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DOE OSTI2022

Plasma technology for lignocellulosic biomass conversion toward an electrified biorefinery

Lignocellulosic biomass conversion to renewable, carbon-neutral materials, fuels, and chemicals is the cornerstone of the transition to a sustainable future bioeconomy. Green energy in the form of electricity needs to be coupled with or substitute conventional thermally driven processes to realize small-scale, economically viable and environmentally friendly biorefineries. Gas discharge plasmas enable the conversion of renewable electric energy, supplied in the form of an electric field, to chemical energy through the formation of a highly reactive environment that can induce several transformations related to agricultural waste valorization processes. Herein, we review the application of plasma technology to lignocellulosic biomass upgrade, aiming to provide the scientific background and technical challenges in this rapidly emerging research field. To bridge the gap between plasma science and biomass valorization technologies, we initially present the technical aspects of plasma reactors related to biomass processing and further discuss the advances in plasma processing for each biomass conversion technology, providing insights into the related plasma chemistry and interaction mechanisms. Here, we first focus on the low and medium-temperature biomass conversion processes, including biomass pretreatment and delignification to promote enzyme or acid-catalyzed hydrolysis to sugars and biomass liquefaction using plasma electrolysis. Then we discuss the high and very high-temperature conversion processes, such as plasma-assisted pyrolysis and gasification to syngas and plasma application to tar removal, combustion, and vitrification. Overall, this review provides knowledge at the interface of plasma science and biomass conversion technology to promote the interaction between the individual communities, which is crucial for the further advancement of the field.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Desalting biocrude for improved downstream processing toward marine fuel application

Hydrothermal liquefaction of wet wastes (e.g., food waste and sewage sludge) offers a promising avenue for producing biocrude, but the resulting product is often contaminated with metals and water, impacting the biocrude upgrading steps to produce final fuel (e.g., jet and diesel). Here this study investigates the use of aqueous solutions of formic acid for desalting biocrudes and improving their quality. The results show that this approach significantly reduces both metal and water content, enabling mild hydrotreatment with reduced hydrogen consumption to further enhance the biocrude's quality. A preliminary technoeconomic analysis based on these experimental results shows that even without optimization, this washing process can yield biocrude with a minimum selling price of $1.87/GGE. Overall, our study demonstrates the potential for using dilute formic acid aqueous solutions to improve the quality of biocrudes, which can lead to more efficient and cost-effective conversion into biofuels.

09 BIOMASS FUELS↗

DOE OSTI2025

Direct flue gas capture for algae cultivation and subsequent valorization: evaluating life cycle emissions and costs

Algae cultivation and processing is an important pathway under discussion within the broader CO 2 capture and utilization umbrella. Here, we discuss the results of a life-cycle analysis and techno-economic analysis of a pilot-scale photobioreactor that uses flue gas directly from natural gas or biogas combustion at 3–5% CO 2 concentration. The system requires minimal freshwater use as it has been successfully run with industrial wastewater and has a much smaller areal footprint compared with open pond cultivation. Introducing the flue gas directly to the photobioreactor avoids the need for CO 2 separation and pressurization, which is undertaken in many other algae cultivation systems. For the end-use of the biomass, the default case assumes conversion of algae to liquid fuels via hydrothermal liquefaction. The results indicate that the pilot-scale system has a higher cost, and comparable greenhouse gas emissions compared to pond-based systems, especially as the grid is anticipated to evolve to a lower carbon intensity. The costs of algae biofuel production range from $\$12–16$ per GGE at the current pilot scale. Depending on whether the source of the carbon is fossil or biogenic, the net emissions are 68 g CO 2 e per MJ and −4 g CO 2 e per MJ respectively. If the marine algae species is used instead of the freshwater species, it offers an additional 16 g CO 2 e per MJ carbon fixation in the form of calcium carbonate. The findings point to broadly desirable trends in GHG emissions and costs, while the discussion aims to shed light on areas that could further improve the scalability of the system.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2026

Performance Testing of the 4kW ESR 2 Refrigerator at JLab

Abstract The End Station Refrigerator 2 (ESR2), a refurbished cryoplant, will replace the ESR1. ESR2 is comprised of the cold box and compressors from the Superconducting Super Collider’s 4 kW, 4.5 K ASST-A plant. It also features a new 10 kL liquid helium dewar, a cryogenic distribution system and new control and utility systems. This plant was reconfigured to provide a cold helium supply at 15 K, 12 K, and 8 K for the experimental hall’s hydrogen targets. The most significant load will be during the MOLLER experiment, which will see a total hydrogen target load of 5 kW at 15 K. This paper details the commissioning results of the 4.5 K refrigeration system in various modes (maximum refrigeration, maximum liquefaction, and a 50/50 mix) at both 100 % and 50 % capacity. We will also evaluate the performance with an expected MOLLER load. Current performance will be compared with the historical commissioning data from the ASST-A plant.

Perry, C. [Cryogenics Department, Thomas Jefferson↗

DOE OSTI2023

Hydrogen storage in liquid hydrogen carriers: recent activities and new trends

Abstract Efficient storage of hydrogen is one of the biggest challenges towards a potential hydrogen economy. Hydrogen storage in liquid carriers is an attractive alternative to compression or liquefaction at low temperatures. Liquid carriers can be stored cost-effectively and transportation and distribution can be integrated into existing infrastructures. The development of efficient liquid carriers is part of the work of the International Energy Agency Task 40: Hydrogen-Based Energy Storage. Here, we report the state-of-the-art for ammonia and closed CO 2 -cycle methanol-based storage options as well for liquid organic hydrogen carriers.

08 HYDROGEN↗

DOE OSTI2022

On various mechanisms of shear wave generation from underground chemical explosions in hard rocks

Significant shear waves observed during underground explosions can make them look similar to natural earthquakes. In the near field, they can be caused by the source geometry and emplacement conditions, heterogeneous and anisotropic properties of the rock mass, relaxation of a non-uniform in situ stress around the source after the departure of the shock wave as well as by activation of nearby faults. Here, the stress relaxation mechanism is important at depth when the difference in main principal stresses becomes significant. Another mechanism of shear motion generation is due to explosive gas flow from the source cavity into the cracks initiated by the shock wave and joints connected to the cavity. Also, the shock wave from the explosion can cause weakening of the rock either due to permanent damage or shock-induced liquefaction at saturated joints. Numerical modelling of underground chemical explosions in hard rock at various confinement stresses has been conducted to compare various mechanisms of shear wave generation and their seismic characteristics with that of a simple fault rupture process observed during an earthquake.

58 GEOSCIENCES↗

DOE OSTI2026

A wide-range thermodynamically consistent constitutive model for dynamic loading of partially saturated porous media

SUMMARY This paper presents a novel thermodynamically consistent constitutive model for partially saturated porous rocks across a wide range of conditions. The material states generated behind the shock wave from an explosive source can vary significantly, ranging from crushed and melted rock near the source to a poroelastic medium in the far field. In the model, rock strength is determined by the effective pressure, which is calculated using two independent equations of state: one for the solid rock and another for the pore fluid. The model accounts for shock-induced liquefaction resulting from fluid pressure buildup in the pore spaces near the explosive source. Simultaneously, it describes the increase in wave propagation speed due to elastic pore contraction in both dry and partially saturated rocks. This model is applied to investigate how fluid saturation affects the amplitude and shape of the generated waves, as well as the residual stress surrounding the cavity formed by spherical explosions.

Vorobiev, Oleg [Lawrence Livermore National Labora↗

DOE OSTI2026

The Use of Machine Learning Models for Predicting the Dielectric Strength of Gases

Technological advancements in high voltage systems have pushed sulfur hexafluoride (SF6) to its operational limits. Furthermore, this gas has other drawbacks including a high liquefaction temperature and a high global warming potential. Therefore, there has been an urgent need to find alternative gases with high dielectric strength (DS). In this work, density functional theory (DFT) is used to calculate molecular descriptors that are fed into an artificial neural network (ANN) and a random forest (RF). These machine learning (ML) models are then used to predict the DS for hundreds of molecules. A finite element model (FEM) is also used to calculate the electric field profile of multiple simple electrode geometries as the applied voltage to the system is increased. Results indicate that the random forest model has better generalization to unseen data than the neural network. The highest DS value predicted by the RF was 2.16 relative to the experimental DS of SF6. The results also demonstrate how choosing a gas with a higher DS and a geometry with minimal edges and corners can significantly increase the operating voltage of an electrical system. Due to its superior generalization, the RF represents the most promising path toward an accurate DS predictor once sufficient experimental data are available.

Mileski, Matthew [AFIT]↗

DOE OSTI2022

LIQUID AIR COMBINED CYCLE

Hybrid integration of thermal energy storage with gas turbines can provide compact, cost-effective, long-duration energy storage while reducing the fuel consumption of dispatchable resources needed for the reliability of renewable dominant electric grids. The Liquid Air Combined Cycle™ (LACC) is a hybrid energy storage system using cryogenic liquid air as an energy storage medium and gas turbine exhaust heat to extract stored energy. The storage tank is charged using liquefaction processes employing electric motor-driven compressors to pressurize the air, heat exchangers to reject heat of compression, and expanders to reduce the temperature and liquefy the air. Proven cryogenic refrigeration processes can be selected based on capital cost (per kg/s of liquid air produced), efficiency (kJ per kg of air produced), and operating factors including startup speed and load following capability. This paper presents results of studies undertaken for the U.S. Department of Energy to evaluate cost and performance tradeoffs for charge and discharge cycle components, optimize charge and discharge cycles, and assess the techno-economic potential of LACC technology.

Conlon, William↗

DOE OSTI2023

Multimodal CO2 Transportation Cost Model

This model provides a cost estimate for transporting CO2 via truck or rail in the United States using commercially available equipment and technologies. The model includes an analysis of direct and indirect CO2 emissions to determine costs per net tonne of CO2 transported. Publicly available data and methods published in the peer-reviewed literature are used to the extent possible; references are available at the bottom of the "Calculations" sheet. Upstream (i.e., liquefaction, buffer storage) and downstream (i.e., buffer storage, reconditioning) activities are included in the model of emissions and costs. All capital and operating expenditures are estimated in the "Calculations" sheet. The cost of financing the project is determined in the "FINEX" sheet. All user inputs are done via drop down menus in on the "User Interface" sheet. Summary results are also provided on the "User Interface" sheet.

Myers, CoreyA↗

DOE OSTI2024

Fighting the climate crisis with caloric heat pumping: Innovations to enable widespread adoption

Caloric heat pumping is a cross-cutting thermal energy technology that can cover a wide range of applications and temperatures, from millikelvins to hundreds of kelvins, with a working medium that has zero global warming potential. The technology promises cost savings and high efficiency, having 60% Carnot efficiency demonstrated to date. The Energy Earthshots™ Initiative, launched by the U.S. Department of Energy, aims to fight the climate crisis and overcome technological barriers to a decarbonized economy. The initiative focuses on the development of energy solutions that increase efficiency, reduce greenhouse gas emissions, and ensure affordability. Three out of eight Energy Earthshots™ look for alternative thermal energy technologies for extensive temperature ranges, from hydrogen liquefaction to metal-treating temperatures. Caloric heat pumping can fulfill all these requirements; however, at the current stage, caloric systems have limited presence in real-world applications. Further, this perspective discusses key efforts to address barriers hindering the widespread adoption of caloric technology. We focus on essential breakthroughs in and effective approaches to material discovery and draw a path to high-power-density, grid-interactive caloric systems to support achieving the ambitious net-zero carbon economy goal.

42 ENGINEERING↗

DOE OSTI2020

Reflectin: Protein Driver of Dynamically Tunable Biophotonics; New Paradigm for Tunably Reconfigurable Materials

We discovered that the reflectins, with architecture and sequences unlike those of any other proteins known, exhibit a novel interplay between signal-controlled nucleation and growth of dynamically arrested liquid-liquid phase-segregated assemblies that uniquely enables the continuous and precise fine-tuning of physical properties governing the color and brightness of light reflected from the membrane-enclosed nanostructures that contain them. Our research included high-resolution structural analyses conducted at the DOE-BES user facilities of the Stanford Synchrotron Light Source and LBL National Laboratory’s Molecular Foundry, leveraging their capabilities for time-resolved SAXS and cryo-TEM with our ongoing genetic engineering, biophysical and computational analyses to identify the structural determinants and mechanisms governing the dynamic behaviors of the reflectins. We augmented these methods with EPR analyses that revealed for the first time the existence of a specific pathway of reflectin assembly. Using dynamic light scattering and continuously monitored circular dichroism and Raman microscopy, we elucidated the progression of structural changes underlying the mechanisms of signal-induced condensation, folding, assembly, liquefaction, dynamic arrest, regulation and reversal.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

A Novel Platform for Algal Biomass Production Using Cellulosic Mixotrophy (CeMix) (Final Technical Report)

This novel project, branded CeMIX for cellulosic mixotrophy, targets solutions for several technological barriers limiting the deployment of algae cultivation in sunny, arid regions (specifically the southwest United States). Opening up the region for algae cultivation could increase DOE’s resource assessments and biofuel potential for the U.S. Mixotrophic metabolism in support of liquid fuel production is completely dependent on the availability of waste organic carbon in order to avoid diversion of food resources for fuel production. The use of cellulosic sugar hydrolysate (CSH) produced via the NREL process provided a standardized carbon source for study of the underlying biochemistry and metabolic adjustments to mixotrophy. Mixotrophic metabolism uses both photosynthetic CO 2 fixation and sugar oxidation to improve biomass productivity and harvest yield. The project was high-risk, high-reward in the sense that adding organic carbon to algal cultivation is an invitation for rapid-growth, heterotrophic contaminants to overtake the culture and consume mineral nutrients needed for algal growth. To help evade this outcome the project focused on acidophilic red algae that require low pH conditions with 40-48°C optimal temperature profiles that define them as low-range thermophiles. This is the only project in the BETO portfolio to utilize extreme conditions of low pH and high operating temperatures to control pathogens and competitors in mass culture. The project yielded five major outcomes. 1) Harvest densities of 5-10 g ash-free dry weight are easily achieved, providing a 10-fold reduction in water required and dewatering demand. 2) Catabolic repression of photosynthesis in G. sulphuraria is conditionally repressed by low oxygen. 3) Mixotrophic growth on cellulosic hydrolysate consumes all C6 and C5 sugars concomitant with increases in floridean starch with little change in lipid content. Protein content can be manipulated between 35 and 54 wt% by varying the C:N molar ratio from 10:1 to 20:1, respectively. 4) Mixotrophic cultures with up to 50 mM total sugar are remarkably stable at pH 2.5 and daily average reactor temperatures of 40°C. 5) Capital costs for glass tubular photobioreactors are prohibitive for liquid fuel production using a hydrothermal liquefaction processing pathway. The economic outlook for covered raceway ponds is better with a project minimum fuel selling price at $3.32 dm 3 GE -1 .

09 BIOMASS FUELS↗

DOE OSTI2021

Improved Hydrogen Utilization and Carbon Recovery for Higher Efficiency Thermochemical Bio-oil Pathways

The goal of this project was to develop a novel integrated direct biomass liquefaction process with improved hydrogen utilization and better carbon efficiency compared to other thermochemical conversion technologies for advanced biofuels production. Reactive catalytic fast pyrolysis, or RCFP, combines a robust hydrodeoxygenation catalyst for in situ pyrolysis in an excess of hydrogen at atmospheric (low) pressure. RCFP was developed to leverage advantages from catalytic fast pyrolysis (process simplicity and improved bio-crude quality) and biomass hydropyrolysis (enhanced hydrodeoxygenation) to produce a thermally-stable, low oxygen containing bio-crude intermediate that can be upgraded in a single conventional hydroprocessing step to produce gasoline- and diesel-range hydrocarbons. In parallel, carbon lost to the aqueous phase was recovered as renewable methane from anaerobic digestion to offset fossil carbon required to meet the hydrogen demand of the integrated process.

09 BIOMASS FUELS↗

DOE OSTI2021

High-Octane Gasoline from Lignocellulosic Biomass via Syngas and Methanol/Dimethyl Ether Intermediates: 2020 State of Technology

The 2020 state of technology (SOT) serves as an update to the 2019 SOT report and details the techno-economic analysis (TEA) results for producing high-octane gasoline (HOG) via indirect liquefaction (IDL). This report only describes changes to the experimental and analysis results from previous SOTs; more details regarding the full process design can be found in the 2015 design report. The conversion pathway presented in this report includes the gasification of biomass, steam reforming and cleanup of the syngas, followed by the conversion of the syngas to HOG via methanol and dimethyl-ether (DME) intermediates. Research efforts in 2020 included the collection of experimental results over a variety of isobutane (iC4) to DME ratios in the feed of the DME-to-HOG reactor, enabling the TEA to identify the effect on modeled product yield and cost. Additionally, a significant re-build of the Aspen Plus model allowed for better integration of new research, however underlying conceptual and economic assumptions remain the same as those detailed in the 2015 deign report. The 2020 SOT also considers the potential for federal carbon tax credits from CO 2 capture in the acid-gas removal step and the impact on the final minimum fuel selling price.

09 BIOMASS FUELS↗

DOE OSTI2021

Evaluate Synergies of Using Hydrothermal Liquification (HTL) and Anerobic Digestion (AD) Treatment Technologies for Wastewater Resource Recovery Facilities (WRRFs)

PNNL has developed Hydrothermal Liquefaction (HTL) technology, which can directly convert sewage sludge to a biocrude oil that can be refined into renewable diesel fuel and provide a significant reduction in the volume of biosolids produced as ash with far less potential environmental impacts associated with disposal. HTL also produces an aqueous byproduct stream that requires treatment before it can be returned to the headworks of the Wastewater Resource Recovery Facilities (WRRF). The goal of this project is to evaluate synergies of using HTL and advanced AD to enable the treatment and recycle of HTL aqueous phase. This CRADA will; 1) formalize and strengthen the working relationship between PNNL and GLWA, 2) jointly evaluate HTL and AD scenarios for WRRFs and 3) help enable the implementation of HTL/AD technology at GLWA and other WRRFs.

09 BIOMASS FUELS↗

DOE OSTI2022

High-Octane Gasoline from Lignocellulosic Biomass via Syngas and Methanol/Dimethyl Ether Intermediates (2021 State of Technology)

The 2021 state of technology (SOT) assessment for the indirect liquefaction (IDL) of lignocellulosic biomass to high-octane gasoline (HOG) via methanol and dimethyl ether (DME) intermediates details the techno-economic analysis (TEA) results and technical progress of the pathway since the 2020 SOT report. A detailed process description and collection of underlying assumptions is given the 2015 design report. In 2021, research efforts rigorously quantified the selectivity of DME to aromatic compounds. As a result, the overall carbon selectivity to hydrocarbon products was updated based upon new findings. Additionally, research conducted over the past few years resulted in successful lower temperature regeneration of NREL's Cu/BEA catalyst with favorable implications on catalyst longevity. Discussions with an engineering firm resulted in an update to the excess air requirement for process combustors (including the char combustor, tar reformer combustor, and catalyst regenerator) in which excess air was reduced from 20% excess to 10%. The cumulative effect of the above efforts was used to calculate a minimum fuel selling price for the modeled pathway. Sensitivity cases examining federal carbon tax credits from CO 2 capture, product selectivity and yield, catalyst lifetime, and other key financial and process parameters were also considered in this assessment.

09 BIOMASS FUELS↗

DOE OSTI2022

A Novel Process for Converting Coal to High-Value Polyurethane Products

Battelle has demonstrated a patented process for making high-value, polyurethane (PU) foam from coal, based on preparing liquefied coal via direct liquefaction, converting it to polyols as an intermediate via ozonation, and then making PU foams from these polyols. This process represents a breakthrough in innovative utilization of U.S. coals, and is applicable to bituminous as well as sub-bituminous coals. The resulting PU foam products are projected to have an extremely high value (i.e., over $\$5,000$ /ton), with nearly 100% of carbon utilization from coalderived liquid feedstock, and 31.5% to 43.5% of the carbon in the PU foam polyol product being bio-based. The targeted products represent an extremely large (i.e., over $80 billion/year), existing PU foam market, which could expand into making coatings and adhesives. The process can further help reduce petroleum imports, while improving the economics of PU foam production. This work was completed with funding from the National Energy Technology Laboratory (NETL), with cost share from the State of Ohio’s Ohio Development Services Agency (ODSA) and others, and has advanced the process to 10 kg/day continuous scale and thus to Technology Readiness Level (TRL) 5. A total of 48 coal-based polyols were prepared and evaluated. The initial 28 polyols focused on range finding for ideal conditions. The later 20 polyols were produced as part of process optimizations. These optimizations were targeted around a continuous ozonolysis process to evaluate extended time reactions and to create the necessary intermediate for production of 1-gallon samples of polyol. The most unique attribute of Battelle’s polyol is in the utilization of coal’s aromaticity to gain final foam rigidity. Typically, polyols depend on the isocyanate fraction and cross-linking to gain rigidity. By utilizing coal, we were able to maintain rigidity while reducing the overall hydroxyl value of the polyol. This is important as lower hydroxyl value leads to greater percent weight of the coal-based polyol because less isocyanate is required for foaming. This leads to greater foam cost savings. This report provides the details, process, and process cost models of the conversion of coal to polyols and further to PU foams. Battelle’s process begins with coal liquids. These liquids can be obtained by two processes: coal coking or pyrolysis to produce coal tar, and Battelle’s biobased coal-to-liquids (CTL) process to produce heavy syncrude after liquifying >85% coal. After liquification, Battelle utilizes ozonolysis to create functionalization on the polyaromatic coal structure. The functionalization is then converted to the final polyester polyol through transesterification, or to hydroxyamide polyol through amidification. Equivalent or better standard properties have been obtained for 2 lb/ft 3 density rigid, water and freon-alternative blown foams, including compressive strength, density, R-value, and dimensional stability. Target applications for these foams are insulation, packaging, and energy-absorbing foams. Some exploratory testing also showed promise for adhesives applications. A detailed economic analysis showed that Battelle’s polyol process is economical, at a 140 metric tons per day (MTD) polyol production scale. An attractive return on investment (ROI) at competitive pricing validates the process is ready for a pilot-plant demonstration. A scale-up plan is provided.

01 COAL, LIGNITE, AND PEAT↗