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DOE OSTI2025

Projected Operational Energy Life Cycle Data 2025

These excel files contain the environmental emission projections for key building energy sources: electricity, natural gas, propane (LPG), and fuel oil. The sources and methods are provided in the report "Projected Operational Energy Life Cycle Data Development: 2025 Update." The report and data are an update to the data previously posted here: https://netl.doe.gov/energy-analysis/details?id=f8890fac-be55-44ac-aaa9-e2888bfabe93

annual energy outlook↗
DOE OSTI2025

Projected Operational Energy Life Cycle Data Development: 2025 Update

This report documents the data sources and methods used to develop the energy life cycle data for use by the National Institute of Standards and Technology (NIST) Engineering Laboratory (EL) to be used for the development of measurement science and incorporation into decision-support tools for evaluating building and facility capital investments. The data are posted separately under DOI 10.18141/2575194.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

New Engineering Concepts to High Energy Density Li-S Batteries

Li-S batteries (LSBs) with energy densities > 500 Wh/kg @ C/5 and >1000 cycles, cycle life operating over wide temperatures has been identified to be critical for meeting the global energy demands. Progress is however, very much limited due to several major hurdles related to the following: (a) poor Li' reaction kinetics (conductivity/diffusivity) enabling full reversible S conversion to Li2S, (b) inferior electron (e) conductivity, specific capacity and cycle life due to electrolyte soluble species of polysulfides (PSs) formed with the reaction of Li ions with sulfur migrating to anode, (c) unstable solid electrolyte interphase (SEI) formation and finally, (d) dendrites that are formed on the Li metal anode severely limiting the cycle life due to polarization at the solid/liquid interfaces causing safety, inferior capacity, energy density, rate, and cycle life issues. Creation of a fully functional economical ≤$80/kWh, high energy density LSBs is vital for enabling its widespread commercial deployment and use in current and next generation electric vehicles.

25 ENERGY STORAGE↗
DOE OSTI2024

INL High-Performance and Sustainable Building Strategy

High-performance buildings are reliable, cost effective, and sustainable structures that minimize energy and water use, reduce solid waste and pollutant emissions, and limit the depletion of natural resources. High-performance buildings also provide a thermally and visually comfortable working environment that increases productivity for building occupants. As Idaho National Laboratory (INL) is the nation’s premier nuclear energy research laboratory, the physical infrastructure requires continual updating and repurposing to help accomplish that mission. INL’s infrastructure must incorporate high-performance sustainable design features to be fiscally responsible and reflect an image of innovation to the public and prospective employees. INL is a large consumer of energy with annual energy costs exceeding $16M. This High-Performance and Sustainable Building Strategy will help engineering and construction project teams design sustainable facilities, reduce life cycle operating costs, and support the INL net-zero plan while providing INL employees with a safe and healthy working environment. With these goals in mind, the recommendations described in this document are intended to form INL’s foundation for sustainable and high-performance building standards. This strategy incorporates the latest federal and Department of Energy (DOE) orders and directives, including DOE Order 436.1A, “Departmental Sustainability,” the DOE Sustainability Plan (SP), the INL Site Sustainability Plan (SSP), and Code of Federal Regulations (CFR). This document identifies the requirements of the “Guiding Principles for Sustainable Federal Buildings” (Guiding Principles) and briefly highlights the Leadership in Energy and Environmental Design (LEED) Gold certification. LEED Gold certification can be used to meet many of the requirements of the Guiding Principles.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Techno-economic and life-cycle analysis of strategies for improving operability and biomass quality in catalytic fast pyrolysis of forest residues

Many of the challenges faced by the first commercial biorefineries were associated with feedstock handling, quality, and cost. Strategies are needed to enable further expansion of biorefineries and meet the growing demand for bio-based fuels and products. Here, we examine 2 key feedstock challenges and mitigation strategies in the context of a catalytic fast pyrolysis (CFP) biorefinery: (1) the operability of the feed system, which may be improved by modifying the minimum particle size fed to the reactor, and (2) the quality of the biomass, which may be improved by employing air classification to remove undesirable material and increase fuel yields. We conduct techno-economic analysis (TEA) and life-cycle analysis for these strategies, employing a discrete event simulation model for biomass preprocessing combined with a series of correlations developed from literature data and a rigorous CFP conversion model. Our results highlight the importance of balancing increased cost and material losses from preprocessing against improved operability and fuel yields. Economics and sustainability were optimized when operating at the lowest minimum particle size, emphasizing the importance of minimizing material losses while maintaining the operability of the process. Economically, additional costs and material losses from air classification could be acceptable due to improved biomass conversion, and an optimum air classification speed was identified; however, the fuel GHG emissions were minimized when air classification was not used. Valorizing material removed during preprocessing as a coproduct could improve economics and sustainability, decreasing the burden of material losses.

09 - BIOMASS FUELS↗
DOE OSTI2025

Future grid mix impacts on whole-building life cycle assessment

Building construction and operation are a significant contribution to global greenhouse gas emissions, so understanding and mitigating emissions is crucial for reliable and realistic emissions accounting. Whole-building Life Cycle Assessment (WBLCA) is an emissions accounting method that considers lifetime environmental impacts of a building during its construction, operation, and eventual end-of-life. When performing WBLCAs, emission calculations from the building's operation over the entire building lifespan are typically based on today's energy grid mixes. This method does not consider changes or advancements in the clean energy proportion within the grid mix and can over or under-inflate results, skewing the ratio of embodied vs. operational environmental impacts. While a variety of prediction tools estimate what future grid emissions might be, predictions can vary widely. To predict the clean energy ratio within future grid mixes and the potential impact these changes might have on WBLCA, annual data from several existing U.S. grid models was averaged and probabilistic modeling was used to extend the usable projections of shorter forecasts. Results show that clean energy sources will likely continue to increase over time, although the rate of growth varies by model. On average, by 2085, the clean energy penetration of the grid is projected to reach ~81% and renewable energy is projected to reach ~71%, although no widespread consensus is reached. To understand how the future grid mix impacts lifetime building emissions within a WBLCA context, the team analyzed two 2021 IECC-compliant all-electric residential buildings: one built from traditional materials and construction processes and the other built with carbon sequestering materials and modular assembly, with a portion of energy generated on site. The results indicate that a moderate estimate of future electricity grid mixes shows a reduction of yearly operational emissions for traditional residential buildings of 55% between 2025 and 2085, and a corresponding reduction of 48% of total emissions over a 60 year building lifespan. This study offers a nuanced approach to account for the variability of future grid mix models and provides an average trend-line based on a robust collection of scenarios.

Life Cycle Assessment (LCA)↗
DOE OSTI2025

AL-CRADA-2025-01 Final Report: American-Made Wind Turbine Materials Recycling Prize Accelerate! Phase 2

This report summarizes the Phase 2 achievements of the Wind Turbine Materials Recycling Prize project led by Critical Materials Recycling (CMR) in partnership with Ames National Laboratory. The team demonstrated the technical feasibility and economic viability of recovering and reusing rare-earth Nd-Fe-B magnets from end-of-life (EOL) wind turbine generators. Through mechanical disassembly, demagnetization, and precision processing, magnets were harvested and characterized to assess structural, compositional, and magnetic properties. Results showed that recovered magnets performed on par with commercial-grade counterparts, enabling their integration into actuator and motor prototypes without redesign. System-level modeling and finite-element simulations validated operational performance, while Life Cycle Cost (LCC) analysis revealed up to 20% material cost savings and 2–3% reductions in overall motor system costs. Life Cycle Assessment (LCA) further confirmed substantial environmental benefits, including a ~94% reduction in global warming potential relative to virgin magnet production. The project’s success was enabled by a tightly integrated partnership between industry and national lab experts, illustrating a viable path for domestic magnet-to-magnet recycling. These findings support a scalable, circular solution for rare-earth material recovery, reducing dependence on imported critical minerals and advancing sustainable clean energy technologies.

Lograsso, Thomas [Ames Laboratory (AMES), Ames, IA↗
DOE OSTI2024

Navigating Exascale Operational Data Analytics: From Inundation to Insight

In this paper, we address the challenges in achieving sustainable data-driven efficiency by providing a detailed exploration of the end-to-end operational data analytics (ODA) framework that evolved through two generations of supercomputer systems at the Oak Ridge Leadership Computing Facility (OLCF). This framework addresses large data streams ingested from heavily instrumented HPC environment that accumulates multi-terabytes per day. We outline the multifaceted data life cycle across HPC procurement, operations, and research & development, identifying key obstacles and design decisions that shape effective strategies in building and supporting data pipelines end-to-end. By sharing key insights and lessons learned from our experience, we offer recommendations for the HPC community on enabling sustainable operational data analytics and beyond. Our contributions aim to bridge the gap between potential and real benefits of operational data, guiding future efforts towards integrated and sustainable operational intelligence in high-performance computing environments.

Shin, Woong↗
DOE OSTI2025

Life-Cycle Analysis of Residential Windows Retrofits: Net GHG Emission Reduction and Payback Periods

Windows are a critical envelope component that plays an important role in the overall performance and environmental impact of a building life cycle. These implications can be embedded in the window lifecycle related to its design, manufacturing, raw materials and transportation, performance during the building’s use (operational), replacements, maintenance and end-of-life. Windows may impact 25% of the heating and cooling energy use, 10% of total building energy use and 45% of the envelope heat transfer (Harris 2022). The impacts of windows on the energy consumption of buildings have been extensively discussed, however, its embodied life-cycle impacts, such as greenhouse gas (GHG) emissions, and the trade-offs between the embodied and its operational emissions are less explored. Understanding the life cycle impacts of windows may subsidize decision making process and inform the development of emerging windows technologies. BTO’s Windows Program has played an important role to increase the adoption of emerging technologies as high-performance windows in the U.S. (Harris 2022) and to consider the GHG emission impacts of the those windows is an important aspect that can support the strategic objectives and the performance targets from the national blueprint for decarbonizing the buildings sector and to reduce the on-site emissions and embodied life cycle emissions from building materials and construction (US DOE 2024).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Machine Learning Based Metamodel for Faster Life Cycle Assessment of Large Portfolio of Buildings

Managing a large portfolio of buildings involves decisions on reuse, retrofit, renovation, rehabilitation, and new construction, influenced by trade-offs between performance metrics such as cost, time, and operational flexibility over the building's life cycle. Traditional life cycle assessment tools for evaluating these metrics can be labor- and compute-intensive, requiring extensive data and modeling for each building. Metamodels (or surrogate models) using machine learning have been explored as faster alternatives, but training these models has been hindered by the limited availability of comprehensive data on key life cycle metrics. Recent advancements in machine learning, particularly deep learning techniques like zero-shot and few-shot learning, allow models to learn from sparse or limited data. We propose a machine learning-based metamodel that leverages these techniques for rapid estimation of key building life cycle metrics. This presentation will cover the model architecture, data collection, training, and validation processes, along with an ongoing case study applied to a large portfolio of buildings. We will discuss the model's performance in terms of accuracy, compute time, limitations, and its potential for expanding to additional life cycle metrics. This data-driven approach offers a promising direction for the rapid evaluation of large building portfolios.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Development of Digital Twin-Informed Predictive Maintenance for Critical Components in Advanced Reactors

Small modular reactors (SMRs) and microreactors, along with other advanced reactor (AR) technologies, are key to the future of nuclear energy. For these systems to achieve low operating costs, high reliability, and flexibility across applications, their operation and maintenance must be optimized. Digital twin (DT) technology is one of the technologies that enables real-time (or faster than real-time) monitoring and prognosis of critical components which are vital for operational efficiency, low costs, and enhanced safety of ARs, accelerating their deployment. DT technology provides dynamic virtual representation of physical assets by integrating real-time data, physics-based models, and advanced analytics, which is critical to optimizing the performance of the entire energy system throughout the life cycle. DTs empower engineers and operators to virtually explore different scenarios, configurations, and control strategies, allowing for the identification of optimal solutions that maximize reactor efficiency, safety, and economics.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Carbon Footprint Analysis of Floating PV Systems

This report, conducted by the Dutch research organization TNO, presents the first detailed life cycle inventory (LCI) analysis of operational floating photovoltaic (FPV) systems. The study, focusing on two operational systems in Western Europe, reveals that FPV systems on small inland water bodies can be a valuable complement to ground-mounted PV systems in terms of greenhouse gas emissions reduction. If PV module degradation is limited, these systems' carbon footprint is 3-4 times lower than the EU grid mix target for 2030. The report compares two FPV systems with different floater compositions (HDPE and steel/HDPE) to hypothetical ground-mounted systems, using comprehensive background data. The findings highlight the necessity for long-term monitoring and thorough environmental assessments. Josco Kester, a scientist at TNO, underscores the potential environmental benefits of these systems, which could enhance the adoption of renewable energy technologies.

14 SOLAR ENERGY↗
DOE OSTI2025

A Perspective on Pathways Toward Commercial Sodium‐Ion Batteries

Lithium-ion batteries (LIBs) have been widely adopted in the automotive industry, with an annual global production exceeding 1000 GWh. Despite their success, the escalating demand for LIBs has created concerns on supply chain issues related to key elements, such as lithium, cobalt, and nickel. Sodium-ion batteries (SIBs) are emerging as a promising alternative due to the high abundance and low cost of sodium and other raw materials. Nevertheless, the commercialization of SIBs, particularly for grid storage and automotive applications, faces significant hurdles. This perspective article aims to identify the critical challenges in making SIBs viable from both chemical and techno-economic perspectives. First, a brief comparison of the materials chemistry, working mechanisms, and cost between mainstream LIB systems and prospective SIB systems is provided. The intrinsic challenges of SIBs regarding storage stability, capacity utilization, cycle stability, calendar life, and safe operation of cathode, electrolyte, and anode materials are discussed. Furthermore, issues related to the scalability of material production, materials engineering feasibility, and energy-dense electrode design and fabrication are illustrated. Finally, promising pathways are listed and discussed toward achieving high-energy-density, stable, cost-effective SIBs.

25 ENERGY STORAGE↗
DOE OSTI2024

Life Cycle Greenhouse Gas Emissions of Coal-Biomass Co-Firing Power Plants with Carbon Capture and Storage

The United States has set a target to achieve the net-zero economy by 2050. Bioenergy with Carbon Capture and Sequestration (BECCS) is one of the promising negative-emission routes in the mitigation portfolio to help meet this goal. Coal-biomass co-firing with carbon capture and storage (CCS) is a key BECCS technology to realize the carbon mitigation at fossil-fuel power plants. The mitigation potential of co-firing option is affected by numerous critical factors, such as biomass properties, co-firing level, and carbon capture rate. The objectives of the study are to characterize and estimate the life cycle greenhouse gas (GHG) emissions and performance of coal-biomass co-firing power plants with CCS, determine the breakeven co-firing level at power plants necessary to achieve net-zero life cycle emissions, and quantify the variabilities and uncertainties in life cycle emissions. The scope of the life cycle assessment includes the fuel supply, combustion-based power generation, and CO2 transport and storage. A fuel-based life cycle module is developed and embedded in the Integrated Environmental Control Model (IECM), a fossil-fuel power plant modeling tool. This study then applies the enhanced IECM to conduct the process-based life cycle assessment for an array of biomass co-firing scenarios. Deterministic analysis indicates that reaching net-zero life cycle emissions in a biomass co-firing plant without CCS deployment is challenging. Combining biomass co-firing and CCS deployment can significantly lower the overall life cycle emissions of power plants. Net-zero life cycle emissions can be achieved with a 20 wt.% co-firing level and 90% CCS when the Powder River Basin coal is co-fired with energy crops or forestry residues. However, the breakeven co-firing level for net-zero emissions depend on the selected fuel properties. Fuel supply and plant operation are the critical stages influencing the life cycle emissions of power plants with 90% CCS. Deployment of deep CCS beyond 90% CO2 capture can remarkably reduce operational emissions and the breakeven co-firing level. With 99% CCS, the breakeven co-firing rate can be reduced to 12% on average. These findings highlight the trade-offs between technical performance and environmental impact of biomass co-firing at coal-fired power plants and emphasize the role of deep CCS in achieving a net-zero emissions future.

Wu, Wanying↗
DOE OSTI2024

Deconstructing the High Voltage Degradation Mechanisms in Na 2/3 Ni 1/3 Mn 2/3 O 2 with Single Crystals and Advanced Electrolyte

Abstract Sodium layered oxide cathodes can uniquely benefit from the existing lithium‐ion battery industry as sodium‐ion batteries gain traction as a potential low‐cost, drop‐in replacement. However, achieving relevant energy density with a suitable cycle life remains a challenge for sodium layered oxides. At high operating potentials, several competing degradation mechanisms prevent P2‐type Na 2/3 Ni 1/3 Mn 2/3 O 2 (≈550 Wh kg −1 ) from achieving meaningful cycle life—with bulk structural instability and surface reactivity being the primary retractors. Herein, the issue of particle cracking is addressed through detailed synthesis methods of “single‐crystal” materials. By comparison to a polycrystalline baseline, the single‐crystal materials quantify the capacity loss due to isolation of active material caused by intergranular particle cracking. The single crystal materials are then employed in cells with an advanced, “localized saturated electrolyte” (LSE) to demonstrate the magnitude of capacity loss due to electrolyte decomposition at the cathode surface. Mitigation of the surface reactivity through the LSE electrolyte effectively demonstrates the elevated importance of surface reactivity at high voltages despite the onset of egregious particle cracking. This work aims to guide future research into understanding molten‐salt assisted syntheses and advance the debate on surface versus bulk degradation.

Darga, Joe↗
DOE OSTI2025

Liquid Alkaline Water Electrolyzers: Comparing Performance across Design, Operation, and End-of-Life Scenarios

Liquid alkaline water electrolysis (LAWE) is a demonstrated technology for hydrogen production, yet a comprehensive life cycle assessment (LCA) of their deployment is lacking. Research leading to improvements to the core component, the electrochemical stack, along with auxiliary system materials and dynamic operation of stacks from variable electricity supply offers new data that allows for detailed modeling and evaluation. Here, we present an LCA of two facility designs based on the current state-of-the-art stack and an advanced stack with zero-gap between electrodes, and capture dynamic electricity use from solar, wind, and hybrid sources and stack recycling strategies. We present life cycle impact factors characterizing the production of 1 kg of hydrogen across 12 environmental, human health, and resource impact categories (TRACI and ReCiPe) in the contiguous United States. As expected, the source of electricity will drive impacts (e.g., 83-94% of carbon intensity); however, we find that operating using wind electricity can lower hydrogen leakage and the overall carbon intensity (1.03 kgCO 2 e/kgH 2 ) relative to solar electricity (2.57 kgCO 2 e/kgH 2 ) at matched 1:1 capacity between LAWE and the electricity source. The deployment of the advanced design and stack recycling lowers impacts across all life cycle stages. We highlight opportunities to further reduce potential impacts, including the balance of plant materials and operation cycles associated with the use of variable wind and solar electricity that result in hydrogen leakage.

08 HYDROGEN↗
DOE OSTI2026

Calcium-Doped High-Voltage Spinel Cathode for Long Cycle Life Lithium-Ion Batteries

With the promises of low cost, high operating voltage, and excellent rate capability, the high-voltage spinel material with the formula of LiNi 0.5 Mn 1.5 O 4 (LNMO) has been considered as one of the most promising cathode materials for nextgeneration lithium-ion batteries (LIBs). However, the adoption of LNMO into practical LIBs is greatly hindered due to its rapid capacity decay associated with its bulk structural instability and interfacial side reactions. To address these issues, we proposed to use the cost-effective calcium (Ca) element as a dopant to stabilize the oxygen framework and surface of the LNMO crystal. The experimental results showed that, with moderate Ca doping, the obtained cathode (Ca 0.05 LNMO) retained a specific capacity of ∼121 mAh/g (∼94.4% capacity retention) after 500 cycles at 0.5 C, compared to ∼73% for the baseline bare sample. Furthermore, the Ca 0.05 LNMO cathode retained ∼84% of its initial capacity, vs the baseline with ∼69%, after 150 cycles at the high temperature of 55 °C. The excellent battery performance of the moderately Ca-doped LNMO cathode is ascribed to its structural and kinetic advantages.

25 ENERGY STORAGE↗