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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Techno-Economic Analysis of Hydrogen-Fueled Solid Oxide Fuel Cell Systems

This technical report presents findings from a techno-economic analysis that assessed the cost and performance implications of fueling solid oxide fuel cell (SOFC) technology with hydrogen fuel. The exothermic hydrogen oxidation reaction results in various impacts when compared to a natural gas SOFC system, which benefits from an endothermic methane reforming reaction. The excess heat generated from the system requires management, thereby increasing system costs. An application where the excess heat can be used in a combined heat and power application seems to be the most economical use of a hydrogen fueled SOFC system.

08 HYDROGEN↗
DOE OSTI2024

Scaleup and Site-Specific Engineering Design for Global Thermostat Direct Air Capture Technology

The overall goal of the project is completion of an initial design of a commercial-scale, Carbon Capture, Utilization, and Storage Direct Air Capture (CCUS-DAC) plant design at three different sites that captures a net of at least 100,000 tonnes per year (TPY) carbon dioxide (CO 2 ) from the atmosphere and considers compression and conditioning of the captured CO 2 for purpose of pipeline transportation to different geological formation sites for deep well injection and underground storage. In addition to the leading system consisting of a scaled-up Global Thermostat DAC unit, overall plant design includes a combined Heat and Power (CHP) unit integrated with a conventional liquid amine-based carbon capture system (90% capture) and compression facilities. These are considered balance of plant (BOP) systems and are required to provide low carbon-intensity steam and power to the DAC process. A second approach involving provision of DAC units modified to directly capture emissions from the CHP unit was initially assessed as an alternative and it was determined to be less mature than considered approach and not included in the scaled-up plant design efforts. Three geographically diverse continental United States locations were selected to better understand the effect of local/regional ambient conditions on scaled-up DAC system performance and project costs: Bucks, Alabama (hot wet climate), Odessa, Texas (dry hot climate), and Goose Creek, Illinois (mid continental climate). The team focused on initial engineering design activities, including the development of project design criteria, initiation of site-specific studies and investigations, completion of DAC system process and equipment design, and definition of balance of plant (BOP) engineering. The purpose of the activities were to develop Technoeconomic Analysis (TEA), Life-Cycle Analysis (LCA), and Environmental, Health, and Safety (EH&S) analysis, and Business Case Analysis (BCA) to validate that the project engineering and scale-up plans of the DAC systems, at each of the three distinct case studies considered, are technically, economically, and environmentally feasible for commercial-scale operation.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to full-scale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to fullscale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Resource Recovery for the Wastewater Industry

This information sheet discusses the technology pillar, Resource Recovery, as a pathway toward improving wastewater infrastructure sustainability and resiliency. To supplement existing literature on current technologies and policies for improving resiliency at wastewater (WW) treatment plants, this document aims to accomplish the following: • Summarize wastewater sludge recovery methods • Summarize biogas production and codigestion methods • Serve as a comprehensive (though not exhaustive) repository for resource recovery for wastewater utilities The Resource Recovery Technical Information Sheet should be viewed as a general guide to established best practices for the water and wastewater (W/WW) sector when considering implementing energy capture technologies. Additional details on associated energy capture avenues such as combined heat and power (CHP), renewable energy, and inline hydropower from tertiary effluent in W/WW facilities are presented in the Energy Capture Technology Information Sheet.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Organic Rankine Cycle Integration and Optimization for High Efficiency CHP Genset Systems (Final Technical Report)

This project successfully advanced the integration of Organic Rankine Cycle (ORC) technology with reciprocating engine–based combined heat and power (CHP) systems to improve electrical efficiency, total CHP efficiency, and grid-responsive operation. Over three budget periods, the work progressed from high-temperature ORC component development and thermodynamic model validation to next-generation system design, working fluid transition, and techno-economic analysis. Key technical accomplishments include development and validation of a thermodynamic model capable of accurately predicting ORC performance across an expanded temperature and pressure envelope; successful identification and validation of low-global-warming-potential (GWP) working fluids—most notably R1233zd(E)—as viable replacements for R245fa; and demonstration of scalable ORC architectures suitable for integration with 1–20 MW class reciprocating engines. These advances enable flexible CHP configurations that can increase electrical output while maintaining high overall utilization of available thermal energy. The project also produced a clean-sheet design for a next-generation ORC system targeting substantially higher power output per unit, supported by detailed component selection, heat exchanger evaluation, and system-level modeling. Techno-economic analyses indicate that ORC-enabled flexible CHP systems can meet or exceed Department of Energy (DOE) efficiency targets while providing value to both facility operators and the electric grid.. Late-stage testing of the largest next-generation ORC prototype identified limitations related to pump net positive suction head (NPSH) requirements and condenser flooding under certain operating conditions. Although these issues constrained full validation of that configuration within the project timeframe, they provided clear and actionable design guidance for future system refinements. Importantly, validated modeling, smaller-scale testing, and working fluid evaluations confirmed the technical viability of the overall approach. In aggregate, this project met its core objectives by establishing validated design tools, de-risking key ORC technologies for CHP applications, and defining a credible pathway toward commercialization of flexible, high-efficiency CHP systems. The results form a strong foundation for continued development and deployment beyond the conclusion of the DOE-funded effort.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Distributed clean energy opportunities for US oil refinery operations

The oil and gas industry is increasingly seeking operational improvements to reduce costs and emissions while improving resilience. This study describes techno-economic analysis of opportunities for distributed energy resources that could be integrated to support oil and gas companies’ economic, environmental, and energy resiliency goals. Specifically, the analysis evaluates solar photovoltaics, wind turbines, battery energy storage, landfill gas, biomass, municipal solid waste-to-energy, solar steam for process heat, combined heat and power, and electrolyzers for hydrogen production at two hypothetical refineries, one located in Louisiana and the other in southern California. These technologies could reduce the sites’ consumption of grid electricity and/or natural gas and thus can help reduce emissions. This study employs the ReOPT tool and System Advisor Model to evaluate the techno-economic potential for clean energy technologies to support refineries in achieving energy goals, including energy cost savings, resiliency, and emissions reductions. Results indicate that the associated costs of emissions reductions via several distributed clean energy technologies are competitive with other emissions reduction strategies such as energy efficiency, reducing flaring, direct carbon capture and sequestration, and markets under certain conditions. There are also cost beneficial opportunities for the use of renewable energy for refining, especially for resilience, depending on local conditions such as resources and utility costs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Methodology to Implement a Microgrid in a University Campus

This paper presents the method we followed to design a microgrid at a university campus based on available resources. Due to introduction of renewable resources to produce energy, a methodology that allows design a microgrid in a university campus is very useful. Hence, we present a series of steps that must be carried out to estimate the resource to be used, the installation, area needed, and the capacity of the systems needed are also described. In addition, the models of the distributed resources that constitutes the microgrid are presented and explained. To validate the proposed methodology, simulations were performed using Opal-RT-LAb. As a test scenario we selected the Mayagüez campus of the University of Puerto Rico where we conducted analysis of the available resource and capacity of the systems is needed to satisfy demand of critical loads, considering a predetermined number of days of austerity. Our study results in determination of dimensions, cost and effectiveness of the microgrid. Simulations results also show that the proposed microgrid satisfy demand with the same reliability, or better, than the traditional electrical network. Additionally, the best options for this purpose are photovoltaic, batteries, and combined heat and power, if the technological advances and availability of resources to the date for Puerto Rico are considered.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Modeling and Optimization of a Nuclear Integrated Energy System for the Remote Microgrid on El Hierro

Nuclear microreactors are a potential technology to provide heat and electricity for remote microgrids. There is potential for the microgrid on the island of El Hierro to use a microreactor, within an integrated energy system (IES), to generate electricity and provide desalinated water. This work proposes a workflow for optimizing and analyzing IESs for microgrids. In this study, an IES incorporating a microreactor, thermal energy storage (TES) system, combined heat and power plant, and a thermal desalination plant was designed, optimized, and analyzed using Idaho National Laboratory’s Framework for Optimization of Resources and Economics (FORCE) toolset. The optimization tool, Holistic Energy Resource Optimization Network (HERON), was used to determine the optimal capacity sizes and dispatch for the reactor and thermal energy storage systems to meet demand. The optimized reactor and TES sizes were found to be 11.61 MWth and 58.47 MWhth, respectively, when optimizing the IES to replace 95% of the island’s existing diesel generation needs. A dynamic model of the system was created in the Modelica language, using models from the HYBRID repository, to analyze and verify the dispatch from the optimizer. The dynamic model was able to meet the ramp rates while maintaining reactor power with minimal control adjustments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Energy Efficiency as a Foundational Technology Pillar for Industrial Decarbonization

The U.S. government aims to achieve net-zero greenhouse gas emissions by 2050 to reduce the severe impacts of climate change. The U.S. industrial sector will become a focal point for decarbonization since it accounts for 33% of the nation’s primary energy use and 30% of its energy-related CO2 emissions. Industrial emissions are also expected to increase by 15% through 2050, making the industrial sector a logical target for decarbonization efforts. Energy efficiency technology pathways provide low-cost, foundational routes to decarbonization that can be implemented immediately. Energy efficiency technology pathways, such as strategic energy management, system efficiency, smart manufacturing, material efficiency, and combined heat and power, are well established and would immediately reduce energy use and emissions. However, their role in the aggressive net-zero decarbonization pathway for the industrial sector is still unclear. This study aims to address energy efficiency pathways for decarbonization, and reviews studies related to these technologies for industrial decarbonization through 2050. This study identifies different strategies for the industrial sector in general and that are specific to six energy-intensive industries: iron and steel; chemical; food and beverage; petroleum refining; pulp and paper; and cement. Finally, a path toward the successful implementation of energy efficiency technologies is outlined.

Strategic energy management↗
DOE OSTI2023

A Comparison of Multiple Macroalgae Cultivation Systems and End-Use Strategies of Saccharina latissima and Gracilaria tikvahiae Based on Techno-Economic Analysis and Life Cycle Assessment

Macroalgae can be processed into various products with the potential to substitute land-based crops; their cultivation can bioextract nutrients from coastal waters. This study investigated the economic cost and environmental impacts of multiple seaweed cultivation platforms, cultivation strategies, and processing/end-use strategies through techno-economic analysis (TEA) and life cycle assessment (LCA) with a focus on Saccharina latissima and Gracilaria tikvahiae. Cultivation platforms included single-layer longline, dual-layer longline, single-layer strip, and dual-layer strip systems. Processing/end-use products included seaweed to biofuel, dried sea vegetables, marketable commercial fertilizer, and animal feed. Economic and environmental costs decreased with dual-layer and strip cultivation systems. Cultivation costs were highest using the common single-layer longline system ($4.44 kg−1 dry weight (dw) S. latissima and $6.73 kg−1 dw G. tikvahiae when cultivated on rotation). The use of the dual-layer strip system reduced cultivation costs to $2.19 kg−1 dw for S. latissima and $3.43 kg−1 dw for G. tikvahiae. Seaweed drying was the major contributor to economic and environmental costs for macroalgae processing. Yet, all scenarios achieved environmental benefits for marine eutrophication. The best environmental performance was observed when biomass was processed to dry sea vegetables, assuming the offset of land-based vegetable production, or used as biofeedstock for anaerobic digestion for combined heat and power.

Wu, Jingjing (ORCID:0000000305311353)↗
DOE OSTI2021

REopt Lite Tutorial: International Locations

NREL’s REopt Lite web tool helps users evaluate the economic viability of distributed photovoltaic (PV), wind, battery storage, combined heat and power, and thermal energy storage systems. REopt Lite was designed for locations within the United States; however, with appropriate adjustments, it is possible to use most of its features for international locations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Beneficial CHP – Is that a Thing? Considering CHP in the Context of Beneficial Electrification

For decades, combined heat and power (CHP) has been promoted and embraced as a cost-effective technology for meeting on-site thermal and electric needs more efficiently and with fewer emissions than separate procurement of those resources. But climate change concerns are leading to a reevaluation of CHP’s benefits. Significantly, natural gas, the most common fuel for CHP and until recently regarded as an environmentally preferable “bridge fuel” in the energy transition to renewables, is increasingly being reexamined amid calls for deep decarbonization and emerging clean energy policies that limit the use of natural gas. Given this trend, electrification has gained traction as a net zero carbon energy strategy. With natural gas being a preferred fuel for CHP, policymakers and others are beginning to question CHP’s role in a cleaner, more electrified future. However, CHP fueled by low carbon fuels such as renewable natural gas and hydrogen may be a more viable path to decarbonizing industrial processes that are difficult to electrify due to technology limitations or cost, and for applications where energy resilience is a critical requirement. This paper seeks to add clarity to a complex issue. It offers a framework for assessing industrial applications where natural gas CHP will provide significant GHG reductions in the near term and provide a more economic and practical path to deep decarbonization in the long term through a transition to low carbon fuels.

Hedman, Bruce↗
DOE OSTI2021

ESPC ESA Webinar Series: ESPC IDIQ Contract Vehicle Overview

This webinar provides instructions and resources for financing distributed energy projects (e.g. on-site renewable energy, storage, and combined heat and power) using an energy savings performance contract (ESPC) energy sales agreement (ESA) through the U.S. Department of Energy (DOE) indefinite-delivery, indefinite-quantity (IDIQ) energy savings performance contract (ESPC) vehicle. The DOE IDIQ ESPC contract vehicle uses a streamlined master contract that allows federal agencies to work with 21 energy service companies holding the current DOE IDIQ ESPC. Topics covered in the webinar include: An overview of the DOE IDIQ contract vehicle; ESA-specific considerations for IDIQ contracts; and Specific use cases. The webinar also provides an overview of the resources available on the Federal Energy Management Program website, such as IDIQ tools and templates. This webinar is the fifth in a series that provides information, best practices, and resources for implementing an ESPC ESA project. ESPC ESAs are a great option for federal sites that are motivated to reduce site costs, have no capital investment funding, and cannot use the U.S. Department of Defense 10 USC 2922a authority for long-term contracting.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

ESPC ESA Training Series: Site-Specific/Stand-Alone Contract Vehicle

This webinar provides instructions and resources for financing distributed energy projects (e.g., on–site renewable energy, storage, and combined heat and power) using an energy savings performance contract (ESPC) energy sales agreement (ESA) through the site–specific/stand–alone contract vehicle. The site–specific/stand–alone contract vehicle is a procurement process using a request for proposal (RFP). Topics covered during the webinar include forming a strong project team, validating the feasibility of the distributed energy project at a site, acquisition planning, RFP development, procurement, proposal evaluation and contract award, and the construction and performance period. This webinar also provides an overview of the resources available in the ESPC ESA Toolkit, such as checklists and templates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

ESPC ESA Webinar Series: ESPC ENABLE Contract Vehicle Overview

This webinar provides instructions and resources for financing distributed energy projects (e.g. on-site renewable energy, storage, and combined heat and power) using an energy savings performance contract (ESPC) energy sales agreement (ESA) through the U.S. Department of Energy's (DOE) ESPC ENABLE contract vehicle. The ESPC ENABLE contract vehicle is a streamlined procurement process that uses a standard investment grade audit tool and standard contract templates. Topics covered in the webinar include: An overview of the ESPC ENABLE contract vehicle; ESA-specific considerations for ENABLE contracts; and Case studies. This webinar also provides an overview of the resources available on the Federal Energy Management Program website, such as ESPC ENABLE templates. This webinar is the fourth of a series that provides information, best practices, and resources for implementing an ESPC ESA project. ESPC ESAs are a great option for federal sites that are motivated to reduce site costs, have no capital investment funding, and cannot use the U.S. Department of Defense 10 USC 2922a authority for long-term contracting.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Impact on Cycle Efficiency of Small CHP Plants from Increasing Firing Temperature Enabled by AM of Turbine Blades

Combined Heat and Power (CHP) systems are gaining popularity because of their potential for high overall thermodynamic efficiency and increased need for distributed power generation. Most CHP systems include a gas turbine for electricity generation and a heat recovery steam generator (HRSG) for steam generation. The steam can be used to power a steam turbine for additional electricity generation or to drive rotating equipment, for space heating, for absorption chillers, etc. A CHP cycle configuration is often driven by the ‘principal’ utility for the facility that it services; steam or electricity. In either case, performance improvements in the gas turbine have the potential to increase the steam and power output from the cycle, which is a direct result of improvements in the gas turbine efficiency and power output. One possible opportunity to improve an existing gas turbine’s performance is to increase the firing temperature with improved turbine cooling and increased compression ratio.<br>In this study, the impact on CHP cycle performance from increasing the turbine firing temperature by 100 °C and improving the turbine blade cooling for a 6-MW scale gas turbine is estimated using an analytical cooled gas turbine model and a steam cycle model. A sensitivity analysis was performed to understand the impact of increasing the internal cooling effectiveness, thermal barrier coating performance and blade material upgrades on gas turbine and CHP cycle efficiency. The impacts of turbine blade cooling improvements were studied for three common CHP cycle configurations identified from the literature. Various definitions for CHP cycle efficiency from the literature are used in the comparisons. The results showed that a 100 °C increase in firing temperature can increase the gas turbine efficiency by 1 percentage point without improving cooling effectiveness and add 2 additional percentage points in efficiency by using advanced turbine blades with higher internal cooling efficiency. Studied engine upgrades showed potential for increasing the CHP cycle efficiency by 3 percentage points while increasing the steam generation rate by 8%.<br>

Uysal, Selcuk Can↗
DOE OSTI2022

A Simplified Tool for Rapidly Deploying Feasibility Analytics for the Non-Technical User

District energy systems efficiently provide thermal energy to multiple buildings and facilities through a network of shared infrastructure. Frequently, district energy systems are centered around combined heat and power (CHP) plants that generate electricity, as well as heating and cooling, to the local buildings. By providing both electricity and thermal energy from a single fuel source and central location, these systems use less fuel, decrease energy and operational costs, and reduce the need for heating and cooling equipment in individual buildings.

CHP, RCDC↗