain-rate, stress-rupture, and creep deformation) of a material across decades.
In recent years, interest in increasing the efficiency of power plants based on steam generation has led to the need to develop and qualify materials capable of operating at steam temperatures and pressures significantly higher than those employed in current power plants. The overall focus of this international program is on using ferritic-martensitic steels to the maximum possible temperature, before switching to austenitic steels and/or Ni-based alloys. The relatively low Cr content of these alloys raises concerns regarding their resistance to steam oxidation at these higher temperatures. Earlier work in this collaboration addressed the reliability of data from atmospheric pressure, laboratory-based steam oxidation tests. This raised issues regarding how representative the laboratory-grown oxides were compared to those formed on service-exposed material and how the tests could be made more reliable by introducing added complexity. In general laboratory-scale exposures are conducted under isothermal conditions at ambient or slightly elevated pressure, using a relatively low flow rate of steam. The coupons used in these tests are normally flat cuboids which have been ground to homogenise the surface and remove any pre-existing features. However, there is a concern that these samples and exposures are not representative of service conditions, and so it is necessary to quantify the influence of transient conditions, such as heat flux, pressure and sample geometry/surface conditions. To address such concerns a new collaborative program of work was initiated to determine the influence of these added features on oxidation kinetics and oxide scale morphology. The overall aim was to improve the understanding of alloy performance in ultrasupercritical (USC) steam conditions and qualify suitable test procedures.
The current project developed a novel HT-CALPHAD/DFT approach, which can quickly design new high-performance structural alloys for the application of FE power plants. The PI will mainly take charge of high-throughput DFT simulations and computational thermodynamics of the selected multicomponent alloy systems for the FE power plant applications. At the end of the project, a novel hybrid model based on high throughput CALPHAD/DFT simulations and computational thermodynamics will be developed to provide guidance on how to identify multi-component new high-performance structural alloys with much less computational effort needed. It will address the extensive computation time needed for DFT on the new alloys design. In addition, it will also address the well-known headache of DFT, i.e. how to make the accurate prediction of the high-temperature equilibria. The novel hybrid model the PI proposed will not only be applied to the design of high-performance structural alloys in FE power plants but in many different applications, such as nuclear reactors. This hybrid modeling approach includes four sections: 1) HT-CALPHAD modeling of Al-Co-Cr-Ni-Fe system with FCC and BCC phase. In this section, 3561 non-equiatomic compositions were randomly generated in order to investigate the phase stability of single FCC and BCC phases. Meanwhile, we proposed a data screening procedure to screen out the good candidates within these compositions, considering the temperature range, average density, and melting temperature, etc. 2) Investigation of FCC-Cr lattice stability in Fe-Cr system. We systematically assessed the reliability of FCC-Cr lattice stability derived by DFT and CALPHAD approaches. Meanwhile, the Fe-Cr binary system was chosen as a case study to verify the Cr lattice stability obtained by both approaches. 3) High-throughput DFT modeling on elastic properties of Al-Co-Cr-Ni-Fe systems. We predicted and established the FCC quinary elastic constant database of the Al-Co-Cr-Fe-Ni systems at 0K by using special quasi-random structure (SQS) approach. The predictions will start with pure elements of Al-Co-Cr-Fe-Ni system and will be continued with binaries, ternaries, quaternaries, and finally the quinary compositions. 3) Modeling of temperature-dependent elastic properties in Al-Co-Cr-Ni-Fe systems. In this part, we predict the thermal expansion coefficient and elastic stiffness coefficient as a function of temperature by applying quasiharmonic approximation. With this approach, the elastic properties of HEAs at elevate temperature can be estimated.