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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Hydrogen Storage for Load-Following and Clean Power: Duct-firing of Hydrogen to Improve the Capacity Factor of NGCC Plants (Final Report, Phase II Pre-Front End Engineering Design Study)

GTI Energy (GTI) and team members Southern Company Services (SCS), Pacific Gas & Electric (PG&E) and the Electric Power Research Institute (EPRI) performed a Phase II Pre-Feed Study under contract DE-FE0032008 for Hydrogen Storage for Load-Following and Clean Power. The configuration of the proposed system consists of subsystems for on-site H 2 production, on-site H 2 storage (up to 54 MWth in commercial vessels) and H 2 combustion in a duct burner in a Heat Recovery Steam Generator (HRSG) integrated with an existing fossil asset. Here, the firing rate of the duct burner is varied to let the plant respond to fluctuations of electrical load and H 2 production is relatively constant by storing H 2 . The proposed system is an improvement over alternate low carbon dispatchable power options. Technoeconomic analyses show H 2 produced with GTI’s patented Compact Hydrogen Generator (CHG) with inherent carbon capture will be lower cost (Levelized Cost of Hydrogen, LCOH) relative to hydrogen produced with a Steam Methane Reformer (SMR) with an amine system for carbon capture. This lower cost hydrogen enables our integrated system to deliver electricity (Levelized Cost of Electricity, LCOE) at 17.4% lower cost relative to a SMR sourced H 2 -fired HRSG (with an amine system for carbon capture) – Steam Turbine Generator (STG). Our analysis using EPRI’s US REGEN macroeconomic model shows our system will have significant demand in the power market and therefore require significant capacity expansion (CHG plants built to deliver hydrogen) to deliver low cost, low carbon power. In Phase II, our Team has completed a detailed system definition including the development of process models, definition of battery limits, Process Flow Diagrams (PFDs), Piping and Instrumentation Drawings (P&IDs), and a plant layout. A preliminary design for the key components of the CHG was developed including component lists & specifications. An evaluation of environmental and permitting considerations was completed and included the development of an Environmental Information Volume (EIV). The duct burners, which are flexible and can burn hydrogen and/or natural gas, were defined and initial CFD analyses were completed.

03 NATURAL GAS↗
DOE OSTI2023

Process-based cost estimation framework for assessing economic viability of environmentally and socially sustainable rare earth element feedstocks

Rare Earth Elements (REEs) are critical raw material inputs that are required to enable the energy transition. Constraints on the U.S. supply of conventional REE feedstocks and the desire to diversify U.S. reliance on foreign supply chains have motivated the pursuit of REE recovery from unconventional feedstocks including waste products. Recovery of REEs from unconventional sources is also motivated by environmental and social considerations, including the potential to offset new mining activity and subsidize the remediation of REE-containing wastes from coal, natural gas, and other mineral extraction activities. Sourcing REEs from unconventional feedstocks would reduce supply chain constraints and minimize the environmental impacts of REE extraction, but current processes to exploit these feedstocks have uncertain technical and economic performance and the processes have not been demonstrated at scale. This work aims to reduce uncertainty in evaluating the performance of new REE production pathways. A database of operating and capital expenses for REE recovery and establish consistent process unit costs for common stages in the conventional supply chain are developed. Market prices are used to develop well-defined methods for determining product values for a diverse set of products that can be generated (e.g. oxalates, alloys, end-use products such as magnets) but are not typically considered in technoeconomic analyses. Finally, to provide insight on the effects of economies of scale and feedstock purity on capital and operating costs, process unit level cost functions relating total costs per kilogram of REE produced are reported. These tools can be applied to assess and facilitate scale-up of REE production from diverse sources of REEs.

Fritz, Alison↗
DOE OSTI2026

Expanding the horizon of bio-naphtha beyond gasoline blend: property characterization and conversion opportunity assessment through technoeconomic and life-cycle analyses

Bio-naphtha, a common by-product of biorefineries, is expected to experience substantial growth in supply due to increasing demands for renewable diesel and synthetic aviation fuel (SAF). However, demand for bio-naphtha itself as a gasoline blendstock is limited because of the electrification of light-duty vehicles. This work investigated valorization opportunities for bio-naphtha from catalytic fast pyrolysis, hydrothermal liquefaction, Fischer–Tropsch synthesis, and hydrotreated esters and fatty acids pathways. These opportunities include producing polymer-grade olefin via steam cracking, SAF via steam cracking followed by olefin oligomerization, and renewable aromatics benzene, toluene, and xylene (BTX) and hydrogen via catalytic reforming. Process models were developed in Aspen Plus V14 and Aspen HYSYS V14 to calculate the mass and energy balances for each conversion step. Technoeconomic assessment and life-cycle analysis were conducted to evaluate the minimum fuel/product selling price, conversion cost, and life-cycle CO2 equivalent (CO2e) emission reduction. Technoeconomic assessment results suggest a minimum fuel/product selling price as low as $1.9/kg of olefins, $6.30/gal of gasoline-equivalent SAF, and $1.2/kg of BTX without any incentives. For all pathways, these prices are dominated by bio-naphtha feedstock costs, which account for at least 76% of the total cost. Compared with petroleum baselines, bio-naphtha-derived SAF, olefins, and BTX can achieve significant CO2e emission reductions from the use of renewable carbon resources. The results of life-cycle analysis and subsequent technoeconomic assessment, incorporating carbon credits, indicate the economic viability of using bio-naphtha for polymer-grade olefin and BTX production, with product costs comparable to market prices.

Xu, Shuang↗
DOE OSTI2024

Environmental and economic analyses of chemical recycling via dissolution of waste polyethylene terephthalate

Globally, more than 1000 organizations and 175 nations are facing the plastic waste problem and have realized the need to transition from “linear-to-circular” economy of plastics. While the current mechanical recycling technologies for plastics are struggling to increase the U.S. plastic recycling rates beyond 9%, chemical recycling technologies become important complementary technologies to the predominant mechanical recycling that are needed to realize the circular economy in plastics supply chains. Dissolution is one such chemical recycling technology that can recycle waste plastic back into high-quality virgin grade plastic. However, the environmental and economic impacts of chemical recycling of waste polyethylene terephthalate (PET) via dissolution technology using a green solvent are unknown. Our study evaluated environmental metrics such as greenhouse gas (GHG) emissions and cumulative energy demand, and economic metrics such as net present value (NPV), minimum selling price, payback period, return on investment, and discounted internal rate of return for three dissolution processes with polymer recovery via anti-solvent, evaporation, and cooling precipitation techniques. The dissolution process with evaporation technique was the most economically favorable, whereas that with cooling technique was the most environmentally favorable. The anti-solvent approach had low economic performance and the highest environmental impacts. The NPV for all of these technologies ranged from $2.67 MM to $10.93 MM for a capacity of 8,400 MT/year and was found to be the highest for dissolution with evaporation approach and the least for anti-solvent approach. The cradle-to-gate GHG emissions and energy demand for PET dissolution processes ranged from 1.33-3.77 kg CO2-eq/kg of chemically recycled (CR) PET and18.9-56.1 MJ/kg of CR-PET, respectively. These economic and environmental metrics will be helpful in evaluating the sustainability of circular PET supply chains in the U.S.

09 BIOMASS FUELS↗
DOE OSTI2023

WaterTAP: Tool for analysis of water treatment systems

This presentation describes the Water treatment Technoeconomic Assessment Platform (WaterTAP), an open-source software tool to analyze water treatment trains. The presentation was provided to the NAWI Alliance Fall Meeting on November 29th 2023 and it includes an overview of the tool and a couple of analyses demonstrating its capabilities. The analyses include a technoeconomic assessment of a novel membrane-based technology called low salt rejection reverse osmosis and a brackish water desalination train with pretreatment.

Dudchenko, Alexander↗
DOE OSTI2024

Opening pathways for the conversion of woody biomass into sustainable aviation fuel via catalytic fast pyrolysis and hydrotreating

Meeting aggressive decarbonization targets set by the International Civil Aviation Organization (ICAO) will require the rapid development of technologies to produce sustainable aviation fuel (SAF). Catalytic fast pyrolysis (CFP) can support these efforts by opening pathways for the conversion of woody biomass into an upgraded biogenic oil that can be further processed to SAF and other fuels. However, the absence of end-to-end experimental data for the process leads to uncertainty in the yield, product quality, costs, and sustainability of the pathway. The research presented here serves to address these needs through a series of integrated experimental campaigns in which real biomass feedstocks are converted to a final SAF product using large bench-scale continuous reactor systems. For these campaigns, the degree of catalytic upgrading during CFP was varied to produce CFP-oils with oxygen contents of 17 and 20 wt% on a dry basis. The CFP-oils were then hydrotreated and distilled into gasoline, diesel, and SAF fractions. Detailed yield and compositional data were obtained for each step of the process to inform technoeconomic and lifecycle analyses, and the fuel properties of the SAF fraction were evaluated to provide first-of-its-kind insight into the quality of the final product. This research reveals opportunities to optimize process carbon efficiency by tuning the degree of catalytic upgrading during the CFP step and highlights routes to produce a high-quality cycloalkane-rich SAF with 85–92% reduction in greenhouse gas emissions compared to fossil-based pathways.

09 BIOMASS FUELS↗
DOE OSTI2022

Solar-Thermal Ammonia Production: A Renewable, Carbon-Neutral Route to Ammonia via Concentrating Solar Thermochemistry [Slides]

Solar Thermal Ammonia Production has potential to produce green ammonia using CSP, air, and water. Air separation to purify N 2 was successfully demonstrated with BSF1585 in packed bed reactor; on-sun reduction reactor under construction. Metal nitrides (MNy) were successfully synthesized and characterized under both ambient and pressurized conditions. Co 3 Mo 3 N shown to successfully produce NH 3 when exposed to pure H 2 at pressures between 5 – 20 bar 600 – 750 °C. Ambient reaction experiments imply there may be a catalytic aspect as well. Technoeconomic and systems analyses show a path towards scale-up.

14 SOLAR ENERGY↗
DOE OSTI2023

Continuous Processing of Carbon Foam Products Made from Coal at Atmospheric Pressure

The main goal of the project was to create a continuous manufacturing process for carbon foam that operates at atmospheric pressure and can generate well-formed carbon foam panels and lightweight aggregates. This objective was accomplished and has enabled a platform where carbon foam products can be manufactured at significantly reduced cost and cycle time relative to the conventional high-pressure batch process, which in turn can enable the manufacture of much larger volumes of carbon foam. All these features should enable carbon foam to enter much larger markets and create meaningful demand for U.S. coal. Carbon foam panels and aggregate both consisted of at least 70 weight percent carbon per program requirements (typical was over 90-wt%), and at least 51 weight percent of the carbon was to be coal derived (typical was over 90-wt% carbon was from coal). Analyses regarding life cycle, technoeconomics, and final technological gaps have been documented in separate reports. This final report documents the methods used to attain the main goal and describes the technical results.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Impact of Tree Age and Anatomical Fraction on Forest Residue Pyrolysis and Hydrotreating

Utilization of cost-advantaged biomass and waste resources to produce clean, domestic biofuels will be a key factor in decarbonizing transportation in the United States. This study investigates how the distribution of anatomical fractions (stem wood, bark, needles, branches) from pine forest residues of different ages impacts pyrolysis and hydrotreating processes, including product composition, carbon efficiency, economics, and overall sustainability. Commercially sourced 13- and 23-year-old loblolly pine residues were chosen to represent available resources; whole tree thinnings, and tops and branches from merchantable timber, respectively. Detailed characterization of the residue samples, product distributions, bio-oil, char, and gas characterization data are presented for 13 experiments, including the individual fractions, blends, and air-classified samples to reduce ash content. Pyrolysis mass balances averaged 97 +/- 3%. As expected, bio-oil yields were lower for the bark, needles, and blends with high proportions of these (53-56% dry basis), and highest for the debarked stem wood (67-71% dry basis). Lower yields were attributed to the high ash content of the needles, but also to the high lignin content in the bark (>50%), which is hypothesized to have led to increased char formation during pyrolysis. Higher-oil yield was generally correlated with total volatiles, hydrogen, oxygen, glucan, and mannan; somewhat correlated with xylan and acetyl content; and negatively correlated with total carbon, fixed carbon, nitrogen, sulfur, and extractives. Air classification of the residues was effective in reducing ash content (1.5% to 0.64%), extractives (~7% to 2%), and sulfur (0.04% to 0.02%), resulting in a small increase in yield, a significant increase in the GC-detectable proportion of oil (27% to 34%) and a net economic benefit. These experimental results were used to conduct technoeconomic and life cycle analyses, which are also summarized here.

biofuels↗
DOE OSTI2024

Unlocking naphtha from polyolefins using Ni-based hydrocracking catalysts

Naphtha (C 5 -C 12 alkanes) is a platform feedstock in the petroleum industry and an ideal target for reutilizing plastic waste at scale. Hydrocracking has emerged as a promising technology for deconstructing polyolefins to naphtha. However, contemporary catalysts rely on Pt to achieve high rates, while earth-abundant metals (EAM) perform poorly. Herein, we develop high-performance Ni/BEA catalysts for polyolefin hydrocracking, achieving complete low-density polyethylene (LDPE) deconstruction with 80 % maximum naphtha yield within 12 h at 250 °C, 60 bar H 2 , and a catalyst-to-polymer ratio of 1:100. These catalysts are versatile, accommodating virgin resins and commercial polymer products, and are directly reusable and regenerable. Comparative analysis highlights that 5Ni/BEA(25) exhibits the highest naphtha productivity of 11.4 $\huge{(}$$\frac{g_{Naphtha}}{g_{cat}{•h}}$$\huge{)}$, surpassing previously reported Pt- and EAM-based catalysts by 2.5–6.2x. Technoeconomic and life-cycle analyses reveal naphtha from LDPE hydrocracking is economically and environmentally competitive to fossil-fuel-derived naphtha. In conclusion, these advancements pave the way for the industrial implementation of earth-abundant Ni-based catalysts in polyolefin hydrocracking, followed by retrofitting steam crackers to address plastics waste at scale.

Circular Economy↗
DOE OSTI2026

Direct electrode-to-electrode regeneration of end-of-life batteries via electrode–electrolyte interphase dissolution

Lithium-ion battery recycling remains constrained by processes that recover metals at the expense of electrode integrity, while even direct recycling typically requires shredding to black mass followed by binder removal, separation, and full electrode refabrication. Here, we introduce direct electrode-to-electrode regeneration (DEER), a simultaneous electrochemical regeneration of used NMC and graphite electrodes from end-of-life batteries in their intact form by dissolving the passivating electrode–electrolyte interphase (EEI). DEER employs 1,3-dimethyl-2-imidazolidinone (DMI), a high donor number solvent that creates a thermodynamic environment favorable for solubilizing redox inactive EEI components. DEER dissolves the thick EEI on both used electrodes while preserving electrode integrity, enabling up to 95% capacity regain and improved cycling stability with a residual LiF-rich interphase. Operando Raman, operando IR, and post-mortem NMR directly track the electrochemically driven dissolution of carbonate-derived EEI species in the used DMI-based recycling electrolyte. Technoeconomic and life-cycle analyses show that DEER reduces the cost of recycled cell manufacturing by 56% relative to pyro- and hydrometallurgy, while lowering energy use and greenhouse gas emissions. Overall, DEER establishes the first validated pathway to directly regenerate and reuse electrodes harvested from truly end-of-life batteries, converting the key interfacial bottleneck into a controllable dissolution process and opening a practical route toward electrode level circularity.

Kim, Kiwon [Cornell Univ., Ithaca, NY (United Stat↗
DOE OSTI2024

Multi-pronged approach to improving carbon utilization by cyanobacterial cultures

The goal of this project was to increase the efficiency of carbon utilization by a Synechocystis biofuel production strain in a photobioreactor system by at least 50% using a multi-pronged approach that combined the best features of both biological and physicochemical CO 2 capture technologies to: 1) increase rates and extent of CO 2 absorption into the culture medium by addition of biocompatible amine solvents and a nanobubble gas delivery system, and 2) increase cellular rates of inorganic carbon uptake and carbon fixation through genetic engineering. In addition, the project plan included evaluating the use of fermentation effluent gases as a CO 2 source and demonstrating performance under outdoor conditions in closed-pond photobioreactor systems. These combined efforts would be guided by integrated technoeconomic and life-cycle analyses. Both physicochemical CO 2 capture technologies explored proved to be successful. The amine solvent monoethanolamine (MEA) was found to be biocompatible with a Synechocystis laurate production strain. Using an adaptive evolution strategy, an MEA-tolerant laurate production strain was developed that showed significantly increased carbon utilization over the parent strain. To our knowledge this was the first time nanobubble (NB) technology had been used as a carbon delivery system for algae production and it also proved quite successful as a proof of concept. Solutions containing CO 2 nanobubbles (Nano-BG11) at concentrations significantly higher than the aqueous CO 2 concentrations achieved with gas sparging were successfully generated and characterized with regard to bubble size (nm), concentration (NB/L), and pH stability as per project plan. Growth studies proved challenging. However, once the source of a puzzling growth defect was found and remedied Synechocystis was able to grow somewhat better in Nano-BG11 than in standard BG11 medium.

09 BIOMASS FUELS↗
DOE OSTI2024

Producing Jet Fuel from Biogas Using Cool GTL SM

GTI Energy advanced the development of Cool GTL SM through a multi-phase project that studied and confirmed the promising value of this technology. It optimized the process by creating an integrated pilot plant capable of producing 50 gallons of total liquid hydrocarbon fuel. It also performed testing campaigns and developed a conceptual commercial design to support technoeconomic and life-cycle analyses, resulting in data that demonstrated a greenhouse gas emissions benefit.

09 BIOMASS FUELS↗
DOE OSTI2021

BETO 2021 Peer Review - Biological Upgrading of Sugars (BUS) 2.3.2.105

The Biological Upgrading of Sugars (BUS) project directly targets the anaerobic conversion of lignocellulosic feedstocks into intermediate molecules readily upgradeable to fuel precursors. Recent efforts on the BUS project have a particular emphasis on the biological production of butyric acid, an intermediate that can be readily upgraded to sustainable aviation fuel, diesel blend-stocks, and high value chemicals. The BUS project approaches this direction through a combination of strain engineering, fermentation process engineering, development of novel separations technologies, and the design and build of pilot scale systems. Our ultimate project goal is to develop an integrated cost-effective process at pilot scale to achieve DOE's MYPP targets of $2.50/GGE. The major thrust of the BUS project over the last project cycle was on the development of integrated processes surrounding the anaerobic production of carboxylic acids using diverse Clostridium species. We developed and expanded genetic tools for several Clostridium species and rewired microbial metabolism in an attempt to maximize substrate utilization and flux towards butyric acid. We designed and built novel bioreactors with an in situ product recovery system enabling the biological production and recovery of highly purified acids. We leveraged this system to generate 100s of grams of acid from corn stover hydrolysate. In this presentation we highlight data surrounding our proposed process and accompanying results from technoeconomic and life-cycle analyses of our integrated process. Finally, we detail plans of our pilot scale reactor system that is in process and discuss our future routes towards achieving economically viable and sustainable diesel and jet blendstocks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Technoeconomic and Emissions Analysis of the Hybrid Redox Process for the Production of Acetic Acid with CO 2 Utilization

The production of oxygenated hydrocarbons, such as acetic acid, using captured CO 2 is a promising pathway to reduce greenhouse gas emissions in the chemical industry. The use of a chemical looping‐based hybrid redox process (HRP) is proposed to convert CO 2 and natural gas into separate CO and syngas streams that can be used to produce various commodity oxygenates, while allowing the beneficial utilization of captured CO 2 . Here, a detailed technoeconomic analysis of HRP applied to the production of acetic acid is presented. Emissions and energy analyses show the ability of HRP to lower the CO 2 emissions for acetic acid synthesis by 74% compared to a conventional steam and autothermal reforming route. HRP also offers a potential 34% reduction in capital costs. Compared to a dry reforming based acetic acid production route, HRP has the potential for significantly lower costs. If integrated with a low carbon energy source, HRP has the potential to achieve a negative emission of greenhouse gas (‐0.50 kg CO 2 per kg acetic acid).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Evaluation of Hybrid FPOG Applications in Regulated and Deregulated Markets Using HERON

Recent changes in the U.S. energy market, such as low natural gas prices and increased electricity production for variable renewable energy (VRE) sources, have led to an economic crisis for existing light-water reactor (LWR) nuclear power plants (NPP). Many owners and operators of LWRs have elected to decommission these plants rather than continue using them as consistent sources of clean baseload power. This has led to exploration of various possibilities to increase the economic viability of these units, including market restructuring to monetize benefits LWRs already provide to the grid through ancillary markets, load following and economic dispatch, and possible integration of secondary systems directly to the NPP for production of additional products through technologies such as hydrogen electrolysis or water desalination. Previous studies have considered the technologies associated with these Integrated Energy Systems (IES) activities, and the analysis of markets for these secondary products. To analyze the economic viability of various system configurations including IES, especially given the uncertainty surrounding load demand, electricity prices, and the availability of VRE resources, the stochastic technoeconomic analysis package HERON (Heuristic Energy Resource Optimization Network) was released earlier this year as an extension of the risk analysis framework RAVEN (Risk Analysis Virtual Environment). HERON focuses foremost on making the complex uncertainty quantification analysis tools approachable for energy systems analysts, also providing general dispatch optimization algorithms for those workflows. HERON continues to be improved and tested as a significant part of the IES viability analyses performed in this work. HERON is not a capacity expansion model. To consider market and grid energy system development in a variety of scenarios, HERON is best used in coupling with modelling tools such as US-REGEN, which sacrifice some of the uncertainty analysis and resolution of HERON's modelling for the ability to efficiently predict the change in the grid energy system's profile due to economic drivers over decades. HERON can then use this information to explore the economic viability of introducing changes to the predicted outcomes, such as the introduction of an IES. In this work, experts at EPRI using US-REGEN provide six projection scenarios for use in HERON stochastic technoeconomic analysis (STEA) in considering the options available for increasing LWR economic viability through introduction of a hydrogen-centric IES using a high-temperature steam electrolysis plant (HTSE), hydrogen storage, and a constant-rate contracted hydrogen consumer. The results obtained are differential in nature; they do not report expected profits for any configuration, but rather report on the possible increase in the NPV of a configuration with respect to a baseline no-IES configuration. Due to the uncertainty captured in the variable net load of the systems, there is likewise uncertainty in the mean values reported. We consider this viability both in terms of a regulated market, where the energy producers and IES are owned and operated by single entity, as well as a deregulated market, where the IES chooses its bid for electricity generation and is then dispatched by the grid system operator. Results indicate that for deregulated markets, the inclusion of the IES is often statistically beneficial. This is especially true in policies that are not favorable towards nuclear, as nuclear is less often dispatched and is forced to deal with frequent idle capacity. In the nominal case as well as the case of carbon tax policies, inclusion of the IES clearly benefited the economic performance of the NPP. In the regulated case, however, there was a trend towards minimizing the IES, likely due to the optimal sizing performed by US-REGEN of the NPP within the system as well as the lack of penalty for idle capacity at the NPP in the regulated market analyses.

99 GENERAL AND MISCELLANEOUS↗