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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Algal Biomass Production via Open Pond Algae Farm Cultivation: 2023 State of Technology and Future Research

The annual State of Technology (SOT) assessment is an essential activity for platform research conducted under the Bioenergy Technologies Office (BETO). It allows for the impact of research progress (both directly achieved in-house at the National Renewable Energy Laboratory [NREL] and furnished by partner organizations) to be quantified in terms of economic improvements in the overall biofuel production process for a particular biomass processing pathway, whether based on terrestrial or algal biomass feedstocks. As such, initial benchmarks can be established for currently demonstrated performance, and progress can be tracked toward out-year goals to ultimately demonstrate economically viable biofuel technologies. NREL's algae SOT benchmarking efforts historically focused both on front-end algal biomass production and separately on back-end conversion to fuels through NREL's "combined algae processing" (CAP) pathway. The production model is based on outdoor long-term cultivation data, enabled by comprehensive algal biomass production trials conducted under the Development of Integrated Screening, Cultivar Optimization, and Verification Research (DISCOVR) consortium efforts, driven by data furnished by Arizona State University (ASU) at the Arizona Center for Algae Technology and Innovation (AzCATI) testbed site. The CAP model is based on experimental efforts conducted primarily under NREL research and development projects. This report focuses on front-end algal biomass production, documenting the pertinent algal biomass cultivation parameters that were input to the NREL open pond algae farm model. Through partnerships under DISCOVR, collaborators at ASU furnished details on cultivation performance metrics including biomass productivity and harvest densities for recent growth trials done at the AzCATI site. The resulting biomass productivity was calculated at 16.7 g/m 2 /day (ash-free dry weight [AFDW], annual average) for seasonal cultivation of Picochlorum celeri TG2 and Monoraphidium minutum 26B-AM biomass strains at the ASU site. Picochlorum celeri achieved the best productivity from April to September, with Monoraphidium minutum 26B-AM being used between October and March. Tetraselmis striata LANL1001, usually part of the strain rotation in previous cultivation SOTs, was supplanted by Monoraphidium minutum 26B-AM in this year's outdoor cultivation trials. Finally, building from an industry case study presented in the 2022 SOT report, in the Appendix of this report we provide an update on further improved data furnished by an industry collaborator and resultant impacts on economics reflecting several seasonal scenarios. This case study provides a supplementary datapoint on work being performed elsewhere with a more dedicated focus on improved compositional quality, producing biomass enriched in lipids as may be more optimal for conversion upgrading to fuels and products.

09 BIOMASS FUELS↗
DOE OSTI2021

Computational Investigation of the Catalytic Hydrodeoxygenation of Propanoic Acid over a Cu(111) Surface

Cu-based alloy catalysts have recently been investigated experimentally for the hydrodeoxygenation (HDO) of biomass-derived organic acids. Here, the HDO of propanoic acid (PAc) has been studied over Cu(111) by mean-field microkinetic modeling based on parameters obtained from first-principles calculations. Models were developed for the gas- and liquid-phase HDO in condensed water and 1,4-dioxane. In agreement with experimental observations, the gas-phase PAc conversion rate is low at 573 K and increases in liquid water by 1 order of magnitude. In all reaction environments, the decarboxylation mechanism is dominant at low hydrogen partial pressures less than 0.1 bar, and the C–COO bond dissociation is the rate-controlling elementary step. This observation contrasts with the rate-controlling step identified over most group VIII metal surfaces, which is the C–OH bond dissociation in the decarbonylation mechanism. At high hydrogen (H 2 ) partial pressures greater than 10 bar, the HDO of PAc produces propionaldehyde that can readsorb and further react through decarbonylation to produce C 2 alkane products, which is conceptually different from the low H 2 partial pressure scenario. At high H 2 partial pressures, the initial hydrogenation at the carbonyl carbon of PAc becomes the rate-controlling elementary step.

Catalysts↗
DOE OSTI2022

Global biomass supply modeling for long-run management of the climate system

Bioenergy is projected to have a prominent, valuable, and maybe essential, role in climate management. However, there is significant variation in projected bioenergy deployment results, as well as concerns about the potential environmental and social implications of supplying biomass. Bioenergy deployment projections are market equilibrium solutions from integrated modeling, yet little is known about the underlying modeling of the supply of biomass as a feedstock for energy use in these modeling frameworks. We undertake a novel diagnostic analysis with ten global models to elucidate, compare, and assess how biomass is supplied within the models used to inform long-run climate management. With experiments that isolate and reveal biomass supply modeling behavior and characteristics (costs, emissions, land use, market effects), we learn about biomass supply tendencies and differences. The insights provide a new level of modeling transparency and understanding of estimated global biomass supplies that informs evaluation of the potential for bioenergy in managing the climate and interpretation of integrated modeling. For each model, we characterize the potential distributions of global biomass supply across regions and feedstock types for increasing levels of quantity supplied, as well as some of the potential societal externalities of supplying biomass. We also evaluate the biomass supply implications of managing these externalities. Finally, we interpret biomass market results from integrated modeling in terms of our new understanding of biomass supply. Overall, we find little consensus between models on where biomass could be cost-effectively produced and the implications. We also reveal model specific biomass supply narratives, with results providing new insights into integrated modeling bioenergy outcomes and differences. The analysis finds that many integrated models are considering and managing emissions and land use externalities of supplying biomass and estimating that environmental and societal trade-offs in the form of land emissions, land conversion, and higher agricultural prices are cost-effective, and to some degree a reality of using biomass, to address climate change.

09 BIOMASS FUELS↗
NASA NTRS2023

Drought-Tolerant Succulent Plants as an Alternative Crop Under Future Global Warming Scenarios in Sub-Saharan Africa

Globally, we are facing an emerging climate crisis, with impacts to be notably felt in semiarid regions across the world. Cultivation of drought-adapted succulent plants has been suggested as a nature-based solution that could: (i) reduce land degradation, (ii) increase agricultural diversification and provide both economic and environmentally sustainable income through derived bioproducts and bioenergy, (iii) help mitigate atmospheric CO 2 emissions and (iv) increase soil sequestration of CO 2 . Identifying where succulents can grow and thrive is an important prerequisite for the advent of a sustainable alternative ‘bioeconomy’. Here, we first explore the viability of succulent cultivation in Africa under future climate projections to 2100 using species distribution modelling to identify climatic parameters of greatest importance and regions of environmental suitability. Minimum temperatures and temperature variability are shown to be key controls in defining the theoretical distribution of three succulent species explored, and under both current and future SSP5 8.5 projections, the conditions required for the growth of at least one of the species are met in most parts of sub-Saharan Africa. These results are supplemented with an analysis of potentially available land for alternative succulent crop cultivation. In total, up to 1.5 billion ha could be considered ecophysiologically suitable and available for succulent cultivation due to projected declines in rangeland biomass and yields of traditional crops. These findings may serve to highlight new opportunities for farmers, governments and key stakeholders in the agriculture and energy sectors to invest in sustainable bioeconomic alternatives that deliver on environmental, social and economic goals.

agriculture↗
DOE OSTI2024

The circular bioeconomy: a driver for system integration

Background: Human and earth system modeling, traditionally centered on the interplay between the energy system and the atmosphere, are facing a paradigm shift. The Intergovernmental Panel on Climate Change’s mandate for comprehensive, cross-sectoral climate action emphasizes avoiding the vulnerabilities of narrow sectoral approaches. Our study explores the circular bioeconomy, highlighting the intricate interconnections among agriculture, forestry, aquaculture, technological advancements, and ecological recycling. Collectively, these sectors play a pivotal role in supplying essential resources to meet the food, material, and energy needs of a growing global population. We pose the pertinent question of what it takes to integrate these multifaceted sectors into a new era of holistic systems thinking and planning. Results: The foundation for discussion is provided by a novel graphical representation encompassing statistical data on food, materials, energy flows, and circularity. This representation aids in constructing an inventory of technological advancements and climate actions that have the potential to significantly reshape the structure and scale of the economic metabolism in the coming decades. In this context, the three dominant mega-trends—population dynamics, economic developments, and the climate crisis—compel us to address the potential consequences of the identified actions, all of which fall under the four categories of substitution, efficiency, sufficiency, and reliability measures. Substitution and efficiency measures currently dominate systems modeling. Including novel bio-based processes and circularity aspects might require only expanded system boundaries. Conversely, paradigm shifts in systems engineering are expected to center on sufficiency and reliability actions. Effectively assessing the impact of sufficiency measures will necessitate substantial progress in inter- and transdisciplinary collaboration, primarily due to their non-technological nature. In addition, placing emphasis on modeling the reliability and resilience of transformation pathways represents a distinct and emerging frontier that highlights the significance of an integrated network of networks. Conclusions: Existing and emerging circular bioeconomy practices can serve as prime examples of system integration. These practices facilitate the interconnection of complex biomass supply chain networks with other networks encompassing feedstock-independent renewable power, hydrogen, CO 2 , water, and other biotic, abiotic, and intangible resources. Elevating the prominence of these connectors will empower policymakers to steer the amplification of synergies and mitigation of tradeoffs among systems, sectors, and goals.

09 BIOMASS FUELS↗
NASA NTRS2015

Simulated Impacts of Climate Change on Water Use and Yield of Irrigated Sugarcane in South Africa

Reliable predictions of climate change impacts on water use, irrigation requirements and yields of irrigated sugarcane in South Africa (a water-scarce country) are necessary to plan adaptation strategies. Although previous work has been done in this regard, methodologies and results vary considerably. The objectives were (1) to estimate likely impacts of climate change on sugarcane yields, water use and irrigation demand at three irrigated sugarcane production sites in South Africa (Malelane, Pongola and La Mercy) for current (1980-2010) and future (2070-2100) climate scenarios, using an approach based on the Agricultural Model Inter-comparison and Improvement Project (AgMIP) protocols; and (2) to assess the suitability of this methodology for investigating climate change impacts on sugarcane production. Future climate datasets were generated using the Delta downscaling method and three Global Circulation Models (GCMs) assuming atmospheric CO2 concentration [CO2] of 734 ppm(A2 emissions scenario). Yield and water use were simulated using the DSSAT-Canegro v4.5 model. Irrigated cane yields are expected to increase at all three sites (between 11 and 14%), primarily due to increased interception of radiation as a result of accelerated canopy development. Evapotranspiration and irrigation requirements increased by 11% due to increased canopy cover and evaporative demand. Sucrose yields are expected to decline because of increased consumption of photo-assimilate for structural growth and maintenance respiration. Crop responses in canopy development and yield formation differed markedly between the crop cycles investigated. Possible agronomic implications of these results include reduced weed control costs due to shortened periods of partial canopy, a need for improved efficiency of irrigation to counter increased demands, and adjustments to ripening and harvest practices to counter decreased cane quality and optimize productivity. Although the Delta climate data downscaling method is considered robust, accurate and easily-understood, it does not change the future number of rain-days per month. The impacts of this and other climate data simplifications ought to be explored in future work. Shortcomings of the DSSAT-Canegro model include the simulated responses of phenological development, photosynthesis and respiration processes to high temperatures, and the disconnect between simulated biomass accumulation and expansive growth. Proposed methodology refinements should improve the reliability of predicted climate change impacts on sugarcane yield.

Climate change↗
DOE OSTI2020

Modeled economic potential for Eucalyptus spp. production for jet fuel additives in the United States

Feedstock price and availability remain a barrier to adoption of cellulosic biofuels. Eucalyptus spp., can produce an energy-dense terpene suitable for high-density synthetic hydrocarbon-type fuel (grade JP-10) production in addition to cellulosic-based feedstock for traditional jet fuels (e.g., grade Jet A) and gasoline. This study modeled economic potential for Eucalyptus to fulfill US fuel markets. Cold-tolerant Eucalyptus was simulated in an annual coppice system for maximized leaf production. Results of the lowest simulated price ($110 t -1 ) show that within 10 years, there is potential to produce 204 million L yr -1 of fuel, including 51 million L yr -1 of JP-10-type fuel, 75 million L yr -1 of Jet A type fuel, and 77 million L yr -1 of gasoline. These quantities of fuel could be valued at approximately $500 million (USD), with feedstock costs totaling approximately $100 million (USD). Longer-term markets (to 20 years) or higher priced (to $220 t -1 ) scenarios show potential for more production. Furthermore, research to determine potential for genetic improvement, delivered fuel costs, and biorefinery siting near existing infrastructure is recommended.

09 BIOMASS FUELS↗
DOE OSTI2022

A multi-product landscape life-cycle assessment approach for evaluating local climate mitigation potential

Increasing demand for land-based climate mitigation requires more efficient management of agricultural landscapes for competing objectives. Here we develop methods for assessing trade-offs and synergies between intensification and carbon-sequestering conservation measures in annual crop production landscapes using the DayCent ecosystem model and the Greenhouse Gases, Regulated Emissions, and Energy Use in Technologies (GREET) life-cycle assessment (LCA) model. We compiled county-scaled crop yields, fertilizer application rates, and tillage intensity for a corn–soybean farming case study landscape in the US state of Iowa. Using DayCent, we estimated a baseline soil organic carbon (SOC) accrual rate of 0.29 Mg C ha -1 y -1 driven by historical increases in crop productivity and reductions in tillage intensity. We then simulated the effects of management interventions targeted toward intensification (stover removal) and SOC sequestration (tillage intensity reduction and winter cover crop addition) individually and in combination. We propose a new multi-product landscape–LCA approach that analyzes marginal changes in corn grain, corn stover, and soybean production from the landscape in terms of their value for biofuel production (corn ethanol, soy biodiesel, and cellulosic ethanol from stover) and associated net displacement of conventional fossil-derived fuel use. This enables us to evaluate both intensification and sequestration effects in common CO 2 -equivalent mitigation units. We also used DayCent-simulated yields under the different land management scenarios to estimate farm-level costs and revenues. Our results show that intensification via collecting 30% of corn stover for biofuel production would increase the total greenhouse gas (GHG) mitigation potential of this landscape by 0.93 Mg CO 2 e ha -1 y -1 and provide $49 ha -1 y -1 of additional net revenue from biomass sales, but would reduce the baseline SOC accumulation rate by approximately 40%. In contrast, integrated approaches that include co-adoption of winter cover cropping and/or tillage intensity reduction would result in increased rates of SOC accumulation above the baseline, achieving simultaneous improvements in both farm profits and the overall GHG mitigation potential of the landscape.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Bioenergy pathways within United States net-zero CO 2 emissions scenarios in the Energy Modeling Forum 37 study

The Energy Modeling Forum 37 study is organized around carbon dioxide (CO 2 ) mitigation scenarios reaching net-zero CO 2 emissions by 2050 in the United States. Here, this paper summarizes the potential contribution of bioenergy use in the electric power, transportation, industrial, and buildings sectors toward meeting that target based on model results. Thirteen modeling teams reported bioenergy consumption in the Reference and Net Zero scenarios. Consumption of bioenergy increased over time in the Reference scenario, from an average across models of 3.2 exajoules (EJ) in 2020 to 3.8 EJ in 2050. Average bioenergy consumption in 2050 increased further to 7.3 EJ in the Net Zero scenario. All scenarios that reach net-zero emissions required some form of carbon dioxide removal to offset emissions that are difficult to reduce. Carbon dioxide removal using bioenergy with CO 2 capture and storage (BECCS) varies widely across models, up to 1000 Mt CO 2 in 2050. Some models rely instead on direct air carbon capture and storage (DACCS), up to 2200 Mt CO 2 , and others use a combination of BECCS and DACCS. Model results show a strong inverse relationship between the amounts of BECCS and DACCS deployed. All modeling teams assumed a carbon sink from land use, land use change, and forestry, further offsetting a portion of emissions from fossil fuels and industry that are expensive to eliminate. Bioenergy consumption in 2050 decreased by an average of 1.5 EJ across eight models in a Net Zero+ scenario relative to the Net Zero scenario, due in part to a lower equilibrium carbon price resulting from optimistic cost assumptions for all energy technologies.

09 BIOMASS FUELS↗
DOE OSTI2024

Potential Adoption and Benefits of Co-Optimized Multimode Engines and Fuels for U.S. Light-Duty Vehicles

Exploring a diverse portfolio of technologies for decarbonization is crucial to understanding the potential impacts of different technological solutions and their associated environmental implications. Using high-octane, high-sensitivity biofuel blends in co-optimized multimode engines can increase engine efficiency and reduce vehicle emissions. Here, the multimode engine research focuses on the benefits of light-duty vehicle engines, which can operate in multiple modes depending on the vehicle's load. Low-temperature combustion can improve efficiency and reduce emissions (such as those from oxides of nitrogen and particulate matter) during low-load operation, while spark ignition performance is maintained in high-load operation. These advanced engines can be optimized to run on blends of biobased fuels. This analysis models scenarios for potential market adoption of co-optimized multimode vehicles fueled by three different bioblendstocks: ethanol, isopropanol, and isobutanol. An integrated modeling approach is used to forecast the energy and environmental impacts of the deployment of co-optimized multimode vehicles and fuels in the light-duty sector over the 2020-to-2050 time horizon. The multidisciplinary approach combines vehicle sales modeling, system dynamics modeling of the biorefining industry, and life cycle assessment to estimate the emissions and energy benefits. The models consider market forces such as consumer preferences for vehicle attributes, biofuel supply and demand dynamics subject to biorefinery capacity build-out and bioresource constraints, and forecasted changes to the U.S. bulk energy system over time. Market adoption of co-optimized vehicles is evaluated across a wide parameter space for incremental vehicle cost and engine efficiency improvement. This analysis reveals that the deployment of co-optimized multimode fuels and vehicles results in up to a 5% reduction in annual sector-wide life cycle greenhouse gas (GHG) emissions by 2050, relative to a business-as-usual scenario, but is also indicates environmental trade-offs, such as higher life cycle water-use. Emission benefits could potentially increase beyond 2050, as the new technologies penetrate the market and gain a foothold. Results also show that, under certain circumstances, vehicles with engines co-optimized for use with high-octane, high-sensitivity biofuel blends can be cost-competitive with conventional gasoline, while reducing GHG emissions. Our modeling results indicate that co-optimized multimode fuels and engines can be strategically leveraged in tandem with electrification to decarbonize the light-duty sector. Co-optimized vehicles could play a role in the early years of the time horizon, while electric vehicles (EVs) could become more competitive in the later years, highlighting the complementary benefits of these technologies for GHG reductions.

Oke, Doris↗
DOE OSTI2022

Future bioenergy expansion could alter carbon sequestration potential and exacerbate water stress in the United States

The maximum future projected bioenergy expansion potential, in scenarios limiting warming to 2°C or below, is equivalent to half of present-day croplands. We quantify the impacts of large-scale bioenergy expansion against re/afforestation, which remain elusive, using an integrated human-natural system modeling framework with explicit representation of perennial bioenergy crops. The end-of-century net carbon sequestration due to bioenergy deployment coupled with carbon capture and storage largely depends on fossil fuel displacement types, ranging from 11.4 to 31.2 PgC over the conterminous United States. These net carbon sequestration benefits are inclusive of a 10 PgC carbon release due to land use conversions and a 2.4 PgC loss of additional carbon sink capacity associated with bioenergy-driven deforestation. Moreover, nearly one-fourth of U.S. land areas will suffer severe water stress by 2100 due to either reduced availability or deteriorated quality. These broader impacts of bioenergy expansion should be weighed against the costs and benefits of re/afforestation-based strategies.

09 BIOMASS FUELS↗
DOE OSTI2026

Simulating competition in the US bioeconomy to produce hard‐to‐electrify transportation fuels using limited biomass resources

This study presents a novel bioeconomy optimization framework, BiOpt, designed to address critical questions regarding the strategic use of limited US biomass resources for biofuel production. By integrating detailed techno-economic analyses, life cycle assessments, and resource assessment data, BiOpt optimizes resource distributions across competing technologies to maximize economic performance and/or minimize greenhouse gas emissions. Using feedstock scenarios from the 2023 Billion Ton Study, the analysis explores optimal biomass allocations across sustainable aviation fuel, diesel, and marine biofuel conversion pathways given varying production targets and policy incentives. Results demonstrate distinct feedstock preferences and pathway utilizations when prioritizing economic returns vs. emissions reductions. For instance, fats, oils, and greases were highly favored in cost-optimized scenarios, while low-carbon feedstocks such as wet waste dominated greenhouse gas-minimized strategies. The findings underscore the pivotal role of policy incentives and technological advances in shaping biofuel supply chains and provide actionable insights for scaling sustainable biofuel production to decarbonize hard-to-electrify sectors. This framework offers a robust tool for policymakers and stakeholders to evaluate biofuel strategies that balance energy output, economic viability, and environmental impact.

09 BIOMASS FUELS↗
DOE OSTI2021

Supply analysis of preferential market incentive for energy crops

This analysis explores the valuation of feedstock quality attributes of switchgrass and miscanthus – two energy crops poised for future expansion – and compares the relative economic availability of these two crops under two scenarios: (i) uniform price assumptions (i.e., no incentive for quality), and (ii) a scenario of a price premium based on convertibility (i.e., an incentive for quality). Given data on cellulose content, hemicellulose content, and their relative convertibility, miscanthus is expected to be 11% more efficient at conversion to biofuels than switchgrass under the biochemical conversion route. Based on this scenario of improved conversion efficiency and associated profit, we simulate an 11% price premium for miscanthus over other feedstocks in a base-case scenario. By adding this price premium, supplies of miscanthus increase over the base case by about 4 million (44%), 94 million (64%), and 166 million (94%) tons in year 0, 10, and 20 after simulated contracts for production are initiated respectively. These results emphasize that custom simulations are needed to quantify feedstock availability if supplies are intended to reflect grower response to industry demands for feedstock quality specifications. Farmers can grow ‘peas or carrots’, and price signals from biorefineries will influence what energy crops they produce. Recognizing that the energy crop mix is tractable according to quality characteristics is relevant both for near-term and long-term biofuels research and development. Here, we recommend accounting for market preferences for quality attributes when estimating potential future supplies of energy crops.

09 BIOMASS FUELS↗
DOE OSTI2022

Bioproducts from high-protein algal biomass: An economic and environmental sustainability review and risk analysis

This report has High-protein algal biomass as an important bio-commodity that has the potential to provide a new source of sustainable protein products. Herein is a critical review that identifies 1) the most relevant sustainability findings related to the processing of proteinaceous algal biomass to higher value protein products and 2) the potential pathways to improve life cycle assessment (LCA) and techno-economic analysis (TEA) metrics, including life-cycle carbon dioxide equivalent (CO 2 eq), life cycle energy, and minimum selling price (MSP) of these products. The critical review of the literature revealed a large variation in model input parameters relating to these metrics. Therefore, a Monte Carlo analysis was conducted to assess the risk associated with these input variations. To understand the uncertainties that propagate into high-protein algae to products’ systems, we reviewed more than 20 state-of-the-art unit operations for algal biomass processing., including cell disruption, protein solubilization, protein precipitation and purification, and protein concentration. We evaluated displacement of proteinaceous products by algal-bioproducts, including ruminant feed, aquaculture feed, protein tablets, and biopolymers and biopolyesters, with prices in the market ranging from 1.9 to 120 $\$$ kg -1 protein. This review realized that the MSP of ruminant and non-ruminant feed ranges from 0.65±0.56 to 2.9±1.1 $\$$ kg -1 protein, and bioplastics’ MSP ranges from 0.97 to 7.0 $\$$ kg -1 protein. Regarding LCA metrics, there is limited research on life cycle energy in proteinaceous biomass concentration and bioproduct systems, reported at 32.7 MJ kg protein -1 , for animal feed displacement. Animal feed emissions in the literature report negative fluxes, representing environmental benefits, as low as -3.7 kgCO 2 eq kg -1 protein and positive fluxes, i.e., global warming potential, as high as 12.8 kgCO 2 eq kg -1 protein. There is limited research on bioplastics life cycle emissions reported at 0.6 kgCO 2 eq kg -1 protein. In general, the studies to date of algae-derived protein bioproducts showed similar life cycle emissions to soybean meals, nylon, polymers, and polystyrenes. Our risk analysis realized that more than 50% of scenarios can result in negative-net life cycle CO 2 eq emissions. This review and risk analysis assess and demonstrate the scenarios that improve economic and environmental sustainability metrics in high-protein algal bioproducts systems.

09 BIOMASS FUELS↗
DOE OSTI2026

Techno-Economic, Feasibility, and Life Cycle Analysis of Renewable Propane: 2025 Update

To clarify the current and future landscape for renewable propane (RP) production, this work evaluates the value proposition of recovering RP from existing and planned hydroprocessed esters and fatty acids (HEFA) biorefineries and surveys emerging technologies under development or deployment. HEFA biorefineries co-produce a propane-rich fuel gas stream, normally used to meet HEFA process heat requirements, from which propane can be recovered and sold to create an additional revenue stream alongside liquid transportation fuels such as renewable diesel (RD) and sustainable aviation fuel (SAF). This report updates and extends a 2022 analysis of RP recovery from HEFA facilities by escalating capital and operating costs to 2024 prices, incorporating recent policy developments (including the Section 45Z Clean Fuel Production Credit), evaluating RP recovery for both RD- and SAF-focused HEFA facilities at two scales (3,000 and 75,000 barrels per day of feedstock), and quantifying the impact of RP recovery on HEFA liquid-fuel carbon intensity (CI) and associated tax credits using the 45ZCF-GREET model. For a 3,000 BPD RD-focused HEFA facility, approximately 3.5 million gallons per year (MGPY) of RP can be recovered; in this base case, the estimated payback period is 18 months based on the total installed cost of the RP recovery equipment and 36 months based on the total capital investment for the entire RP recovery project. The payback period is slightly shorter for the analogous SAF-focused configuration (approximately 4.3 MGPY RP). Sensitivity analysis shows that CAPEX magnitude, RP recovery plant scale, and CI-driven tax credit valuations are the dominant determinants of project viability. RP recovery may increase the CI of HEFA liquid fuels, which can reduce liquid-fuel tax credits (a key revenue stream for the HEFA biorefinery) and lengthen payback periods. However, RP recovery generally remains economically favorable across a wide range of plausible scenarios and market conditions. The report also summarizes emerging pathways that could expand future RP supply.

09 BIOMASS FUELS↗
DOE OSTI2026

A mathematical design framework for membrane pre-concentration in energy-efficient recovery of fermentation products

Due to the dilute nature of products manufactured via fermentation and cell-free bioprocessing, dewatering is a common unit operation in downstream processing (DSP) for bioproduct recovery, but it is typically energy intensive. To improve DSP energy efficiency for bio-based small molecules, integrating high-pressure membrane pre-concentration is a promising process option. However, this approach is typically constrained by a tradeoff between concentration factor (CF) and product recovery (PR), namely increasing the CF typically results in greater product loss, and vice versa. Here we developed a model that enables process design guidelines to: (i) identify scenarios in which the additional energy consumption and product loss from membrane pre-concentration are justified for use in DSP, and (ii) determine the optimal CF that minimizes process specific energy consumption. We compared the energy consumption of high-pressure membrane-integrated processes to evaporation-only processes and applied the model to an experimental case study for the separation and purification of butyric acid from Clostridium tyrobutyricum fermentation using an in situ product recovery (ISPR) process. The model estimated that integrating a tangential-flow reverse osmosis (RO) pre-concentration unit could reduce process energy consumption up to 45%. The use of advanced membrane pre-concentration technologies, such as negative rejection membranes and organic solvent reverse osmosis (OSRO), have the potential to further reduce the overall process specific energy consumption up to 96%, projected based on modeling. Overall, membrane pre-concentration, especially when strategically integrated prior to an evaporation step with optimized process conditions, holds significant potential for improving DSP energy efficiency, particularly in applications requiring substantial solvent removal for product recovery from dilute mixtures.

09 BIOMASS FUELS↗
DOE OSTI2024

Implications of pond reliability on the techno-economic and life cycle environmental impacts of algal biofuels

Despite extensive research on algal bioproducts, there is limited understanding of how pond contamination affects their economics and environmental impacts. This work compared the costs and environmental impacts of algal biofuels across different pond failure scenarios. Pond failure was simulated by a reliability model based on pond mean-time-to-failure (MTTF). The reliability model was integrated with a process model to analyze the impacts of pond failure on the operations of algal farms and biorefineries. Process model outputs were used for techno-economic analysis and life cycle assessment to determine the minimum fuel selling price (MFSP), global warming potential (GWP), and freshwater consumption impacts of algal biofuels for five MTTF scenarios of 20, 54, 80,120, and 350 days, assuming an average mean-time-to-reset of 7 days. Results show that higher MTTFs reduce the cost and environmental impact of algal biofuels, but with diminishing returns. The average MFSPs for the 20-day, 54-day, and 350-day MTTF scenarios were $\$3.52$, $\$2.54$, and $\$2.10$ per liter of gasoline equivalent, respectively. The GWP for the same scenarios were 131, 96, and 83 g CO 2eq MJ –1 , respectively. This study highlights the significant impact of larger seed trains, required under low MTTFs, on the costs and greenhouse gas emissions of algal biofuels. Moreover, the work shows that algal biofuels fail to be cost-competitive with conventional fuels, even when productivities are increased from 17 to 35 g m –2 d –1 . Furthermore, this work is the first to explore the implications of pond failure on the sustainability of algal biofuels and provides valuable insights to algae farmers on how to reduce the costs and financial risks of algal cultivation through process design and pond management strategies.

09 BIOMASS FUELS↗