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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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45 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A critical review and meta-analysis of energy demand, carbon footprint, and other environmental impacts from carbon fiber manufacturing

The demand for carbon fibers and carbon fiber-reinforced polymers (CFRPs) is rapidly growing due to their outstanding mechanical properties and potential to enhance sustainability, particularly for lightweighting applications. However, carbon fibers are typically produced from fossil-based feedstocks, involve energy-intensive processes, and have limited options for sustainable end-of-life management or circularity. Despite these challenges, the energy demand and lifecycle environmental implications of their production remain poorly understood. Here, we conduct a critical literature review and meta-analysis of carbon fiber manufacturing, revealing significant variations in reported energy demand, carbon footprint, and lifecycle inventory data. Our analysis makes two novel contributions. First, we identify key underlying factors driving these variations. Second, we highlight that carbon fiber, far from being a homogeneous product, has grades varying substantially in mechanical properties, end-use markets, energy intensity of manufacturing processes, and therefore environmental impacts—an aspect often underrepresented in life cycle assessments. We assert that current data are insufficient for reliably evaluating environmental impacts, posing a risk of misleading decision-making. Addressing this gap requires new lifecycle inventory datasets clearly incorporating carbon fiber heterogeneity and key influencing factors identified in this study. Additionally, we propose actionable recommendations, including a checklist, to advance sustainability in the carbon fiber sector.

CED↗
DOE OSTI2026

Heat Pump Retrofits for Central Plant Hydronic Heating Systems: A Software Toolkit for Screening and Design

Retrofitting existing central plants with high-efficiency heat pump technologies can play a crucial role in achieving long-term planning goals. Modern heat pump technologies are able to use waste heat recovery to meet a building's heating demand, but there is a lack of accessible tools designed for non-HVAC experts, such as building owners, to quickly and easily conduct what-if analysis, e.g., estimating retrofit costs and payback period for their partial or full equipment replacement. This paper introduces an open-source software toolkit designed to facilitate the initial screening and decision-making of heat pump retrofits in existing central plants using a building's yearly load profile from metered or utility bill data. The toolkit evaluates the technical and economic viability of replacing traditional central plant equipment with various options including water-to-water or air-to-water heat pumps, which can provide efficient and lower-cost heating and cooling. It allows users to compare current central plant configurations with retrofit scenarios, assessing energy consumption, life-cycle costs, and environmental impact. The toolkit offers (1) a web-based tool designed for user-friendly access by a broad audience and (2) Python-based source code for researchers and engineers conducting parametric studies and design parameter optimization. The toolkit compares a typical central plant configuration to a configuration that uses a heat pump to supply hydronic heating and cooling. The output metrics include energy consumption and output of each equipment, life-cycle cost analyses and metrics, and environmental impact of the system.

Excell, L↗
DOE OSTI2020

Risk Model for EM Decision Support Toolsets

The Government Office of Accountability (GAO) has published several reports identifying the need for the Department of Energy (DOE) Office of Environmental Management (EM) to address mounting costs for DoE's cleanup program. DOEEM could greatly benefit from independent decision tool-sets/models that would allow them to evaluate options and inform business decision at the enterprise level considering site-specific life cycle costs and system plans. Program goals: Develop a tool-set that enables EM to independently evaluate alternatives, assess outcomes from different contracting strategies, and inform critical decisions for the enterprise. Project goals: Adaption of a Risk Model for integration with complimentary tool-sets for project level decision making. Operational Events: Discrete event model that evaluates operational variables (e.g. capacity, throughput, maintenance constraints) and identify bottlenecks. Identifying and Bounding Project Risk: Identify risks that impact confidence in meeting goals (e.g. production). Life cycle Cost: Evaluate impacts of staffing levels, inventory, and capital investments on life cycle costs. Methods and approach: Monte Carlo Analysis is being executed to generate results: Input derives from Risk Register Data; Tied to Projected and Target Schedules; Incorporates float duration within the model. Assumes associated risk mitigation actions being completed within a timeline of five fiscal years. Metrics include: Confidence in Meeting Production Goal; Confidence in Safety Standards; Confidence in Continuous Operation; Other Metrics can be added as appropriate regarding specific site needs. The adapted risk model can be used as a stand alone decision tool or can be integrated complementary tool-sets (i.e. process and cost models) for project-specific decisions. These support tool-sets can then be integrated with others for site- and complex- level evaluations. Future work includes designing an adaptable and modular framework that would allow integration of multiple tool-sets for holistic and/or targeted evaluation of alternative strategies for decision making that could lead to risk and cost reduction across the enterprise.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Reliability-Informed Economic and Energy Evaluation for Bi-Level Design for Remanufacturing: A Case Study of Transmission and Hydraulic Manifold

Abstract Design for remanufacturing (DfRem) is one attractive strategy that encourages the reuse of a product and extends the product's life cycle. Traditional design processes often only consider product reliability at an early design stage. However, from the perspective of environmental sustainability, it is becoming increasingly important to evaluate the long-term economic and environmental impacts of design decisions during early-stage design. We propose a bi-level DfRem framework consisting of system-level reusability allocation and component-level design tradeoff analysis, considering reliability and product warranty policy. First, a system-level reusability allocation problem aims at a theoretical exploration of the design space where all the components comprising the system are allocated certain reuse rates to achieve target energy savings with minimum cost. Following the theoretical exploration at the system level, a component-level analysis looks at practical design options for each component and trades-off between the overall cost and energy consumption for multiple remanufacturing cycles. Both levels of the framework require modeling component reuse for multiple remanufacturing cycles, which we achieve by using a branched power-law model that provides probabilistic scenarios of reusing the component or replacing it with a new part. We demonstrate the utility of this framework with the case study of an infinitely variable transmission (IVT) used by some agricultural machines manufactured by John Deere and show snapshots of a prototype software tool that we developed for easy use by designers.

Engineering↗
DOE OSTI2020

Lighting Policy Options to Incentivize the Circular Economy

Energy codes and energy efficiency policy are primed for significant shifts in the coming decade. Consumers are increasingly asking manufacturers to take responsibility for products over the course of the product lifespan, including at end-of-life. Consumer demand for social and environmental responsibility may push new codes and policies that incentivize the circular economy. Within the lighting sector, for example, rapid innovations have created large energy savings but also created a complex waste stream. Traditional energy code approaches to lighting efficiency have considered only lighting power density or energy-based metrics. Shifting codes and policy to consider environmental impacts of the product lifecycle could include circular economy mechanisms such as product deposits or service-based business models. In this paper we consider the possible structures for both codes and policies, and provide an analysis of the merits of each policy using life cycle assessment and sustainability index (SI).

Dillon, Heather↗
DOE OSTI2023

Supply Chain Energy and Greenhouse Gas Analysis Using the Materials Flows through Industry (MFI) Tool: Examination of Decarbonization Technology Scenarios for the U.S. Glass Manufacturing Sector

Glass manufacturing is a major part of the U.S. economy, and glass products in multiple sectors - flat glass, container glass, and fiberglass - are a part of everyday life. Despite glass manufacturing's long history, there are still many opportunities for glass production to improve in terms of both in overall energy consumption and greenhouse gas (GHG) emission reduction. Scenarios for the flat, container, and fiberglass sectors show the effect that each improvement has on primary energy demand and GHG emissions, starting from an industry baseline that reflects current manufacturing practices. Using the National Renewable Energy Laboratory's Material Flows through Industry tool, multiple scenarios are examined for each glass sector by applying a combination of energy reduction, increased electrification, hydrogen cofiring, a more renewable electric grid, and increased use of cullet. Additional decarbonization options are possible for glass but are left for later analysis due to cost, feasibility, or data issues. Primary energy demand can be reduced by 75%-83% compared to baseline inputs, depending on the sector, and GHG emissions are reduced by 82%-86%. Applying the maximum level of improvements listed here has the potential to save over 300 million GJ and 25 million metric tons of GHGs by 2050.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Circularity in polymers: addressing performance and sustainability challenges using dynamic covalent chemistries

The circularity of current and future polymeric materials is a major focus of fundamental and applied research, as undesirable end-of-life outcomes and waste accumulation are global problems that impact our society. The recycling or repurposing of thermoplastics and thermosets is an attractive solution to these issues, yet both options are encumbered by poor property retention upon reuse, along with heterogeneities in common waste streams that limit property optimization. Dynamic covalent chemistry, when applied to polymeric materials, enables the targeted design of reversible bonds that can be tailored to specific reprocessing conditions to help address conventional recycling challenges. In this review, we highlight the key features of several dynamic covalent chemistries that can promote closed-loop recyclability and we discuss recent synthetic progress towards incorporating these chemistries into new polymers and existing commodity plastics. Next, we outline how dynamic covalent bonds and polymer network structure influence thermomechanical properties related to application and recyclability, with a focus on predictive physical models that describe network rearrangement. Finally, we examine the potential economic and environmental impacts of dynamic covalent polymeric materials in closed-loop processing using elements derived from techno-economic analysis and life-cycle assessment, including minimum selling prices and greenhouse gas emissions. Throughout each section, we discuss interdisciplinary obstacles that hinder the widespread adoption of dynamic polymers and present opportunities and new directions toward the realization of circularity in polymeric materials.

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

Development of wind turbine blade recycling baselines in the United States

Over the past several years, the wind energy industry has received scrutiny regarding wind turbine blade (WTB) recycling due to the landfilling of WTBs caused by a lack of industrially viable recycling solutions. The amount of WTBs that will need to be recycled is set to increase in the United States as the deployment of wind energy is expected to rapidly grow to meet the nation's energy goals by 2035. While significant progress has been made worldwide, it is still unclear which WTB recycling solutions would be the most cost and energy effective within the United States for the existing fleet of wind turbines. To guide researchers and industry with a clear path forward, a range of options for WTB recycling in the United States are modeled through development of baseline scenarios and the use of formal life cycle assessment (LCA). Model data have been collected through literature review, industry engagement, and expert opinion regarding current end of life practices and considerations surrounding equipment, labor, and logistics. A detailed baseline for WTB decommissioning processes has been developed and used to assess alternative approaches, such as on-site shredding to compare the impacts on greenhouse gas (GHG) emissions. The developed LCA model and baseline scenarios for WTB recycling is used to assess the current WTB decommissioning practices in the United States along with emerging recycling pathways, including cement kiln co-processing and pyrolysis. Initial findings indicate that there are different approaches to decommissioning WTBs in the United States, each of which has unique implications for recycling. In light of this finding, additional results from the modeling will be used to better understand decommissioning practices and assist in making educated decisions on recycling pathways for the future. Throughout the analysis, focus was given to where international efforts might differ from the United States. WTB recycling is occurring worldwide, and different countries have different drivers for creating markets for recycled WTB materials. The contrasts and similarities between the United States and other countries offer insight to areas of opportunity that the United States could investigate and areas that can be readily transferred from existing solutions. By modeling and characterizing the current decommissioning practices and potential recycling solutions for the United States, a clearer vision will be created for pathways forward as to how to handle end of life WTBs to enable more efficient and cost-effective opportunities for material recovery from end-of-life WTBs.

Korey, Matt↗
DOE OSTI2024

Active Seismoelectric Monitoring of CO 2 Injection

Conference presentation at Carbon Capture, Utilization, and Storage (CCUS) Conference 2024, Houston, Texas, March 11–13, 2024. We investigated the use of active seismoelectric monitoring (ASE) to determine its effectiveness in detecting CO 2 injected deep underground and as an additional monitoring option for carbon storage projects. The EERC performed an ASE survey in February of 2023 at Pennel oil field near Baker, Montana, as part of the U.S. Department of Energy-sponsored Williston Basin CO 2 Field Laboratory in conjunction with operating partner Denbury Inc. The field site is part of the Cedar Creek Anticline geologic structure, with CO 2 planned for injection into a stacked storage complex (SSC) in the Interlake Formation containing both a residual oil zone and a conventional reservoir. The objective was to test the ASE method’s ability to characterize baseline fluid distribution in both the near surface and the SSC prior to CO 2 injection.

04 OIL SHALES AND TAR SANDS↗