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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

The importance of maldistribution matching for thermal performance of compact heat exchangers

Compact heat exchangers have gained increased attention in recent years, particularly in demanding applications where high temperatures, high pressures, and/or high power densities are required. For decades, the heat exchanger (HX) community believes that flow maldistribution is a key factor for HX effectiveness, that is, reducing the degree of flow maldistribution (MALD) can help increase the HX effectiveness. Therefore, significant efforts have been devoted in the past to optimizing the header geometry to minimize flow maldistribution. This work was initially motivated by this, and the original goal was to figure out a HX header design with the lowest maldistribution. However, by systematically constructing a comprehensive maldistribution matrix, the analysis revealed that the HX effectiveness is not actually determined by the MALD, but instead dominated by the degree of maldistribution mismatch (MISM). This conclusion was also theoretically generalized, which indicated that matching of the local heat capacity rate is key for achieving maximum performance. The MISM provides a local means of tracking this information, while the MALD only provides a global approximation of the maldistribution itself. With this new perspective, flow maldistribution needs not necessarily be avoided, but instead matched between two fluid streams, to improve the HX performance. We demonstrated that by carefully designing the header geometry to match the velocity profiles of the two fluids in a 2 MW PCHE with molten salt and supercritical carbon dioxide (sCO2) as the heat transfer fluids, the HX could achieve a higher effectiveness even when the maldistribution increased. Finally, a technoeconomic study using a CSP system as an example revealed that the use of this new HX design paradigm could result in CSP capital cost savings as large as 16.6%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Mining Air for Fuels and Fine Chemicals

The Intergovernmental Panel on Climate Change’s 2021 report underscores that Direct Air Capture (DAC) is an essential component to limiting global warming to 2 °C, yet separating CO 2 from air and its subsequent concentration for conversion into carbon neutral fuels/chemicals or permanent storage remains energy intensive and costly. Further, most DAC technologies rely on repetitive capture and release cycles that reduces the amount of time the DAC materials are able to collect CO 2 and increases wear and tear. Moisture swing (MS) sorption within anion exchange materials utilizes differences in relative humidity to capture and concentrate CO 2 up to 500-fold with negligible energy inputs and low-cost sorbents. Molecular modeling predicts that membranes with a dry and wet side would actively transport CO 2 from its dry side to its wet side against a counter flow of H 2 O evaporating on the dry side, however, existing MS materials are too brittle to be processed into membranes to test this hypothesis. This project brought together experts in DAC materials and design, techno-economic analysis and project management at Arizona State University (ASU), polymer processing at University of Texas at Austin (UTA) and modeling gas transport and exchange at Norther Arizona University (NAU) to develop hollow fiber membranes that use energy from water evaporation to continuously pump CO 2 from air against a concentration gradient to the membranes interior and requiring significantly less energy than current DAC technologies. While this project did not meet its ultimate objectives of demonstrating an active CO 2 pumping membrane, a number of key accomplishments were made in developing low-cost, flexible anion exchange membranes (AEM) at 3.5 m 2 scale, characterizing the ionic and molecular transport within MS materials, and developing several analytical and mathematical models of the MS and pumping process leading to new fundamental knowledge about key rate limiting steps of CO 2 flux in anion exchange membranes at low water activity. Technoeconomic models show that if CO 2 fluxes ≥ 25 µmol CO 2 m -2 s -1 (membrane surface area) are achieved that cost ≤ $\$$100/tonne CO 2 captured, purified and compressed to pipeline quality is possible. The knowledge gained in this research will guide future research in developing new materials toward overcoming these rate limiting steps that in turn could enable transformative and disruptive DAC technologies needed for capturing gigatons of CO 2 per year needed to limiting global warming to 2 °C.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Technoeconomic assessment of distillation heat transfer intensification using aeroelastically fluttering reeds

Dry cooling, where forced air is the heat transfer medium, is a preferable cooling method in arid locations lacking readily available process water. However, such locations often experience high ambient temperatures that limit the effectiveness of air cooling. The objective of this study is to quantify the economic and energetic benefits of heat transfer intensification via the implementation of aeroelastically fluttering reeds to the air-cooled condenser of a methanol distillation column. Condenser size and performance, regarding recovered methanol and required fan power, is evaluated across condenser operating temperatures (T cond ) from 60 to 62°C and heat transfer coefficients (U) U base –2U base for a range of inlet air temperatures based on ambient temperature data from Yuma, Arizona. Under typical design sizing, condenser capital cost was reduced by 6%–35% (1.3U base –2U base ) and nominal methanol recovery was increased from 0.26% to 0.38% (T cond = 62–60°C). At optimized condenser size, all enhanced U and T cond pairs increase methanol recovery and reduce fan power costs compared to the optimal Ubase reference. Overall, using enhanced heat transfer to maintain condenser temperature under a wider range of inlet conditions, rather than to reduce operation temperature, produces more favorable performance. Methanol price is not a determining factor in which pairs are profitable. Analysis was repeated for a global warming scenario, revealing more valuable improvements under elevated temperatures. Energy savings from condenser improvement to a methanol production system are not significant with respect to an optimized conventional system. Furthermore, unit economic and energetic incentives suggest implementation of fluttering reeds may be justified in other applications.

42 ENGINEERING↗
DOE OSTI2025

Supercritical water desalination and oxidation (SCWDO): Effectiveness on complex solutions, technoeconomic, and CO 2 impact for produced water treatment

The modern energy-economy is increasingly causing the production of highly saline brines, including from produced water. Supercritical water desalination can concentrate and extract minerals from these brines, but the effects of mixed salt interactions, organic degradation with additives, and the technology's economics are not well understood at supercritical condition. The present study evaluated and experimentally studied an integrated supercritical water desalination and oxidation (SCWDO) process for treating real-produced water samples from oil/natural gas field. The complex interactions between the various anions and cations in produced water were extensively evaluated. Most of the divalent and trivalent ions were extracted below 250 °C while the majority of the monovalent salt were removed between 380 to 410 °C. The treated real produced water was of drinking water quality, with <500 mg/l of total dissolved solid (TDS) and with 100% organics removal. Furthermore, the heat liberated during the organic oxidation could be utilized internally and for electricity generation for enhanced the energy efficiency and lower cost of produced water treatment. With system optimization, the proposed SCWDO process can essentially be made a net zero energy process. A novel process flow diagram for the commercial scale self-powered hybrid SCWDO technology was proposed as a cost-effective produced water treatment to mitigate the environmental crises. Techno-economic analysis showed that produced water treatment cost with SCWDO can be reduced to 2–3 $/m 3 and can be up to 60 % cheaper to traditional deep well reinjection. Additionally, the proposed SCWDO process could achieve net negative CO 2 emission.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

First-Principles Cost Estimation of a Sodium Fast Reactor Nuclear Plant

A multi-tiered cost analysis is performed to estimate full costs of a nuclear power plant (NPP) based on sodium-cooled fast reactor (SFR) technology. To address the lack of fully transparent cost estimations from past undertakings for NPPs, we have developed a detailed and first-principles-based cost estimate for a generalized SFR NPP. Our intent is to achieve a high degree of transparency with our cost assumptions and develop a cost model that is flexible and easily extendable to variations in NPP design and other nuclear reactor types. Furthermore, we strive to achieve a clear organization of costs and complete identification of key cost drivers based on first principles. To this end, the cost results of our analysis as given in Table 24 and Table 25 are organized and categorized into a code of accounts (COA) under development at Idaho National Laboratory (INL). Varying degrees of first-principles methods are employed, such as design for manufacture and assembly® (DFMA® ), to elucidate costs in all process levels of the plant equipment, buildings and site structures, personnel, and other miscellaneous but significant cost elements. These approaches have been successfully applied in past cost analysis projects and are designed to enable rapid and flexible cost estimation. Application of these techniques for evaluating NPP costs is similar in concept to the full, detailed estimation of construction and fabrication costs determined in a later stage of NPP development. Note that our approach tries to avoid use of other past analysis results and data such as those from the legacy Energy Economic Data Base (EEDB) Program, as these resources are based on historical NPP costs and thus may not be indicative of new reactor technologies or construction and fabrication/manufacturing techniques. However, we provide a comparison of our SFR NPP cost results in Table 90 against those included in the EEDB for a representative pressurized water reactor (PWR).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Development of an enzyme cocktail to bioconvert untapped starch in sweet sorghum processing by-products: Part II. Application and economic potential

Demand for bioethanol and other biochemicals produced from agricultural crops has increased. Sweet sorghum has been identified as a promising bioenergy crop as it can produce starch, sugar, and fibrous biomass. During processing, starch accumulates in the juice sediments and clarification mud. And, while currently not recovered, it can be made accessible for fermentation by enzymatic hydrolysis. The enzymatic hydrolysis of starch in sweet sorghum processing streams was investigated, followed by fermentation of the resulting glucose to ethanol. The juice sediment contained sufficient starch to increase fermentable sugars by 127%, allowing a final ethanol titer of 11.1 vol%. The economics for fermentation of only dissolved sugars (Scenario 1) versus dissolved sugars and hydrolyzed starch (Scenario 2) were compared using a technoeconomic model. Fixed capital cost was found to be similar for both scenarios. For a set harvest period, Scenario 2 could produce 20% more ethanol; however, if the distillation by-product was dried and marketed as animal feed, Scenario 1 was more cost effective. A plant producing 5.6–5.7 Mkg of fuel ethanol per year had a minimum selling price of $0.67/kg of ethanol with concurrent production of animal feed and zero cost sweet sorghum processing. Finally, even with these optimistic assumptions, the estimated production cost was higher than the current wholesale price of fuel ethanol.

09 BIOMASS FUELS↗
DOE OSTI2024

HERO CarbonSAFE Phase 2 Project in the Columbia River Basalt Group

The Hermiston, Oregon Basalt CarbonSAFE Phase II project (HERO CarbonSAFE) seeks to accelerate the deployment of commercial carbon dioxide (CO2) storage projects in basaltic rocks. Basalt CO2 storage has several advantages to conventional saline storage reservoirs including 1. The potential for rapid mineralization of CO2, 2. Associated decreases in pressure and CO2 migration risks, 3. Reduced long-term monitoring requirements with respect to plume tracking, 4. Widespread geographic distribution and, 5. Large storage potential due to thickness, porosity, and CO2 interactions with basalt. And for locations such as the Pacific Northwest, Hawaii, Iceland, India and Japan, basalts may offer the only economically feasible option for local CO2 storage. However, there are limited field-scale assessments of CO2 storage in basalt, and current carbon capture utilization and storage (CCUS) permitting and regulatory frameworks were developed for conventional saline reservoirs. HERO CarbonSAFE is designed to address research gaps and uncertainties associated with basalt storage. Specifically, the project will assess the feasibility of CO2 injection in the deep layered basalts, long-term storage (mineralization), practical approaches for large-scale implementation (50+ million metric tons of CO2 over 30 years), lithology-specific risks, and the technoeconomic potential for CO2 storage in basalts. The HERO CarbonSAFE project will assess feasibility of developing a commercial-scale (50+ million metric tons of CO2) geological storage complex within the Columbia River Basalt Group (CRBG), a layered continental flood basalt complex that underlies Calpine’s natural gas-fired Hermiston Power Project (HPP) in Hermiston, OR (Figure 1). Under this 2-year CarbonSAFE Phase II project, the HERO team will conduct a data acquisition campaign that includes drilling a stratigraphic well to a total depth of ~1,500 m into the thick layered basalts proximal to HPP. A comprehensive well logging and hydrologic testing program will be augmented with new core collected from flow zones and sealing units, and comprehensive laboratory testing to help refine the kinetic rates of mineralization. The newly acquired information will be integrated with existing data from regional wells to correlate basalt injection zone properties to develop storage hub/commercial-scale models. Using these models, the project team will evaluate injection scenarios to define the technical and economic potential for storing a minimum of 50 million metric tons of CO2 over a 30-year period, along with a robust sensitivity analysis on key parameters governing reservoir viability for sustainable injection over a commercial project lifetime. Specific technical objectives of HERO are: (1) assessing the reservoir response of a series of stacked layered reservoir flowtop sequences occurring in this area of the CRBG to commercial-scale injection volumes; (2) extending prior efforts by the project team to characterize the deep layered basalts encountered in regional studies, to leverage prior investments by U.S. Department of Energy’s (DOE) Carbon Storage program; (3) leveraging DOE’s mineralization characterization efforts to advance model parametrization for commercial scale injection of CO2 in basalts; (4) conducting risk assessments associated with scaling up to commercial storage hub injection goals, while validating DOE’s National Risk Assessment Partnership (NRAP) tools, to identify potential constraints that would prevent the CRBG from serving as a commercial-scale storage complex; (5) developing mitigation plans to address identified risks; (6) developing a commercial-scale injection and monitoring, verification and accounting (MVA) strategy; (7) utilizing computational models to define and minimize, if possible, the Area of Review (AoR) under Class VI regulations; and (8) developing a robust CO2 management strategy for CRBG that also considers a regional source/sink approach that is responsive to stakeholder needs and industrial demand. Specific institutional objectives are: (1) identifying and developing plans to mitigate the nontechnical challenges associated with the build-out of a commercial-scale storage complex within the CRBG with integrated CO2 sources; (2) implementing the community outreach plan; (3) conducting regulatory research, including a survey of issues related to pore space ownership, MVA and long-term assurance of mineralization-based storage, to support an eventual application for a UIC Class VI permit; (4) advancing the project’s plan for CO2 liability management; and (5) continuing to refine and update the project’s economic model. The final objective is the preparation of a comprehensive Site Characterization Plan that draws upon the technical and institutional feasibility assessments to prepare the project for future commercialization efforts.

58 GEOSCIENCES↗
DOE OSTI2023

Technoeconomic Model and Pathway to <$2/kg Green Hydrogen Using Integrated Halide Perovskite Photoelectrochemical Cells

The cost of gray hydrogen produced via fossil fuel-based steam-methane reforming has led the U.S. Department of Energy to specify <$\$$2/kg H 2 as a target for commercially competitive green hydrogen generation methods. Integrated photoelectrochemical cells have been proposed as a solar-to-hydrogen conversion technology. In this paper we describe a technoeconomically feasible pathway to reaching <$\$$2/kg green H 2 using integrated photoelectrochemical cells with halide perovskite photoabsorbers, low-cost conductive barriers, and low precious metal-content catalysts in an aqueous, membrane-separated cell. A base-case solar-to-hydrogen conversion efficiency of 20%, stable lifetime of 10 years, and a combined electrocatalyst-plus-panel cost of $\$$50/m 2 enabled a levelized cost of hydrogen of $\$$2.43/kg, which dropped below $\$$2/kg with improved performance metrics including material cost, improvements in process design, or subsidies. We relate these metrics to lab-scale reports to recommend best research practices for scientists and funding agencies working at this intersection of photovoltaics, electrocatalysis, and surface science.

$1/kg↗
DOE OSTI2025

OR-AGENT framework – Architecting electrified heavy-duty drayage applications

The widespread adoption of zero-emission vehicles in heavy-duty (HD) commercial freight transportation faces considerable technoeconomic challenges. For heavy-duty trucks, ensuring high uptime, cost parity with diesel, and safety standards is especially critical as these vehicles operate over long distances with heavy loads, where any downtime or off-nominal behaviors significantly impacts logistics, productivity, and the total cost of ownership. Unlike traditional diesel refueling, BEV charging infrastructure must be co-optimized with vehicle deployment, operational demands, and grid capacity to ensure cost-effective and reliable freight operations. However, the lack of a standardized ownership and service model has led to a fragmented approach—where commercial vehicle operators may invest in, own, and maintain both vehicle/batteries and charging/energy infrastructure. This disconnect may exclude energy service providers from the equation, forcing fleet operators to explore ‘behind-the-fence’ energy solutions that increase capital investment, operational downtime, overhead costs, and, in some cases, net carbon emissions. To address these issues, this study introduces OR-AGENT (Optimal Regional Architecture Generation for Efficient National Transport), a comprehensive modeling framework that integrates powertrain architectures, charging infrastructures, and energy backbone systems into a cohesive strategy. In this paper, OR-AGENT is applied to develop an interconnected systems architecture for energy efficiency and resiliency enhancement of heavy-duty drayage vehicles at the Port of Savannah, GA. This framework showcases an interconnected systems approach to electrifying heavy-duty drayage vehicles at the Port of Savannah, GA. The study assessed BEVs with 400–1200 kWh battery capacities, accounting for seasonal variations in weather and freight routing. A diverse charging mix (150 kW–1250 kW) was evaluated alongside grid capacity constraints, cost, and carbon intensity analysis, leading to the development of a strategic microgrid/Distributed Energy Resources (DER) deployment architecture to ensure a reliable and sustainable transition. However, the findings also highlight the need for alternative zero-emission solutions for remaining trips, such as larger batteries, electrified roadways, hydrogen powertrains, or net-zero emission fuels. In conclusion, the findings are incorporated into a Total Cost of Ownership (TCO) model to identify optimal architectures for an interconnected electrified ecosystem.

Commercial vehicles↗
DOE OSTI2024

Low-Cost Heliostat for High-Flux Small-Area Receivers (Final Technical Report)

This project analyzed a two-stage heliostat concept consisting of a tracking stage and a concentrating stage. The tracking stage uses mirrors mounted on a common drive that move to track the sun. The concentrating stage consists of stationary mirrors that each have a unique angle to direct rays towards a small-area, high-flux, point-focused receiver. By splitting the collection and concentrating process into two stages, multiple small, inexpensive mirrors can share a structure and be controlled by a single drive in the tracking stage. The project effort developed modeling techniques that were specifically relevant to this two-stage heliostat concept. Both field-level and unit-level models were developed. The field-level model does not explicitly consider unit-level losses which are predicted by the unit-level model and then integrated into the field-level model through a correlation referred to as an efficiency modifier. This approach is referred to as the two-model approach; the development and demonstration of this two-model approach for a multi-stage heliostat technology is a key outcome of this work. The field-level model is used to design a field that hits a specific design day power given a set of heliostat design parameters. An oversized field is simulated and then heliostat units are removed based on their annual energy production in order to generate the highest performing field. The field reduction procedure fits a smooth curve fit to annual energy production as a function of position in the field which has the effect of reducing the noise that is otherwise caused by the Monte Carlo ray tracing technique. This approach is referred to as the annual energy fit method and substantially reduces computational run time for a given field level modeling accuracy. The annual energy fit approach enables the selection of a properly sized, high-performing field using orders of magnitude fewer rays than would otherwise be possible and the development of this approach is a second key outcome of this work. These models are used within a genetic optimization algorithm in order to optimize the geometric parameters associated with a heliostat in order to achieve the lowest cost per unit of collected design day power. The cost modeling that underlies the optimization is a simple, scaling type analysis backed up by a much more detailed Design for Manufacture and Assembly (DFMA) analysis. Although the figure of merit used for optimization was not cost per mirror area, this metric is reasonable to use as a means of comparison. The optimally designed 500 kW design has a tracking mirror specific cost of $181.85/m 2 , which is significantly larger than the target value and also larger than the current state of the art. The cost of the torque-tube type linkages contributed substantially to the overall cost. Based on this observation, potentially attractive alternative design configuration utilizing a capstan type actuation system should be investigated. Finally, NREL compared the performance of the two-stage heliostat to the performance of a focused and different sized flat conventional heliostats and showed that, as expected, additional losses versus the convention heliostat caused by a worse cosine efficiency, two stages of reflection, and interstage interactions. The two-stage heliostat requires around 75% more reflective area than a flat 1x1 meter conventional heliostat (similar to a focused heliostat) and 40% more than a flat 2x2 meter conventional heliostat.

14 SOLAR ENERGY↗
DOE OSTI2026

Polymer Deconstruction and Redesign Strategies for Plastics Recycling

Advancing plastics recycling requires both the selective deconstruction of existing polymers and the design of new materials that enable efficient reuse without loss of performance. This perspective highlights an integrated approach that is rooted in polymer chemistry, catalysis, and process engineering which can enable a circular plastics economy. Here, we outline recent advances in catalytic, solvolytic, and enzymatic pathways for plastic deconstruction, and examine the molecular design principles driving next-generation recyclable-by-design and bio-based polymers. Despite these advances, major knowledge gaps remain in understanding the evolution of polymer morphology and catalyst structure during deconstruction, assessing deconstruction processes with realistic polymers, and offering redesigned polymers with competitive cost and environmental advantage over conventional plastics. United States Department of Energy (U.S. DOE) national laboratories offer unique capabilities to address these challenges through in situ and operando characterization, high-throughput experimentation, environmental studies, technoeconomic and life cycle assessment, scale-up support, and collaboration networks. Advances made in understanding plastic deconstruction mechanisms and structure-property correlations of redesigned polymers inform emerging research directions including autonomous experimentation, real-time feedback-enabled process optimization, and protein engineering for enzymatic depolymerization.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Techno-Economic Wind Blade Manufacturing Model to Identify Opportunities for Cost Improvements Phase II IACMI Project 4.6/4.8

In IACMI Project 4.6 and IACMI Project 4.8, an Excel-based Techno-Economic Model (TEM) of the manufacturing process for composite wind turbine blades and a DELMIA Factory Flow Simulation of a generic wind blade manufacturing facility was developed. Together, these two tools provide a combined economic modeling capability that accounts for the material, labor, overhead and full-lifecycle operating costs associated with wind blade manufacturing as well as the impact of process flow and factory layout on overall manufacturing efficiency. The tools provide a novel means of detailed comparative analysis of the economic feasibility of proposed technologies and process changes for blade manufacturing. The modeling tools were developed with close support from members of industry and visits to multiple blade manufacturing facilities. With industry oversight, a detailed generalized manufacturing process plan and facility layout were developed with manufacturing parameters, material costs and economic factors based on historical data. Dassault Systèmes and the University of Texas at Dallas (UTD) contributed to the development of the Techno-Economic Model by providing macros to enable the generation of Bill of Material (BOM) data from a 3D blade design in either CATIA or NuMAD format, respectively. The TEM was built with the capability to directly import a Bill of Materials for economic analysis, and with the addition of the macros provided by Dassault and UTD, the TEM can directly import blade designs from both CATIA and NuMAD file formats. The modeling tools developed in Project 4.6 were used to investigate four wind blade manufacturing concepts in detail and select one to explore with laboratory-scale experimentation in Project 4.8. The four manufacturing concepts that were investigated were down-selected by the full project team from a larger list of concepts. The selections were made based on a number of criteria ranking viability and level of interest for each concept. The ‘One-Step Close’ manufacturing concept was ultimately selected for investigation in Project 4.8 and the demonstration was performed at the NREL CoMET facility. The TPI advanced manufacturing facility in Warren, RI contributed the production of several prototype components, the designs for which were developed by Janicki Industries. The demonstration project provided clear indication of the viability of the One-Step Close manufacturing concept for blade manufacturing and good validation of the Techno-Economic Model’s prediction of its economic impact.

17 WIND ENERGY↗
DOE OSTI2024

Shallow Geothermal Resources for Cooling Applications at the University of Hawai‘i

Scientists at Berkeley Lab have teamed up with The University of Hawai‘i at Manoa (UH Manoa) through the U.S. Department of Energy’s (DOE’s) Energy Transitions Initiative Partnership Project (ETIPP) to evaluate the technological and market feasibility of shallow geothermal heat exchanger (GHE) technology for building cooling, energy efficiency, and emissions reduction applications in Hawai’i. The team is assessing the data necessary to model the feasibility of deploying this technology, the actual models that will be used, and what hurdles need to be overcome to install a demonstration case. UH has an abundance of geologic and geothermal data and is looking to the national labs’ expertise to execute this analysis. UH is also interested in investigating policy, regulatory, and business conditions advantageous for implementation of a pilot project, and more broad deployment of this technology in Hawai‘i. In many locations around the world, the demands for heating and cooling are roughly balanced over the course of the year, so GHEs do not cause significant long-term changes in subsurface temperature. This is not the case in Hawai’i, where the demand for heating is very small, meaning that over time, GHEs will add heat to the subsurface. If temperatures increase significantly, GHE systems will not work as designed. Regional groundwater flow has the potential to sweep heated water away from boreholes, thereby maintaining the functionality of the GHE system. Significant regional groundwater flow requires two things: a sufficiently large driving hydraulic head gradient (usually closely related to surface topography), and sufficient porosity and permeability to enable groundwater to flow in large enough quantities to enable near-borehole temperatures to be maintained at ambient values. Hawai‘i’s volcanic terrain offers ample surface topographic variation. The lava itself shows an extremely large range of porosity and permeability, making it crucial to select sites with large enough values of these properties. Numerical modeling of coupled groundwater and heat flow can be used to determine how large is large enough. Both closed-loop and open-loop systems are being investigated. Another option being considered is using cool seawater as the source of chill. Currently work is progressing on two fronts. A hydrogeologic model for a closed-loop system is being developed for the Stan Sheriff Center at the UH Manoa campus, where a subsurface karst system immediately downgradient of the borefield may provide efficient removal of heated groundwater. The team will also develop a technoeconomic model for this site to compare the cost of cooling using a GHE system with the costs of operating the current air conditioning system. At the state scale, geographic information system (GIS) layers of various attributes relevant for GHE are being combined to develop an overall favorability map for employing GHE in Hawai‘i.

Doughty, C↗
DOE OSTI2023

Dispatch analysis of flexible power operation with multi-unit small modular reactors

The relevance of nuclear power plant flexible power operation (FPO) is rising due to increased penetration of variable renewables. Small Modular Reactors (SMRs) such as NuScale are envisaged to have multiple units on one site. This provides opportunities for coordinating FPO between units, but also introduces challenges as common services (e.g., refueling equipment) must be shared between units and fuel loadings may be standardized. It is therefore important to quantify whether FPO with SMRs is economically beneficial. Here, this paper quantifies the economics of FPO on different timescales to analyze refueling outages of such multi-unit SMRs. A 24-h price-taker profit maximization of SMR operation is first solved considering revenues from wholesale power and ancillary service (AS) markets. The results are then used to find the most profitable operation strategy over several years for multiple units at the site accounting for the physics and materials limits on NPP operation, including refueling outages. Results show a small but appreciable participation of nuclear into AS, contributing 4% of revenues. Due to the longer fuel cycle, over a decade of operation the units’ refueling outages drifted by 3 months, ultimately leading to refueling during summer.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Assessment of NuScale SMR Steam Heat Augmentation for Chemical Plant Decarbonization

Nearly 50% of the total energy consumed by the industrial sector in the United States is used to produce process steam with natural gas and coal-fired boilers1 . This project conducts a technoeconomic assessment of a NuScale Small Modular Reactor (SMR) coupled with a chemical plant as an Integrated Energy System (IES) where nuclear produces steam and electric power to meet the requirements of a large chemical plant. In a 2020 study, ORNL evaluated the feasibility of using advanced SMRs, including the NuScale design, to supply energy to the Eastman Chemical Plant. However, since that report was published, NuScale received NRC approval for its uprated 77 MWe design with 56% more power and has also introduced a high-temperature, high pressure, steam heat-augmentation system, a key focus of the new study. The new study also benefits from revised capital costs, a 10-day refueling outage time, reduced plant staffing, higher capacity factors, and a site boundary Emergency Planning Zone methodology. The study consists of a techno-economic assessment of two possible energy sources (nuclear and natural gas) in a number of steam and power generation configurations (NuScale Power Modules (NPMs), boilers and combinations of both) to satisfy the steam and power demand with the most reliable and cost competitive system. A total of 2,947.3 klb/hr of steam and 72.5 MWe of electricity are required for the demonstration case. A range of scenarios and solutions are explored, from a 12-NPM plant (3,000 MWth)—with excess capacity and redundancy, capable of supplying a significant amount of extra power to the grid—to a 4-NPM (1,000 MWth) plant—supplemented with existing boilers or grid power for redundancy. The study uses historical steam and power data from a chemical plant and examines the sensitivity to natural gas and grid power cost variations. Scenarios with up to two times gas and electricity costs were considered. Profitability in a 60-year time horizon was analyzed, consistent with NuScale’s design life specification. A steady-state site integration and reliability analysis was performed, and trade-offs were identified.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Multifunctional landscapes for dedicated bioenergy crops lead to low-carbon market-competitive biofuels

Switchgrass is a promising feedstock for cellulosic biorefineries, due to its ability to maintain comparatively high biomass yields across a wide range of soil and climatic conditions. However, there is an incomplete understanding of the economic and environmental tradeoffs associated with cultivating switchgrass on low-productivity land for conversion to biofuels. This study surveys prior literature and demonstrates a new integrated assessment framework, including agroecosystem, ecosystem services valuation, technoeconomic, and life-cycle assessment models, to quantify and contextualize the economic and environmental impacts of switchgrass cultivation on marginal land with downstream conversion to biofuels. Monetizing and incorporating the value of ecosystem services, such as improved water quality benefits from nitrate and sediment reductions, climate change mitigation benefits from CO 2 emission reduction, and recreational and pollination benefits from increased biodiversity, the modeled multifunctional landscape reduces the ethanol production cost by 33.3–58.9 cents/$\scriptsize{L}$-gasoline-equivalent ($\$$1.3–2.2/gge). Planting switchgrass in low productivity land improves soil health, resulting in the carbon footprint reduction credit of 12.8–20.2 gCO 2e /MJ. For an improved switchgrass-to-ethanol conversion pathway with the maximum benefits from ecosystem services, the minimum ethanol selling price and carbon footprint of ethanol, respectively, could reach to 31 cents/$\scriptsize{L}$-gasoline-equivalent (47% reduction relative to average gasoline price) and 3 gCO 2e /MJ (97% reduction relative to gasoline). In conclusion, this low carbon renewable ethanol leads to substantial State and/or Federal policy incentives (~$\$$1/$\scriptsize{L}$-gasoline-equivalent) providing a large benefit to biorefinery operators, farmers, and the public as a whole.

09 BIOMASS FUELS↗
DOE OSTI2021

Preliminary Environmental and Financial Viability Analysis of Circular Economy Scenarios for Satisfying PV System Service Lifetime

PV deployment has grown rapidly in recent decades, and this growth is expected to continue. At the same time, the rapid increase in PV panel efficiencies offers the opportunity to repower/revamp existing installations - replacing operational, lower-efficiency panels before the end of their 30-year service lifetime with newer, higher-efficiency panels. As a result, an increasing volume of PV panels could be decommissioned well before reaching the end of their 30-year service lifetime. Two broad strategies can be applied to manage the expected increase in decommissioned PV panels: (i) recycle prematurely decommissioned panels, and (ii) prevent recycling of these panels by satisfying the typical service lifetime of 30 years through circular economy strategies such as repair and reuse. Each strategy presents an environmental and economic trade-off. Retaining and satisfying the lifetime of the older, lower-efficiency panels avoids environmental burdens from recycling or landfilling but incurs burdens from additional repair and forgoing the opportunity to install newer panels with greater electricity-generation capabilities. This study assesses whether satisfying the expected service lifetime of a PV system through circular economy scenarios generates a greater environmental and financial benefit than recycling used panels and installing newer panels with higher efficiencies. The circular economy scenarios include repair and reuse of the PV system. Specifically, the study determines whether it is better for the environment to keep a PV panel in use for its 30-year service life after accounting for potential repair and additional transportation, or to replace older panels with more efficient new ones. In addition, we explore whether satisfying the service lifetime of PV panels proves competitive with the recycling route from a financial perspective.

14 SOLAR ENERGY↗
DOE OSTI2024

Nuclear Thermal Energy Storage Configurations for Industrial Combined Heat and Power Supply: Conceptual Study and Engineering Designs

The industries examined in this report primarily rely on moderate-temperature heat provided by gas- or coal-fired boilers and combined heat and power (CHP) plants, delivered through standard process steam systems. High-temperature energy demands are often industry-specific and typically exceed the capabilities of high-temperature gas-cooled reactors (HTGRs). While it is technically feasible to replace process steam from fossil-based heat sources with nuclear energy, certain industries, such as methanol production and pulp and paper, face technoeconomic challenges in integrating nuclear energy without major changes or a technological shift. This is mainly due to the limited external energy demand remaining after the use of internal byproducts, waste heat recovery, and simple efficiency improvements. Achieving full decarbonization of these processes with nuclear energy would require significant technological advancements, involving experimental technology and substantial investments, making widespread adoption in existing industrial plants unlikely in the near term. This study reviews TES options in the context of enabling a flexible CHP supply while maintaining a steady nuclear heat input. Heat storage systems that interface between the reactor primary fluid and the CHP system offer superior performance and flexibility. Specifically, steam extraction downstream of the reheater with a two-tank molten-salt TES appears as the best solution regarding thermodynamic system benefits and system drawbacks. Using selected system configurations, a conceptual design of an industrial energy park was developed for industries with varying energy demands, such as steel production plants utilizing electric arc furnaces (EAFs) and chemical plants, as well as for those with constant energy demands, like petroleum refineries. This design highlights the capabilities of TES and explores its potential business cases. The study also conceptually develops the potential for integrating additional energy sources with nuclear systems through the implementation of TES. The potential of the HTGR-TES-CHP system was also evaluated considering key uncertainties such as industrial demand profiles, external grid access availability, and eligible tax credit levels, using the Holistic Energy Resource Optimization Network. Sensitivity of net present value to these uncertainties was analyzed to determine the optimal number of nuclear reactors (and CHP systems) and the suitable TES capacity. The results were interpreted from a decision-maker’s perspective, focusing on three key areas: deployment strategy (oversized units vs. undersized units with TES support), industrial process characteristics (thermal-intensive single profiles vs. electricity-intensive combined profiles), and operational goals (maximizing profits vs. minimizing natural gas (NG) consumption or external grid dependence). The optimization results indicate that the HTGR-TES-CHP system significantly reduces reliance on NG boilers for individual industrial processes by 9-60% (in NG capacity factor), with an average reduction of 38%, compared to standalone NG boiler operation case (Business As Usual [BAU]). For combined industrial processes, the reduction ranges from 37-77%, with an average of 60%. Additionally, the system greatly reduces dependence on external grids. In meeting industrial electrical demands, a 33-100% self-sufficient internal electricity supply is achieved for single industrial process, with an average of 74%, compared to the BAU scenario, where 100% of electricity is imported. For combined processes, 35-100% of internal electricity demands are met by the reactor, with an average of 73%. At last, the relative NG price levels at which the proposed HTGR-TES-CHP system can cost-effectively enter the market currently dominated by existing NG boilers were estimated. For a moderate HTGR CAPEX level ($\$$2500/kWth, $\$$6329/kWe), the analysis suggests that NG prices must be 2.5 to 7 times higher than HTGR variable operating and maintenance costs for single industrial process, and 5.5 to 9.5 times higher for a combined process scenario. Tax credit modeling shows that the Investment Tax Credit significantly reduces the price threshold needed to break even, making the system competitive with NG boilers in certain cases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗