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DOE OSTI2026

Transformative Efficiency and Automation in Modular Homes (TEAMH)

This report documents the Transformative Efficiency and Automation in Modular Homes (TEAMH) project, which evaluates the integration of advanced building envelope technologies and automation-assisted modular construction to improve residential energy performance and construction efficiency. The study investigates high-performance insulation systems, including vacuum insulation panels (VIPs), combined with light gauge steel (LGS) modular construction and factory automation. Laboratory testing, whole-building energy modeling across multiple climate zones, and factory demonstrations were conducted to assess thermal performance, energy savings, and production efficiency. Results indicate that upgraded envelope assemblies can achieve up to ~50% heating and ~34% cooling energy savings relative to IECC 2018 code-compliant homes, while automation-assisted construction can reduce wall assembly time by 24%–46% compared to conventional wood framing. The findings demonstrate the potential for scalable, high-performance modular homes that deliver significant energy savings with competitive projected costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Corrosion-Resistant Plug Materials for Geothermal Well Fluid Control

Conventional cements and plugs are challenged by corrosion in CO 2 -rich and extreme geothermal environments, due to the hostile chemistry and high temperatures. Thermite-based sealing and well intervention technologies are being applied in the oil and gas industry, combining the energy delivery capability of thermite materials with the sealing characteristics of low melt temperature alloys. The thermite reaction products (ceramics) and the sealing alloys used in these plugs both have very attractive corrosion properties, and their operating envelopes extend into geothermal conditions. Thermite plugs and platforms, without supplemental sealing materials, have been considered for nuclear waste isolation, carbon sequestration, and geothermal applications due to the geochemical stability of the ceramic product and its very high service temperature. This study addresses corrosion resistance of the thermite reaction products. A range of engineered thermite systems which yield thermite reaction products including pure aluminum oxide, feldspar, or aluminosilicate solid solutions (in addition to the iron produced in thermite reactions) was developed. These materials were evaluated for their strong acid resistance (pH 1), carbonate resistance (sodium carbonate) and thermal shock resistance (600 °C heating → cold water quenching repeated three times). Performance of different materials was evaluated based on the changes in mechanical properties, water-fillable porosity, phase changes under stress conditions. The aluminosilicate product exhibited very good corrosion resistance, both from material loss and strength perspectives, while the other products performed with varying degrees of stability. This paper presents the results of the thermite corrosion studies and describes the novel tools being deployed, and under development, to satisfy challenging barrier and intervention applications.

02 PETROLEUM↗

DOE OSTI2021

Fuel Property Effects of a Broad Range of Potential Biofuels on Mixing Control Compression Ignition Engine Performance and Emissions

Conventional diesel engines will continue to hold a vital role in the heavy- and medium-duty markets for the transportation of goods along with many other uses. The ability to offset traditional diesel fuels with low-net-carbon biofuels could have a significant impact on reducing the carbon footprint of these vehicles. A prior study screened several hundred candidate biofuel blendstocks based on required diesel blendstock properties and identified 12 as the most promising. Eight representative biofuel blendstocks were blended at a 30% volumetric concentration with EPA certification ultra-low-sulfur diesel (ULSD) and were investigated for emissions and fuel efficiency performance. This study used a single cylinder engine (based on the Ford 6.7L engine) using Conventional Diesel Combustion (CDC), also known as Mixing Control Compression Ignition (MCCI). The density, cetane number, distillation curve and sooting tendency (using the yield sooting index method) of the fuels were measured. Start of injection (SOI) timing and exhaust gas recirculation (EGR) sweeps were conducted at three separate speed-load operating points to examine fuel effects on the NOX/soot and NOX/efficiency trade-offs as well as to evaluate EGR tolerance. The results show that the biofuel blends all reduced NOX and soot emissions without penalty to engine efficiency, even improving efficiency for some of the blends at certain points, with one particular blend of polyoxymethylene ethers (POMEs) improving efficiency at all points while drastically reducing soot by 79%.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Constraint-dependent CTOA determination for stable ductile crack growth

The crack tip opening angle (CTOA) has been used as a reliable fracture toughness to characterize stable crack growth for thin-wall structures in low-constraint conditions. Recently, it is found that CTOA can also be utilized as a robust fracture parameter to describe the arrest fracture toughness for gas transmission pipelines in ductile steels. For better understanding the concept of CTOA, this paper presents a brief review on the CTOA definitions and its test methods. And then, four CTOA models are developed for determining the CTOA toughness using conventional single edge notched bend (SENB) specimens, including the load–displacement linear fit model, the logarithmic load–displacement linear fit model, the stable tearing energy model, and the J-differentiation model. Here fracture test data from SENB specimens in A285 carbon steel are employed to evaluate the proposed CTOA models. The results show that these CTOA models can determine either identical or comparable critical CTOA values for stable ductile crack growth using the SENB specimens. A constraint-corrected CTOA resistance curve and a constraint-corrected critical CTOA equation are also obtained for A285 carbon steel.

42 ENGINEERING↗

DOE OSTI2021

Comprehensive process and environmental impact analysis of integrated DBD plasma steam methane reforming

Utilization of electricity generated from renewable sources to obtain hydrogen, H 2 , is of critical importance to decrease the overall carbon footprint. Here in this work, integration of a dielectric discharge barrier (DBD) plasma reactor to convert low calorific value gas, such as landfill gas or coal mine gas into hydrogen, into the existing steam methane reforming (SMR) technology was evaluated using process design considerations. In particular, a DBD-enhanced catalytic SMR reactor was modeled to operate at near atmospheric pressure and 500 °C sequentially with the conventional reformer to obtain ~ 65 kmol/hr H2 for distributed production. This allowed decreasing the size of the conventional reformer albeit at the increased overall electricity consumption. Calculated process economics showed that only at an electricity cost of less than $0.004/kWh does the hybrid DBD plasma process derived H 2 price become competitive with that of the conventional SMR. A Life Cycle Assessment framework was used to compare environmental impacts from the conventional SMR, hybrid DBD SMR and hybrid DBD SMR utilizing only onshore wind-derived electricity. Larger environmental impacts in the plasma reformer were obtained due to the use of electricity for the plasma reforming operation, which was modeled as coming from the typical U.S. grid mix. Utilizing only 100% wind-derived electricity provided certain environmental benefits, except for the ecotoxicity impact where the wind power scenario modeled here only reduced ecotoxicity impacts associated with electricity by 30%.

08 HYDROGEN↗

DOE OSTI2021

A Detailed Vehicle Modeling & Simulation Study Quantifying Energy Consumption and Cost Reduction of Advanced Vehicle Technologies Through 2050

The U.S. Department of Energy (DOE) Vehicle Technologies Office (VTO) and Hydrogen and Fuel Cell Technologies Office (HFTO) aim to develop sustainable, affordable, and efficient technologies for transportation of goods and people. Translating investments in advanced transportation component technologies and powertrains to estimate vehicle-level fuel savings potential is critical for understanding DOE’s impact. In this work, we simulated technologies funded by VTO and HFTO for light duty vehicles. The simulations were performed across: (1) Multiple powertrain configurations (conventional, power-split, extended-range electric vehicle, battery electric drive, and fuel-cell vehicles); (2) Vehicle classes (compact car, midsize car, small sport utility vehicle [SUV], midsize SUV, and pickup trucks); and (3) Fuels (gasoline, diesel, natural gas, hydrogen, and battery electricity). These various technologies are assessed for six different timeframes: laboratory years 2015 (reference), 2020, 2025, 2030, and 2045. A delay of five years is assumed between laboratory year and model year (the year the technology is introduced into production).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

EIA Thermoelectric Water Cooling Data

The U.S. Energy Information Administration (EIA) collects water cooling data for the electric power industry in the United States. This submission includes annual data from 2014 to 2019. Each spreadsheet details the generator type, fuel consumption, water consumption, cooling type, and equipment status, location, and water source for each plant.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Optimization of energy requirements for CO 2 post-combustion capture process through advanced thermal integration

The energy optimization modeling work described here was performed to determine efficiency improvements that could be achieved for existing coal-fired power plants to retrofit a partial CO 2 capture from the post-combustion flue gas for carbon sequestration through thermal integration. The work presented includes optimization of the mono-ethanol amine (MEA)-based post-combustion CO 2 capture to reduce energy requirements that could be achieved at existing power plants by thermal integration of the steam turbine cycle, boiler, CO 2 compression train and post-combustion CO 2 capture process to offset efficiency and capacity losses that would be incurred by retrofit or implementation of post-combustion CO 2 capture. Furthermore, partial CO 2 capture, involving treatment of less than 100% of the flue gas leaving the plant and modular design of the CO 2 scrubbing system, was also investigated. Thermal integration of the steam turbine cycle with boiler and CO 2 compression train improved cycle and plant performance and offset, in part, the negative effects of post-combustion CO 2 capture. The best-analyzed integration options improved gross power output by 5% and net unit efficiency by 1.57%, relative to the conventional MEA process. Operating with 40% CO 2 capture increased gross power output by 11.6–14% (depending on the MEA thermal integration option), relative to the conventional MEA integration and 90% CO 2 capture. The improvement in net unit performance is larger compared to the improvement in turbine cycle performance because of the CO 2 compression work, which is also reduced by partial CO 2 capture.

42 ENGINEERING↗

DOE OSTI2024

A Multidisciplinary Approach to Integrated Energy Systems: Advanced Nuclear Plants with Thermal Storage for Dynamic and Flexible Operation in Diverse Markets

Energy supply, distribution, and demand are continuously evolving in accordance with the integration of new power generation sources. In the United States, there is a progressive shift toward incorporating fluctuating energy sources such as wind and solar into the energy mix, alongside the distributed generation. Simultaneously, we are seeing a revolution in consumer technologies such as electric vehicles, energy devices for both residential and commercial use, and industrial processes—all contributing to a fundamental change in energy consumption dynamics. These scenarios have led to huge demand for enhanced flexibility from nuclear power plants (NPPs), requiring them to operate with unprecedented adaptability. Furthermore, advanced NPPs (A-NPPs) could potentially apply to scenarios in which power generation flexibility is prioritized over its current and conventional baseload generation capacity for traditional demand patterns. The present work covers several configurations for coupling nuclear energy production with thermal energy storage (TES). Previous work evaluated systems entailing a simple nuclear-TES configuration that used steam as a heat source for the TES of three different advanced reactors (ARs), but its heat diversion ratio (HDR) for charging was limited. The present work proposes a new configuration that features full decoupling of the nuclear reactor and the power cycle, using reactor coolant (i.e., gas) as a heat source for the TES and offering a theoretically unlimited HDR. This configuration is, however, more complex, as both high- and low-temperature TES (HT-TES and LT-TES) systems are required in order to cover the extended temperature range. Although this configuration imposes certain limitations on the discharge system configuration, it also presents the opportunity to design a more efficient system. For this case in particular, a steam reheat cycle is advantageous. Conventional TES systems take advantage of nominal efficiency when discharging, whereas the reheat cycle in the fully decoupled TES system affords a significant efficiency increase over conventional cases. Material selection, component/equipment sizing, and costing analyses were performed, followed by economic dispatch and size optimization. Dynamic models were developed for the decoupled system in order to generate insights into aspects of off design operation (e.g., drops in cycle efficiency), and these models enable exploration of potential mitigation strategies for addressing such drops. The models also highlight the need to design fail-safes that ensure continuous operational stability and minimize the impact of power ramping on the reactor parameters.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Integrated Reference Electrodes in Anion-Exchange-Membrane Electrolyzers: Impact of Stainless-Steel Gas-Diffusion Layers and Internal Mechanical Pressure

Alkaline-membrane electrolyzers operating in pure water might provide scalable low-cost H 2 production but currently lag in performance and durability compared to commercial technologies. Typically, membrane–electrode assemblies (MEAs) are optimized in electrolyzers by changing one parameter at a time and assessing the resulting system performance via two-electrode polarization and impedance measurements. These approaches are limited in their ability to assign performance changes and durability to specific electrodes or processes. We integrate a reference electrode with the MEA to separate anode and cathode responses in both polarization and impedance measurements. Here we illustrate the power of the approach by showing how the fiber diameter of stainless-steel gas-diffusion layers (GDLs) affects performance solely at the anode, while changing the thickness of the cathode GDL simultaneously affects the performance of the anode and cathode due to changes in internal pressure from mechanical compression. This finding was obscured in conventional two-electrode measurements. The work thus guides both high-performance alkaline-membrane water-electrolyzer development and illustrates a useful strategy to study structure–activity relationships in the MEA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Unconventional excited-state dynamics in the concerted benzyl (C7H7) radical self-reaction to anthracene (C14H10)

Abstract Polycyclic aromatic hydrocarbons (PAHs) are prevalent in deep space and on Earth as products in combustion processes bearing direct relevance to energy efficiency and environmental remediation. Reactions between hydrocarbon radicals in particular have been invoked as critical molecular mass growth processes toward cyclization leading to these PAHs. However, the mechanism of the formation of PAHs through radical – radical reactions are largely elusive. Here, we report on a combined computational and experimental study of the benzyl (C 7 H 7 ) radical self-reaction to phenanthrene and anthracene (C 14 H 10 ) through unconventional, isomer-selective excited state dynamics. Whereas phenanthrene formation is initiated via a barrierless recombination of two benzyl radicals on the singlet ground state surface, formation of anthracene commences through an exotic transition state on the excited state triplet surface through cycloaddition. Our findings challenge conventional wisdom that PAH formation via radical-radical reactions solely operates on electronic ground state surfaces and open up a previously overlooked avenue for a more “rapid” synthesis of aromatic, multi-ringed structures via excited state dynamics in the gas phase.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Non-disruptive error field identification based on magnetic island healing

Here a technique to identify intrinsic error fields (EFs) in tokamaks with minimized risk of disruption is demonstrated on the DIII-D tokamak. The method extends the conventional driven magnetic island ‘compass scan’ approach by modifying asynchronous control waveforms to enable prompt healing of the island instability. Healing of the island is achieved by reducing the imposed non-axisymmetric coil current and raising the density (here via gas fueling). The method is also shown to support multiple island threshold measurements per pulse, thus reducing the number of dedicated pulses necessary to conduct an EF identification. Non-linear modeling with the TM1 code reproduces the experimental results and approximately recovers the critical density required for island healing. Island healing is explained in the non-linear modeling by an increase in the viscous coupling between the static island and the nearby flowing plasma, thus healing the island as it accelerates into the plasma frame. Due to both simplicity and risk minimization, this technique is suitable for plasma-based EF identification in the early commissioning stages of future disruption-averse tokamaks such as ITER and SPARC.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Single-shot spatiotemporal plasma density measurements with a chirped probe pulse

In this work, we present the development and demonstration of a diagnostic for the measurement of the spatial and temporal evolution of plasma density in a single shot. Single-shot Advanced Plasma Probe HolographIc REconstruction (SAPPHIRE) utilizes a chirped probe pulse, a diffractive optical element, a self-referenced interferometer, and an interference bandpass filter to achieve high-fidelity electron density measurements suitable for underdense plasmas that exhibit cylindrical symmetry. The method overcomes limitations in conventional diagnostics, such as reliance on shot-to-shot reproducibility, while capturing plasma dynamics on picosecond timescales with micron-level spatial resolution. The capabilities of SAPPHIRE are demonstrated through measurements of laser-driven plasma channels in helium–nitrogen gas jets. SAPPHIRE demonstrates the formation and expansion of plasma channels in a single shot and the propagation of supersonic ionization fronts while revealing shot-to-shot variations in the plasma profiles. Experimental results are validated against theoretical models and scaling laws, underscoring the robustness and accuracy of this technique. By enabling ultrafast, high-resolution plasma diagnostics in a single exposure, SAPPHIRE represents a transformative advancement in plasma measurement technology.

Grace, Elizabeth S. [Lawrence Livermore National L↗

DOE OSTI2023

Gradient Amine Sorbents for Low Vacuum Swing CO 2 Capture at Ambient Temperature

The growing concerns over CO 2 emissions have led to the development of various methods for CO 2 capture. CO 2 capture by amine-based sorbents has been achieved by temperature (thermal) swing adsorption (TSA) process, pressure swing adsorption (PSA) process, and temperature pressure or vacuuming swing adsorption (TPSA or TVSA) process for CO 2 capture. Amine sorbents for energy-efficient TSA, PSA, VSA, TPSA or TVSA CO 2 capture should possess a capability which allow adsorbed CO 2 to desorb and amine sorbent to be regenerated at low temperatures or low vacuums. Development of such amine sorbents would significantly decrease energy consumption and sorbent degradation during the regeneration step. The objective of this project is to develop a low vacuum swing adsorption (VSA) process for the capture of CO 2 from air. The focus is on the development of amine sorbent which allows CO 2 to adsorb in the form of weakly adsorbed CO 2 . The weakly adsorbed CO 2 species can be collected from the sorbent by applying a low vacuum at ambient temperature. Specifically, no heating (i.e., thermal energy) is needed for regeneration of amine sorbents. This novel sorbent allows VSA to be operated at ambient temperature without a significant energy demand. This process eliminates the energy-intensive heating and cooling process in temperature swing adsorption (TSA) process. Ambient temperature operation could prolong the lifetime of sorbent and minimize the maintenance cost. Extensive sorbent studies with in-situ infrared spectroscopy have revealed the modifications of conventional amine sorbents with additives can increase the fraction of weakly adsorbed CO 2 . The amine sorbents with loaded CO 2 can be regenerated in part by the following approaches: (i) mild heating to temperatures below 70 °C, (ii) flowing purging gas over modified amine sorbents at temperatures below 40 °C, (iii) vacuuming at pressure below 0.2 atm and temperatures below 40 °C. The performance of these modified amine sorbents has been tested in a 60 grams VSA unit at ambient temperatures. The results show that weakly adsorbed CO 2 which can be desorbed from modified amine sorbents with purging gas at 100 cc/min can also be evacuated at a vacuum of 1 psia at room temperature. A preliminary techno- economic analysis indicates the major cost of the VSA process with modified amine sorbents stems from the operation of vacuum pumps. Thus, developing an excellent sealing with minimum leakage for the VSA unit is the most critical task for further the development of this VSA technology.

36 MATERIALS SCIENCE↗

DOE OSTI2025

ROTA-CAP™: An Intensified Carbon Capture System Using Rotating Packed Beds (Final Scientific/Technical Report)

GTI Energy and Carbon Clean Solutions Limited successfully designed, constructed, and operated an integrated ROTA-CAP carbon capture skid. ROTA-CAP™ is a process intensification technology, applied for post-combustion carbon capture, which utilizes the centrifugal forces generated from rotation of rotating packed beds as well as advanced solvents to achieve increased mass transfer rates 1-2 orders of magnitude higher than conventional columns while substantially decreasing footprint. The test skid, which consisted of a dual stage RPB absorber with external interstage cooling and a single stage RPB regenerator, was operated at capacities up to 0.5 tonne/day of CO 2 capture with flue gas concentrations ranging from 4% to 22% CO 2 by vol. CO 2 removal rates greater than 95% were achieved, with CO 2 product purity also exceeding 95% by vol. Over 1,600 hours of operation were accumulated throughout the project, including over 1,000 hours of operation of the with real flue gas containing at least 9.8% CO 2 by vol. The skid was operated continuously for 24 hours per day and 7 days per week over the course of 7 long-term test campaigns, with the campaigns ranging from approximately 2-4 weeks per campaign. A techno-economic analysis was performed, and a cost of capture of $\$$41.18/tonne CO 2 was calculated for the ROTA-CAP process, compared to $\$$45.75/tonne for a Cansolv-based process. These results show a cost reduction of approximately 10% compared to the Cansolv-based process. Although this still exceeds the target cost of capture of $\$$30/tonne specified for this project, GTI expects that the cost of capture can be further reduced through further optimization of the design and technology. GTI also performed an engineering design review to determine the scale-up potential of the technology, with the results of the preliminary assessment indicating that it appears to be feasible to scale up the RPB technology to 4,000 TPD. It was also determined that both horizontal and vertical rotor orientations are feasible, though there are mechanical advantages to the vertical orientation.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2026

Photo-Reactive Amine-Based Direct Air Capture and Conversion of CO2

This study presents a novel photochemical approach to direct air capture (DAC) and CO2 conversion, utilizing a ruthenium-modified mesoporous TiO2 composite infused with linear polyethyleneimine (L-PEI) and enhanced by light absorbing and earth abundant titanium nitride (TiN). This light-activated system operates at ambient pressure and addresses long-standing challenges in conventional amine-based thermal reactive carbon capture (RCC), including amine degradation and CO2 slip. Our findings demonstrate that L-PEI effectively stabilizes CO2 adsorption and facilitates high-yield methanation over 50 cycles with a non-flammable forming gas mixture (approximately 5% H2). Comparatively, composites incorporating small-molecule amines exhibited poor stability under illumination, while highly mobilie branched PEI (B-PEI) formulations suffered from significant catalyst deactivation. A technoeconomic analysis suggests that methane synthesis via this platform could be achieved at costs below $5/kg under current electrocatalytic hydrogen pricing. These findings highlight the potential of this approach to enhance energy security by enabling decentralized, scalable fuel production from atmospheric CO2.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Spatiotemporal variations of albedo in managed agricultural landscapes: inferences to global warming impacts (GWI)

Albedo can be used to quantify ecosystem and landscape contributions to local and global climate. Such contributions are conventionally expressed as radiative forcing (RF) and global warming impact (GWI). We contextualize our results within landscape carbon production and storage to highlight the importance of changes in albedo for landscape GWI from multiple causes, including net ecosystem production (NEP) and greenhouse gas (GHG) emissions. Objective To examine the spatiotemporal changes in albedo (Δα) in contrasting managed landscapes through calculations of albedo-induced RF (RF Δα ) and GWI (GWI Δα ) under different climatic conditions. Methods We selected five contrasting landscapes within the Kalamazoo River watershed in southern Michigan USA as proof of concept. The daily MCD43A3 MODIS (V006) product was used to analyze the inter- and intra-annual variations of growing season albedo. In addition, the variations of RF Δα and GWI Δα were computed based on landscape composition and climate. Results The RF Δα (-5.6 W m -2 ) and GWI Δα (-1.3 CO 2eq ha -1 year -1 ) were high in forest-dominated landscapes, indicating cooling effects and CO 2eq mitigation impacts similar to crops. The CO 2eq mitigation of cropland-dominated landscapes was on average 52% stronger than forest-dominated landscapes. In the landscape with the highest proportion of forest, under dry and wet conditions CO 2eq mitigation was reduced by up to 24% and ~ 30%, respectively; in one cropland-dominated landscape wet conditions reduced CO 2eq mitigation by 23%. Conclusions Findings demonstrate that quantifying spatiotemporal changes in albedo in managed landscapes and under different climatic conditions is essential to understand how landscape modification affects RF Δα and GWI Δα and thereby contributes to ecosystem-level GWI.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

High Energy Systems for Transforming CO 2 to Valuable Products (Final Report)

The objective of this project is to develop the Direct E-Beam Synthesis (DEBS) process that uses high-energy electron beams (E-Beam) to break chemical bonds. This allows the production of valuable chemicals, such as acetic acid, methanol, and carbon monoxide, at relatively low severity (pressure near one atmosphere and temperatures <150°C) from near-pure CO 2 captured from a pulverized coal-fired power plant and methane, imported as natural gas. Creating such valuable products will offset the cost of carbon capture and storage. Through this project, we have designed, constructed, and operated an E-Beam reactor to examine the feasibility of performing dry reforming reaction without a catalyst using only DEBS. We have verified the production of syngas with 1:1 H2:CO ratio and calculated that the energy cost for conversion is about 5.2 eV/molecule of product for dry reforming reaction which is similar to the energy cost for conversion using conventional thermochemical conversion but under significantly milder conditions (room temperature and atmospheric pressure). We have performed a technoeconomic analysis (TEA) to estimate the total capital requirement and the cost of production for a 99.4 MMSCFD syngas production plant via non-catalytic Direct E-Beam Synthesis (DEBS) technology utilizing a high-energy electron beam (E-Beam) accelerator. No assumption is made for syngas utilization downstream, and the incoming reactants are pure CO 2 from carbon capture (assumed to be at zero cost) and natural gas. The Total As-Spent Cost (TASC) was calculated to be $\$242.5$ million, resulting in a levelized cost of syngas (LCOS) of $\$175.84$/tonne (metric) at a natural gas price of $\$6.24$/MMBTU1. The cost of syngas is primarily determined by the price of natural gas. If the cost of the CO 2 feedstock is assumed to be non-zero, then the price of the CO 2 feed also heavily influences the levelized cost of syngas. The potential impact on the cost of electricity from syngas revenue is significant. Following DOE NETL’s guidance, a lifecycle analysis (LCA) was conducted to compare the cradle-to-gate life cycle emissions of GTI Energy’s novel Direct E-Beam Synthesis (DEBS) process that produces syngas via the reaction of methane and carbon dioxide to the emissions of a state-of-the-art Steam Methane Reforming (SMR) process that also produces syngas via the reaction of methane and steam. The DEBS process results in less GHG emissions than SMR (with CO product as the basis of comparison). openLCA was used for the LCA and the results show that the total global warming potential (GWP) of DEBS is 0.981 kg CO 2 e per kg CO product, while the SMR process has a global warming potential of 2.573 kg CO 2 e per kg CO product. The ratio of the GWP of the proposed product system to the comparison product system is 0.381. This percent change is 61.9% lower GWP than SMR.

20 FOSSIL-FUELED POWER PLANTS↗