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NASA NTRS1996

Cost Models for MMC Manufacturing Processes

Processes for the manufacture of advanced metal matrix composites are rapidly approaching maturity in the research laboratory and there is growing interest in their transition to industrial production. However, research conducted to date has almost exclusively focused on overcoming the technical barriers to producing high-quality material and little attention has been given to the economical feasibility of these laboratory approaches and process cost issues. A quantitative cost modeling (QCM) approach was developed to address these issues. QCM are cost analysis tools based on predictive process models relating process conditions to the attributes of the final product. An important attribute, of the QCM approach is the ability to predict the sensitivity of material production costs to product quality and to quantitatively explore trade-offs between cost and quality. Applications of the cost models allow more efficient direction of future MMC process technology development and a more accurate assessment of MMC market potential. Cost models were developed for two state-of-the art metal matrix composite (MMC) manufacturing processes: tape casting and plasma spray deposition. Quality and Cost models are presented for both processes and the resulting predicted quality-cost curves are presented and discussed.

Elzey, Dana M.↗

NASA NTRS2001

Development Cycle Time Simulation for Civil Aircraft

Cycle Time Reduction (CTR) will be one of the major factors affecting the future of the civil aerospace industry. This focus is the end reflection of the level of competition in the commercial large carrier aircraft industry. Aircraft manufacturer must minimize costs and pass a portion of those savings onto buyers. CTR is one strategy used to move the manufacturing firm down the cost curve. The current NASA Airframe Development Cycle Time Reduction Goal is 50% by year 2022. This goal is not achievable based on the program analysis done by the LMI/GRA team. This may mean that the current roster of NASA CTR programs needs to be reexamined or that the program technology progress factors, as determined by the NASA experts, were understated. Programs that duplicate the reductions of others should be replaced with non-duplicative programs. In addition, new programs targeting a specific part of the cycle can be developed.

Spitz, William↗

NASA NTRS2004

Ground-Based Telescope Parametric Cost Model

A parametric cost model for ground-based telescopes is developed using multi-variable statistical analysis, The model includes both engineering and performance parameters. While diameter continues to be the dominant cost driver, other significant factors include primary mirror radius of curvature and diffraction limited wavelength. The model includes an explicit factor for primary mirror segmentation and/or duplication (i.e.. multi-telescope phased-array systems). Additionally, single variable models based on aperture diameter are derived. This analysis indicates that recent mirror technology advances have indeed reduced the historical telescope cost curve.

Stahl, H. Philip↗

NASA NTRS1986

Cost Risk Analysis Based on Perception of the Engineering Process

In most cost estimating applications at the NASA Langley Research Center (LaRC), it is desirable to present predicted cost as a range of possible costs rather than a single predicted cost. A cost risk analysis generates a range of cost for a project and assigns a probability level to each cost value in the range. Constructing a cost risk curve requires a good estimate of the expected cost of a project. It must also include a good estimate of expected variance of the cost. Many cost risk analyses are based upon an expert's knowledge of the cost of similar projects in the past. In a common scenario, a manager or engineer, asked to estimate the cost of a project in his area of expertise, will gather historical cost data from a similar completed project. The cost of the completed project is adjusted using the perceived technical and economic differences between the two projects. This allows errors from at least three sources. The historical cost data may be in error by some unknown amount. The managers' evaluation of the new project and its similarity to the old project may be in error. The factors used to adjust the cost of the old project may not correctly reflect the differences. Some risk analyses are based on untested hypotheses about the form of the statistical distribution that underlies the distribution of possible cost. The usual problem is not just to come up with an estimate of the cost of a project, but to predict the range of values into which the cost may fall and with what level of confidence the prediction is made. Risk analysis techniques that assume the shape of the underlying cost distribution and derive the risk curve from a single estimate plus and minus some amount usually fail to take into account the actual magnitude of the uncertainty in cost due to technical factors in the project itself. This paper addresses a cost risk method that is based on parametric estimates of the technical factors involved in the project being costed. The engineering process parameters are elicited from the engineer/expert on the project and are based on that expert's technical knowledge. These are converted by a parametric cost model into a cost estimate. The method discussed makes no assumptions about the distribution underlying the distribution of possible costs, and is not tied to the analysis of previous projects, except through the expert calibrations performed by the parametric cost analyst.

Dean, Edwin B.↗

DOE OSTI2023

Potential Availability of and Supply Curves for Low-Cost, Dispatch-Constrained Electricity

Among other changes, variable renewable energy (VRE) - primarily wind and solar photovoltaics - is achieving a growing share of total generation. High VRE penetrations may result in an increased level of curtailment and thus suppress the value of additional VRE. This VRE, that either would not be built due to price suppression or would be curtailed, can be considered a resource that we define as low-cost, dispatch-constrained electricity (LDE). LDE could be used for various applications which value low-cost electricity and can operate at reduced capacity factors. Examples include electrolytic hydrogen production and carbon capture. This report provides initial estimates of the quantity and availability of the potential LDE resource in the U.S. under scenarios with high VRE penetrations. It also provides supply curves that can be used in subsequent analysis of the opportunity to use the LDE. We modeled several scenarios using capacity expansion and production cost models for LDE prices ranging from $\$ $0/MWh to $\$ $30/MWh. These LDE prices, coupled with low renewable energy cost assumptions, resulted in VRE penetrations ranging from 48-66% in 2050. The resulting LDE supplies range from 100 - 300 TWh/yr at a price of $\$ $0/MWh to 3,500 - 4,200 TWh/yr at $\$ $30/MWh. Increasing LDE prices increases wind and photovoltaics deployment; however, other generation technology capacities do not decrease equivalently in our models. Thus, additional generation is available but the capacity of traditional dispatchable generation is only reduced slightly. The available LDE is concentrated in the central and southwest U.S. regions because of their high wind and solar resources.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Quantifying Distribution System Resilience From Utility Data: Large Event Risk and Benefits of Investments

We focus on blackouts in electric distribution systems that have a large cost to customers. To quantify resilience to these events, we show how to calculate risk metrics from the historical outage data routinely collected by utilities' outage management systems. Risk is defined using a customer cost exceedance curve. The exceedance curve has a heavy tail that implies large fluctuations in large blackout costs, and this makes estimating the mean large cost in the usual way impractical. To avoid this problem, we use new resilience metrics describing the large event risk; these metrics are the probability of a large cost event, the annual log cost resilience index, and the average of the logarithm of the cost of large-cost events or the slope magnitude of the tail on a log–log exceedance curve. Resilience can be improved by planned investments to upgrade system components or speed up restoration. The benefits that these investments would have had if they had been made in the past can be quantified by “rerunning history” with the effects of the investment included, and then recalculating the large event risk to find the improvement in resilience. An example using utility data shows a 2% reduction in the probability of a large cost event due to 10% wind hardening and 6%–7% reduction due to 10% faster restoration in two different areas of a distribution utility. This new data-driven approach to quantify resilience and resilience investments is realistic and much easier to apply than complicated approaches based on modeling all the phases of resilience. Moreover, an appeal to improvements to past lived experience may well be persuasive to customers and regulators in making the case for resilience investments.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Modeling the Cost of CO2 Saline Storage on a Regional and National Level

This poster presents the results of using the FECM/NETL CO2 Saline Storage Cost Model (CO2_S_COM) to evaluate the cost of saline storage in potential storage formations in the lower 48 U.S. states. Costs were calculated for 314 saline storage formations in the CO2_S_COM geologic property database. These results were used to generate national and regional cost-supply curves. In addition, a sensitivity analysis was performed that quantified how modifying several input variables in CO2_S_COM affected the costs. Poster presented (virtual) at the 2024 AGU Conference, December 9-13, 2024, Washington, D.C.

Morgan, David [NETL]↗

NASA NTRS2020

Enabling Assurance in the MBSE Environment

A number of specific benefits that fit within the hallmarks of effective development are realized with implementation of model-based approaches to systems and assurance. Model Based Systems Engineering (MBSE) enabled by standardized modeling languages (e.g., SysML®) is at the core. These benefits in the context of spaceflight system challenges can include [1]: • Improved management of complex development • Reduced risk in the development process • Improved cost management • Improved design decisions With appropriate modeling techniques the assurance community also can improve early oversight and insight into project development. NASA has shown the basic constructs of SysML in an MBSE environment offer several key advantages, within a Model Based Mission Assurance (MBMA) initiative [2, 3]. These include the following: • Model viewpoints that promote rapid and systematic assessment of requirements coverage, hazard tagging and risk management • Embedded safety assessments for launch vehicles • Deployment of model assisted development of reliability products - Failure Modes and Effects Analyses (FMEAs) and Fault Trees • Test Planning • Validation and Verification of complex functions • Support of Assurance Case development for complex systems In addition, while there are benefits to be harvested, there is a realization that these do not come without effort and cost. Enabling model-based approaches requires structure, not only in an organizational context, but in a modeling context as well. There can be a steep learning curve and costs associated to train skilled modelers. But, on the other hand, not all of the assurance community need to be modelers. Models themselves must conform to ontologies that enable assurance. This places constraints upon the models and modelers. Optimums have yet to be developed where resources and constraints on modeling must be traded off in the organization and modeling efforts for projects. A number of barriers need to be overcome, as well, which pose challenges to the developers of the software that supports MBSE/MBMA. Information and data must be made to flow seamlessly through the life cycle. Because there is a wide variety of tools used in the community, to avoid the problems of the past of silos, delays, and diverging interests, information should flow among these tools to support the “single source of truth” paradigm of MBSE. This will greatly facilitate MBMA and advancement of assurance functions.

Evans, John W.↗

DOE OSTI2026

FLOW BATTERY COST AND COMMERCIALIZATION TOOL (FlowBaCC) v.1.0

The Flow Battery Cost and Commercialization Tool (FlowBaCC) is a python-based framework used to project the costs and commercialization timelines for redox flow batteries. FlowBaCC combines learning curves for component costs and performance with adoption curves for market diffusion to project future system costs. The tool uses the bottom-up, spreadsheet-based Battery Performance and Cost Model for Flow Batteries (BatPaC-Flow) as the engine to translate learning curve inputs into full system costs. FlowBaCC provides capital costs and levelized costs of energy storage. The tool enables scenario analysis, sensitivity analysis, and uncertainty quantification (via grid and Monte Carlo methods).

Fu, Xiaoxu [Argonne National Laboratory (ANL), Arg↗

DOE OSTI2020

A Detailed Vehicle Simulation Process to Support CAFE and CO 2 Standards (MY 2021–2026 Final Rule Analysis)

In 1975, Congress passed the Energy Policy and Conservation Act (EPCA), requiring standards for corporate average fuel economy (CAFE), and charging the U.S. Department of Transportation (DOT) with the establishment and enforcement of these standards. The Secretary of Transportation has delegated these responsibilities to the National Highway Traffic Safety Administration (NHTSA). NHTSA has contracted the DOT Volpe National Transportation Systems Center (Volpe Center) to provide analytical support for NHTSA’s regulatory and analytical activities related to fuel economy standards. Unlike long-standing safety and criteria pollutant emissions standards, fuel economy standards apply to manufacturers’ overall fleets rather than to individual vehicle models. In developing the standards, NHTSA made use of the CAFE Compliance and Effects Modeling System (the “CAFE model”), which was developed by DOT’s Volpe Center for the 2005-2007 CAFE rulemaking and has been continually updated since. The model is the primary tool used by the agency to evaluate potential CAFE stringency levels by applying technologies incrementally to each manufacturer’s fleet until the requirements under consideration are met. The CAFE model relies on numerous technology-related and economic inputs such as market forecasts and technology cost and effectiveness estimates; these inputs are categorized by vehicle classification, technology synergies, phase-in rates, cost learning curve adjustments, and technology “decision trees.” The Volpe Center assists NHTSA in the development of the engineering and economic inputs to the CAFE model by analyzing the application of potential technologies to the current automotive industry vehicle fleet to determine the feasibility of future CAFE standards, the associated costs, and the benefits of the standards.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Calibrating Constant Elasticity of Substitution Technologies to Bottom-up Cost Estimates

We propose a method for calibrating an industry-level technology to engineering (bottom-up) estimates with a particular focus on abatement opportunities. As a demonstration, substitution elasticities across inputs are adjusted in the nested cost function for the electricity sector to best fit a target marginal abatement cost (MAC) curve derived from engineering assessments of available technologies. Elasticities are optimized over an entire relevant range of the MAC, whereas current techniques use local point estimates under little or no abatement. In the context of fitting to a given MAC we evaluate alternative nesting structures and find that, while complexity in nesting improves the fit, even relatively simple nesting structures can reasonably approximate the target MAC. In our example, focused on the electricity sector, we find standard elasticities adopted in top-down models moderately overstate abatement costs relative to the engineering targets. In our preferred specification the most important adjustment is to escalate the substitution elasticity between energy and value-added inputs. This is consistent with an argument that the current set of point estimates fail to properly account for new capital-based technologies. These conclusions, however, are sensitive to our assumption about output-intensity abatement and consumer price responsiveness, both of which are not delineated in engineering estimates.

abatement cost↗

DOE OSTI2020

The impact of behavioral and geographic heterogeneity on residential-sector carbon abatement costs

Analyses of monetary and emissions savings from residential efficiency upgrades usually neglect behavioral differences between consumers. Variations in behavior are frequently large: 13% of the U.S. population sets thermostats for cooling at 20 °C (68 °F) or lower and 15% at 25.5 °C (78 °F) or higher. Efficiency analyses should account for behavioral heterogeneity as well as variations in climate and housing characteristics. We model energy and economic savings of efficiency upgrades for U.S. single-family detached houses, accounting for differences in thermostat settings, climate zone, fuel prices, and home characteristics. We consider five efficiency interventions: wall insulation, attic insulation, air sealing, high-efficiency furnaces, and high-efficiency air conditioners. Energy and economic savings vary widely by consumer; the average net present value for wall insulation is $3,020 United States Dollar (USD), but considering heterogeneity, it has a 10th percentile value of -$231 and 90th percentile value of $5,000. Neglecting heterogeneity, technology upgrades can be prioritized from lower to higher carbon abatement costs: air conditioners, wall insulation, furnace, air sealing, and attic insulation. Accounting for heterogeneity reorders this prioritization, and consumer-specific conditions affect mitigation costs such that technologies are mixed in with one another and are no longer arranged one after another. These results indicate that interventions to improve efficiency should consider differences between consumers.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

The implications of uncertain renewable resource potentials for global wind and solar electricity projections

Studies exploring long-term energy system transitions rely on resource cost-supply curves derived from estimates of renewable energy (RE) potentials to generate wind and solar power projections. However, estimates of RE potentials are characterized by large uncertainties stemming from methodological assumptions that vary across studies, including factors such as the suitability of land and the performance and configuration of technology. Based on a synthesis of modeling approaches and parameter values used in prior studies, we explore the implications of these uncertain assumptions for onshore wind and solar photovoltaic electricity generation projections globally using the Global Change Analysis Model. We show that variability in parametric assumptions related to land use (e.g. land suitability) are responsible for the most substantial uncertainty in both wind and solar generation projections. Additionally, assumptions about the average turbine installation density and turbine technology are responsible for substantial uncertainty in wind generation projections. Under scenarios that account for climate impacts on wind and solar energy, we find that these parametric uncertainties are far more significant than those emerging from differences in climate models and scenarios in a global assessment, but uncertainty surrounding climate impacts (across models and scenarios) have significant effects regionally, especially for wind. Our analysis suggests the need for studies focusing on long-term energy system transitions to account for this uncertainty.

14 SOLAR ENERGY↗

DOE OSTI2026

Powered By reV [Slides]

The reV model empowers users to calculate energy capacity, generation, and cost based on geospatial intersection with grid infrastructure and land-use characteristics. The tool can model a single site up to an entire continent at temporal resolutions ranging from five minutes to hourly, spanning a single year or multiple decades. By automating access to resource data at unprecedented scale, fidelity, and flexibility, the reV model integrates formerly disparate analysis frameworks in the fields of resource modeling, technical potential, and energy cost supply curves.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

GCAM v4.3 SSP-RCP-GCM Output Products

Supplemental dataset to: Graham N.T., M.I. Hejazi, M. Chen, E. Davies, J.A. Edmonds, S.H. Kim, and S. Turner, et al. 2020. "Humans drive future water scarcity changes across all Shared Socioeconomic Pathways." Environmental Research Letters 15, no. 1:Article No. 014007. PNNL-SA-151297. doi:10.1088/1748-9326/ab639b This analysis makes deterministic classifications of how, when water resources are limited and constrained, the human and climate systems interact. The relative effects of both systems on water scarcity are quantified at global and basin scales across 15 global futures that include five different socioeconomic conditions (the Shared Socioeconomic Pathways, SSPs) and four different climatic conditions (the Representative Concentration Pathways, RCPs). These 15 scenarios are used to first analyze a 'Human Alone' component by isolating the human impact on future scarcity. This is accomplished by holding all climate variables to their 2005 levels while altering socioeconomic growth and technological change. General circulation model (GCM) derived climate impacts for five models are applied to establish 75 'Human and Climate' scenarios which allows for the quantification of climate impacts. Climatic impacts to water supply, agricultural productivity and change, hydropower availability, and building energy demands are applied from 5 different bias-corrected GCMs to make a suite of 75 climate runs. By subtracting the human derived impacts from the 'Human Alone' scenarios, from the 'Human and Climate' scenarios the climate impact is isolated. First, the drivers of future water scarcity are evaluated by isolating the impacts that both humans and climate have while accounting for feedbacks between humans, energy, and land. Secondly, the simultaneous impacts that human and climate systems have on water scarcity are analyzed by determining whether each system is increasing or decreasing scarcity in all global water basins. Below we describe the GCAM model, the scenario components, climate derived impacts, and the calculations of scarcity changes and attribution. This study uses the global change assessment model (GCAM), with inclusions of water constraints to both renewable and nonrenewable sources of water, to investigate the relative contributions of climate and human systems on water scarcity regionally and globally under a wide range of scenarios. GCAM links socioeconomics, the energy system, land-use change, climate, and the water sector. GCAM is a market-equilibrium model that allows for prices to be adjusted within each time step to ensure that the supply and demand of goods and services remains equilibrated at each time step allowing for simultaneous market clearing across sectors. This study accounts for a limited supply of water by employing cost resource curves across all 235 basins that follow a logit formulation to determine the share of each water source (renewable surface water, nonrenewable groundwater, and desalinated water) needed to meet the water demands within all basins. As depletion of various water sources increases the extraction price increases, which leads to compounding price increases on the goods and services that require higher-priced water sources.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

Cleaner Chips: Decarbonization in Semiconductor Manufacturing

The growth of the information and communication technology sector has vastly accelerated in recent decades because of advancements in digitalization and Artificial Intelligence (AI). Scope 1, 2, and 3 greenhouse gas emissions data of the top six semiconductor manufacturing companies (Samsung Electronics, Taiwan Semiconductor Manufacturing Corporation, Micron, SK Hynix, Kioxia, and Intel) were gathered from the publicly accessible Carbon Disclosure Project’s (CDP) website for 2020. Scope 3 emissions had the largest share in total annual emissions with an average share of 52%, followed by Scope 2 (32%) and Scope 1 (16%). Because of the absence of a standardized methodology for Scope 3 emissions estimation, each company used different methodologies that resulted in differences in emissions values. An analysis of the CDP reporting data did not reveal information on strategies implemented by companies to reduce Scope 3 emissions. The use of renewable energy certificates had the largest effect on decarbonization centered on reducing Scope 2 emissions, followed by the deployment of perfluorocarbon reduction technologies to help reduce Scope 1 fugitive emissions. Technology-specific marginal abatement costs of CO2 were also estimated and varied between −416 and 12,215 USD/t CO2 eq., which primarily varied depending on the technology deployed.

42 ENGINEERING↗

NASA NTRS1972

Computer-controlled environmental test systems - Criteria for selection, installation, and maintenance.

Applications for presently marketed, new computer-controlled environmental test systems are suggested. It is shown that capital costs of these systems follow an exponential cost function curve that levels out as additional applications are implemented. Some test laboratory organization changes are recommended in terms of new personnel requirements, and facility modification are considered in support of a computer-controlled test system. Software for computer-controlled test systems are discussed, and control loop speed constraints are defined for real-time control functions. Suitable input and output devices and memory storage device tradeoffs are also considered.

Chapman, C. P.↗

NASA NTRS1994

Predictability in space launch vehicle anomaly detection using intelligent neuro-fuzzy systems

Included in this viewgraph presentation on intelligent neuroprocessors for launch vehicle health management systems (HMS) are the following: where the flight failures have been in launch vehicles; cumulative delay time; breakdown of operations hours; failure of Mars Probe; vehicle health management (VHM) cost optimizing curve; target HMS-STS auxiliary power unit location; APU monitoring and diagnosis; and integration of neural networks and fuzzy logic.

Gulati, Sandeep↗