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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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DOE OSTI2021

Developing Technology Performance Level Assessments for Early-Stage Wave Energy Converter Technologies: Preprint

The advantage of using Technology Performance Level (TPL) in conjunction with Technology Readiness Level (TRL) assessments in guiding technology development trajectories to successful outcomes in less time, at less overall cost, and with less encountered risk has been well articulated in the literature. In partnership with industry and international collaborators, a TPL assessment methodology for grid-connected applications has been developed through the application of the systems engineering approach. Metrics under seven different categories have been developed, weighted based on their relative relevance, and combined to yield a composite score. The methodology has been implemented in a spreadsheet tool plus a web application specifically aimed at assessing early stage (TRL 1-3) concepts. The target use cases are (a) technology developers improving their design, to find fatal flaws early, to get feedback on current design, to identify areas of improvement that will yield the highest return on investment, (b) reviewers assessing technologies in competitions or for making funding decisions, (c) investor or project developer doing due diligence, (d) policy makers landscaping the technology domain for formulating R&D strategy. The methodology and the tools are undergoing continuous improvement based on the experience and lessons learnt from applying it to internal and external marine energy technology development projects. The methodology is also being adapted for assessing WECs servicing markets outside the continental grid - broadly categorized as Powering the Blue Economy (PBE) applications. Such applications have vastly different functional requirements entailing a modification of the methodology to account for their higher risk tolerance, reduced price sensitivities, lower power needs, different permitting protocols, etc. This paper presents the latest status of the TPL assessment methodology and tools, describes its adaptation to select PBE markets, and explores its extension to other domains where it could provide a comprehensive and holistic measure of a nascent or disruptive technology's technoeconomic performance potential.

metrics↗
DOE OSTI2021

Developing Technology Performance Level Assessments for Early-Stage Wave Energy Converter Technologies

The advantage of using Technology Performance Level (TPL) in conjunction with Technology Readiness Level (TRL) assessments in guiding technology development trajectories to successful outcomes in less time, at less overall cost, and with less encountered risk has been well articulated in the literature. In partnership with industry and international collaborators, a TPL assessment methodology for grid-connected applications has been developed through the application of the systems engineering approach. Metrics under seven different categories have been developed, weighted based on their relative relevance, and combined to yield a composite score. The methodology has been implemented in a spreadsheet tool plus a web application specifically aimed at assessing early stage (TRL 1-3) concepts. The target use cases are (a) technology developers improving their design, to find fatal flaws early, to get feedback on current design, to identify areas of improvement that will yield the highest return on investment, (b) reviewers assessing technologies in competitions or for making funding decisions, (c) investor or project developer doing due diligence, (d) policy makers landscaping the technology domain for formulating R&D strategy. The methodology and the tools are undergoing continuous improvement based on the experience and lessons learnt from applying it to internal and external marine energy technology development projects. The methodology is also being adapted for assessing WECs servicing markets outside the continental grid - broadly categorized as Powering the Blue Economy (PBE) applications. Such applications have vastly different functional requirements entailing a modification of the methodology to account for their higher risk tolerance, reduced price sensitivities, lower power needs, different permitting protocols, etc. This paper presents the latest status of the TPL assessment methodology and tools, describes its adaptation to select PBE markets, and explores its extension to other domains where it could provide a comprehensive and holistic measure of a nascent or disruptive technology's technoeconomic performance potential.

metrics↗
DOE OSTI2020

Scaling Deep Energy Retrofits for Residential Walls - Energy, Cost, and Economic Assessment of Five Wall Systems

Providing strong economic and performance value is a primary challenge of convincing homeowners to implement deep energy retrofits to their wall systems. This study combines energy modeling and technoeconomic assessment of six experimental residential retrofit wall systems to typical existing homes in cold climates to evaluate their energy performance and cost effectiveness. Deep energy retrofits can significantly improve the energy performance of a home’s thermal envelope, help manage indoor environmental pollutants, increase homeowner comfort, increase building value, and register significant energy and cost savings in the process. We are evaluating exterior wall retrofit components and construction practices to measure and recommend steps to improve financial performance for manufacturers, installers and consumers. This study leverages a literature review, inputs from an advisory group made up of thermal enclosure experts, and simulations to identify state-of-the-art technologies for energy efficient wall systems that are suitable for cold and very cold climate zones. This paper will present results from energy modeling of six experimental wall systems compared to one baseline, that inform cost and energy performance of the subject wall systems.

Ganguli, Sumitrra↗
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 OSTI2022

Assessment Framework of Marine Hydrokinetic Technologies for Microgrid Applications

Communities in Alaska that are not connected to a regional grid (referred to hereafter as grid-islanded Alaskan communities) rely heavily on stand-alone generators with imported diesel fuel as the primary source of energy. Several of these grid-islanded Alaskan communities have the potential to harness significant wave, tidal, and hydrokinetic power; many also have hydropower or wind potential that could complement these resources. The implementation of marine and hydrokinetic energy focused microgrids in these communities would diversify their energy profiles, with the potential in many communities to keep costs flat while reducing dependance on diesel. This would enhance resilience and reduce environmental impacts. This seedling proposal will systematically identify grid-islanded coastal communities in Alaska with wave, tidal, and hydrokinetic energy potential to add fuel diversity to generation, applying microgrid integration methods and strategies that will meet the community’s needs. This proposal is in partnership with the Alaska Center for Energy and Power (ACEP) and XENDEE Corporation who bring extensive expertise in Alaskan communities and microgrid technoeconomic assessment, respectively. This project will deliver: (1) a database of grid-islanded communities that are candidates for MHK based microgrids, (2) an assessment of possible microgrid integration methods and strategies related to tidal, wave, and hydrokinetic technologies, and (3) a MHK development plan for the XENDEE Microgrid design platform and planning tool that can serve these grid-islanded communities and project developers. In the final stage, the planning tool will allow for the comprehensive comparison between diesel based and MHK based renewable generation.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

High Temperature Steam Electrolysis Process Performance and Cost Estimates - DOE Hydrogen Program AMR Presentation

Technology readiness levels (TRLs) of electrolysis systems have dramatically increased in recent years as the interest in clean hydrogen production and decarbonization of transportation, industrial and other sectors increases across the globe. This is especially true of high temperature steam electrolysis (HTSE) / solid oxide electrolysis cell (SOEC) systems which show promise of much higher system efficiencies than other more developed electrolysis technologies. This possibility of higher efficiencies of HTSE / SOEC systems has been previously assumed to be theoretically possible but in recent years it has become less theoretical and more realistic as an increasing amount of suppliers complete lab and pilot tests showing very promising results. Research in the areas of manufacturing techniques, material selection, electrode and electrolyte compositions, and balance of plant size and integration continues at a fast pace as an increasing number of suppliers both internationally and domestically become involved. The advantages of HTSE become more pronounced when HTSE is coupled with nuclear power plants (NPPs). This is because thermal energy produced by the nuclear reactor can be used in a series of heat transfer loops and heat exchangers to vaporize HTSE feedwater, which drastically improves the economics of the process. Idaho National Laboratory (INL) has been very involved in the research and modeling of HTSE systems for a number of years, in collaboration with other national laboratories, academia, and industry stakeholders both on the hydrogen production as well as the hydrogen demand side. The modeling completed over the years on a large variety of projects has led to a wealth of knowledge at INL including in the area of the technoeconomic assessment (TEA) of HTSE systems. TEAs include process modeling of the HTSE systems to calculate system energy requirements and equipment sizing, followed by estimation of capital and operating costs to enable calculation of the levelized cost of hydrogen (LCOH). The TEA work performed has produced incremental improvements and tuning of the methods, assumptions, models, and results of the analyses as well as providing some opportunities for validating these results. The purpose of this document is to record the current baseline HTSE analyses led by INL to show the current status of assumptions and costs of these systems. Given the rapid development of this technology, the variety of suppliers entering the space, and the increasing attention government and industry are giving to such systems, this document may be updated on a periodic basis with updated analysis and assumptions. This document compiles various analyses results and approaches completed over a period of years into a single document to be used as a baseline going forward. It represents what the INL HTSE analysis group assumes to be the internal best estimate of the current operation, costs, and landscape of the HTSE industry state of the art capability for current SOEC technology in an Nth-of-a-Kind (NOAK) plant, which in this study is defined as existence of the manufacturing capacity to support previous deployment of N = 100 count of 25 MWe modular HTSE blocks (with modular equipment component cost reductions specified as following a 95% learning curve). That said, this is a public document and as such so no proprietary data was used or included in this report. There may be HTSE suppliers that have performance specifications, and cost estimates, and test data that differ from the analysis presented in this document. This document is meant to be a best conservative estimate of the technology and not an absolute reference.

08 HYDROGEN↗
DOE OSTI2022

Electrochemical Mitigation of Corrosion in Molten Chloride Salts During CSP Plant Operation

We are designing an electrochemical flow-cell for removal of corrosive impurities from molten chloride salt Gen3 Concentrating Solar Power (CSP) plants during plant operation. Corrosive impurities will inevitably form in molten chloride salts upon exposure to air and moisture. We previously showed that even small amounts of these impurities, especially MgOHCl, will be detrimental in Gen3 CSP plants, necessitating prohibitively expensive containment alloys and frequent replacement of corroded components. Pre-purification of salt with Mg metal at temperatures above 650 degrees C is the current method for removing corrosive impurities from chloride salts before they are introduced to CSP systems. However, this is not a suitable method for impurity removal during plant operation. First, this method will produce MgO particulates which will damage plant components. Second, Mg metal is solid at the low temperature point (500 degrees C), so the purification will not proceed at a fast rate. At the high temperature point, Mg is soluble. In this case, fast purification may proceed, but dissolved metal is likely to precipitate out in cold-temperature point components, causing damage. In contrast, our electrochemically driven method allows fast Mg-based purification to proceed at the low temperature point, without formation of harmful particulates and without the risk of Mg metal precipitation. This novel approach is inspired by electrorefining techniques that are widely employed in industrial metallurgy for removal of impurities from metals. Impurities in the incoming molten salt will be reduced to inert MgO at the cathode, which can be removed by periodically washing the cell with acid. Simultaneously, Mg dissolution at the anode will ensure salt composition is maintained, with no net removal of Mg2+. We have validated this electrochemical approach at lab scale under static conditions with batch rectors. Furthermore, we have performed analytical modeling and technoeconomic analysis to produce a preliminary engineering design for the purification flow cell.

CSP↗
DOE OSTI2022

Additional Analysis of Carbon Capture at Industrial Facilities

This poster provides summary cost details for a technoeconomic analysis of CO2 capture from flue gas generated by cement plants, conducted by U.S. Department of Energy National Energy Technology Laboratory and presented at the 2022 Carbon Management Project Review Meeting held in Pittsburgh, PA (August 15-19, 2022). A range of modern cement plant configurations was considered, along with different fuel types (coal, coke, and natural gas) and two levels of CO2 capture (95% and 99%). The sensitivity of capture cost to a range of modeling assumptions (such as fuel price, financing assumptions, utilization rate, and plant size) was also conducted, to show possible cost ranges that could be expected for decarbonization of typical cement plants in the U.S.

Hughes, Sydney↗
DOE OSTI2022

Solar and Storage Techno-Economic Analysis Tutorial for the IEEE Photovoltaic Specialist Conference (PVSC)

This tutorial will highlight the most recent efforts from the National Renewable Energy Laboratory (NREL) to track solar photovoltaic (PV) technology trends and manufacturing costs, project levelized cost of electricity (LCOE), and project levelized cost of solar plus storage (LCOSS) for systems across the globe. We will begin with an overview of the global PV supply chain and 2021 benchmark input data for NREL's crystalline silicon (c-Si) and thin film PV module manufacturing cost models. The framework that we follow and will review during this tutorial provides a methodology to prepare bottom-up manufacturing cost models including the items within the U.S. Generally Accepted Accounting Principles (GAAP) and the International Financial Reporting Standards (IFRS). For the polysilicon, wafer, cell conversion, and module assembly steps of the c-Si supply chain, and for thin film modules, we will review input data and methods useful for calculating the costs of goods sold (COGS); research and development (R&D) expenses; and sales, general, and business administration (S, G, &A) expenses. This 2021 benchmark analysis is compiled for state-of-the-art c-Si and thin film module manufacturing. We will also review methods for our 2021 system benchmark costs calculations and LCOE technoeconomic analysis of PV systems and solar plus storage systems. Next generation technologies that lower PV manufacturing and installation costs, reduce operations and maintenance (O&M) expenses, and improve system energy yield will also be highlighted. Techniques for comparing LCOE performance will also be reviewed. We look forward to sharing NREL's extensive work in these areas and discussing ideas for future directions.

cost models↗
DOE OSTI2022

HOPP - Hybrid Optimization and Performance Platform

The Hybrid Optimization and Performance Platform, HOPP, is a wind + solar + battery + X design software for optimizing co-located, utility-scale hybrid plants down to the component level for different markets and technoeconomic objectives. Key technology and financial inputs to the HOPP model that inform the objective to be optimized are presented. The layout and performance integration is combined with optimal dispatch and full financial modeling within an optimization framework. With an example scenario, optimal sizing and layout results are shown in a sensitivity analysis of prices for two hybrid configurations.

batteries↗
DOE OSTI2023

Techno-Economic Analysis of Dynamic Building Envelopes Comprising Phase Change Materials and Switchable Insulations: Preprint

Integrating phase change materials (PCMs) in building envelopes is a recognized technique to reduce the space heating/cooling loads and provide load shedding and shifting capacity. However, PCM benefits have been found to reduce dramatically with increase in the insulation requirements. Dynamic building envelopes that can alter their thermal resistance based on the indoor and outdoor conditions can effectively harness free ambient heating/cooling, thereby greatly enhancing the benefits of the PCM-integrated envelope in managing thermal loads. In this study, we examine various combinations of PCMs and switchable insulations and compare their combined impact on heat flow through the building envelope. Using numerical analysis, we investigate the PCM- and switchable insulation-integrated building walls, calculate the potential energy saving benefits compared to the conventional static walls, and finally perform technoeconomic analysis to estimate the acceptable cost of the technology under various payback period scenarios.

dynamic building envelopes↗
DOE OSTI2023

NETL Direct Air Capture Center

In 2022 Congress authorized the $25M National Energy Technology Laboratory Direct Air Capture Center. The facility will be specifically targeted at accelerating the commercialization of technologies beyond the conceptual stage which have not yet reached full pilot-scale (TRL 3 to 6). The ability to operate over a wide range of conditions will help the developers to understand how their technologies respond in different climates, from summer to winter and arid to tropical. NETL recognizes that DAC technology is still early in its evolution, and a wide variety of highly varied technologies are being explored. The Center will be designed with substantial flexibility to accommodate the rapidly evolving technological landscape. Testing systems at three scales will be included: lab-scale systems designed to examine the long-term stability of DAC materials, bench-scale module testing systems capable of probing flow dynamics, and small pilot-scale skid rooms able to test prototype DAC units under a wide variety of climate conditions. The NETL DAC Center will feature dedicated engineering, technician, scientific and logistical support for experimental system design, installation, operation of experiments, and interpretation of results for projects including but not limited to kinetics of absorption/desorption, thermal duty, and post-mortem elemental characterization to understand degradation. The NETL DAC Center projects will also have access to dedicated process modeling and analysis to evaluate the technoeconomic aspects of new technologies. NETL’s Systems Engineering and Analysis (SEA) team, the Carbon Capture Simulation Initiative (CCSI), and the Institute for the Design of Advanced Energy Systems (IDAES) are all potential collaborators with NETL’s testing partners from industry, academia, and other research institutions. NETL also has world class capabilities in device scale modeling (i.e., MFIX) that will be available to help design more efficient contactors and optimize unique internal configurations that can be realized by advanced manufacturing. The talk will cover the design and capabilities of the center, the planned availability, and feedback will be solicited from the audience on DAC testing needs.

Luebke, David↗
DOE OSTI2023

Machine-Learning Assisted Identification of Battery Life Models

Predictive battery life models are commonly utilized to extrapolate degradation trends observed during accelerated aging tests for simulation of degradation in real-world applications. Thus, fitting accelerated aging data as accurately as possible and with low uncertainty is crucial for making believable projections of battery lifetime, but it is challenging to identify algebraic expressions that accurately fit multivariate degradation trends. A review of models published in literature reveal some common expressions for fitting calendar aging data, which is only dependent on temperature and state-of-charge, but no consistency across many models for fitting cycle aging data, indicating the need for a statistically rigorous data driven approach for developing empirical models. This talk will describe a machine-learning assisted method for identification of predictive battery life models utilizing bilevel optimization and symbolic regression. Bilevel optimization with cross-validation is used to statistically determine cell- and stress-dependent model parameters, while symbolic regression identifies both linear and multiplicative candidate expressions to predict stress-dependent degradation rates by selecting low-order subsets of features from a generated feature library. Because model expressions are identified empirically, it is crucial to ensure resulting models behave according to physical expectations, so the stability of models for interpolation or extrapolation is interrogated qualitatively through simulation and quantitatively through cross-validation and uncertainty quantification via bootstrap resampling. This model identification approach substantially improves upon models identified purely using expert judgement in terms of both accuracy and uncertainty. Model simulation and validation is then conducted by deriving a state-equation form of the predictive model, enabling simulation of battery aging under dynamic stresses. This enables validation of the predictive battery model on lab-based tests with varying conditions or on drive-cycle or application-cycle testing protocols. Parameter uncertainty can be carried forward into model simulation, giving lifetime estimates and confidence windows for cell- or system-level lifetime. The financial impact of battery model uncertainty can be estimated by incorporating uncertainty into a technoeconomic model.

battery↗
DOE OSTI2023

Accelerating commercialization of direct air capture technology

In 2022 Congress authorized the $25M National Energy Technology Laboratory Direct Air Capture Center. The facility will be specifically targeted at accelerating the commercialization of technologies beyond the conceptual stage which have not yet reached full pilot-scale (TRL 3 to 6). The ability to operate over a wide range of conditions will help the developers to understand how their technologies respond in different climates, from summer to winter and arid to tropical. NETL recognizes that DAC technology is still early in its evolution, and a wide variety of highly varied technologies are being explored. The Center will be designed with substantial flexibility to accommodate the rapidly evolving technological landscape. Testing systems at three scales will be included: lab-scale systems designed to examine the long-term stability of DAC materials, bench-scale module testing systems capable of probing flow dynamics, and small pilot-scale skid rooms able to test prototype DAC units under a wide variety of climate conditions. The NETL DAC Center will feature dedicated engineering, technician, scientific and logistical support for experimental system design, installation, operation of experiments, and interpretation of results for projects including but not limited to kinetics of absorption/desorption, thermal duty, and post-mortem elemental characterization to understand degradation. The NETL DAC Center projects will also have access to dedicated process modeling and analysis to evaluate the technoeconomic aspects of new technologies. NETL’s Systems Engineering and Analysis (SEA) team, the Carbon Capture Simulation Initiative (CCSI), and the Institute for the Design of Advanced Energy Systems (IDAES) are all potential collaborators with NETL’s testing partners from industry, academia, and other research institutions. NETL also has world class capabilities in device scale modeling (i.e., MFIX) that will be available to help design more efficient contactors and optimize unique internal configurations that can be realized by advanced manufacturing. The talk will cover the design and capabilities of the center, the planned availability, and feedback will be solicited from the audience on DAC testing needs.

Luebke, David↗
DOE OSTI2023

Evaluation of Composite Materials for Heliostat Cost Reduction

This is an evaluation of composite materials for heliostat cost reduction, including the motivation, reference heliostat model, characteristic wind loads, selection of pultruded structural composites, and technoeconomic analysis using equivalent deformation.

composite materials↗
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↗