Life cycle impact and cost analysis of quarry materials for land-based enhanced weathering in Northern California
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32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
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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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Data for An End-to-End Pipeline for Succinic Acid Production at an Industrially Relevant Scale Using Issatchenkia orientalis
Microbial production of succinic acid (SA) at an industrially relevant scale has been hindered by high downstream processing costs arising from neutral pH fermentation for over three decades. Here, we metabolically engineer the acid-tolerant yeast Issatchenkia orientalis for SA production, attaining the highest titers in sugar-based media at low pH (pH 3) in fed-batch fermentations, i.e. 109.5 g/L in minimal medium and 104.6 g/L in sugarcane juice medium. We further perform batch fermentation using sugarcane juice medium in a pilot-scale fermenter (300×) and achieve 63.1 g/L of SA, which can be directly crystallized with a yield of 64.0%. Finally, we simulate an end-to-end low-pH SA production pipeline, and techno-economic analysis and life cycle assessment indicate our process is financially viable and can reduce greenhouse gas emissions by 34–90% relative to fossil-based production processes. We expect I. orientalis can serve as a general industrial platform for production of organic acids.
Metabolomics↗
A System-Level Cost Modeling Framework for Design for Remanufacturing: A Case Study of an Agricultural Machine Transmission
Remanufacturing offers significant environmental and economic benefits by restoring end-of-life products to as-new conditions. Although extensive research has been conducted on the topic, the adoption of remanufacturing practices remains limited across various industries. A primary barrier to broader implementation is the substantial upfront investment required, which necessitates reliable cost modeling to justify potential future savings. Most existing models treat components independently and ignore inter-component dependencies. We develop a probabilistic, system-level cost modeling framework that integrates reliability, reusability, and a dependency matrix to capture cascading effects across components over multiple life cycles. Our model identifies those critical components that maximize remanufacturing benefits across a product's many lives. A toy example and an industry case study (John Deere PowrQuad transmission subassembly) illustrate how design alternatives affect cumulative cost. Using a Monte Carlo simulation (MCS) to perform life cycle cost analysis on the system with different design changes, we show the normalized average cost savings after three remanufacturing cycles. Accounting for dependencies meaningfully alters cost projections and ignoring them underestimates accumulated cost by up to 20% in our examples. Furthermore, the results of our study confirm that accounting for component interdependencies is necessary to produce cost estimates that meet industry standards.
Life Cycle Analysis and Design↗
Solventless, Ambient-Pressure Production of Bio-Based Lactones Over Earth-Abundant, Mixed Metal Oxide Catalysts for Circular Polyesters
Transitioning to a circular plastics economy will require use of renewable feedstocks, energy-efficient processes, and closed-loop recyclable polymers, such as polyesters. A key challenge lies in sustainably sourcing monomers used to make recyclable polyesters. This work presents a catalytic platform utilizing earth-abundant Cu(x)Ca(1-x)O mixed metal oxides for the oxidative dehydrocyclization of bio-based diols to lactones, which are advantaged for energy-efficient ring-opening polymerization. Operating below 200 degrees C, at ambient pressure, and without solvent, the process uses air as the sole oxidant, achieving high yields of lactones across a broad substrate scope of C4-8 diols in the liquid phase. The oxidative dehydrocyclization reaction is thermodynamically downhill due to water formation and energy-efficient compared to incumbent, non-redox pathways utilized in fossil carbon-based industrial processes for lactone production. Mechanistic studies reveal facile redox cycling of Cu2+-O(Ca2+)-Cu2+ interfacial sites unique to the developed catalyst. Techno-economic analysis and life cycle assessment estimate 40% lower energy demand and 15% lower GHG intensity per mass of butyrolactone produced compared to the fossil carbon-based route. Liquid-phase oxidative dehydrocyclization offers a promising approach for scalable lactone production from renewable, bio-based diols to enable circular polyesters.
36 MATERIALS SCIENCE↗
Unlocking the biofuel power of cover crop in Washington State: Enhancing potential through hydrothermal liquefaction
This study evaluates cover crops in Washington State (WA) as a renewable feedstock for hydrothermal liquefaction (HTL), supported by techno-economic (TEA) and life cycle (LCA) analysis. In the Pacific Northwest, fallow land is the common winter practice, generating no income for farmers. Over three years, field trials at two representative sites—Puyallup (cool, wet) and Othello (irrigated, no-till)tested triticale, hairy vetch, crimson clover, winter pea, and fava bean preceding cash crops. Biomass yields, composition, soil impacts, and net revenue were assessed across removal treatments. HTL conversion produced 32–37 wt% biocrude, lower than 48 wt% for sewage sludge, with modeled cradle-to-grave carbon intensities of 26–31 g CO 2 e/MJ and minimum fuel selling prices (MFSP) of $\$$6.75–$\$$7.18 per gallon gasoline equivalent (GGE), comparable to other lignocellulosic feedstocks. No significant changes were observed in soil carbon, nitrogen, or subsequent cash crop yields after cover crop removal. Farmer profitability was possible, particularly for triticale and hairy vetch at $\$$60 per dry ton. To address seasonal variability, blending with wastewater sludge was evaluated. All scenarios delivered >70 % carbon intensity reductions relative to fossil fuels, and with Renewable Identification Number (RIN) credits, MFSPs below $\$$2.5 GGE were achievable. These results demonstrate that cover crops can generate new revenue streams for farmers while serving as a flexible, low-carbon feedstock. Integrating cover crops with waste biomass offers a practical pathway to expand the bioeconomy and support year-round renewable fuel production.
Biofuels↗
Waste Management, Circular Economy and Life Cycle Assessment
This presentation covers analysis research strategies and approaches for life cycle assessment, circular economy and waste management.
circular economy↗
Sustainable Herbaceous Energy Crop Production in the Southeast United States
This project aims to develop a comprehensive assessment of the economic viability and environment sustainability of energycane and biomass sorghum for bioenergy development in the southeast United States. Data on biomass production, economics, and environmental sustainability of energycane and biomass sorghum were collected across four states (Texas, Louisiana, Georgia, and Florida) in multi-year field experiments. Comprehensive data analyses were conducted to address 13 subject areas
09 BIOMASS FUELS↗
Retrofitting Holcim Ste. Genevieve Cement Plant with CO2 Capture Plant Using Air Liquide Cryocap™ FG Technology
The global cement manufacturing industry is a major contributor to carbon dioxide emissions. The International Energy Agency's "Net Zero Emissions by 2050 Scenario" identifies CCS as a major strategy for meeting that goal. This project is among the first attempts to transfer capture technology developed at coal-fired power plants to the cement industry. The main objective of the project is to execute and complete a front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separates 95% of the total CO2 emissions at the Holcim (US) Ste. Genevieve cement manufacturing facility using Air Liquide’s Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology. The Holcim Ste. Genevieve cement plant in Missouri, US, boasts one of the largest single cement production lines in the world, with a capacity of approximately 12,000 t/day. The plant currently uses traditional fuels, namely coal and petcoke. The captured CO2 will be pipeline and geological storage grade. The industrial host site emits approximately 3.0 million tonne CO2/yr. Air Liquide’s Cryocap™ technology has been developed over the last 18+ years for CO2 capture applications. It has been shown to be applicable to a variety of industrial applications (e.g., steel, cement, SMR, Fluidized Catalytic Crackers (FCCs)). Cryocap™ FG consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The project team is led by the Prairie Research Institute at the University of Illinois at Urbana-Champaign. The tasks include: complete FEED study for retrofitting the industrial facility with a carbon capture system to support developing a detailed cost estimate; business case analysis outlining the anticipated revenue and credits if projects was built and operated; technoeconomic analysis (TEA) outlining how capture system achieves DOE capture goals; and life cycle (LCA) analysis demonstrating zero net carbon emissions. The FEED study was successfully completed. This includes completing the process basis of design; preliminary engineering; outside battery limits (OSBL) detailed engineering including a Zero Liquid Discharge (ZLD) wastewater treatment system; inside battery limits (ISBL) detailed engineering [1]. An overall project capital cost estimate within a -20%/+30% accuracy was developed. The major contributors to the Total Plant Cost (TPC), by system, are the costs associated with the Outside Battery Limit (OSBL) section of the plant which includes a new river water intake structure and a Zero Liquid Discharge (ZLD) system. By cost category, the major contributors to the TPC are equipment and subcontractor costs, followed closely by engineering, construction management, home office and contractor fees. The TEA has been created to reflect the findings of the project. It analyzes the economic performance of the Cryocap™ technology by reviewing the estimated capital costs, operating cost, and revenue. The Cost of Capture (COC) associated with the Cryocap™ technology for 95% CO2 capture, when considering NETL 2018 economic assumptions (42/58 debt/equity ratio, 5.15% interest on debt and 1.42% return on equity in real dollars) and 2022 economic assumptions (42/58 debt/equity ratio, 8.82% interest on debt and 4.90% return on equity in real dollars) was found to be much lower than that for the DOE-NETL’s base-line cases. The highest contributors to the COC are annualized capital expenditures (CAPEX) and electricity consumption which can be offset by using lower cost renewable sources. The LCA was conducted using OpenLCA which is an open-source software that is recommended by NETL. The database utilized for this study was a modified version of TRACI 2.1 (developed by the US. Environmental Protection Agency’s National Risk Management Research Laboratory and modified by NETL). The Cryocap™ FG technology does not consume fuels in significant quantities and does not utilize specialized chemical solvents subject to decomposition, such as those utilized in amine-based carbon capture systems. The Cryocap™ FG technology mainly utilizes electricity as its energy input; hence, its calculated emissions are mainly associated with the generation of electricity offsite and are dependent on the energy matrix of the grid at the time of project implementation. The water consumption impact of the Cryocap™ FG is mostly for makeup of the water lost by evaporation in the cooling tower; however, the carbon capture plant will be equipped with a ZLD system to avoid effluent streams and minimize water consumption. The successful construction and operation of this plant based on this study results will provide a means to demonstrate an economically attractive and transformational capture technology that can be used to retrofit existing plants and be deployed at new plants.
01 COAL, LIGNITE, AND PEAT↗
Life Cycle Inventories and Data Gap Analysis for Rare Earth Elements: Neodymium and Dysprosium from Mining to Magnets
The United States demand for Neodymium-Iron-Boron (NdFeB) magnets, produced from rare earth elements (REEs) such as (Nd) and Dysprosium (Dy), far exceeds its nascent domestic production capacity, rendering it reliant on vulnerable global supply chains dominated by China. To guide research and development investments in securing U.S. REE supply, defensible benchmark metrics across environmental, economic, and social dimensions are needed. In this study, we built globally-representative, process-based cradle-to-cradle life cycle inventories for Nd and Dy in NdFeB magnets lifecycles, encompassing primary material acquisition, beneficiation, smelting and refining, metal processing, specialty alloy and chemical transformation, subcomponent manufacturing, consumer application (use phase) and end-of-life management. We carried out detailed literature review, and applied process engineering principles to build industry-representative upscaled life cycle inventories for both metals. We used these models to conduct bottom-up literature review and gap analysis on existing literature, compilation of data sources for each life cycle stage (and transformations where necessary), and a preliminary technoeconomic analysis (TEA)/life cycle costing analysis (LCCA). Findings from this work emphasize the need for metal specific, representative REE LCIs to establish robust benchmarks for advancing sustainable REE technologies and guiding R&D in REE supply chains.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Evaluation of sustainable waste management: An analysis of techno-economic and life cycle assessments of municipal solid waste sorting and decontamination
This study evaluates the economic and environmental feasibility of Municipal Solid Waste (MSW) sorting and decontamination technologies across urban, suburban, and rural areas. Using Techno-Economic Analysis (TEA) and Life Cycle Assessment (LCA), the research assesses cost-effectiveness and environmental impacts, with a focus on cost variability analyzed through Monte Carlo simulations. Findings indicate significant cost differences based on population density: rural areas incur high costs up to $$764/ton due to low waste volumes and limited infrastructure, whereas suburban and urban areas have more feasible costs ranging from $36.3 to $142.5/ton. Environmental impacts also vary, with greenhouse gas emissions at 171 kg CO 2 eq/ton for copy paper and 118.6 kg CO 2 eq/ton for plastics. PM2.5 levels are 9.1 g/ton for copy paper and 6.3 g/ton for plastics, with sorting lines being the main contributors. Monte Carlo simulations reveal a 50% probability of costs being below $$102.26/ton for copy paper and $115.8/ton for plastics in suburban settings. Further, the study underscores the importance of customized waste management strategies to improve economic viability and sustainability based on local conditions.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Voltage and temperature effects on low cobalt lithium-ion battery cathode degradation
Degradation of low cobalt lithium-ion cathodes was tested using a full factorial combination of upper cut-off voltage (4.0 V and 4.3 V vs. Li/Li + ) and operating temperature (25 °C and 60 °C). Half-cell batteries were analyzed with electrochemical and microstructural characterization methods. Electrochemical performance was assessed with galvanostatic cycling, cyclic voltammetry (CV), and electrochemical impedance spectroscopy (EIS) supported by distribution of relaxation times (DRT) analysis. Electrode microstructure was characterized with scanning electron microscopy (SEM), X-ray diffraction (XRD), and X-ray absorption near edge structure (XANES) imaging. Higher cut-off voltage cycling shows presence of NiO x formation, a low diffusivity rock-salt phase, in both CV and XRD data. XRD patterns confirmed that the rock-salt phase was beginning to form at the low cut-off voltage at high temperature, but in much lower intensity than at the high cut-off voltage. Higher temperature accelerates degradation processes at both voltages. Degradation factors at high temperature include NiO x formation, cathode material dissolution, and electrolyte decomposition. SEM analysis suggests that supporting phases may isolate and disconnect active material particles reducing capacity retention and battery life cycle. DRT analysis and XANES imaging show that both high temperature samples revealed a NiO x phase based on an increased diffusive impedance and a visible shift in the XANES spectra. The low cut-off voltage, high temperature sample showed a split peak and shift to lower energies indicating early formation of the NiO x phase. The diffusive impedance, which hinders intercalation and deintercalation, is driven by the formation of the NiO x phase. While primarily driven by cut-off voltage, elevated temperature also contributes to this degradation mechanism.
electrochemical impedance spectroscopy↗
Integrating Chemical Catalysis and Biological Conversion of Carbon Intermediates for Deriving Value-Added Products from Carbon Dioxide
Carbon dioxide valorization represents an appealing approach to reducing greenhouse gases in the atmosphere. While electrocatalysis is an effective tool to reduce CO 2 into small carbon compounds, it becomes increasingly challenging to efficiently produce compounds with more carbon atoms. In contrast, while biological systems struggle to utilize CO 2 , they can readily upcycle other small carbon compounds. This project explores the use of a two-stage process that electrocatalytically converts CO 2 into methanol, formate, or acetate which is subsequently utilized by Methylotuvimicrobium alcaliphilum 20Z to produce medium chain length polyhydroxyalkanoate. A techno-economic analysis and life cycle assessment evaluates the commercial viability of the process as well as its carbon emissions. We show here an enhanced CO 2 -to-methanol electroconversion step coupled with the use of a microbial culture adapted to the process conditions to be the optimal configuration for economic potential.
09 BIOMASS FUELS↗
Economic and environmental performance of biomass gasification for renewable natural gas production in the context of the U.S. natural gas supply
Bioenergy technologies offer potential for reducing greenhouse gas (GHG) emissions. One such promising technology is biomass gasification, which is the conversion of biomass into renewable natural gas (RNG) for use with a natural gas combined-cycle power generation system. However, the associated economic and emission effects need to be better understood to enable optimal decision-making and avoid missed opportunities for enhancing efficiency and increasing system circularity. This analysis explores opportunities to (1) decarbonize natural-gas-based systems and (2) leverage the extensive US natural gas infrastructure to mobilize biomass resources to achieve environmental and economic benefits. Here, in this analysis, the research team used a spatially explicit biomass logistics model (integrated with relevant biomass availability, technoeconomic analysis, and life cycle assessment information) to simulate economically optimal biomass allocation for RNG production and use for decarbonization in the United States. Results show that the United States has the potential to produce 9203 million GJ of RNG within the expected range of $\$$12–30/GJ. Further analyses tested the overall RNG production system's sensitivity to economic and emissions parameters of nine different processes. The sensitivity analysis results indicate that the median carbon abatement cost of RNG is most sensitive to changes in emissions associated with conversion processes and land use changes. These findings provide a deeper understanding of RNG's economic and emission potential for decision-making and guiding future research.
09 BIOMASS FUELS↗
Implications of pond reliability on the techno-economic and life cycle environmental impacts of algal biofuels
Despite extensive research on algal bioproducts, there is limited understanding of how pond contamination affects their economics and environmental impacts. This work compared the costs and environmental impacts of algal biofuels across different pond failure scenarios. Pond failure was simulated by a reliability model based on pond mean-time-to-failure (MTTF). The reliability model was integrated with a process model to analyze the impacts of pond failure on the operations of algal farms and biorefineries. Process model outputs were used for techno-economic analysis and life cycle assessment to determine the minimum fuel selling price (MFSP), global warming potential (GWP), and freshwater consumption impacts of algal biofuels for five MTTF scenarios of 20, 54, 80,120, and 350 days, assuming an average mean-time-to-reset of 7 days. Results show that higher MTTFs reduce the cost and environmental impact of algal biofuels, but with diminishing returns. The average MFSPs for the 20-day, 54-day, and 350-day MTTF scenarios were $\$3.52$, $\$2.54$, and $\$2.10$ per liter of gasoline equivalent, respectively. The GWP for the same scenarios were 131, 96, and 83 g CO 2eq MJ –1 , respectively. This study highlights the significant impact of larger seed trains, required under low MTTFs, on the costs and greenhouse gas emissions of algal biofuels. Moreover, the work shows that algal biofuels fail to be cost-competitive with conventional fuels, even when productivities are increased from 17 to 35 g m –2 d –1 . Furthermore, this work is the first to explore the implications of pond failure on the sustainability of algal biofuels and provides valuable insights to algae farmers on how to reduce the costs and financial risks of algal cultivation through process design and pond management strategies.
09 BIOMASS FUELS↗
Life‐cycle greenhouse gas emissions associated with nuclear power generation in the United States
Under the 2022 Inflation Reduction Act, tax credits of up to $3/kgH 2 are available to hydrogen producers if they generate emissions at levels below 0.45 kgCO 2 e/kgH 2 , spurring producers to explore how hydrogen production via electrolysis using electricity generated by nuclear power may qualify for such tax credits. With uranium as a primary fuel for nuclear power plants (NPPs) and no on-site emissions, the upstream emissions associated with nuclear fuel supply chains largely determine the carbon intensity of nuclear energy. Using the GREET (Greenhouse gases, Regulated Emissions, and Energy use in Technologies) model, we evaluated the life-cycle greenhouse gas (GHG) emissions of uranium production and the use of uranium to generate electricity in light water reactor (LWR) NPPs. We evaluated the process chemicals and energy inputs throughout the nuclear fuel supply chain to identify the major contributors to nuclear fuel cycle GHG emissions. Such emissions are estimated at 3.0 gCO 2 e/kWh at NPPs in the United States. The greatest share of nuclear fuel cycle GHG emissions—comprising 53% of total emissions—are associated with electricity consumption throughout the fuel supply chain. We extended the analysis to include an evaluation of the carbon intensity of H 2 production via electrolysis using nuclear power from LWRs. Finally, we examined the impact of future (2035 and 2050) electricity supply chain scenarios on nuclear fuel cycle GHG emissions. Our analysis revealed a decrease of 33% (2035) and 46% (2050) in the carbon intensity of nuclear electricity relative to current nuclear fuel cycle GHG emissions.
greenhouse gas emissions↗
Demonstration and technoeconomic analysis of dodecanol production from acetate using metabolically engineered Escherichia coli
In a circular bioeconomy, the one-way conversion of petroleum to chemicals and CO 2 is replaced with processes that reduce CO 2 to energy carriers and useful materials that are returned to CO 2 upon combustion. A circular bioeconomy that relies on photosynthesis to generate sugars as the chief energy carrier and precursor to chemical building blocks has yet to overcome many recalcitrant aspects of plant-based photosynthesis, namely, high feedstock costs, arable land scarcity, food competition, and fertilizer overuse. Acetate is a potential sustainable energy carrier because it can be produced from CO 2 either electrocatalytically or by acetogens via the Wood-Ljungdahl pathway. Here, in this work, we conducted a metabolic engineering study of Escherichia coli 's ability to convert acetate into dodecanol as a model oleochemical product. We performed techno-economic and life cycle analyses to determine break-even points with alternative fossil fuel-based strategies and identified critical process performance parameters for supporting an industrial acetate-based bioprocess. These analyses showed that oleochemical yield is the primary driver of minimum oleochemical selling price and carbon intensity. Therefore, to increase yield on acetate, we deleted the aceBAK operon, which facilitates funneling of acetate into biomass instead of product. We performed additional strain engineering to increase flux towards dodecanol and increase acetate uptake. Finally, we demonstrated increased yield in controlled bioreactors, improving from 13% of the maximum theoretical yield to 37%. Rigorous uncertainty analyses assuming a range of market conditions and future technological performances resulted in 88% and 37% of simulated scenarios having lower carbon intensities than fossil fuel-based routes and lower minimum selling prices than the market price.
Acetate↗
Preliminary Techno-Economic Assessment of Gas Switching Reforming (GSR) of Natural Gas for Pure Hydrogen Production and Power Generation with Integrated CO2 Capture
The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) is an advanced auto-thermal reforming technology that produces hydrogen or syngas from natural gas. It integrates inherent CO2 capture by utilizing a specialized oxygen carrier in a single fluidized bed reactor, eliminating the need for complex, energy-intensive post-combustion separation. GSR technology builds upon Chemical Looping Reforming (CLR), an experimentally proven technology with strong potential for scaling up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H₂) and a combined cycle (GSR-CC) in which high-purity H₂ is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H₂ production by ~30% and improved efficiency relative to prior studies. For GSR-H₂, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H₂, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ~75% of total global warming impacts (~2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.
03 NATURAL GAS↗
Perspectives for sustainability analysis of scalable perovskite photovoltaics
We propose a multi-scale analytics and modeling framework to fill the gap in integrating circular solar economy principles with ecosystem and climate commitments, enabling a holistic sustainability analysis of perovskite PVs.
Tian, Xueyu [Systems Engineering, College of Engin↗