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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Microwave-Assisted Dehydroaromatization of Flare Gas: Reactor Modeling, Plant-Wide Simulation and Economic Feasibility Analysis

Flaring is widely practiced in the oil, gas, and petrochemical sectors to ensure safety during upsets and maintenance but emits large amounts of GHGs, causing energy and economic losses. In the U.S., about one-third of Bakken gas (~250 MMSCFD) and ~100 MMSCFD from Eagle Ford are flared. Recovering this gas is essential for sustainability. Existing recovery methods—compression and reinjection (EOR), conversion to NGL, LNG/CNG, GTL, and GTW—are often limited by flowrate, composition, and variability, especially in unconventional wells. This study develops a microwave-assisted dehydroaromatization (DHA) process to convert flare gas into benzene, toluene, ethylene, and naphthalene. A laboratory reactor model is scaled up into a modular plant-wide system. Techno-economic (TEA) and life-cycle (LCA) analyses evaluate performance and sustainability, with sensitivity studies on plant capacity, electricity cost, and catalyst price confirming strong economic potential.

dehydroaromatization↗
NASA NTRS1985

GPACC program cost work breakdown structure-dictionary. General purpose aft cargo carrier study, volume 3

The results of detailed cost estimates and economic analysis performed on the updated Model 101 configuration of the general purpose Aft Cargo Carrier (ACC) are given. The objective of this economic analysis is to provide the National Aeronautics and Space Administration (NASA) with information on the economics of using the ACC on the Space Transportation System (STS). The detailed cost estimates for the ACC are presented by a work breakdown structure (WBS) to ensure that all elements of cost are considered in the economic analysis and related subsystem trades. Costs reported by WBS provide NASA with a basis for comparing competing designs and provide detailed cost information that can be used to forecast phase C/D planning for new projects or programs derived from preliminary conceptual design studies. The scope covers all STS and STS/ACC launch vehicle cost impacts for delivering payloads to a 160 NM low Earth orbit (LEO).

Source record↗
DOE OSTI2020

Wall Upgrades for Deep Energy Savings in Residential Buildings: Interim Results from a Multi-Year Study

The Pacific Northwest National Laboratory, Oak Ridge National Laboratory and the University of Minnesota are conducting a three-year, multipart study on residential retrofit wall assemblies. The project is funded by the U.S. Department of Energy’s Building Technology Office and will identify, test and verify wall assemblies for hygrothermal performance in retrofit applications. The study includes a comprehensive literature review and expert advisory group, which inform wall selection. Selected wall assemblies are then thermally simulated using EnergyPlus and THERM, and hygrothermally simulated using WUFI, to model both thermal and moisture performance of the wall assembly. Eight wall assemblies are then experimentally tested in an in-situ laboratory environment at the University of Minnesota, with a typical residential wall used as a baseline. The in-situ experiment looks at the physical hygrothermal performance of each assembly. The simulation and experimental results will be combined with an economic analysis to produce a techno-economic study of residential wall systems for deep energy retrofits. This paper presents progress after year one of the study. Wall system modeling and laboratory testing is scheduled to begin in November, 2019. We will discuss the parameters for wall selection and experimental design, which includes approaches to modeling and simulation, along with the physical experiment design. This paper will also outline the parameters for the techno-economic analysis, and criteria used to inform model development.

Antonopoulos, Chrissi A.↗
NASA NTRS1974

The October 1973 NASA mission model analysis and economic assessment

Results are presented of the 1973 NASA Mission Model Analysis. The purpose was to obtain an economic assessment of using the Shuttle to accommodate the payloads and requirements as identified by the NASA Program Offices and the DoD. The 1973 Payload Model represents a baseline candidate set of future payloads which can be used as a reference base for planning purposes. The cost of implementing these payload programs utilizing the capabilities of the shuttle system is analyzed and compared with the cost of conducting the same payload effort using expendable launch vehicles. There is a net benefit of 14.1 billion dollars as a result of using the shuttle during the 12-year period as compared to using an expendable launch vehicle fleet.

Source record↗
DOE OSTI2021

Towards cost-competitive middle distillate fuels from ethanol within a market-flexible C2 platform-based biorefinery concept

Ethanol to middle distillates (ETMD) is a promising pathway to produce sustainable liquid fuels to decarbonize the hard-to-electrify transportation sectors due to (1) the abundant sugar/starch and lignocellulosic biomass, (2) the existing deployment scale of fuel ethanol production (similar to 29 billion gallons per year globally), and (3) emerging opportunities in C2+ alcohol synthesis from CO2. Here we report a conceptual market-responsive biorefinery centered around a new ETMD pathway based on one-step ethanol to butene-rich olefins (ETO) over a Cu-Zn-Y/Beta catalyst. Specifically, this ethanol conversion pathway comprises one-step ETO, oligomerization, and hydrotreating. This ETO is distinct from that in the conventional ethanol-to-jet process which is based on two-step ethanol to ethylene and ethylene oligomerization to butenes. Butene-rich olefins can be shifted to butadiene-rich products by simply changing the reaction atmosphere from hydrogen to inert gas over the same ETO catalyst. Leveraging the experimental results, baseline techno-economic analysis (TEA) and sensitivity analysis indicate that the ethanol conversion cost is $0.60 per gallon gasoline equivalent (GGE), with opportunities for further cost reduction via improving the liquid hydrocarbon yield and space velocities, and process optimization on balancing dewatering of ethanol feed prior to the ETO step. The minimum fuel selling price (MFSP) of liquid hydrocarbons derived from corn starch ethanol with butadiene as coproduct is $1.64 per GGE, in the range that is cost competitive with petroleum kerosene-type jet fuel. Projected MFSP for cellulosic ethanol (corn stover) derived hydrocarbons is below $3.00 per GGE and co-production of butadiene further reduces the MFSP to $1.70 per GGE. The Well-to-Wake life-cycle analysis indicates that 85% greenhouse gas emission reduction can be achieved when using corn stover compared to petroleum reference and the associated carbon credits will provide significant economic incentives to favor the cellulosic ethanol-derived hydrocarbon fuels. This study demonstrates a low-cost pathway to middle distillate fuels leveraging existing ethanol infrastructure, where catalysis innovation drives the reduction of process complexity and flexible coproduction of a value-added chemical product.

Zhang, Junyan↗
NASA NTRS1979

Solar thermal power plants in small utilities - An economic impact analysis

A study was performed to assess the potential economic impact of small solar thermal electric power systems in statistically representative synthetic small utilities of the Southwestern United States. Power supply expansion plans were compared on the basis of present worth of future revenue requirements for 1980-2000 with and without solar thermal plants. Coal-fired and oil-fired municipal utility expansion plans with 5 percent solar penetration were 0.5 percent and 2.25 percent less expensive, respectively, than the corresponding conventional plan. At $969/kWe, which assumes the same low cost solar equipment but no improvement in site development costs, solar penetration of 5 percent in the oil-fired municipal reduced revenue requirements 0.88 percent. The paper concludes that some solar thermal plants are potentially economic in small community utilities of the Southwest.

Bluhm, S. A.↗
DOE OSTI2023

Cost and Life Cycle Analysis for Deep CO 2 Emissions Reduction for Steel Making: Direct Reduced Iron Technologies

Among heavy industrial sectors worldwide, the steel industry ranks first in carbon dioxide (CO 2 ) emissions. Technologies that produce direct reduced iron (DRI) enable the industry to reduce emissions or even approach net‐zero CO 2 emissions for steel production. Herein, comprehensive cradle‐to‐gate (CTG) life cycle analysis (LCA) and techno‐economic analysis (TEA) are used to evaluate the CO 2 emissions of three DRI technologies. Compared to the baseline of blast furnace and basic oxygen furnace (BF–BOF) technology for steel making, using natural gas (NG) to produce DRI has the potential to reduce CTG CO 2 emissions by 33%. When 83% or 100% renewable H 2 is used for DRI production, DRI technologies can potentially reduce CO 2 emissions by 57% and 67%, respectively, compared to baseline BF–BOF technology. However, the renewable H 2 application for DRI increases the levelized cost of steel (LCOS). When renewable natural gas (RNG) and clean electricity are used for steel production, the CTG CO 2 emissions of all the DRI technologies can potentially be reduced by more than 90% compared to the baseline BF–BOF technology, although the LCOS depends largely on the cost of RNG and clean electricity.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Economic Extraction and Recovery of REEs and Production of Clean Value-Added Products from Low-Rank Coal Fly Ash

The University of North Dakota (UND) Energy & Environmental Research Center (EERC) teamed with Pacific Northwest National Laboratory (PNNL) , the North Dakota Industrial Commission Lignite Research Program, and commercial partners Basin Electric Power Cooperative, Great River Energy, and Southern Company to execute a Cooperative Agreement funded by the U.S. Department of Energy’s (DOE’s) National Energy Technology Laboratory (NETL) focused on identifying unique pathways and pretreatments to extract rare-earth elements (REEs) from low-rank coal (LRC) ash in a more economical and environmentally benign manner than current methods. The EERC drew upon the unique and deep knowledge of the team regarding LRC geochemistry, ash transformation mechanisms during combustion, and fly ash chemistry in the approach to understand the portioning of REEs in LRC ash. A comprehensive characterization effort was undertaken to fully establish the form, associations, and partitioning of the REEs and other elements/minerals of interest in fly ash, as well as the ash chemistry, mineralogy, and morphology. Using this information, the team tested methods of REE extraction to take advantage of the unique and advantageous properties of LRC ash. Multiple complementary approaches were evaluated that combined both novel and proven methods to develop an extractive process for REEs and other high-value metals from LRC ash that provide technological and economic progress on the current state of the art. Methodologies were also evaluated for the potential to synergistically remove toxic metals while extracting other high-value metals from the ash, generating a clean, safe ash material as a value-added product. This would eliminate waste and offer significant additional revenue potential. Based on laboratory-scale testing, an initial high-level technical and economic analysis to estimate operating expenses and product revenues to guide future phases of technology development was implemented. By focusing on minimizing process steps and consumptive use of extraction solutions, a tunable, economically viable process for REE extraction from LRC ash was developed. The tunable process has the ability to be adjusted to adapt to the differing ash chemical and physical properties that are characteristic of LRC ash. This is key to deployment as a commercial process. In demonstrating the process, the EERC was able to illustrate mixed REE concentration greater than the goal of 2 wt%. High-level economic analysis of the process with LRC ash of moderate REE levels demonstrated the potential of the process, but recovery of just the REEs was insufficient to cover operational costs. With the additional extraction of other high-value metals found in LRC ash, the process economics approach would break even, and it is anticipated that with process optimization, the developed process could potentially be economically sound. The same economic analysis performed utilizing LRC ash with high levels of REEs showed the recovery of the REEs alone would make the process economically viable even without further optimization.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2019

Deep Direct-Use Feasibility Study Numerical Modeling and Uncertainty Analysis using iTOUGH2 for West Virginia University

To reduce the geothermal exploration risk, a feasibility study is performed for a deep direct-use system proposed at the West Virginia University (WVU) Morgantown campus. This study applies numerical simulations to investigate reservoir impedance and thermal production. Because of the great depth of the geothermal reservoir, few data are available to characterize reservoir features and properties. As a result, the study focuses on the following three aspects: 1. model choice for predicting reservoir impedance and thermal breakthrough: after investigating three potential models (one single permeability model and two dual permeability models) for flow through fractured rock, it is decided to use single permeability model for further analysis; 2. well placement (horizontal vs. vertical) options: horizontal well placement seems to be more robust to heterogeneity and the impedance is more acceptable; 3. Prediction uncertainty: the most influential parameters are identified using a First-Order-Second-Moment uncertainty propagation analysis, and the uncertain range of the model predictions is estimated by performing a Monte Carlo simulation. Heterogeneity has a large impact on the perdition, therefore, is considered in the predictive model and uncertainty analysis. The numerical model results and uncertainty analysis are used for economic analysis. The dataset submitted here support the described study. Manuscript is submitted to Geothermics, will be linked once paper is accepted.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Energy Arbitrage with Hydrogen: HTSE + Combustion Turbine

The Light Water Reactor Sustainability (LWRS) program seeks to keep Nuclear Power Plants (NPPs) competitive in the changing energy market. The Flexible Plant Operation and Generation (FPOG) pathway investigates Energy Storage Systems (ESS) to give operators an alternative to curtailment or paying to put power on the grid. This work investigates the concept of diverting heat and electricity to High Temperature Steam Electrolysis (HTSE) to produce hydrogen when grid demand is low, storing that hydrogen, then burning it in a combustion turbine to produce zero-emission electricity when grid demand is high. A process model of the combustion turbine was developed in Aspen HYSYS, which was used to complete a parametric analysis and techno-economic analysis.

08 HYDROGEN↗
NASA NTRS1980

An economic systems analysis of land mobile radio telephone services

This paper deals with the economic interaction of the terrestrial and satellite land-mobile radio service systems. The cellular, trunked and satellite land-mobile systems are described. Parametric equations are formulated to allow examination of necessary user thresholds and growth rates as functions of system costs. Conversely, first order allowable systems costs are found as a function of user thresholds and growth rates. Transitions between satellite and terrestrial service systems are examined. User growth rate density (user/year/km squared) is shown to be a key parameter in the analysis of systems compatibility. The concept of system design matching the price demand curves is introduced and examples are given. The role of satellite systems is critically examined and the economic conditions necessary for the introduction of satellite service are identified.

Leroy, B. E.↗
DOE OSTI2021

Proceedings of the 2021 Airborne Wind Energy Workshop

On March 2-3, 2021, the National Renewable Energy Laboratory (NREL) conducted a virtual workshop to evaluate the status, potential development, and technical viability of AWE systems as a source of energy in the United States. Stakeholder input provided at the workshop will contribute to the report to Congress. This report summarizes key workshop findings, current technology research and development activities in the United States, and opportunities and potential modes of collaboration and coordination for future technology research and development activities. The workshop focused on U.S. stakeholders in AWE, with approximately 100 experts and industry stakeholders from AWE technology developers, operators, engineering firms, consultants, government, national laboratories, and university researchers. The workshop began with an explanation from DOE's Wind Energy Technologies Office (WETO) Technology Manager, Ben Hallissy, of the context and purpose of the workshop, including a request from Congress that the U.S. Department of Energy (DOE) deliver a "report on the potential for, and technical viability of, airborne wind energy systems to provide a significant source of energy in the United States, including a summary of research, development, demonstration, and commercialization needs, including an estimate of Federal funding requirements, to further examine and validate the technical and economic viability of airborne wind energy concepts over the 10-year period." The workshop began with brief introductions from attendees who explained their interest in AWE. Nicolas El Hayek of Planair summarized the proceedings from the AWE workshop held in September 2020 by the International Energy Agency (IEA) Wind Task 11. This was followed by a presentation by Roland Schmehl of TU-Delft summarizing European AWE R&D efforts. Chris Vermillion of North Carolina State University and Jason Jonkman of NREL presented an overview of U.S. R&D efforts. Then five panelists discussed AWE markets, sizes of AWE systems, challenges, and opportunities. Panelists included: Cristina Archer, professor at the College of Earth, Ocean, and Environment and associate director at the Center for Research in Wind (CReW) at the University of Delaware; Stephan Brabeck, chief technology officer at SkySails; Thierry Delahave, innovation and technology development lead at Saipem; Rob Creighton, founder and chief executive officer at WindLift; and David Schaefer, founder and chief executive officer at eWind Solutions. The second day of the workshop began with a brief overview of five key topics that are crucial to enabling AWE in the United States. These topics range from estimates of the U.S. wind resource, technical generation potential, economic analysis, environmental challenges, status of current technology and R&D activities, and needed activities to enable commercialization of AWE. This set the stage for a robust discussion in breakout groups where individuals could offer their opinions on the potential opportunities for AWE in the United States. The following topics were discussed in the breakout groups: resource potential and energy output, technical potential, social and environmental impacts, and permitting, techno-economic analysis and markets, technology assessment and upscaling and demonstration and commercialization needs. The second day concluded with reports by the NREL research team, communicating the key themes and outcomes from each of the breakout group discussions.

17 WIND ENERGY↗
DOE OSTI2022

Produced Water and Waste Heat-aided Blowdown Water Treatment: Using Chemical and Energy Synergisms for Value Creation

The project objective was to develop a cooling blowdown water (BDW) treatment process utilizing produced water (PW) and low-grade heat to maximize water reuse and saleable by-product generation while reducing chemical and energy footprints of the treatment. The proposed treatment process consists of mixing, softening, organics and suspended solids removal, reverse osmosis (RO), thermal desalination, and brine electrolysis. BDW samples collected from a local coal-fired power plant and PW samples from two shale gas production wells were used in this study. Each treatment unit was first designed and tested to quantify its treatment efficiency, and its chemical and energy requirements. In addition, a process model was developed and model simulations were conducted based on the experimental results and literature data to optimize the treatment process. A techno-economic analysis was conducted to quantify chemical and energy savings as well as production of 10-lb brine as a saleable product. With the field-collected BDW and PW samples, mixing experiments determined a volumetric mixing ratio 10:1 (BDW:PW) resulted in the best performance of multivalent ions removal and largest chemical savings for softening. Softening of the BDW/PW mixtures using alkaline chemicals (Na 2 CO 3 and NaOH) achieved 95%-100% removal of scaling-forming cations (Ca, Mg, Fe, Ba, Sr) and 60% of silicon, and 10% of total organic carbon (TOC). The mixing and softening treatments yielded an effluent with total dissolved solids (TDS) concentration of 23 g/L. Activated carbon (AC) filtration removed TOC to a low level (< 3 mg/L) and further removed remaining scale-forming divalent metals and silica from the softened water. The AC filtration resulted in a slight reduction of TDS from 23 g/L to 20 g/L, leaving behind only mostly monovalent ions (i.e., sodium and chloride) in the filtered water. These pretreatments yielded a feed water that met the criteria of the downstream reverse osmosis (RO) to prevent membrane fouling. A cross-flow RO system was used to further concentrate the TDS of the AC effluent. Various factors including TDS, pH, and applied pressure were examined and optimal conditions were determined for the co-treatment process. An integrated process consisting of mixing, softening, AC filtration and RO was used to treat a continuous flow (0.25 – 1.2 L/min, or 0.07 – 0.32 gpm) and successfully generated RO permeate as product water (TDS < 0.5 g/L) for reuse in cooling operation, and a concentrate (TDS ~ 45 g/L) to be further treated in a thermal desalination unit. These flow rates meet the FOA’s criterion of 0.01 – 1 gpm. Overall, the co-treatment of BDW/PW allowed shorter ramp-up time compared to treatment of BDW alone. It resulted in 40% and 55% savings of Na 2 CO 3(s) and NaOH, respectively, compared to treating the BDW and PW individually for the same level of softening. The co-treatment also resulted in a 29% energy saving compared to treatment of BDW only for the level of TDS concentration. A thermal desalination system was designed using CFD simulations and manufactured in the WVU Innovation Hub for further treatment of the RO concentrate to generate 10-lb brine. The system has a design flow rate of 2 gpm and has been successfully tested. A bench-scale brine electrolysis system was developed for on-site generation of chlorine/hypochlorite (Cl 2 /OCl - ) and caustic soda (NaOH) as useful chemicals for the co-treatment process. Using salt solutions (0.5 M and 1 M), the system achieved faradaic efficiencies of 93%-97% and 70%-77% for caustic soda and chlorine/hypochlorite generation, respectively. An economic analysis showed that the electricity costs for on-site generation of these chemicals were significantly lower than the chemical prices offered by suppliers. An industrial-scale process model consisting of mixing, softening, AC filtration, RO, thermal desalination, and brine electrolysis was developed using the Aspen Plus V9 in conjunction with Aspen Custom Modeler V9. The model serves as a solvable Aspen Plus model and as basis to form the costing infrastructure. In addition, techno-economic analysis considering capital, operating, and transportation costs was conducted. An optimization solution showed that produced water for mixing is still advantageous in low quantities. The optimum solution approaches a leveled cost of water (LCW) of 2 $/m 3 which becomes cost competitive with nominal water treatment prices.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Low-Temperature Plasma Treatment for Enhanced Recovery of Highly Valued Critical REEs from Coal (Final Report)

The principle objective of this project was to develop a novel process flowsheet using low-temperature plasma treatment (LTP) integrated with conventional hydrometallurgical processes to recover rare earth elements (REEs), especially highly valued REEs (i.e. scandium and critical REEs), from coal and coal byproducts. LTP treatment was used to pretreat the solid feed material prior to leaching in an effort to improve the leaching characteristics of the REEs and potentially reduce acid consumption. Initially, a detailed experimental program was performed on a laboratory LTP furnace to identify a set of process parameter values to be used for assessing the enhanced leaching performance achieved on four specific gravity fractions of West Kentucky No. 13 and Fire Clay coarse coal refuse materials. High-temperature oxidation (HTO)) was also evaluated as a means for improving REE leachability on the same fractions of both coal sources. The lixiviants used to assess leachability improvements included: i) untreated water, ii) 0.1 M ammonium sulfate solution and iii) 1.2 M sulfuric acid solution at a temperature of 75°C. The laboratory data was used to develop multiple process flow sheets using HTO only to produce a rare earth oxide mix concentrate or utilizing both LTP and HTO treatment processes to generate a high purity heavy REO mix concentrate and a light REO mix concentrate. A techno-economic analysis was performed on each circuit. Low-temperature plasma oxidation was found to enhance REE leaching characteristics for all specific gravity (SG) fractions of the West Kentucky No. 13 coarse refuse material. The leaching recovery improvement was preferentially achieved for the heavy REEs with higher values obtained when treating the lower density fraction material. For example, the leaching recovery for the heavy REEs in the untreated 1.6 SG Float fraction material was 8% in a 0.1 M ammonium sulfate solution. After LTP treatment for 32 hours, heavy REE recovery increased to 33%. The corresponding recovery value for the light REEs was 10%. These findings indicate a strong affinity of the heavy REEs with the organic material, which is the component being reduced in content during the LTP treatment. Scanning electron micrographs showed the development of a honeycomb structure with increased LTP treatment with higher surface area as confirmed from BET measurements. Higher surface area promotes improved leaching efficiency due to enhance chemical interactions. When using 1.2 M sulfuric acid, the LTP treatment was found to provide a heavy REE recovery increase from 23% to 53% for the 1.6 SG Float fraction which corresponded to an ash content increase from around 20% to 35%. However, LTP treatment provided no improvement in leaching characteristic for the 2.2 SG sink material in the acid solution, which was likely due to the low organic content. The LTP treatment of the Fire Clay SG fractions provided no improvement in REE leaching characteristic, which may be due to the association with REE minerals such as monazite and REE-associated mineral matter such as clays. High temperature oxidation using temperatures in the range of 600-750OC was found to significantly enhance the leaching characteristics of both the light and heavy REEs for all density fractions in both coarse coal refuse materials. Generally, the increase in light REE recovery for the West Kentucky material was from 15% for the untreated material to 90% for the HTO treated material at 600°C. Recovery values dropped significantly when using temperatures below 600°C and above 750°C. The impact of the excessive temperatures was most likely a result of sintering. For the heavy REEs, HTO significantly improved recovery in the lighter SG fractions, which may be due to an affinity with the organic content. Only limited heavy REE recovery improvement was obtained for the denser SG fractions. Another benefit of HTO is the conversion of calcium-based minerals to a very soluble calcium oxide, which is removable using a mild acid solution, and the conversion of Fe minerals to relatively insoluble minerals such as hematite and magnetite. The pregnant leaching solution produced from the leaching of all SG fractions obtained from both coal sources was treated using two stages of solvent extraction procedurally modeling a rougher-cleaner circuit followed by oxalic acid precipitation. Rare earth oxide products having a purity greater than 97% was produced from nearly all of the SG fractions. A novel process flowsheet was developed based on the selective leaching of heavy REEs that was made possible through LTP treatment of West Kentucky No. 13 coarse refuse followed by salt leaching. In the flowsheet, coal refuse material is ground to a top size of 1mm and then treated by LTP. The treated material is mixed into a 0.1 M ammonium sulfate solution and then filtered to produce a heavy REE enriched pregnant leach solution. The heavy REEs are concentrated by two stages of selective precipitation to produce a heavy REE mix oxalate and then roasted to obtain a heavy REO mix concentrate. The solid residues remaining after salt leaching is dried and then subjected to HTO treatment followed by concentration using selective precipitation and roasting to produce a light REO mix concentrate. An alternative circuit was developed using HTO treatment only to treat 100% of the coarse refuse material followed by selective precipitation and roasting to generate a high purity REO mix product. A techno-economic analysis performed for the treatment of West Kentucky No. 13 and Fire Clay coarse refuse based on a hypothetical 500-tph plant revealed that the net present value for all scenarios was significantly negative. Primary reasons include: i) a substantial decrease in the basket value of the final product relative to the feed and ii) high chemical costs relative to the amount of product generated. The basket value reduction was primarily due to little to no scandium recovery due to poor leaching characteristics when using low acid concentrations as necessitated by the low feed grades. Operating costs were primarily influenced by the chemical costs relative to the kilograms of concentrate produced and feed grade. For the Fire Clay coarse refuse material, the total operating cost was estimated to be $354 per kg of REO produced which was higher than the basket value of the REO product ($276/kg). Approximately 37% of the total cost was the sulfuric acid used during the leaching process. A comparative analysis performed to assess the economic viability of using low-temperature plasma furnaces found that market value enhancement for the generation of both heavy REO and light REO concentrates will be needed in addition to significant technology advancements to reduce the cost of plasma furnaces.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Massachusetts and New England SAF Study [Slides]

The Massachusetts Port Authority established a project to assess feedstock availability to produce SAF near 10 New England airports. A techno-economic analysis was conducted to determine renewable fuels and SAF that could be produced from these feedstocks. The resource assessment found municipal solid waste, woody biomass, and food waste were most abundant. The techno-economic analysis found that potential fuel production varied widely based on location, feedstock, and technology production pathway. An assessment of infrastructure readiness to handle SAF was conducted. It was determined that SAF produced outside of New England should be blended in other regions with more capacity and flexibility and delivered to New England as Jet A is today. For SAF produced in New England, there are terminals that have existing infrastructure to receive, blend, and distribute SAF/Jet A blends.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Chemical recycling of mixed textile waste

Globally, less than 0.5% of postconsumer textile waste is recycled, with the majority incinerated or ending up in landfills. Most postconsumer textiles are mixed fibers, complicating mechanical recycling due to material blends and contaminants. Here, we demonstrate the chemical conversion of postconsumer mixed textile waste using microwave-assisted glycolysis over a ZnO catalyst followed by solvent dissolution. This approach electrifies the process heat while allowing rapid depolymerization of polyester and spandex to their monomers in 15 minutes. A simple solvent dissolution enables the separation of cotton and nylon. We assess the quality of all components through extensive material characterization, discuss their potential for sustainable recycling, and provide a techno-economic analysis of the economic feasibility of the process.

Science & Technology - Other Topics↗