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DOE OSTI2025

Open-source microreactor design models for technoeconomic assessments

Technoeconomic analyses for advanced nuclear technologies are essential for identifying cost drivers which allow for optimizing the technology to achieve better economic performance. Microreactors are emerging as a promising and reliable-energy solution, offering inherent safety, low capital investment, and rapid deployment capabilities. Past studies have conducted technoeconomic analyses for microreactors, but there remains a need for open-source technoeconomic models that can enhance collaboration, transparency, and consistency when performing this type of analysis. The present article introduces an open-source technoeconomic model for microreactors based on bottom-up cost estimation. Since no real cost data for microreactors exists, this model leverages cost data and insights gleaned from the Microreactor Applications, Research, Validation and Evaluation (MARVEL) project. It estimates the first-of-a-kind cost of two microreactor technologies and can also calculate the N th of a kind (NOAK) cost via accounting for learning and mass factory production. The two technologies considered in this paper are the liquid–metal thermal reactor (LTMR) and the gas-cooled microreactor (GCMR). In conclusion, the goal of this study is to demonstrate bottom-up cost estimation of these microreactor technologies and provide the cost estimation models that other users can leverage for various applications such as design optimization and financial planning.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

NAWI Research Spotlight: Technoeconomic Assessment of Brine Valorization from Brackish Groundwater

This NAWI Research Spotlight Webinar was presented to the NAWI Alliance on June 27, 2024. The presentation describes project progress to date on a technoeconomic assessment of brine valorization from brackish groundwater. Desalination at inland brackish groundwater treatment plants is currently limited by high costs of concentrate management and disposal. With current methods, 5-25% of the feed is disposed of as concentrate, with 98% of disposal using conventional methods (i.e. no byproduct recovery). This project aims to assess the technical and economic feasibility of industrial ecosystems to desalinate brackish groundwater and supply existing and potential markets for clean concentrate or other bulk constituents from the brine.

Fritz, Alison↗

DOE OSTI2026

Expanding the horizon of bio-naphtha beyond gasoline blend: property characterization and conversion opportunity assessment through technoeconomic and life-cycle analyses

Bio-naphtha, a common by-product of biorefineries, is expected to experience substantial growth in supply due to increasing demands for renewable diesel and synthetic aviation fuel (SAF). However, demand for bio-naphtha itself as a gasoline blendstock is limited because of the electrification of light-duty vehicles. This work investigated valorization opportunities for bio-naphtha from catalytic fast pyrolysis, hydrothermal liquefaction, Fischer–Tropsch synthesis, and hydrotreated esters and fatty acids pathways. These opportunities include producing polymer-grade olefin via steam cracking, SAF via steam cracking followed by olefin oligomerization, and renewable aromatics benzene, toluene, and xylene (BTX) and hydrogen via catalytic reforming. Process models were developed in Aspen Plus V14 and Aspen HYSYS V14 to calculate the mass and energy balances for each conversion step. Technoeconomic assessment and life-cycle analysis were conducted to evaluate the minimum fuel/product selling price, conversion cost, and life-cycle CO2 equivalent (CO2e) emission reduction. Technoeconomic assessment results suggest a minimum fuel/product selling price as low as $1.9/kg of olefins, $6.30/gal of gasoline-equivalent SAF, and $1.2/kg of BTX without any incentives. For all pathways, these prices are dominated by bio-naphtha feedstock costs, which account for at least 76% of the total cost. Compared with petroleum baselines, bio-naphtha-derived SAF, olefins, and BTX can achieve significant CO2e emission reductions from the use of renewable carbon resources. The results of life-cycle analysis and subsequent technoeconomic assessment, incorporating carbon credits, indicate the economic viability of using bio-naphtha for polymer-grade olefin and BTX production, with product costs comparable to market prices.

Xu, Shuang↗

DOE OSTI2024

Technoeconomic Assessment of Phosphoric Acid and Rare Earth Element Recovery from Phosphoric Acid Sludge

Sustainability faces many challenges, including the availability of materials necessary for technological advancement. Rare earth elements (REEs), for example, are key materials for several manufacturing industries that can unlock renewable energy and sustainable development. In this study, a decanter centrifuge has been employed to successfully separated phosphoric acid and REE-containing particles from phosphoric acid sludge with concentrations ranging from 1000 to 2200 ppm REEs. Operating efficiently with up to 35 wt.% solids, the centrifuge was demonstrated to achieve approximately 95% phosphoric acid recovery and 90% REE recovery in a single pass, eliminating the need for additional processing steps. This breakthrough supports a proposed rare earth oxide (REO) recovery process integrating phosphoric acid (PA), elemental phosphorus (P4), and REO into two potential pathways: PA-REO and PA-P4-REO. These processes aim to reintroduce recovered phosphoric acid into the main product to significantly increase output and revenue. Post-separation, phosphorus-rich particles can be converted to P4, while REE-containing solids undergo further treatment including acid leaching, extraction/stripping, precipitation, and calcination to produce a marketable REO material. Technoeconomic analysis indicates promising profitability, with the PA-REO process showing a delta net present value (ΔNPV) of USD 441.8 million over a 12-year period and expected return within a year of construction, while the PA-P4-REO process yields a ΔNPV of USD 178.7 million over a 12-year return period. Both pathways offer robust financial prospects and demonstrate the feasibility of commercial-scale REO recovery from phosphoric acid sludge, offering an economically feasible approach to produce REEs for future sustainable development challenges related to sustainability.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advanced nuclear reactor integration opportunities for the pulp and paper industry in the U.S. context: Technical perspectives, gap analysis, and preliminary technoeconomic assessment

Pulp and paper (P&P) manufacturing requires a large amount of low-pressure (LP) steam to digest, wash wood fibers and dry pulp into paper. Most of the LP steam is extracted from backpressure turbines that produce power from high-pressure (HP) steam. This HP steam is generated from burning wood waste material; bark is burned in hog boilers, and lignin is boiled in a black liquor recovery boiler. In a typical integrated P&P mill, 50–100% of the steam is produced from these sources, while additional steam is produced in natural gas (NG), fuel oil, or coal boilers. The other energy-intensive process in the plant is the chemical-recovery section (e.g., lime kiln), which requires high-temperature processing from NG combustion to retrieve and recirculate spent chemicals. This paper assesses the energy and heat demand and material balances of a typical generic kraft pulp mill, along with the nuclear heat, steam, and power integration opportunities to replace conventional combustion systems. The paper also addresses steam and electricity generation through a comprehensive technical and engineering gap analysis of five different nuclear-integration opportunities and their process economics, thus enabling the lignin and bark to be further processed into biobased chemicals or fuels, as well as the potential to reduce overall emissions from kraft pulping. Preliminary findings have shown that the P&P industry could achieve technological benefits by integrating their current manufacturing process with small modular nuclear reactors (SMNRs) on a national level. This research aims to set the path forward for a cleaner and more resilient P&P industry.

Advanced nuclear reactor↗

DOE OSTI2024

Assessment of Technoeconomic Opportunities in Automation for Nuclear Microreactors

Achieving full decarbonization of all economic sectors remains a challenge, especially in niche markets. For example, remote communities and industrial or mining activities detached from the main electric grid heavily rely on fossil fuels, similar to urban and industrial microgrids with combined heat and power needs. A combination of renewables and energy storage is often not suitable due to cost, reliability, intermittency, and large storage requirements. Small nuclear reactors with a flexible purpose could serve these applications. Microreactors (MR) are a class of reactors that are compact, factory manufactured, transportable, and self-regulating. Typically, they generate much less power than their large reactor counterparts. The main advantages of microreactors include the versatile nature of the energy produced, the reliability of supply, and freedom from having to transport and store large quantities of fuels on-site, coupled with the absence of dependence on an electrical grid. A strong business case is needed to move from the microreactor prototype to the commercialization phase. In fact, fossil fuels are still relatively inexpensive, and in the near term, carbon credits will be available to virtually compensate for emissions. For microreactors, one of the main costs in operation and maintenance (O&M) is their staffing levels. In this study, we investigate how to optimize the number (and thus the cost) of workers, moving from a traditional, fully manned, on-site personnel approach to an unmanned, remote personnel approach. We examine four different staffing models that can be implemented as the technology matures and evolves. We estimate the staffing needs of each model and build a business case to justify the substitution of on-site personnel with adequate technologies. To do so, we propose a cost model to quantify potential cost reductions from automating O&M activities. The model accounts for both the reduction in cost derived from the reduced number of full-time-equivalent (FTE) employees and the increase in cost derived from the need to buy new control hardware as needed. Applying the cost model that we created to different scenarios, an on-site O&M cost reduction exceeding 80% can be expected. Additionally, we found that it is more impactful to focus on automating routine O&M tasks rather than attempting to automate transient management (shutdowns, restarts, monitoring condition deviations). In fact, transients typically account for less than 1% of the total FTE time spent on the reactors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Geothermal Power Systems Analysis: Outcome of Industry Stakeholders Workshop: Preprint

Geothermal cost and performance evaluation implemented via technoeconomic assessment (TEA) modeling is critical for the Department of Energy (DOE) and other geothermal industry stakeholders in assessing the current state of geothermal technologies and to identify existing hurdles to commercially viable geothermal development. The Geothermal Electricity Technology Evaluation Model (GETEM) is a major TEA tool used in estimating the economic feasibility and levelized cost of energy (LCOE) of conventional hydrothermal systems and enhanced geothermal systems (EGS). Since 2021, GETEM has been transitioning from an intricate spreadsheet model to a user-friendly tool within the System Advisor Model (SAM) developed by the National Renewable Energy Laboratory (NREL). Apart from enabling an expanded visibility of the geothermal model among other renewable resources, having GETEM in SAM has the advantage of simulation automation, better usability, updates tracking, active user inputs/feedback, and extended financial modeling. GETEM is used in developing supply curves for the Annual Technology Baseline (ATB). The ATB data are inputs to the Renewable Energy Potential (reV) and the Regional Energy Deployment System (ReEDS) models. The geothermal module in NREL’s reV model assesses the geothermal energy potential in the conterminous United States by defining the geospatial intersection of geothermal resources with existing grid infrastructure within the constraint of land use characteristics. The ReEDS model is a capacity expansion model used for simulating the long-term build-out and operation of the US generation and transmission system based on current energy costs and policies. To ensure enhanced representation of current industry trends in our model transitions and development, we organized a two-day virtual workshop to elicit geothermal industry stakeholder input and recommendations on our current approaches and assumptions on technoeconomic, resource assessment, and deployment scenarios modeling of geothermal technologies. Participants included developers, operators, investors, regulatory agencies, system modelers, national laboratory researchers, consultants, and other stakeholders. In this workshop, we gained stakeholder insights on current geothermal plant performance (i.e., capacity factors), updated drilling costs and learning curves, and next generation technologies such as closed loop and superhot rock geothermal. Other outcomes from this workshop and its impact on future geothermal development feasibility, resource availability, and capacity expansion studies are compiled and discussed.

Annual Technology Baseline↗

DOE OSTI2024

WaterTAP 0.12 Release

The Water treatment Technoeconomic Assessment Platform (WaterTAP) is an open-source Python-based software package that supports the simulation and optimization of process-scale water treatment trains. WaterTAP seeks to provide the broader water research community with an integrated modeling capability to evaluate cost, energy, and environmental tradeoffs across water treatment options and identify high impact opportunities for innovation including novel materials, processes, and systems. An updated version of WaterTAP is released quarterly and each includes documentation and release notes.

IDAES↗

DOE OSTI2024

WaterTAP 1.0 Release

AS↗

DOE OSTI2024

WaterTAP 0.11 Release

IDAES↗

DOE OSTI2024

Initial Feasibility Assessment of Agrivoltaics in Jackson County, IL

Consistent with concerns raised in other rural communities, the agricultural community in Jackson County, IL is reluctant to install ground based photovoltaic (PV) systems on prime agricultural land. Agrivoltaic solutions have the potential to mitigate community concerns of conversion of farmland to solar energy by allowing for both energy production and farming practices to occur on the same land area. To assess the potential for agrivoltaics in Jackson County, IL, the Jackson County Coalition requested technical assistance to perform an initial technoeconomic assessment, resource assessment, and feasibility assessment based on the unique agricultural context present in the area. In this paper, the National Renewable Energy Laboratory (NREL) interviewed five Jackson County experts for five key crops (vineyards, strawberries, pumpkins, apple and pear orchards, and hemp) to examine potential for agrivoltaics integration and identify key barriers that could hamper development. NREL performed technoeconomic analysis for different agrivoltaic system designs to determine the economic constraints and opportunities of agrivoltaics development. Overall, there is no one path for agrivoltaics success in Jackson County. Pilot projects can assist in demonstrating agrivoltaic feasibility to stakeholders reluctant to be first adopters. Based on preliminary analyses, agrivoltaic integration with vineyards may prove most feasible as the per acre returns of grapes are comparable with the returns needed to offset higher solar development costs for agrivoltaic systems. In terms of technical specifications of solar, pumpkins and strawberries could be integrated into more traditional solar designs, but there are concerns with shading and pest control. There is no one size fits all solution, and many options may need exploring before a workable solution is found.

14 SOLAR ENERGY↗

DOE OSTI2025

Assessment of NuScale SMR Steam Heat Augmentation for Chemical Plant Decarbonization

Nearly 50% of the total energy consumed by the industrial sector in the United States is used to produce process steam with natural gas and coal-fired boilers1 . This project conducts a technoeconomic assessment of a NuScale Small Modular Reactor (SMR) coupled with a chemical plant as an Integrated Energy System (IES) where nuclear produces steam and electric power to meet the requirements of a large chemical plant. In a 2020 study, ORNL evaluated the feasibility of using advanced SMRs, including the NuScale design, to supply energy to the Eastman Chemical Plant. However, since that report was published, NuScale received NRC approval for its uprated 77 MWe design with 56% more power and has also introduced a high-temperature, high pressure, steam heat-augmentation system, a key focus of the new study. The new study also benefits from revised capital costs, a 10-day refueling outage time, reduced plant staffing, higher capacity factors, and a site boundary Emergency Planning Zone methodology. The study consists of a techno-economic assessment of two possible energy sources (nuclear and natural gas) in a number of steam and power generation configurations (NuScale Power Modules (NPMs), boilers and combinations of both) to satisfy the steam and power demand with the most reliable and cost competitive system. A total of 2,947.3 klb/hr of steam and 72.5 MWe of electricity are required for the demonstration case. A range of scenarios and solutions are explored, from a 12-NPM plant (3,000 MWth)—with excess capacity and redundancy, capable of supplying a significant amount of extra power to the grid—to a 4-NPM (1,000 MWth) plant—supplemented with existing boilers or grid power for redundancy. The study uses historical steam and power data from a chemical plant and examines the sensitivity to natural gas and grid power cost variations. Scenarios with up to two times gas and electricity costs were considered. Profitability in a 60-year time horizon was analyzed, consistent with NuScale’s design life specification. A steady-state site integration and reliability analysis was performed, and trade-offs were identified.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2026

Biorefinery siting and sizing to achieve the US Billion‐Ton Bioeconomy vision: A case study using a gasification–Fischer–Tropsch process

Achieving a secure, abundant, and affordable energy future requires a robust and adaptable energy strategy, with bioenergy playing a pivotal role. Biomass-based energy presents a promising pathway to use domestic resources while fostering economic opportunities in rural areas. Despite the potential to source more than 1 billion dry short tons of biomass annually in the US, significant infrastructure and economic barriers hinder full utilization for energy production. This study used the Biofuel Infrastructure, Logistics, and Transportation (BILT) model to assess biorefinery siting and scale and determine the number and size of facilities required to maximize use of the US biomass potential. A spatially agnostic approach first assessed the effects of facility capacity and transportation constraints on biomass use. Then, a spatially explicit analysis integrated county-level biomass availability from the US Department of Energy's 2023 Billion-Ton Report and technoeconomic assessments to evaluate different biorefinery deployment scenarios. The results indicate that an optimized mix of facility sizes is essential to leverage biomass resources fully across varying regional production densities to maximize use of the US biomass potential. Larger biorefineries or co-located smaller facilities significantly enhance biomass use while reducing costs through economies of scale. These findings underscore the importance of strategically balancing facility capacity and spatial distribution to optimize the bioenergy supply chain. In conclusion, this study provides critical insights for advancing the US bioenergy economy by aligning biorefinery deployment with biomass resource availability and economic viability.

BILT Model↗

DOE OSTI2024

Modeling Cost of Offshore Carbon Storage in Saline Reservoirs

Poster presentation to the AAPG-SEG-SPE CCUS 2024 Conference. Offshore saline reservoirs provide a significant and accessible resource for geologic carbon storage (CS). The offshore environment requires distinct approaches to site selection, operations, monitoring, and risk that affect the technoeconomic assessment of offshore CS projects. The National Energy Technology Laboratory (NETL) has developed a CS cost model for offshore saline reservoirs known as CO2_S_COM_Offshore. Based on NETL’s widely used CO2_S_COM cost model for onshore saline CS, CO2_S_COM_Offshore enables technoeconomic analysis of CS in offshore areas. This model comprehensively incorporates multiple facets of offshore CS projects, from regional evaluation and site selection to permitting, transport, operations, monitoring, site closure, and decommissioning. Developed to model cost for offshore United States (US) Exclusive Economic Zones, aspects of this model can be adapted to international projects. Presented at the SPE/AAPG/SEG Carbon Capture Utilization and Storage Conference in Houston, TX, March 11-13, 2024.

Mark-Moser, Mackenzie K.↗

DOE OSTI2024

Carbon storage cost modeling for the offshore Gulf of Mexico

Groundbreaking for geologic carbon storage (GCS) projects in the offshore Gulf of Mexico is imminent, and there is great interest in utilizing this region for GCS projects. Offshore saline reservoirs provide a significant and accessible resource for GCS. However, conducting GCS in the offshore environment will pose distinct challenges pertaining to site selection, operations, infrastructure use, and monitoring compared to operating onshore that ultimately affect technoeconomic assessment of offshore GCS projects. Carbon storage and transport costs are critical to project developers looking to deploy carbon storage in the offshore environment. We present CO2_S_COM_Offshore, a model developed by the National Energy Technology Laboratory (NETL) as a screening-level offshore saline GCS cost modeling tool. Based on NETL’s widely used CO2_S_COM cost model for onshore saline CS, CO2_S_COM_Offshore enables technoeconomic analysis of GCS in offshore areas. This model comprehensively incorporates multiple facets of offshore GCS projects, from regional evaluation and site selection to permitting, transport, operations, monitoring, site closure, and decommissioning. In general, the model can explore the cost implications for potential offshore GCS project(s) by enabling the user to change several project operational and financial attribute configurations. Key inputs include offshore storage formation options, CO2 injection rate and duration, infrastructure types, monitoring intensity, project financing, and post-injection site care duration. Supporting cost algorithms within CO2_S_COM_Offshore were compiled utilizing S&P Global’ s QUE$TORTM cost estimation software alongside a variety of open-source scientific literature. In addition to reviewing key model components, we discuss several sensitivity analyses, input variabilities, and results on analysis of break-even CO2 price required by a project based on different regulation/policy and operational scenarios for the offshore Gulf of Mexico. These results indicate the value of modeling offshore GCS specifically, and the potential of offshore GCS within a decarbonization value chain. Presented at the 41st USAEE/IAEE North American Conference, 3-6 November 2024, Baton Rouge, LA, United States.

Mark-Moser, Mackenzie K.↗

DOE OSTI2025

Optimal design of power constrained bipolar membrane electrodialysis over a wide brine range

Bipolar membrane electrodialysis enables the in-situ production of high value products (e.g., acid and base) from clean brine, which is essential for a sustainable future. A technoeconomic assessment (TEA) was conducted on extraction of value from brine using the WaterTAP framework to identify optimal cost across a wide design space. Here, in the power constrained regime, increasing supplied salt concentration does not necessarily result in reduced cost or increased NaOH concentration. A detailed analysis elucidates the critical roles of water dissociation, limiting currents, and sodium diffusion play in shaping the landscape of levelized cost. Among these, water splitting predominantly influences the TEA outcomes across most of the optimal design space. Sensitivity analysis further demonstrates that membrane properties controlling water dissociation significantly impact the unit cost. The results indicate that innovations targeting improvements in water disassociation should be prioritised to effectively reduce the levelized cost of product production.

Bipolar membrane electrodialysis↗

DOE OSTI2026

Multilevel Analysis of Electrochemically Mediated Methanolysis of Poly(ethylene terephthalate) (PET)

Here, this study presents a multilevel analysis of electrochemically mediated methanolysis as a promising method for reducing the environmental impacts of plastic recycling, with a focus on depolymerizing poly(ethylene terephthalate) (PET) into dimethyl terephthalate (DMT). Instead of conventional chemical PET depolymerization, this electrochemical approach provides distinct technical advantages in process control and efficiency. At the process level, key operational parameters, including applied current and reaction time, were systematically investigated to optimize PET conversion and DMT selectivity. The electrochemical approach was directly compared to equivalent chemical methanolysis systems and demonstrated superior performance in terms of PET conversion and DMT selectivity. Building on these findings, a technoeconomic assessment identified the current economic bottlenecks and revealed that improvements in process design, DMT selectivity, PET conversion, and energy efficiency are key to reducing the overall process cost and enabling future implementation. While further optimization is required for market competitiveness, these results establish a performance baseline for the electrochemically mediated PET methanolysis process and underscore the importance of combining process-level innovation with systems-level evaluation in the development of sustainable recycling technologies.

chemical recycling↗

DOE OSTI2025

DeSelenator: A Se-Removal Process for Environmental Decontamination of Wastewaters from Coal-Burning Power Plants

Selenium may become a toxic contaminant of freshwater systems when released into the environment through industrial wastewaters from mining, coal-burning power plants, or oil refining. Efficient and cost-effective Se-removal technologies are therefore necessary to reduce Se concentrations in these wastewaters to below the regulatory discharge limits. In this study, we have demonstrated an effective process that removes Se, mostly as selenate anions, from wastewaters generated by coal-burning power plants. This process, dubbed DeSelenator, leverages the high concentration of sulfate relative to selenate in the wastewater and the propensity of these oxyanions to cocrystallize with benzene-bis-iminoguanidinium (BBIG) cations into extremely insoluble salts (on par with BaSO 4 ). The SO 4 2− /SeO 4 2− cocrystallization with BBIG removes over 90% of S and Se from the wastewater. Following removal of the precipitate by filtration, the filtrate is passed over an anion-exchange resin that further reduces selenium concentration to 5 ppb, the EPA’s regulatory limit for freshwater systems. Finally, the effluent is passed over an activated carbon column, which removes 99.8% of the residual BBIG ligand remaining after crystallization, allowing for the safe discharge of the treated water into the environment. The Se-removal process was first optimized in the lab at the bench scale and then tested in the field at the Tennessee Valley Authority’s Bull Run coal-burning power plant. A technoeconomic assessment found the cost of water treatment with DeSelenator is on par with that of the active biological method, which is currently considered a state-of-the-art Se-removal technology.

anions↗