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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Opportunities for Utilization of Low-Cost Algae Resources: Techno-Economic Analysis Screening for Near-Term Deployment (Parts 1 and 2)

This report presents a comprehensive techno-economic analysis (TEA) for the production, collection, or procurement of several low-cost algae resources that may otherwise be considered "waste" biomass materials today, as well as the utilization of these materials through exemplary conversion processes to produce renewable fuels and chemicals. In contrast to conventional TEA models attributed to large-scale algae "farming" approaches, which may be able to produce substantially more biomass and thus fuels/products at a national scale in the future, this assessment focuses on understanding opportunities and costs for such "waste" algal biomass resources as may be available at considerably lower cost today. Economics for base case assumptions and a range of sensitivity scenarios are presented, employing conversion technologies that are simple and well understood, and thus may be deployed at smaller community scale in the near term, as a means to support and expand a nascent algae industry on the way to employing a larger commercial algae farm approach for commodity-scale production. Specifically, three algal biomass resources are considered in this assessment, as may be sourced from (1) municipal wastewater treatment (WWT) utilizing algae in place of more conventional technologies for nitrogen/phosphorus removal, (2) collection and removal of harmful algal bloom (HAB) biomass as proliferates in certain inland water bodies, and (3) procurement of residual biomass following commercial lipid extraction (EXT) operations performed at smaller scale by industry today focused on higher-value nutraceutical applications. These three resources are evaluated through two conversion pathways: (1) combined algal biomass processing (CAP) through a simple/low-complexity configuration, and (2) anaerobic digestion (AD). The CAP pathway produces liquid fuels and chemical coproducts (polymer for off-site upgrading to bioplastics), whereas the AD pathway produces biogas (specifically renewable natural gas [RNG]) and crop fertilizer coproducts. To streamline the discussion, this report is broken into two sections: Part 1 focuses on WWT-derived biomass, and Part 2 on HAB and EXT biomass.

09 BIOMASS FUELS↗
DOE OSTI2021

Crystallization and Phase Transformations of Aluminum (Oxy)hydroxide Polymorphs in Caustic Aqueous Solution

Gibbsite, bayerite, and boehmite are important aluminum (oxy)hydroxide minerals in nature and have been widely deployed in various industrial applications. They are also major components in caustic nuclear wastes stored at various U.S. locations. Knowledge of their crystallization and phase transformation processes contributes to understanding their occurrence and could help optimize waste treatment processes. While it has been reported that partial conversion of bayerite and gibbsite to boehmite occurs in basic solutions at elevated temperatures, systematic studies of factors affecting the phase transformation as well as the underlying reaction mechanisms are non-existent, particularly in highly alkaline solutions. We explored the effects of sodium hydroxide concentrations (0.1~3 M), reaction temperature (60~100 ?) and aluminum concentrations (0.1~1 M) on the crystallization and transformation of these aluminum (oxy)hydroxides. Detailed structural and morphological characterization by X-ray diffraction (XRD), scanning electron microscopy (SEM), and nuclear magnetic resonance (NMR) spectrometry revealed that these processes depend largely on the reaction temperature and the Al/OH- ratio. When 1 = Al/OH- = 2.5, the reactions favor formation of high crystallinity precipitates, whereas at Al/OH- ratio ? 2.5 precipitation ceases unless the Al concentration is higher than 1 M. We identified pseudoboehmite, bayerite and gibbsite as intermediate phases to bayerite, gibbsite and boehmite, respectively, all of which transform via dissolution-reprecipitation. Gibbsite transforms to boehmite in both acidic and weak caustic environments at temperatures above 80 oC. However, a ‘bar-shaped’ gibbsite morphology dominates in highly caustic environments (3 M NaOH). The findings enable a robust basis for selection of various solid phases by tuning the reaction conditions.

aluminum (oxy)hydroxide polymorphs, crystallizatio↗
DOE OSTI2023

Chapter 4: "Waste"-to-Energy for Decarbonization - Transforming Nut Shells Into Carbon-Negative Electricity

This chapter presents a study demonstrating waste pistachio nut shells as a renewable feedstock for climate-friendly electricity generation via industrial gasification technology. The study includes biomass feedstock characterization (i.e., pistachio waste critical material attributes), process variability (i.e., bulk material handling), and overall operational reliability and conversion performance through extended testing. Additionally, techno-economic analysis (TEA) and life cycle assessment (LCA) were performed to assess the economic feasibility and environmental impact of the technology to transform agricultural waste to biopower. For processing pistachio waste material, among critical material attributes, fines content in the biomass (<1/4") had the largest potential to reduce the operating time of the gasifiers due to plugging. Pelletizing fines and co-feeding them with the mixed pistachio waste increased the average feed density, feed rate, and biochar production. Compared to pine wood chips, mixed pistachio waste yielded higher biochar quantity but slightly reduced quality. In general, a systematic Quality by Design methodology is the preferred approach for designing preprocessing and material conveyance systems, where a downstream technology (end user) for the produced intermediate is specified at the outset. TEA results show that the biochar production rate and selling price had an overwhelming impact on the modeled Minimum Electricity Selling Price (MESP), which ranged from 35.5 to 39.9 cents/kWh for the cases studied (16 h/day operational basis). Moreover, LCA results show that the valorization of pistachio shells for biopower generation is a "carbon negative" process that can help decarbonize the U.S. electricity grid. The specific carbon intensity was -0.29 to -0.71 kg CO2e/kWh, compared to 0.45 kg CO2e/kWh for the average U.S. electricity mix. Biochar production from pistachio waste as a potential means for carbon sequestration was a significant driver for the LCA. The highly stable biochar permanently sequesters a considerable fraction of biochar carbon in the ground, more than enough to offset the life cycle emissions, and can be a complementary climate change mitigation strategy.

bio-char↗
DOE OSTI2026

Closing the loop on plastics: Biological and hybrid routes for converting plastic waste to polyhydroxyalkanoates

Polyhydroxyalkanoate (PHA) production from plastic-derived substrates offers a promising route to mitigate plastic pollution while reducing dependence on conventional PHA feedstocks. Plastic waste represents an abundant carbon source for microbial fermentation, but efficient conversion remains limited by incomplete deconstruction, inhibitory intermediates, low carbon recovery, and challenges in process integration. Plastic-derived streams contain diverse compounds, including fatty acids, hydrocarbons, fatty alcohols, aldehydes, esters, and aromatic compounds generated during depolymerization. These intermediates can be metabolized by selected microorganisms, particularly Pseudomonas species with versatile fatty-acid and hydrocarbon pathways, as well as Cupriavidus necator and mixed microbial cultures. Unlike reviews that address plastic upcycling or PHA biosynthesis separately, this review focuses on the deconstruction–fermentation interface that governs plastic-to-PHA conversion. It consolidates current progress in plastic deconstruction, substrate conditioning, microbial metabolism, fermentation control, polymer recovery, and techno-economic and life-cycle considerations. Here, by emphasizing substrate composition, biological compatibility, plastic‑carbon recovery, and final polymer quality, the review identifies priorities for scalable and environmentally sustainable PHA production from plastic-derived substrates.

42 ENGINEERING↗
DOE OSTI2021

Vapor-Liquid Partitioning of Methylmercury Compounds: Fundamental Data to Support the Savannah River Site Liquid Waste System: Henry's Law, Solubility and Vapor Pressure Determination for Representative Methylmercury Compounds

The Savannah River Site (SRS) Liquid Waste System (LWS) contains approximately 66 tons of mercury within the liquids, salts, and sludges that are currently being processed into final wasteforms for disposal. Mercury concentrations within the system exceed those typically experienced in environmental or industrial systems; thus, management of mercury compounds continues to be a priority for SRS. In the LWS, waste is vitrified into a borosilicate glass wasteform that contains most of the radioactivity, while the lower activity solutions are dispositioned in a low-level grout wasteform, or “saltstone”. The alkaline, high ionic strength caustic wastes are pumped, evaporated, and otherwise managed throughout the LWS and Defense Waste Processing Facility (DWPF) as they are stored and prepared for conversion to the final wasteforms. Because of the complexity of this system, a key component of effective mercury management in the LWS requires analysis of mercury in various physical phases. The high concentration of mercury within the SRS LWS has the potential to generate vapor-phase contamination. Elemental mercury (Hg 0 ), dimethylmercury ((CH 3 ) 2 Hg), and methylmercury (CH 3 Hg + ) are among species known or suspected to contribute to the flux of mercury from liquid to vapor phase (Iverfeldt and Lindquist, 1982). Chemical speciation affects not only mercury behavior in LWS operations but may also affect the performance of mercury treatment and removal technologies in the LWS.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

How much is surface dopant enough to maximize CO2-to-liquid chemicals conversion at industrially relevant current density?

This invited talk will be presented at the symposium "Waste Feedstock to Fuels and Petrochemicals”, Fuels and Petrochemical Division at the 2024 AIChE Annual Meeting. In this study, we will discuss how minute amount of surface heteroatoms would maximize CO2 reduction to formate/formic acid at industrially relevant current densities and high selectivity which was validated by both experimental and computational studies. The outstanding performance of the best-in-class catalysts in both H-cell and full-cell electrolyzer cell is also demonstrated. Our findings would provide additional design concepts of high performance CO2R electrocatalysts.

Nguyen Phan, Thuy Duong↗
DOE OSTI2023

Cold-cap structure in a slurry-fed electric melter

We report as glass batch is charged into an electric melter, a cold cap forms on the glass melt surface. Heat transfer to the cold cap from the molten glass below and the melter atmosphere above determines the melting rate. A mathematical model of the cold cap and the experimental kinetic data of the feed-to-glass conversion that were collected for several simulated low-activity and high-level waste melter feeds allowed us to develop relationships between the internal structure of the cold cap, its properties, its thickness, and the internal heat transfer. This contribution shows the distribution of major crystalline phases and the cumulative evolution of gases within the cold cap. It also examines the temperature, conversion degree, and heating rate the melter feed is experiencing during the passage through the cold cap and their effects on the cold-cap bottom temperature and morphology, which are important for the computational fluid dynamics simulations of melters.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Enhancing methane production of anaerobic digested sewage sludge by advanced wet oxidation & steam explosion pretreatment

Anaerobic digestion (AD) of sewage sludge is associated with lowered carbon conversion efficiency due to the recalcitrance of microbial cells in the Waste Activated Sludge (WAS) from the aeration basins with 50 % of the dry weight still being present after AD. The effect of Advanced Wet Oxidation & Steam Explosion (AWOEx) pretreatment on the methane yield at variable temperatures (165–200 °C), residence time (15–45 min) and oxygen dosage (1%–10% based on VS concentration) was tested in this study. Central composite design (JMP® Pro) was used to design 19 runs of AWOEx pretreatment of dewatered digested sewage sludge (DADSS) at different operating conditions. After pretreatment the DADSS was fed to 19 bioreactors operated in semi-continues mode at 37 °C. The highest average methane yields of 183 mL/g VS and 170 mL/g VS were found for the bioreactors receiving DADSS pretreated at 165 °C with a retention time of 15 min and 10 % O2 (Condition 1), and, 182.5 °C with a retention time of 15 min and 5.5 % O2 (Condition 2). This corresponds to an increase in the methane production of 156.2 % and 140.5 % compared to the methane production from the DADSS without pretreatment.

09 BIOMASS FUELS↗
DOE OSTI2023

Hydrothermal catalytic conversion of oleic acid to heptadecane over Ni/ZrO 2

There is growing interest in the substitution of expensive noble metal catalysts with low-cost earth-abundant metals in applications targeting biofuels production from waste organic feedstocks. Here, nickel (Ni) catalysts supported on zirconium dioxide (ZrO 2 ), both with and without copper (Cu) as a co-metal, were tested in hydrothermal reactions of unsaturated and saturated C18 fatty acids as models for waste oil feedstocks. In contrast to recent reports, this study showed no enhancement of nickel's activity for fatty acid conversion to alkane products when Cu was present. Ni/ZrO 2 prepared by metal coprecipitation methods converted 100% of oleic acid with 25% selectivity to heptadecane after 5h of reaction at 350 °C using methanol as a hydrogen donor source, increasing to 41% heptadecane after 20 h. Lower yields were observed with catalysts prepared by wet impregnation and using alternative hydrogen donor sources (glycerol, formic acid). Greater selectivity to heptadecane was also observed at higher temperatures (370 °C) and when the initial fatty acid had greater saturation. Longer term exposure to hydrothermal media led to metal sintering and catalyst deactivation. Findings support a path forward to the development of earth-abundant metal catalysts for the upgrading of waste organic feedstocks.

09 BIOMASS FUELS↗
DOE OSTI2020

The scaling economics of small unit operations

We present a correlation that represents the capital costs of the components of even very small modular facilities. Conversion of distributed feedstocks (eg, associated natural gas, biomass, and carbonaceous wastes) could provide a small fraction of the liquid fuels now used for transportation in the U.S. (~6%),or nearly half of the chemical products now made from petroleum. However, those resources tend to be available at small geographically distributed sites, and they are difficult or expensive to transport to a distant processing center. Modular, and likely intensified, processes that can be numbered up promise to enable utilizing such distributed resources. Early stage economics evaluation of those processes requires cost estimates for the components, which are likely smaller in scale than can be accommodated by the 0.6 power law typically used in chemical engineering

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Effect of metal-free mesoporous silica incorporated ZSM-5 composite on thermo-catalytic pyrolysis of polypropylene

Although different zeolites impregnated with transition metals have been used in catalytic deconstruction of waste plastics to other products, the influence of hierarchical structures on conversion and product selectivity in plastic upcycling has not been thoroughly investigated. This research explores a transition metal free zeolite-based hierarchical composite, synthesized by incorporating SBA-15 in ZSM-5 framework, for efficient thermos-catalytic upcycling of polypropylene (PP). Thermogravimetric analysis reveals that ZSM-5@SBA-15 can break down PP at a significantly lower temperature, 240 °C, compared to that of pristine PP using ZSM-5 or SBA-15. In addition, pyrolysis of PP at 400 °C using ZSM-5@SBA-15 composite outperforms ZSM-5 or SBA-15 used separately and yields 90 % conversion with 70 % selectivity to propene. The presence of mesopores in the catalyst appears to reduce the diffusion resistance of intermediate products for successive scission, thereby reducing the activation energy of reaction and improving catalytic activity. In conclusion, the hierarchical composite ZSM-5@SBA-15 has significant potential for upcycling of PP into valuable monomers and lighter olefins, with lower energy demands, enhancing the economic feasibility of the process.

ZSM-5@SBA-15↗
DOE OSTI2025

State of the Art in Thermal Catalytic Upgrading of Biomass and Biomass-Derived Intermediates

Biomass-derived energy sources represent a promising domestic route for fuel and chemical production, taking advantage of largely underutilized biological and waste resources. Heterogeneous catalysis plays a key role in these biomass conversion processes, as reflected by all American Society for Testing and Materials–approved pathways for producing sustainable aviation fuel proceeding through a catalytic step. This concise review seeks to establish the state of the art in thermal catalytic process development for various biomass-derived feedstocks and the current enabling capabilities that aid this development. Research needs are identified and described throughout the article, as further advancements in heterogeneous catalysis are required to improve the affordability and realize the full potential of biomass-derived products.

09 BIOMASS FUELS↗
DOE OSTI2024

A Step toward Process Electrification: Microwave-Assisted Co-Gasification of Waste Plastics and Biomass to Produce Clean Energy

Barely 9% of the 353 million metric tons of plastic waste produced worldwide over the last two decades has been recycled, with the majority of it being either landfilled or incinerated. Recycling and upcycling plastic waste is thus essential in mitigating environmental pollution. Gasification is the thermochemical conversion of solid carbon feedstock at high temperatures using a gasifying agent to produce hydrogen-rich syngas. Existing gasification technologies are energy-intensive and require high operating temperatures (>1000 °C), leaving them uncommercial. Microwave heating has sparked attention in a variety of chemical processes due to its specific advantages over traditional heating technologies, such as rapid and selective heating to improve process efficiency. NETL’s research team recently investigated the synergistic advantages of corn stover and mixed plastics in producing hydrogen-rich syngas via microwave heating. As a continuation of the research, this study provides an outlook over the non-catalytic versus catalytic effects of plastic-corn stover gasification via process electrification to enhance H2 production, minimize undesired tar, and improve process efficiency. Our aim is to provide complete electrification of the existing gasification process by using waste plastics as a starting block to produce valuable fuel and support the nation’s net zero goals.

Abedin, Ashraf↗
DOE OSTI2022

Challenges and Opportunities Associated with the Municipal Solid Waste

Municipal solid waste (MSW) is one of the important challenges in today’s world. A continuous surge in population, increasing living standards, and rapid urbanization are generating an enormous quantity of MSW. Improper management of this MSW often leads to the release of greenhouse gases, emission of particulate matters, and formation of dioxins, which all ultimately contributes to climate change. Recycling these wastes via landfills with gas recovery and/or energy and material production via thermal and chemical conversions could be viable options to manage these challenges. Recycling of MSW is difficult because it is very heterogeneous in nature. The heterogeneity of MSW varies significantly from country to country and from one municipality to another. Such variation depends mainly on the waste management regulations and industrial structure of each region. The quantity and the quality of MSW are critical for determination of the handling and management. This presentation will discuss the statistics (e.g., source, quantity, quality, etc.) of MSW following by the current state-of-the-art technologies for handling those wastes. The key challenges handling those wastes and possible improvements of the handling processes will be discussed further. Finally, the potential opportunities for MSW, especially the contributions to the bio-energy field, will be discussed.

09 BIOMASS FUELS↗
DOE OSTI2023

Genome engineering allows selective conversions of terephthalaldehyde to multiple valorized products in bacterial cells

Deconstruction of polyethylene terephthalate (PET) plastic waste generates opportunities for valorization to alternative products. We recently designed an enzymatic cascade that could produce terephthalaldehyde (TPAL) from terephthalic acid. Here, we showed that the addition of TPAL to growing cultures of Escherichia coli wild-type strain MG1655 and an engineered strain for reduced aromatic aldehyde reduction (RARE) strain resulted in substantial reduction. We then investigated if we could mitigate this reduction using multiplex automatable genome engineering (MAGE) to create an E. coli strain with 10 additional knockouts in RARE. Encouragingly, we found this newly engineered strain enabled a 2.5-fold higher retention of TPAL over RARE after 24 h. We applied this new strain for the production of para-xylylenediamine (pXYL) and observed a 6.8-fold increase in pXYL titer compared with RARE. Altogether, our study demonstrates the potential of TPAL as a versatile intermediate in microbial biosynthesis of chemicals that derived from waste PET.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Polyethylene upcycling to long-chain alkylaromatics by tandem hydrogenolysis/aromatization

The current scale of plastics production and the accompanying waste disposal problems represent a largely untapped opportunity for chemical upcycling. Tandem catalytic conversion by platinum supported on γ-alumina converts various polyethylene grades in high yields (up to 80 weight percent) to low-molecular-weight liquid/wax products, in the absence of added solvent or molecular hydrogen, with little production of light gases. The major components are valuable long-chain alkylaromatics and alkylnaphthenes (average ~C 30 , dispersity Ð = 1.1). Coupling exothermic hydrogenolysis with endothermic aromatization renders the overall transformation thermodynamically accessible despite the moderate reaction temperature of 280°C. This approach demonstrates how waste polyolefins can be a viable feedstock for the generation of molecular hydrocarbon products.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Synthetic Calcium Carbonate Production by Carbon Dioxide (CO 2 ) Mineralization of Industrial Waste Brines

The global scale of CO 2 emission has crossed 36 B tons, and the United State represents 14% of the total emissions. In light of the high cost associated with current CO 2 capture processes ($60-to-150 per ton of CO 2 ), carbon capture and utilization (CCU), wherein CO 2 is converted to beneficial products, provides a pragmatic path to overcome the economic barrier for CO 2 emissions control. In particular, CO 2 mineralization offers an attractive route as it produces high-value mineral carbonates that sequester CO 2 in a stable form. For instance, fine precipitated calcium carbonate, a valuable product with unit price in the range of $230-280/t and a global market projected to reach 99 M tons in 2020, can be produced by capturing CO 2 within aqueous Ca 2+ solution. However, two critical challenges need to be overcome—(i) the need for costly processes such as electrolysis or addition of alkali hydroxides to maintain alkalinity during mineralization, and (ii) the geographic availability of Ca-rich solutions (or brines) which often renders efficient integration with power plants impractical. To simultaneously address these challenges, this project developed two novel routes to enable carbonate production based on efficient CO 2 mineralization. In one variation, the project developed a new alkaline carbonation process to capture CO 2 and produce calcite precipitates from coal ashes. Herein, coal ash is carbonated first in a sodium carbonate solution. The carbonation reaction produces sodium hydroxide and raises the solution pH. This high-pH hydroxide solution is then used for CO 2 capture, which converts the sodium hydroxide solution back to sodium carbonate to repeat the carbonation cycle. The carbonated ash residue is refined with a CO 2 pressure swing step to produce high-purity precipitated calcium carbonate. In another variation, Ca-rich produced water brine serves as the Ca-source to mineralize CO 2 . An H + /Na + ion-exchange cycle was designed to provision alkalinity during mineralization and regenerate the ion-exchange reagent in brines with high salinity. Ca-depleted brines can then be treated within a centralized water treatment facility. Both variations beneficially utilize reject streams—such as coal ashes and brines from oil and gas extraction or CO 2 storage operations—that are available at substantial quantities in the vicinity of coal power plants within the U.S. In addition to technology development, this project included techno-economic and life-cycle analysis to identify technically and economically appropriate solutions for power plants in different geographic locations. Taken together, the project provides a unique route to integrate CO 2 emissions control and waste handling/treatment for coal power plants, while producing a high-value product to offset the economic burden associated with waste management. The developed processes utilize post-desulfurization flue gas from coal-fired power plants as is. The CO 2 conversion reactions are performed in alkaline brines at ambient pressure from the flue gas, thereby minimizing the energy burden. By beneficiation of industrial waste streams with low energy input, the processes offers significant technical advantages in energy and CO 2 footprint over the current paradigm of precipitated calcium carbonate production, which involves calcination of limestone at processing temperatures in excess of 800 °C. Overall, this project developed viable CO 2 mineralization processes while strategically maximizing the economic benefit.

01 COAL, LIGNITE, AND PEAT↗