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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

BETO 2021 Peer Review - Biomethanation to Upgrade Biogas to Pipeline Grade Methane WBS 5.1.3.102

We are developing, innovating and de-risking a biomethanation process capable of megawatt-scale deployment that upgrades biogas waste streams to produce pipeline quality renewable natural gas (RNG). Biomethanation is a two-step process using a methanogenic microorganism to convert renewable hydrogen (H2) and waste carbon dioxide (CO2) to renewable methane (CH4) - the primary component in natural gas. Using biogenic CO2 from biogas sources like dairies, wastewater treatment plants, and landfills allows production of this drop-in direct replacement fuel to participate in the growing number of carbon markets; like California's Low Carbon Fuel Standard and the Federal Renewable Fuel Standard. The end-of-project goal is to demonstrate pipeline quality RNG production (> 95% CH4, < 4% H2, <1% CO2, < 0.2% O2 and < 4 parts per million hydrogen sulfide) using real biogas feedstocks. We will accomplish this goal by designing and building a pressurized (18 bar) mobile lab-scale (20L) bioreactor research platform, including integrated electrolyzer system, based on lessons learned from operating the 700L pilot system from Southern California Gas Company. In collaboration with Electrochaea, natural gas utilities and Argonne National lab, will provide the data to establish a preliminary range of carbon intensity to help accelerate the deployment of utility-scale H2 production and qualify the biomethanation pathway process for RNG production.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Environmentally-Friendly Fixatives with Embedded Intelligence for Dust Management at Contaminated Sites – 21266

Wind or rain can potentially spread loose hazardous contaminants from piles of rubble and soil waiting to be trucked to a landfill site for disposal. Water, which is plentiful near remediation sites, is the traditional dust suppressant during demolition, post-demolition sizing and encapsulation as well as soil trucking activities. However, water can mobilize the toxic metal contaminants in the soil into the ground water. Ground water is highly regulated and contaminant removal is costly. InnoSense LLC (ISL) is developing DustSafe™ as a cost-effective alternative to water for various decontamination & decommissioning (D&D) applications. It is a sprayable dust abatement solution designed to actively trap, remediate, and aid in visualizing hazardous materials while preventing their dispersion by wind, water or impact. Aside from application as a dust suppressant to trap airborne toxic and radiological hazards during demolition activities, with customization DustSafe can be used to locate/characterize and remediate hazards prior to D&D activities.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Biogas Biocatalysis

Biogas derived from anaerobic digestion of waste streams such as biorefinery wastewater, animal, agricultural, and municipal solid waste, offers a versatile renewable energy source. Total domestic methane potential from landfill material, animal manure, wastewater, and organic waste, combined with biogas generated from AD of lignocellulosic biomass, is estimated to offer >4 quadrillion Btu potential energy. This energy could displace nearly half of current domestic natural gas consumption in the electric power sector and all consumption in the transportation sector. However, despite this promise of this feedstock, its gaseous state prevents facile integration with extant transportation and industrial infrastructure. Microbial conversion of biogas to liquid fuel and chemical intermediates offers valorization potential. However, biogas biocatalysis is currently limited by poor substrate gas-to-liquid mass transfer, low conversion efficiencies, and incomplete biogas utilization. To this end, the Biogas Biocatalysis AOP aims to develop a carbon- and energy-efficient biogas bioconversion process via techno-economic-informed strain and fermentation engineering strategies. Efforts here will improve both process economics and sustainability via process-intensified, carbon-efficient biogas bioconversion to value-added platform molecules, enabling bolt-on deployment for valorization of biogas derived from standalone AD infrastructure.

BASIC BIOLOGICAL SCIENCES,BIOMASS FUELS↗
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 OSTI2022

Preprocessing of municipal solid waste towards thermal insulating material

Municipal solid waste (MSW) is one of the significant challenges in today’s world. A continuous surge in population, increasing living standards, and rapid urbanization are generating an enormous quantity of MSW. For example, the Environmental Protection Agency (EPA) reported that the total generation of MSW in the United States in 2018 was 292.4 million tons. 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. Depending on the inherent chemical and structural properties of unrecycled wastes, the carbon structures can be tailored for processing and reuse in manufacturing of structural composites, building materials such as insulation, carbon dense reactant materials such as activated carbon, and so on. According to the EPA’s estimation, MSW in the United States is approximately 23% paper and paperboard, 12% plastics, 6% wood and 6% is textiles. Thus, this research focused on the feasibility of using the MSW as insulation material for the construction sector. The goal of this work was to determine the range of particle sizes, consolidation ratios, and component blends that can achieve insulation R-values within at least 70% that of traditional blown cellulose fiber. To achieve this goal, we designed the testing matrix based on five different component blends, three different particle sizes, and three different compaction level. An American Society for Testing and Materials (ASTM) method (C-739) was used to measure the R-value of the insulation material. Results showed that, adding more paper component in addition to smaller particle size and loose compaction made the insulation similar to the traditional blown cellulose fiber insulation as the R-value was within a range of 2.5-3.0 per inch.

42 ENGINEERING↗
DOE OSTI2023

BOTTLE 1 - Introduction and BOTTLE Overview

The Bio-Optimized Technologies to keep Thermoplastics out of Landfills and the Environment (BOTTLE) Consortium aims to develop robust processes to upcycle existing waste plastics and to develop new plastics that are recyclable-by-design, both in direct alignment with DOE's Strategy for Plastics Innovation. We accomplish our work in the BOTTLE Consortium through an organizational framework that includes three primary research tasks, Deconstruction, Upcycling, and Redesign, which are supported by three cross-cutting tasks, Analysis, Characterization, and Modeling, BOTTLE also has tasks focused on Industry Engagement and Diversity, Equity, and Inclusion (DEI). This presentation will review the approach and management structure of BOTTLE, the importance of analysis-guided research, and the key metrics for carbon, economic, energy, and greenhouse gas emissions. In the FY21-FY23 period, BOTTLE has drafted and enacted a comprehensive DEI plan, assembled a world-class Technical Advisory Board (TAB) to provide constructive feedback on our performance, had our first in-person all-hands meeting in summer 2022, and on-boarded and off-boarded research activities based on active project management and analysis. From an impact perspective, BOTTLE researchers have published over 40 peer-reviewed manuscripts (many in leading journals), submitted >30 patent applications, and initiated 6 funds-in industry partnerships.

BIOMASS FUELS↗
DOE OSTI2023

Performance and Cost Potential for Direct-Fired Supercritical CO2 Natural Gas Power Plants

Direct-fired supercritical CO2 (sCO2) power cycles are being explored as an attractive alternative to natural gas combined cycle (NGCC) plants with carbon capture and storage (CCS). Therefore, understanding their performance and cost potential is important for the commercialization of the technology. This study presents the techno-economic optimization results of natural gas-fired, utility-scale power plants based on the direct sCO2 power cycle, which are lacking in public literature. To identify the optimum plant configuration, the study considered multiple cases with varying levels of thermal integration with the plant air separation unit (ASU). Several design variables for each power cycle configuration were identified and optimized to minimize the levelized cost of electricity (LCOE) for each case. The optimization design variables include the sCO2 cooler outlet temperatures, recuperator approach temperatures, and pressure drops. High fidelity models for recuperators, coolers, and turbines were developed and used to capture the impact of design variables on plant efficiency and capital costs. The optimization was conducted using a combination of manual sensitivity analyses and automated derivative-free optimization algorithms available under NETL’s Framework for Optimization and Quantification of Uncertainty and Sensitivity platform. The optimized direct sCO2 power plants offered similar or slightly higher plant efficiencies than the reference NGCC plants based on the F-class gas turbine with CCS. The LCOE of the optimized direct sCO2 plants is 13 to 17% higher than the reference NGCC plants with CCS due to high capital costs associated with the ASU and sCO2 power block, though there is significant room for improvement due to the high uncertainty in component capital costs for these new plants. Recuperators make up over 50% of the sCO2 power block costs. Consequently, any research and development efforts to reduce the recuperator capital costs will benefit the technology’s commercialization. The study also presents preliminary results showing the impact of co-firing landfill gas and natural gas on plant efficiency, LCOE, and CO2 emissions.

Pidaparti, Sandeep↗
DOE OSTI2023

Performance and Cost Potential for Direct-Fired Supercritical CO2 Natural Gas Power Plants

Direct-fired supercritical CO2 (sCO2) power cycles are being explored as an attractive alternative to natural gas combined cycle (NGCC) plants with carbon capture and storage (CCS). Therefore, understanding their performance and cost potential is important for the commercialization of the technology. This study presents the techno-economic optimization results of natural gas-fired, utility-scale power plants based on the direct sCO2 power cycle, which are lacking in public literature. To identify the optimum plant configuration, the study considered multiple cases with varying levels of thermal integration with the plant air separation unit (ASU). Several design variables for each power cycle configuration were identified and optimized to minimize the levelized cost of electricity (LCOE) for each case. The optimization design variables include the sCO2 cooler outlet temperatures, recuperator approach temperatures, and pressure drops. High fidelity models for recuperators, coolers, and turbines were developed and used to capture the impact of design variables on plant efficiency and capital costs. The optimization was conducted using a combination of manual sensitivity analyses and automated derivative-free optimization algorithms available under NETL’s Framework for Optimization and Quantification of Uncertainty and Sensitivity platform. The optimized direct sCO2 power plants offered similar or slightly higher plant efficiencies than the reference NGCC plants based on the F-class gas turbine with CCS. The LCOE of the optimized direct sCO2 plants is 13 to 17% higher than the reference NGCC plants with CCS due to high capital costs associated with the ASU and sCO2 power block, though there is significant room for improvement due to the high uncertainty in component capital costs for these new plants. Recuperators make up over 50% of the sCO2 power block costs. Consequently, any research and development efforts to reduce the recuperator capital costs will benefit the technology’s commercialization. The study also presents preliminary results showing the impact of co-firing landfill gas and natural gas on plant efficiency, LCOE, and CO2 emissions.

Pidaparti, Sandeep↗
DOE OSTI2023

Industrial Waste to Value in the Circular Economy

This paper will outline a waste to value project currently underway. The project will profitably process 100,000 metric tons per year of secondary aluminum salt slag, which is currently landfilled, into recycled salt and refractory aggregate.

Ormond, Paul↗
DOE OSTI2023

Environmental and Economic Implications of Emerging Plastic Recycling Technologies

Recycling will play a crucial role in mitigating plastic pollution and promoting a circular economy for polymers. Quantitative analysis can help guide the optimization and implementation of these plastic management strategies, enabling increased circularity while minimizing costs, energy use, greenhouse gas emissions, and other environmental impacts. This talk will outline the Bio-Optimized Technologies to keep Thermoplastics out of Landfills and the Environment (BOTTLE) Consortium's approach to analysis-guided plastic recycling research. Stringent process modelling, life cycle assessment, and techno-economic analysis are used to benchmark the technical feasibility, environmental impacts, and costs of chemical and biological recycling technologies in comparison to conventional fossil fuel-based plastic manufacturing. Across emerging recycling strategies, several key challenges become apparent - including plastic feedstock pretreatment requirements, high energy or chemical use, and recycled plastic yields and quality - highlighting opportunities for future innovation. Through this consistent and in-depth analysis approach, BOTTLE aims to provide the plastics community with key metrics and insights to drive plastic recycling innovation towards a more sustainable and circular economy.

circular economy↗
DOE OSTI2023

Coupling Waste Feedstocks to Microbial Protein for a Circular Food System

The global food system is responsible for approximately 34% of annual greenhouse gas (GHG) emissions and up to 85% of water consumption. This critical sector suffers from intensive and inefficient land and water use, the generation of multiple (solid, liquid, and gaseous) waste streams, and high fuel, fertilizer, and pesticide consumption. The production of waste-derived microbial protein (MP) represents a promising alternative for reducing the environmental impacts of protein production relative to conventional agriculture. MP can be mass-produced in volumetrically scalable cultivation processes on short timescales, enabling facile up-scaling with lower greenhouse gas emissions, land use, and water impacts than animal and, in some cases, plant protein production. MP can also be produced from waste feedstocks, diverting waste from landfills or the natural environment. Here, we present the availability and suitability of waste feedstocks for MP production, as well as the fermentation and downstream processes required to convert MP into human food products. We discuss the challenges and opportunities facing waste-derived bacterial MP and highlight key areas for innovation in both the microbiology and process design space for a more sustainable and circular food system.

BASIC BIOLOGICAL SCIENCES,ENERGY PLANNING, POLICY,↗
DOE OSTI2023

Biomethanation to Upgrade Biogas to Pipeline Grade Methane

NREL is working closely with DOE, Electrochaea GmbH, and Southern California Gas Company (SoCalGas) to reduce costs of a biomethanation process capable of megawatt-scale deployment that upgrades organic biogas waste streams to produce pipeline quality renewable natural gas (RNG). Biomethanation is a two-step process using a single-celled methanogenic archaea that converts low-carbon low-cost hydrogen (H2) and waste carbon dioxide (CO2) to produce renewable methane (CH4). The process upgrades the biogenic CO2 - while allowing the CH4 to pass through - from biogas sources like dairies, wastewater treatment plants, and landfills. The CH4 produced is a drop-in direct replacement fuel and producers can participate in the growing number of carbon markets; like California's Low Carbon Fuel Standard and the Federal Renewable Fuel Standard. NREL and Argonne National Laboratory have completed a life cycle analysis using the GREET model to show that the biomethanation process produces RNG that is carbon negative even when H2 production via low-temperature water electrolysis is driven by the existing carbon intensity of California's electricity grid. And of course, even further carbon negative (-233 kg CO2e/kWh) when the electricity is produced from low-carbon sources like wind and solar. Leveraging lessons learned from operating SoCalGas' 700L 18-bar bioreactor system, NREL is designing and building a flexible RD&D platform that will enable field trials at biogas and other CO2 sources. A custom 16' long trailer will house a 20L 18-bar bioreactor, 3 - 25 kW proton exchange membrane electrolyzer, and dosing, thermal, and controls systems to support operations with only power, biogas, and water feedstocks required by the field locations. The end-of-project goal is to demonstrate pipeline quality RNG production (> 95% CH4, < 4% H2, <1% CO2, < 0.2% O2 and < 4 parts per million H2 sulfide) using real biogas feedstocks - thereby recycling both greenhouse gases for injection into the natural gas network or to be used onsite.

biogas upgrading↗
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 OSTI2024

Challenges in Tracking Waste Reduction Performance Improvement in Manufacturing Plants

The recently released Circularity Gap Report 2023 by Circle Economy Foundation found that the circularity score for the global economy is declining. This indicates that material extraction from virgin sources is climbing over earlier years. As per data released by US Geological Survey, material use in the US economy has increased exponentially with the expanding US economy over last century. EPA tracked municipal solid waste from 1960 to 2018 and found that 50% of the waste is destined for landfills. EPA estimates that US industry is responsible for 2.7 billion ton of solid non-hazardous waste annually in our mostly linear economy model. The circular economy framework aims at decoupling economic value generation from virgin materials extraction from nature. The linear model of material extraction and disposal at end of life is highly unsustainable. Manufacturing companies have realized this and in their commitments to sustainability are adopting ambitious waste reduction targets. Through Better Plants program US Department of Energy has established Waste Reduction Network where it is offering technical assistance to partners to achieve these ambitious waste reduction goals. Basic requirements of establishing a target include identifying a baseline, quantifying waste performance, and measuring progress over time. One problem faced by industry is the unstandardized metrics to quantify waste performance that may not be well suited to demonstrate progress. In this paper, we research methods traditionally used to measure waste performance and highlight advantages, gaps and limitations of each method. Suitability of the methods applicable to different manufacturing circumstances are also examined. Finally, we present a case study of a large manufacturer that faced inconsistencies in their tracked measurement metric. A solution was proposed to alter the methodology to enable more accurate waste performance tracking against a baseline.

Chaudhari, Subodh↗
DOE OSTI2025

Thermomechanical Separation of Biogenic and Non-biogenic Carbon from Non-Recyclable MSW

The effective separation of biogenic and non-biogenic carbon from non-recyclable municipal solid waste (n-MSW) presents a significant challenge in the United States. Currently, there are no efficient methods available to address this issue, hindering the potential for maximizing waste utilization and reducing landfilling rates. This project aims to develop and implement a combine thermomechanical separation techniques to separate biogenic and non-biogenic carbon within n-MSW, ultimately facilitating greater resource recovery and enhancing the efficiency and environmental impact of waste management practices.

09 - BIOMASS FUELS↗
DOE OSTI2026

Electronic Waste (E-Waste) Recycling: Barriers and Opportunities for State, Local, and Tribal Governments

Electronic waste, or e-waste, encompasses end-of-life electrical and electronic equipment, including computers, monitors, televisions, printers, cell phones, household appliances with electronic components, and small consumer devices containing batteries or circuitry. E-waste is one of the fastest-growing components of the U.S. waste stream, with nearly 8 million tons generated in 2022. E-waste presents two related public-interest considerations. First, e-waste contains economically and strategically important materials: base metals (copper, aluminum, iron, steel), precious metals (gold, silver, platinum group metals), and critical materials such as rare earth elements, gallium, and indium that appear on the U.S. Geological Survey's (USGS) 2025 List of Critical Minerals. Second, many electronic devices contain hazardous constituents - including lead, mercury, cadmium, and brominated flame retardants - as well as rechargeable batteries that can pose fire risks during handling. Effective management of these constituents helps protect workers, communities, and the environment. In the United States, it is estimated that less than 20% of e-waste is formally collected and recycled, leaving over 6 million tons landfilled or otherwise unrecovered. This fact sheet provides state and local decision-makers an overview of (1) e-waste composition and recoverable materials, (2) technology pathways used to recover those materials, and (3) examples of operational and partnership structures used to provide e-waste recycling capacity in the United States. It is intended to complement existing collection-program guidance available through U.S. Environmental Protection Agency (EPA) and other sources.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗