Reduce, Reuse, Recycle: Reevaluating Old Coal Cores for New Purposes
Description of core characterization efforts at NETL, with a focus on using older cores for critical mineral evaluation with new techniques.
core characterization↗
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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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2016 U.S. Petroleum Fuels Life Cycle Baseline
The National Energy Technology Laboratory (NETL) has performed a well-to-wheels life cycle assessment (LCA) of petroleum production and refining for the United States (US), both from international and domestic oil sources. This analysis largely follows the same methods and framework established by Cooney et al., which performed a greenhouse gas (GHG) LCA of crude products for the 2014 data year (Cooney et al., 2017). Results are presented for six major petroleum products (gasoline, diesel, jet fuel, fuel oil, coke, bunker/residual fuel oil) across each of the five Petroleum Administration for Defense Districts (PADDs) and at the national US level. However, there are at least seven other refinery outputs (liquified petroleum gas, refinery fuel gas, hydrogen, petrochemical feedstocks, asphalt, sulfur) that are modeled but not shown in this report for brevity. Petroleum product amounts are compared against those reported by US Energy Information Administration (EIA) for each region.
02 PETROLEUM↗
Heat Transfer of Supercritical Carbon Dioxide in 3D-Printed Tubes with Internal Ribs and Yttria Stabilized Zirconia Coating
This technical report describes measurements performed in NETL’s Heat Exchanger Experimental Test (HEET) facility using supercritical carbon dioxide as the working fluid. 3D printed tubes with internal ribs and yttria stabilized zirconia (YSZ) exterior coatings were employed in the heat exchanger. Heat transfer and friction factor enhancements from the internal ribs were characterized over a range of flow conditions. Additionally, the thermal resistance from the YSZ coating was characterized for both a freshly applied coating and a coating subjected to thermal aging.
36 MATERIALS SCIENCE↗
Project-specific considerations for retrofitting carbon capture technology to power generating and industrial facilities
The National Energy Technology Laboratory (NETL) has previously reported on learnings from 7 FEED studies examining retrofitting power plants with capture. This presentation builds on this effort by highlighting learnings from 3 additional FEED studies examining retrofitting power plants with capture and 7 FEED and pre-FEED studies examining retrofitting industrial plants with capture. This includes a discussion of the design, performance, and cost implications associated with (1) site-specific considerations such as water availability, land availability, and site accessibility, and (2) host-plant-specific factors such as flue gas specifications, operational mode, and allowable degree of integration between the capture system and host plant.
FEED Studies↗
Techno-Economic Analysis of Compressed Air Energy Storage and Hydrogen Production from Variable Renewable Energy
This study presents the techno-economic analysis (TEA) results of integrating electrolysis hydrogen (H 2 ) production, compressed air energy storage (CAES), and H 2 -fired combustion turbines in a high variable renewable energy (VRE) market environment. The inconsistent nature of VRE creates challenges for power producers in maintaining a stable electrical grid as it is increasingly utilized. The mission of the National Energy Technology Laboratory (NETL) is driving innovation and delivering energy solutions, and a multiangle approach involving H 2 production, energy storage, and next-level H 2 -fired combustion turbine generator (CTG) technologies could provide one solution for the nation’s growing electrical grid issues with increasing VRE sources. The H 2 production and CAES concept were investigated due to its ability to provide utility-scale H 2 -fueled power generation with large-scale energy storage capabilities. Two facilities with CAES and natural gas-fired CTGs (in McIntosh, Alabama, and Huntorf, Germany) have been operating for decades. In contrast, this study investigates the potential to replace the natural gas fuel with H 2 fuel. This concept has been publicly presented by both Siemens Energy and Bechtel Global Engineering, Construction & Project Management (Bechtel) at two different power generating levels. The CAES and air expansion/combustion turbine power generation in this study are primarily based on the Siemens Energy system (Bailie, Aug. 10-11, 2021) (Scheller, Feb. 21, 2023). The inclusion of a H 2 turboexpander generator is from Bechtel (Gülen, Sep. 6, 2022). A block flow diagram of the proposed process is illustrated in Exhibit ES-1.
08 HYDROGEN↗
Engineering Core-Clad Structures in Single-Crystal Sapphire Fibers via Dopant Segregation
This poster was displayed at UPISC. It details NETL advancements in single crystal optical fiber.
coal fired power plant generation↗
Where the Past Meets the Future: Reevaluating Historic Drill Cuttings for Critical Minerals Exploration
This presentation describes NETL's capabilities to process and examine historic drill cuttings in search of resources required for American Energy Dominance.
58 GEOSCIENCES↗
The Effect of Flow on CO2 Corrosion of Self-Healing Metallic Coatings
Internal corrosion is an issue that affects natural gas pipelines, a significant part of the United States’ energy infrastructure. Over time, this corrosion has worn away longstanding pipelines due to the original construction materials used for the lines and impurities in the gas and liquid streams flowing through them. The main impurities in natural gas are H2O, CO2, H2S, and O2. One of the leading causes of corrosion is the CO2 dissolved in water, giving rise to carbonic acid formation, which can further dissolve the steel pipe. The National Energy Technology Laboratory (NETL) has been studying different solutions to this problem. One potential answer is a self-healing sacrificial metallic coating applied by a novel cold spray technique. This study explored the impact of flow on corrosion with this coating and carbon steel when exposed to a saturated CO2 environment by simulating the pipeline flow profile in a small-scale lab setting. The samples were evaluated using multiple electrochemical techniques that found corrosion rates and were backed up with surface analysis to conclude the behavior of the corrosion mechanisms. The cold spray coating exhibited steel corrosion protection under flow conditions. This study has significantly advanced our understanding of CO2 corrosion, particularly in the context of natural gas pipelines and coating design.
carbon steel↗
FlowDash Geothermal Energy Enhancer: Where is Next Geothermal Resource? Machine Learning + Multiple Datasets => Geothermal Exploration Indication?
This is the presentation delivered at the 2025 GEODE Datathon competition. GEODE is a consortium of experts that addresses technology and knowledge gaps in geothermal energy, leveraging technology and best practices from the oil and gas industry. NETL team was awarded the 1st place in the engineering track. 2025 GEODE Datathon had a total of 42 teams from top universities and several major industrial companies. This awarded work is founded on a robust idea and innovative approach that uses machine learning coupled to multiple datasets to visualize geothermal “sweet” spots/indications in Great Basin based on the data provided from the GEODE Datathon. The use case also leveraged other datasets and demonstrated insightful and valuable indications for geothermal exploration.
Geothermal energy, Machine learning, Multiple Data↗
Dynamic Evaluation of the Upper Tyler Formation and Well Stimulation Fluid Interactions Using Micro-CT Imaging
Abundant concentrations of swelling clays in the oil-bearing upper Tyler Formation inhibit unconventional well stimulation techniques and associated long-term oil and gas production success. Laboratory evaluation of the geochemical interactions between the formation material and various stimulation fluids may help identify innovative approaches that provide a solution to successful well stimulation and subsequent oil production. The objective of this research was to understand the complexities of well stimulation fluid and clay mineral interactions within the Tyler Formation and identify potential fracturing fluid formulations that mitigate swelling properties of the clays in the reservoir to enhance stimulation success and promote long-term oil and gas production. Collaboration with the National Energy Technology Laboratory (NETL), utilizing their Tescan DynaTOM micro-CT analysis instrumentation, provided an innovative approach to understand real-time, dynamic interactions of the formation material and various potential stimulation fluids. Results are anticipated to identify key mechanisms occurring at the micro-scale level and provide insight into modified stimulation techniques uniquely suited for successful production applications.
enhanced oil recovery↗
Preliminary Screening Techno-Economic Analysis of Industrial SOFC/SOEC and Reversible SOC Integration
National Energy Technology Laboratory (NETL) provides system-level process, cost, and market analyses on solid oxide cell (SOC) based technologies. Specifically, techno-economic analyses (TEA), market assessments, and other technology evaluations serve to guide the U.S. Department of Energy (DOE) Office of Fossil Energy and Carbon Management (FECM) Reversible Solid Oxide Fuel Cell (R-SOFC) Program technology goals and objectives. These studies are key to describing how the technologies contribute to improving domestic energy infrastructure in a clean, efficient manner. This effort seeks to elucidate the potential integration opportunities between reversible SOCs and industrial systems which would aid in SOC commercialization and deployment. These preliminary screening-level results show what opportunities exist for power generating SOFCs, hydrogen producing SOECs, and point-source carbon capture. Improvements can be seen through changes in cost of electricity, cost of hydrogen, and cost of carbon capture.
reversible SOC↗
Review of DOE-Sponsored FEED Studies for Retrofitting Existing Fossil Power Plants with Carbon Capture Technology
NETL has been reviewing recently published DOE-funded FEED studies for retrofitting fossil power plants with carbon capture technology. This presentation, prepared for the 8th IEAGHG CCS Cost Network Workshop, presents learnings from reviewing these FEED studies.
carbon capture and storage (CCS) retrofit↗
Impacts of Small-Scale Heterogeneity on Large-Scale Subsurface Flow
Discussion of NETL's CT scanning and core characterization capabilities, followed by a rapid review of several recent publications that utilize these capabilities to answer reservoir questions at the micro scale with relevance to field scale operations.
core characterization↗
Supersaturating Water with CO 2 via Nanobubble Formation
The subsurface storage of CO 2 is limited by the solubility of CO 2 in brine. One proposed solution to increase the volume fraction of CO 2 in a reservoir is by injecting the CO 2 at high pressure in nanobubble form. These nanobubbles, diameter <50 nm, would be small enough that they would only undergo Brownian motion, preventing them rising under buoyancy and escaping the formation. There has also been some experimental work that suggests the present of these nanobubbles significantly (~2x) increase the solubility of gaseous CO 2 in the aqueous phase. NETL and ExxonMobil will test the viability of this strategy to increase the volume fraction of CO 2 in a subsurface reservoir, determine the stability of these nanobubble systems, and understand the ultimate limits of increasing the CO 2 volume fraction.
54 ENVIRONMENTAL SCIENCES↗
Onset of Fluidization in MP-PIC Simulations using MFIX-Exa
Fluidized bed reactors are used across a variety of industries, including for energy processes like pyrolysis that result in low-cost energy products. Design and scale-up of fluidized beds is de-risked by modeling and simulation, utilizing tools like NETL’s MFIX-Exa High-Performance Computing (HPC) code for reacting multiphase flow. This report summarizes an investigation into the breadth of problems to which MFIX-Exa may be applied, specifically with regard to low fluid velocities and the onset of fluidization. A simple fluidization study is conducted both experimentally and numerically for particles of interest, then reactor simulations are compared to cold flow experiments for uniform distributor plates. Approaches for modeling bubble caps are also presented.
discrete particle method↗
SuperLab 2.0 Showcase: Connecting Five Labs to Tackle Grid Complexity and Unlock Unique Grid Asset Potential
SuperLab 2.0 (5-Lab Demo) is a collaborative, national-scale experiment showcasing the coordination of geographically distributed energy assets in real time. The demonstration integrates 25 physical and digital assets, spanning wind, PV, batteries, electrolyzers, DC fast chargers, microgrid controllers, building automation systems, small modular reactor (SMR), control centers, and gas turbines, across five DOE national laboratories-NLR, INL, NETL, LBNL, and SNL. These assets are unified using Energy Sciences Network (ESnet), a low-latency, high-performance U.S. Department of Energy's (DOE) network, and controlled via a centralized energy controller hosted at NLR's ARIES facility. The demonstration validates the ability to stress-test hybrid energy systems under dynamic scenarios to de-risk advanced control strategies for greater resilience and flexibility. SuperLab 2.0 (5-Lab Demo) showcased a major advancement in federated national laboratory collaboration, enabling real-time, cross-laboratory experimentation to coordinate geographically dispersed distributed energy resources (DERs) using various communication protocols and networks. SuperLab 2.0 (5-Lab Demo) built on previous demonstrations conducted between NLR-PNNL and NLR-INL connecting diverse assets including distant protection devices, a SMR simulator, and a high temperature electrolyzer (HTE). Previous demos were based on a single connection between two labs with minimal coordination challenges. The 5-Lab demo with a centralized controller, distributed testbeds across different geographical locations, and use of protocols-based communication represents a scenario closer to real-world grid operations that coordinate resources across a region to meet system needs. This experiment studied how local DER controllers interact with a centralized energy controller during normal and abnormal events to maintain reliability. The SuperLab team across the five labs implemented a notional power system model equivalent of transmission and distribution lines, represented by the data networks interconnecting the labs. Each lab continuously exchanged local parameters (such as P and Q) from its Hardware-In-Loop (CHIL) and Power Hardware-In-Loop (PHIL) assets through centralized energy controller at NLR, enabling real-time interaction and coordination across sites. By leveraging ESnet as the communication backbone, the team successfully operated the distributed assets as a unified power system, with each bus represented by a different laboratory. This setup mirrors how assets interact in real-world power systems across dispersed locations with various protocols and latencies. At each lab site, assets were operated using their own local controllers which were coordinated through an overarching operation and control layer of centralized energy controller, equivalent to how an energy management system (EMS) orchestrates assets across a regional or national grid. SuperLab's federated connectivity utilized a Digital Real-Time Simulators (DRTS)-type gateway to connect Controller Hardware-In-Loop (CHIL) and PHIL assets between labs. To enable this federated connection through ESnet, a deterministic network was established where latency variations were consistent. This consistency allowed the development of digital filters for the power system assets across CHIL and PHIL interfaces to avoid unstable and unreliable grid conditions. This report provides an overview of the cross-laboratory configuration and offers insights into interconnecting geographically distributed research assets to test them as if they were co-located. This experiment represents a step toward linking nine DOE national laboratories, enabling nation-wide simulations that can address utility-driven challenges with grid resilience, flexibility, and modernization.
24 POWER TRANSMISSION AND DISTRIBUTION↗
New opportunities in produced water management: A market-based approach to produced water trading
Produced water (PW) is a byproduct of oil and gas (O&G) production. Obtained alongside the more valuable energy products, PW is usually characterized by high levels of salinity and often contains many contaminants (chemicals, soluble and insoluble oil, organics, etc.) making it unsuitable for release without substantial treatment. Couple this with the fact that PW is typically obtained at multiple times the rate of oil or gas, and the added transport, treatment, and disposal costs become a serious challenge for operators. These realities have led to ad-hoc practices including cooperation between industry competitors to recycle, share, or otherwise mitigate PW costs. The National Energy Technology Laboratory (NETL) in partnership with the Ground Water Protection Council (GWPC) is pursuing novel technology solutions to address PW issues that complement or improve ad-hoc practices adopted by operators. In this paper, we observe that well-established market management practices used in electrical power generation have natural analogues in the PW supply chain. These parallels open up a new line of research where we view PW management as a market equilibrium problem, and explore solutions that foster active and data-based collaboration among operators through market structures similar to power markets, with the ultimate objective of improving PW management costs and recycling rates. Here, we make a case for our observations, present a PW market clearing optimization model that shows how such a market system could operate in the O&G space, and provide an illustrative case study for demonstration.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Revisiting Dimensionless Parameters Quantifying Film Cooling
This paper describes a dimensional analysis of film cooling effectiveness for crossflow-fed film cooling holes. An additional parameter is required to account for swirl inside the film cooling hole. Computations based on Reynolds-Averaged Navier-Stokes (RANS) show significant improvements in cooling effectiveness when the coolant supply velocity is decreased. NETL experimental data was used to validate these computational results.
advanced gas turbines↗