Engineering topics

Hartley, Damon S.

Publications and source records attributed to Hartley, Damon S..

At least 19 records

DOE OSTI2024

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↗

DOE OSTI2024

Woody Feedstock 2022 State of Technology Report

The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement in this mission, Idaho National Laboratory completes an annual SOT report for n th -plant and 1 st -plant woody biomass feedstock logistics. The purpose of the SOT is to provide the status of feedstock supply system technology development for woody biomass to biofuels relative to technical targets and cost goals from specific design cases, based on data and experimental results. Conventional feedstock supply systems need to be modified to meet the demands of conversion pathways, specifically to have the ability to adjust the quality of the raw biomass materials. Advanced systems incorporate innovative methods of material handling, preprocessing and supply chain configuration. In advanced designs, variability of the raw biomass can be reduced to produce feedstocks of a uniform format, moving toward biomass commoditization. Against this backdrop, the 2022 Woody SOT for low-ash woody feedstocks utilizes feedstock fractionation by incorporating technologies that can separate the biomass into its anatomical fractions (wood, bark, needle, and extrinsic ash) to reduce impurities and attempt to maximize the retention of usable fractions that satisfy downstream quality considerations. By using a series of air classification steps, this strategy can reduce the extrinsic ash in forest residues, separate out a majority of the incoming needles (which can be supplied to alternate markets), and maximize the retention of whitewood in the usable fraction. The fractionated forest residues are then mixed with clean-pine chips in a 50-50 blend to prepare the feedstock for the desired conversion pathway. The n th -plant analysis estimated the delivered cost for the feedstock at $\$$69.23/dry ton (2016$\$$) which represents a $\$$6.64/dry ton decrease compared to the cost estimate of the 2021 Woody SOT supply system for low-ash woody feedstocks. The quality requirements in the 2022 Woody SOT were identical to those of the 2021 Woody SOT at = 1.00 wt % ash and = 50.51 wt% carbon. The cost savings derive primarily from reductions in dry matter losses during air classification. The GHG emissions for the n th -plant analysis were estimated at 178.39 kg CO2e/dry ton compared to 178.71 kg CO 2 e/dry ton in the 2021 Woody SOT, a decrease of 0.32 kg CO2e/dry ton. The small change stems from an increase in emissions attributed to preprocessing and slightly larger savings in emissions from transportation. In the 1 st -plant analysis of the 2022 Woody SOT system, the average throughput was estimated to be approximately 2,128 dry tons/day or 96.51% of the name plate capacity. During the simulation the daily throughput ranged from 1,090 dry tons/day to 2,200 dry tons/day, or 49.43% to 99.75% of the daily nameplate capacity. After the year of operation 722,403 tons of processed feedstock were produced in total without regard to quality considerations (99.64% of the annual nameplate capacity). The variability in throughput was primarily caused by equipment failures in the system. Regular failures, downtime caused by routine maintenance per manufacturer guidelines, contributed to a majority 62.50% of failures and 62.60% of downtime. Failures due to wear were the other cause of disruption within the system, impacting the rotary shear and orbital screen and accounting for 37.50% of the failures and 37.40% of the total downtime. Ultimately the system was on stream for 87.84% during the simulation period, which is only 2.16 percentage points below the nth-plant assumption for on-stream time. The production cost of the system averaged $\$$71.66/dry ton. The costs ranged from a minimum of $\$$71.23/dry ton to a maximum of $\$$2,115.30/dry ton. When dry matter losses (disposed low-quality fractions as well as other losses such as in grinders) were considered the costs increased to an average of $\$$75.11/dry ton with a minimum of $\$$74.69/dry ton and a maximum of $\$$2,136.86/dry ton...

09 BIOMASS FUELS↗

DOE OSTI2024

PET and polyolefin plastics supply chains in Michigan: present and future systems analysis of environmental and socio-economic impacts

Many actions are underway at global, national, and local levels to increase plastics circularity. However, studies evaluating the environmental and socio-economic impacts of such a transition are lacking at regional levels in the United States. In this work, the existing polyethylene terephthalate and polyolefin plastics supply chains in Michigan were compared to a potential future (‘NextCycle’) scenario that looks at increasing Michigan’s overall recycling rate to 45%. Material flow analysis data was combined with environmental and socio-economic metrics to evaluate the sustainability of these supply chains for the modeled scenarios. Overall, the NextCycle scenario for these supply chains achieved a net 14% and 34% savings of greenhouse gas (GHG) emissions and energy impacts, when compared with their respective baseline values. Additionally, the NextCycle scenario showed a net gain in employment and wages, however, it showed a net loss of revenue generation outside of Michigan due to the avoided use of virgin resins in Michigan.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Characterizing value-added pellets obtained from blends of miscanthus, corn stover, and switchgrass

The current pellet industry primarily relies on woody biomass. Inclusion of a diverse feedstock, such as herbaceous biomass, is necessary to meet the rising demand for pellets in heat and power generation, and for biofuel production. This study was motivated by the need to densify biomass, improving its naturally low energy density, to reach the required pellet standards for biofuel conversion. Here, we developed value-added miscanthus pellets blended with different ratios of corn stover and switchgrass and analyzed their chemical, physical, and mechanical properties. Pure miscanthus pellet durability index (PDI) was less than 85 %, well below the ISO 17225-6 standard for herbaceous pellets. While increasing switchgrass and corn stover ratios increases durability beyond 94 %, it also increases ash content from 1.6 % to 4.6 %, a quality unfavorable for biofuel conversion. The moisture content of the blended pellets varied from 7.12 % to 12.45 %, and positively correlated with the durability of the pellets. Pure miscanthus pellets had the highest bulk density, 633 kg/m 3 , while pellets containing 75 % miscanthus and 25 % corn stover had the lowest density, 564 kg/m 3 . The findings of this study also identified a decrease in the pellet bulk density with the increase in ash content and pellet diameter.

09 BIOMASS FUELS↗

DOE OSTI2024

Liquid Fed Pyrolysis of Polyethylene Films: Environmental and Economic Assessments of Co-located and Remotely-Located U.S. Facilities

Polyethylene (PE) films are one of the highest production volume plastic products, but they have very low recycling rates. A novel liquid fed pyrolysis process (LFP) is an advanced recycling technology that can be applied to waste PE films. In this work, two environmental and six economic metrics were evaluated for the LFP process under different scenarios with a baseline production capacity of 8,400 Metric Tons (MT) of pyrolysis products/year. The studied scenarios considered process improvement such as heat integration, changing the final product yields, and location of the LFP process facility (i.e., co-located at a petrochemical facility or located remotely). Results show that producing refined pyrolysis wax in remote areas is the most environmentally favorable and profitable scenario. The LFP process co-located at a petrochemical facility and selling only liquid and gaseous pyrolysis products to the facility would require a capacity of >18,000 MT/year to be economically feasible. Heat integration led to greenhouse gas emission savings of at least 14%, 19%, and 32% for the pyrolysis oil, gas, and wax products, respectively. Fianlly, the LFP process in remote and less populated locations producing a high yield of refined wax may be a feasible solution for increasing recycling rates of PE films.

Advanced recycling↗

DOE OSTI2024

Nth-plant scenario for blended pellets of Miscanthus, Switchgrass, and Corn Stover using multi-modal transportation: Biorefineries and depots in the contiguous U.S.

The sustainability of the biofuel industry depends on the development of a mature conversion technology on a national level that can take advantage of the economies of scale: the nth-plant. Here, this study addresses the logistic challenge of mobilizing national cellulosic feedstock supplies for a sustainable bioenergy industry. A Mixed Integer Linear Programming (MILP) model was developed and updated to deliver on-spec biomass that considers both a desired quantity and quality at the biorefinery. Our supply chain analysis includes multi-modal transport (truck and rail), varying depot and biorefinery sizes, and feedstock blends of corn stover (harvested by either a two- or three-pass method), switchgrass, and miscanthus. The following US states: Illinois, Kansas, Missouri, North Carolina, Oklahoma, Georgia, and Texas were identified as key locations for producing accessible miscanthus. Based on our most optimistic scenario, using trucks as the only transportation mode in 2040 with a cost target of $\$$79/dt, corn stover, switchgrass, and miscanthus could help meet 48% of the EPA target, 173 million dry tons that translate into 7.8 billion GGE. The addition of rail transportation for biomass delivery to biorefineries could help meet 79% of the EPA target, 283 million dry tons that translate into 12.7 billion GGE.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

Solvent based dissolution–precipitation of waste polyethylene terephthalate: economic and environmental performance metrics

Evaluating six economic and two environmental performance metrics for recycling of waste PET via solvent-based dissolution–precipitation processes.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Value Proposition of Coatings or New Alloys on Hammer Wear

The goal of this Case Study was to compare the cost savings from improving the life span of parts that wear within a system to the additional material cost required to reach varying levels of improved life span. We recognize that the failure limits and system performance are representative of a single system that may or may not exist in the real world, however, our goal for this analysis was not to provide an answer for a specific system or to provide a full understanding the economics of all potential systems. The analysis was performed using relative changes from the base alloy cost and considered relative improvements in part life in order to generalize the comparison without referencing specific alloys or coatings that might be employed. Ultimately, this work provides a first check of the potential for improving wear characteristics of grinder hammers to provide a meaningful and impactful benefit to biomass preprocessing and conversion systems.

biomass conversion↗

DOE OSTI2023

Impact of Anatomical Fractionation of Corn Stover on Hammer Mill Throughput and Energy Consumption

ash content↗

DOE OSTI2023

Particle Scale Impacts on Deconstruction Energy of Pine Residues

The goal of this Case Study was to quantify the impacts of variable moisture and ash on hammer mill throughput and energy consumption and on generation of fines that are not able to be fed to conversion, as compared to a status quo Base Case system. Also considered was convertible carbon content (minimum carbon specification) and maximum ash content and the delivered feedstock cost impacts of not being able to feed residue not meeting both specifications to the conversion reactor. Laboratory data on the impacts of input particle size and moisture content on the exit particle size were received from FCIC Subtask 5.2: Preprocessing, High Temperature Conversion Preprocessing from their single particle impact population balance modeling study (Tiasha Bhattacharjee, INL). Additional throughput and energy consumption data were obtained from FCIC Subtask 5.2 (Jordan Klinger, INL) for the same grinder with a 6 mm screen in place. These data were utilized to develop the necessary response surface equations to perform throughput analysis using discrete event simulation. Because the ash contents in the separated fines had not been analyzed in the laboratory at the time of the model runs, we chose to assume that the ash distributed proportionally with total mass into the overs and unders in the disk screen following grinding.

energy consumption↗

DOE OSTI2023

Air Classification of Forest Residue for Tissue and Ash Separation Efficiency

The goal of this Case Study was to evaluate the performance of air classification of logging residues toward meeting conversion CMAs for carbon and ash contents, as compared to the static status quo Base Case system in which the residues are first dried and then ground in a hammer mill with a 6 mm screen and fines less than 1.18 mm are removed. Also considered were moisture and ash impacts on throughput and Overall Operating Effectiveness (OOE), as well as delivered feedstock cost and minimum fuel selling price (MFSP). Laboratory data on the impacts of fan speed and moisture content on the separation efficiency of soil ash, needles and bark from white wood were received from FCIC Subtask 5.2: Preprocessing, High Temperature Conversion Preprocessing (Jordan Klinger and Tiasha Bhattacharjee, INL). Average throughput and energy consumption data were obtained from the Bioenergy Feedstock National User Facility (BFNUF) (Neal Yancey, INL) for the same air classifier. These data were utilized to develop the necessary response surface equations to perform throughput analysis using discrete event simulation. Feedstock-Conversion Interface Consortium. Because the Base Case status quo system utilizes drying prior to grinding, we modeled the Case Study with drying prior to air classification and subsequent grinding of the separated white wood to isolate the individual quality and cost impacts of air classification relative to the Base Case system.

CMA↗

DOE OSTI2023

Importance of incorporating spatial and temporal variability of biomass yield and quality in bioenergy supply chain

Abstract Biofuels made from biomass and waste residues will largely contribute to United States’ 2050 decarbonization goal in the aviation sector. While cellulosic biofuels have the potential fuel performance equivalent to petroleum-based jet fuel, the biofuel industry needs to overcome the supply chain barrier caused by temporal and spatial variability of biomass yield and quality. This study highlights the importance of incorporating spatial and temporal variability during biomass supply chain planning via optimization modeling that incorporates 10 years of drought index data, a primary factor contributing to yield and quality variability. The results imply that the cost of delivering biomass to biorefinery may be significantly underestimated if the multi-year temporal and spatial variation in biomass yield and quality is not captured. For long term sustainable biorefinery operations, the industry should optimize supply chain strategy by studying the variability of yield and quality of biomass in their supply sheds.

09 BIOMASS FUELS↗

DOE OSTI2023

A decision support tool for e-waste recycling operations using the hen-and-chicks bio-inspired optimization metaheuristic

E-waste from end-of-life electrical and electronic devices is one of the fastest growing waste streams from households and businesses. E-waste recycling yields environmental sustainability and economic benefits. Due to continuous changes in e-waste types and compositions, recycling businesses face challenges to optimize their operational configuration to achieve better economic and environmental performance. To help e-waste recyclers mitigate this problem, we have developed a modular decision support tool called the Comprehensive Manufacturing Assessment Tool (CMAT) that can simulate both e-waste recycling operations and economics. This tool can give valuable insights regarding the profitability of the entire operation and different e-waste types. In addition, a new bio-inspired metaheuristic optimization algorithm, hen-and-chicks optimization (HACO), was developed to assign manpower to different workstations to maximize operational efficiencies. According to the results of our case study, laptops, desktops, and computer peripherals are the three electronic waste products that produce the most profit. Our examination of the sensitivity of material prices shows that the price of steel has the most significant influence on total profit, because it is the most widely used material in the majority of electronic devices. We have released the decision support tool as open-source software under a general public license. It could be customized for other recycling industries beyond e-waste to achieve business sustainability by making their operations more efficient.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Improving knife milling performance for biomass preprocessing by using advanced blade materials

Mechanical preprocessing of biomass, including size reduction, is a crucial step in converting biomass into biofuel. However, feedstock inevitably contains abrasive intrinsic and extrinsic inorganics that may cause excessive tool wear in preprocessing. Here, this work demonstrates that performance of a knife mill can be significantly improved by applying a more wear-resistant blade material. A series of full-scale knife mill tests were performed for size reduction of forest residue using blades of tungsten carbide (WC–Co), iron-borided tool steel, and diamond-like carbon (DLC) coated tool steel. Blade material loss was quantified in correlation to the amount of feedstock processed and wear mechanisms were investigated via worn surface characterization. While the thin DLC coating was removed quickly, the WC-Co and iron-borided blades improved the tool life by 8X and 3X compared with the M2 tool steel blades (baseline), respectively. The in-situ throughput and power consumption measurements provided additional insights. The WC-Co and iron-borided blades had ~3X higher throughput than the baseline blades by the end of the test with lower normalized power consumption. The experimental results were then used as input for a techno-economic analysis, which suggested that the more wear resistant blades could cut the knife milling cost by $2–3 per ton of biomass processed with downtime reduced by 65–85%.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Integrated Land Suitability Assessment for Depots Siting in a Sustainable Biomass Supply Chain

A sustainable biomass supply chain would require not only an effective and fluid transportation system with a reduced carbon footprint and costs, but also good soil characteristics ensuring durable biomass feedstock presence. Unlike existing approaches that fail to account for ecological factors, this work integrates ecological as well as economic factors for developing sustainable supply chain development. For feedstock to be sustainably supplied, it necessitates adequate environmental conditions, which need to be captured in supply chain analysis. Using geospatial data and heuristics, we present an integrated framework that models biomass production suitability, capturing the economic aspect via transportation network analysis and the environmental aspect via ecological indicators. Production suitability is estimated using scores, considering both ecological factors and road transportation networks. These factors include land cover/crop rotation, slope, soil properties (productivity, soil texture, and erodibility factor) and water availability. This scoring determines the spatial distribution of depots with priority to fields scoring the highest. Two methods for depot selection are presented using graph theory and a clustering algorithm to benefit from contextualized insights from both and potentially gain a more comprehensive understanding of biomass supply chain designs. Graph theory, via the clustering coefficient, helps determine dense areas in the network and indicate the most appropriate location for a depot. Clustering algorithm, via K-means, helps form clusters and determine the depot location at the center of these clusters. An application of this innovative concept is performed on a case study in the US South Atlantic, in the Piedmont region, determining distance traveled and depot locations, with implications on supply chain design. The findings from this study show that a more decentralized depot-based supply chain design with 3depots, obtained using the graph theory method, can be more economical and environmentally friendly compared to a design obtained from the clustering algorithm method with 2 depots. In the former, the distance from fields to depots totals 801,031,476 miles, while in the latter, it adds up to 1,037,606,072 miles, which represents about 30% more distance covered for feedstock transportation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Techno‐economic assessment of single‐stream feedstock logistics supply chain for corn stover and grain

Abstract The state‐of‐technology for corn stover harvest is a multi‐pass system that collects the stover after grain harvest. An alternative is a single‐stream system where the grain and stover are harvested as a bulk material co‐stored and preserved by anerobic fermentation, and finally, co‐transported to a biorefinery. In the present work, four single‐pass whole‐plant bulk systems were compared with a conventional multi‐pass bale system. The single‐stream systems consisted of the harvest of corn grain and a portion of the stover fraction. Four machine configurations were simulated. This work predicted that a multi‐pass bale system would result in a material cost of 111.80 $2021 Mg –1 stover DM delivered to the biorefinery gate. Alternatively, the lowest cost single‐stream system was the self‐propelled forage harvester (SPFH) configured with the whole‐plant header, which delivered feedstock for 74.76 $2021 Mg stover DM –1 . In addition to machine configuration, a sensitivity analysis was performed to understand important drivers of feedstock cost. These analyses revealed that feedstock cost increased with moisture content, fertilizer price, and biorefinery size, and decreased with harvest season length, crop yield, and grower participation. This work demonstrated that single‐stream systems could reduce corn stover feedstock costs in comparison with state‐of‐technology systems. © 2022 The Authors. Biofuels, Bioproducts and Biorefining published by Society of Industrial Chemistry and John Wiley & Sons Ltd.

09 BIOMASS FUELS↗

DOE OSTI2022

Value proposition of coatings or new alloys on hammer wear

The goal of this Case Study was to elucidate the value of improving of the life of parts that wear within a system in terms of the additional material cost that it takes to reach the level of improvement. We recognize that the failure limits and system performance are representative of a single system that may or may not exist in the real world, however, our goal of this project was not to provide an answer for a specific system or to provide a full understanding the economics of all potential systems. The analysis was performed using relative changes from the base alloy cost and considered relative improvements in part life in order to generalize the comparison without referencing specific alloys or coatings that might be employed. Ultimately, this work provides a first check of the potential for improving wear characteristics of grinder hammers to provide a meaningful and impactful benefit to biomass preprocessing and conversion systems. Key takeaways include: • Increasing the life of hammers by 3× provides a delivered feedstock cost benefit of approximately $\$2.25$/dry ton assuming that the relative cost of the hammer material of construction is not increased. • The feasible area of relative hammer cost increase ranges from 110% to 122% of the relative life increase, i.e., a 3× life increase can cost 3.66× the cost of the original hammers • Beyond a 3× increase in relative hammer life, little economic benefit is realized • Even when moisture impacts are included, the relationship between relative hammer cost and relative hammer life was reduced only slightly to a range of 108% to 116% • From the simulation we would expect delivered feedstock costs to be within ±$1.10/dry ton, based on the uncertainty analysis

09 BIOMASS FUELS↗

DOE OSTI2022

Impact of anatomical fractionation of corn stover on hammer mill throughput and energy consumption

The goal of this Case Study was to quantify the impacts of variable moisture and ash on hammer mill throughput and energy consumption and on loss of very wet stover that causes failures in the first stage grinder and that are not able to be fed to conversion, as compared to a status quo Base Case system. Also considered was convertible carbohydrate content (minimum total carbohydrate specification) and maximum ash content and the delivered feedstock cost impacts of not being able to feed stover not meeting the total carbohydrate specification to the conversion reactor. Laboratory data on the impacts of moisture content and tissue fraction on throughput and energy consumption in a stage 2 hammer mill were received from FCIC Subtask 5.1. Additional air classifier throughput, energy consumption and separation efficiency data were obtained from FCIC Subtask 5.1 for the new air classifier, which has three exit streams (lights, middle and heavies). These data were utilized to develop the necessary response surface equations to perform throughput analysis using discrete event simulation. Because the ash contents and particle sizes had not been analyzed in the laboratory at the time of the model runs, we assumed that the ash distributed proportionally with total mass into the lights and heavies in an air classifier having two exit streams (lights and heavies) and that the lights fraction from the air classifier was not removed. Key takeaways from this Case Study are that due to lower energy consumption, it is more cost effective to hammer mill fractionated corn stover tissues than whole stover. Reduction of grinding energy was significant and may possibly be connected to particle-particle interactions in the grinder that lead to increased residence time of leaves and husks, resulting in decreased throughput and higher generation of fines when milling whole stover. While we did not see significant impacts to throughput, this was due to moisture failures of the first stage grinder in each system dominating failures and downtime. The operating cost savings of reduced grinding energy savings in the second stage hammer mills alone was high enough to offset the added capital cost of the air classifier and extra grinding line.

09 BIOMASS FUELS↗