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All sourcesNASA NTRSDOE OSTI
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 OSTI2021

Long-term variability of root production in bioenergy crops from ingrowth core measurements

Long-term determination of root biomass production upon land-use conversion to biofuel crops is rare. To assess land-use legacy influences on belowground biomass accumulation, we converted 22-year-old Conservation Reserve Program (CRP) grasslands and 50+-year-old agricultural (AGR) lands to corn (C), switchgrass (Sw) and restored prairie (Pr) biofuel crops. We maintained one CRP grassland as a reference (Ref). We hypothesized that land-use history and crop type have significant effects on root density, with perennial crops on CRP grasslands having a higher root biomass productivity, while corn grown on former agricultural lands produce the lowest root biomass. Methods The ingrowth core method was used to determine in situ ingrowth root biomass, alongside measurements of aboveground net primary productivity (ANPP). Ancillary measurements, including air temperature, growing season length and precipitation were used to examine their influences on root biomass production. Important Findings Root biomass productivity was the highest in unconverted CRP grassland (1716 g m-2 yr-1) and lowest in corn fields (526 g m-2 yr-1). All perennial sites converted from CRP and AGR lands had lower root biomass and ANPP in the first year of planting but peaked in 2011 for switchgrass and a year later for restored prairies. Ecosystem stability was higher in restored prairies (AGR-Pr: 4.3 ± 0.11; CRP-Pr: 4.1 ± 0.10), with all monocultures exhibiting a lower stability. Root biomass production was positively related to ANPP (R2 = 0.40). Overall, attention should be given to root biomass accumulation in large-scale biofuel production as it is a major source of carbon sequestration.

Environmental Sciences & Ecology↗
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 OSTI2020

Building Blocks from Biocrude: High-Value Methoxyphenols (Final Scientific/Technical Report)

Integrating biofuels production with bioproducts presents an opportunity to explore options for recovering high-value chemicals as additional revenue-generating products from biofuel conversion pathways. Thus, the overall objective of this project was to develop a comprehensive separation strategy to economically recover valuable methoxyphenols (MPs) consisting of guaiacol, 4-methylguaiacol, 4-ethylguaiacol, 4-propylguaiacol, eugenol, and isoeugenol from biocrude as building blocks to demonstrate that bioproducts could enable cost-effective production of biofuels via integrated catalytic pyrolysis and hydroprocessing. The upgradability of the remaining biocrude fraction to biofuel after separation of the products was evaluated by hydrotreating. Finally, techno-economic analysis (TEA) was performed to examine the economic potential of recovering select MPs from biocrude in parallel with biofuels production.

09 BIOMASS FUELS↗
DOE OSTI2022

The contribution of bioenergy to the decarbonization of transport: a multi-model assessment

The expected growth in the demand for passenger and freight services exacerbates the challenges of reducing transport GHG emissions, especially as commercial low-carbon alternatives to petroleum fuels are limited for shipping, air and long-distance road travel. Biofuels can offer a pathway to significantly reduce emissions from these sectors, as they can easily substitute for conventional liquid fuels in internal combustion engines. In this paper, we assess the potential of bioenergy to reduce transport GHG emissions through an analysis leveraging various integrated assessment models and scenarios, as part of the 33rd Energy Modeling Forum study (EMF-33). Furthermore, we find that bioenergy can contribute a significant, albeit not dominant, proportion of energy supply to the future transport sector: in scenarios aiming to keep the temperature increase below 2 °C by the end of the twenty-first century, models project that in 2100 bioenergy can provide on average 42 EJ/yr (ranging from 5 to 85 EJ/yr) for transport (compared to 3.7 EJ in 2018), mainly through lignocellulosic fuels. This makes up 9–62% of final transport energy use. Only a small amount of bioenergy is projected to be used in transport through electricity and hydrogen pathways, with a larger role for biofuels in road passenger transport than in freight. The association of carbon capture and storage (CCS) with bioenergy technologies (BECCS) is a key determinant in the role of biofuels in transport, because of the competition for biomass feedstock to provide other final energy carriers along with carbon removal. Among models that consider CCS in the biofuel conversion process the average market share of biofuels is 21% in 2100 (ranging from 2 to 44%), compared to 10% (0–30%) for models that do not. Cumulative direct emissions from the transport sector account for half of the emission budget (from 306 to 776 out of 1,000 GtCO 2 ). However, the carbon intensity of transport decreases as much as other energy sectors in 2100 when accounting for process emissions, including carbon removal from BECCS. Lignocellulosic fuels become more attractive for transport decarbonization if BECCS is not feasible for any energy sectors. Since global transport service demand increases and biomass supply is limited, its allocation to and within the transport sector is uncertain and sensitive to assumptions about political as well as technological and socioeconomic factors.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

The economic and environmental costs and benefits of the renewable fuel standard

Abstract Mandates, like the renewable fuel standard (RFS), for biofuels from corn and cellulosic feedstocks, impact the environment in multiple ways by affecting land use, nitrogen (N)-leakage, and greenhouse gas (GHG) emissions. We analyze the differing trade-offs these different types of biofuels offer among these multi-dimensional environmental effects and convert them to a monetized value of environmental damages (or benefits) that can be compared with the economic costs of extending these mandates over the 2016–2030 period. The discounted values of cumulative net benefits (or costs) are then compared to those with a counterfactual level of biofuels that would have been produced in the absence of the RFS over this period. We find that maintaining the corn ethanol mandate at 56 billion l till 2030 will lead to a discounted cumulative value of an economic cost of $199 billion over the 2016–2030 period compared to the counterfactual scenario; this includes $109 billion of economic costs and $85 billion of net monetized environmental damages. The additional implementation of a cellulosic biofuel mandate for 60 billion l by 2030 will increase this economic cost by $69 billion which will be partly offset by the net discounted monetized value of environmental benefits of $20 billion, resulting in a net cost of $49 billion over the 2016–2030 period. We explore the sensitivity of these net (economic and environmental) costs to alternative values of the social costs of carbon and nitrogen and other technological and market parameters. We find that, unlike corn ethanol, cellulosic biofuels can result in positive net benefits if the monetary benefits of GHG mitigation are valued high and those of N-damages are not very high.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Production of Biocrude in an Advanced Photobioreactor-Based Biorefinery

Algenol Biotech, the National Renewable Energy Laboratory (NREL), Georgia Institute of Technology, Arizona State University, and Reliance Industries formed a team to advance the state of the art in algal biomass production and downstream processing technologies, with the end goal of a sustainable, economically viable biofuel intermediate (BFI, biocrude) product. The project included examination of high value co-product production as a market entry strategy and for enhancing the economics of a biorefinery for BFI production. The project targeted innovations in biology, operations, and engineering. The goals of the project were: BFI productivity greater than 4,000 gal-BFI/acre-yr on an annualized basis; energy efficient innovations in downstream operations resulting in an energy expenditure less than 10% of the BFI energy content and a carbon footprint reduction of more than 60% compared to fossil alternatives; and a comprehensive Techno-Economic Analysis (TEA) that identifies limiting factors for commercial viability of a photobioreactor (PBR)-based biofuel product. The project achieved the overall objectives. Strain development efforts led to the identification of a strain (Cyanobacterium sp. AB1166) that, relative to the previous best strain (Cyanobacterium sp. AB1), exhibited a ~10% increase in productivity under commercially-relevant cultivation conditions and also resulted in cultures with a >50% reduction in viscosity such that harvesting efficiency was improved; these results represent achievement of key project milestones. Progress was also made at NREL in altering the biochemical composition of algal biomass to improve the yield of BFI produced via HTL. These strain enhancements coupled with improved outdoor cultivation practices, including semi-continuous operation, increased areal biomass productivity by nearly 80% over the established baseline productivity. The annualized productivity achieved (26.8 g/m2-d), paired with HTL conversion yields realized at NREL and RIL (38% ± 2% BFI), translates to 4,100 gal-BFI/acre-yr, exceeding the FY20 BETO goal of 3,700 gal-BFI/acre-yr. Significant progress was also demonstrated in large scale PBR-based production system design, operability, and cost reduction. A 24,000-L production module comprised of 240 interlinked PBRs was constructed and successfully operated outdoors for over one year in Fort Myers, Florida. Aided by a state-of-the-art productivity model, the productivities achieved convincingly demonstrated scalability of laboratory results determined at the mL to L scale to large-scale outdoor operations exceeding 20,000 L. The system was used to cultivate Arthrospira platensis (Spirulina), an industrially-relevant cyanobacterium and source for phycocyanin, an approved blue food colorant that Algenol is developing as a risk reduction strategy for future biofuel projects and as a potential business opportunity. A key project milestone to develop phycocyanin extraction and purification technologies was achieved ahead of schedule, and product samples received positive feedback from potential customers. The production and downstream operations data generated in this project were used to conduct and refine Techno-Economic and Life Cycle Assessments to provide research guidance for reducing the costs and environmental footprint of algal biofuel and co-product manufacturing plants. Several CO 2 supply scenarios for an algal biorefinery were identified as being capable of providing a large (>60%) reduction in carbon footprint in comparison to gasoline. The TEA assessments incorporated detailed comparisons of PBR versus open pond production systems, yielding a 3-fold higher areal productivity for PBRs and suggesting overall production cost parity for the two systems. The progress in this ABY2 project addressed many of the the barriers identified for the Advanced Algal Systems R&D Program and are directly relevant to achieving the established BETO goals associated with large scale biofuel production and cost reduction.

09 BIOMASS FUELS↗
DOE OSTI2022

Water Availability for Biorefineries in the Contiguous United States and the Implications for Bioenergy Production Distribution

Renewable biofuel production depends on many factors, including feedstock availability, refinery and shipment infrastructure, and in particular, water availability. This study assesses water requirement and availability for mainstream biorefinery technologies in the contiguous United States (CONUS). The assessment is conducted in newly defined spatial units, namely, biorefinery planning boundaries, considering feedstock availability, transportation cost, and refinery capacity requirement for cost-effectiveness. The results suggest that the total biorefinery water use in the CONUS by 2030 will be low compared to the total water availability. However, biorefinery water requirements can aggravate the water stress situation in many regions, including the Great Plains, California Central Valley, and the upper Columbia-Snake River basin in Washington. Bioenergy productions in these regions can be largely constrained by water. Here, it is projected that biofuel production will concentrate in Northern Plains, Lake States, and Corn Belt regions, which contribute 94.4% of the conventional, 86.1% of biodiesel, and 54.8% of cellulosic biofuel production mandated by the renewable fuel standard. If biorefineries are constrained to use less than 10% of the locally available water, up to 7% of planned cellulosic biofuel production will be affected. Findings from this study can aid the sustainable planning of national bioenergy production.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Combining biotechnology with sustainability: feasibility of bioenergy sorghum in generating high-value bioproducts

Biofuels generated through fermentation of plant-derived lignocellulosic biomass are currently not competitive with fossil fuels. Here, a framework is described for the engineering of valuable coproducts to improve the economic feasibility of biofuel production. To accomplish this goal, the desirable traits of the bioenergy crop Sorghum bicolor are harnessed via modern engineering approaches. A robust analysis is provided to highlight the scientific basis, costs, regulatory challenges, and lucrative nature of coproduct development. Sustainable biofuel production could also have far-reaching societal impacts, especially in the context of our rapidly changing global climate. This perspective suggests that the path to profitable biofuel production is attainable and encourages consideration of similar approaches by the biotechnology industry.

09 BIOMASS FUELS↗
DOE OSTI2024

Estimated attribution of the RFS program on soybean biodiesel in the U.S. using the bioenergy scenario model

Biofuels are supported by various governmental policies in the U.S. and globally as an alternative transportation fuel for environmental, geopolitical, and economic reasons. Much debate surrounds the effectiveness of these policies as well as the overall net environmental effect of increased biofuels use. In the U.S., recent studies have shown that the Renewable Fuels Standard (RFS) Program, overall, may not have been the leading driver of the ethanol industry from 2005 to 2020, contrary to common perception. Similar scrutiny has not been applied to biodiesel. Here, this study uses the Bioenergy Scenario Model, a well-vetted system dynamics model, to retrospectively apportion historical biodiesel production between the RFS Program and other potentially influential drivers, such as the economics of biodiesel vs. diesel, the Biodiesel Tax Credit (BTC), California's Low Carbon Fuel Standard, and other factors. From 2002 to 2020 about 36% of biodiesel production can be attributed to the RFS Program, 35% to the BTC, and the rest to other factors. Thus, the overall effect of the RFS Program appears much larger on biodiesel than on corn ethanol. The finding that the same policy may have very disparate effects on different biofuels helps inform the design of future policies on biofuels.

09 BIOMASS FUELS↗
DOE OSTI2025

Palm oil deoxygenation with glycerol as a hydrogen donor for renewable fuel production using nickel-molybdenum catalysts: The effect of support

Palm oil, one of the most widely used vegetable oils, offers significant potential as a sustainable feedstock for biofuel production. This study explores the deoxygenation of palm oil using glycerol as a hydrogen donor, with nickel-molybdenum (NiMo) catalysts supported on commercial alumina (Al 2 O 3 ), and zeolite (HZSM-5) comparing with self-prepared zirconia (ZrO 2 ). The catalysts were synthesized via incipient wetness impregnation and evaluated for their performance in biofuel production. NiMo/Al 2 O 3 exhibited the lowest oxygen removal efficiency (68.5 %), while NiMo/HZSM-5 achieved a higher oxygen removal (74.3 %) but also demonstrated the highest coke formation. The type of support material influenced the resulting biofuel range, with NiMo/HZSM-5 and NiMo/ZrO 2 favoring jet fuel production, whereas NiMo/Al 2 O 3 was more suitable for diesel production. Notably, NiMo/ZrO 2 exhibited the highest performance in palm oil deoxygenation while minimizing coke formation. These findings highlight NiMo/ZrO 2 as a promising catalyst for efficient and stable biofuel production, with the support material significantly influencing product yield and fuel quality.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Green hydrogen from microalgal liquefaction byproducts with ammonia recovery and effluent recycle for developing circular processes

Hydrothermal liquefaction is a promising technology for microalgae-based biofuel production. However, hydrothermal liquefaction’s aqueous wastes have little established reuse, and contain significant fractions of toxic ammoniacal nitrogen. Careful reuse of this waste can assure microalgae-based biofuels are produced with less environmental impact and larger energy efficiency. Microbial electrolysis cells were investigated to valorize this waste product by converting the leftover organics into hydrogen and remove ammonia. Waste hydrothermal liquefaction aqueous phase from two microalgal strains, Tetraselmis sp. and Chlorella sp. were used as feedstocks for hydrogen production in microbial electrolysis cells. Chlorella and Tetraselmis aqueous phase-fed microbial electrolysis cells reach an average current density of 5.1 ± 0.19 A/m 2 and 3.8 ± 0.08 A/m 2 . Compound removal rates and mass removal percentages were also investigated for each feedstock. Additionally, acetic acid, propionic acid, ethanol, and glycerol were effectively removed from the aqueous byproduct. Further, microbial electrolysis cells separated up to 34.3% of ammoniacal nitrogen present in the aqueous phase. Charge transfer analysis indicated that proton transfer, not ammonium transfer, contributed to the majority of the hydrogen production in the cathode. Finally, the microbial electrolysis cell effluent was reused to grow the same microalgal strains, leading to the development of a circular biofuel production system. Microalgae regrowth studies using microbial electrolysis cell effluent showed nearly complete removal of total organic carbon, but significantly less removal of total nitrogen. Tetraselmis sp. growth occurred with the Tetraselmis-derived MEC effluent, however, the control medium without effluent produced the most growth. These findings support the possibility of a circular biofuel framework using MECs, but additional constraints, including the removal of inorganic contaminants, are necessary to realize the circular processes.

09 BIOMASS FUELS↗
DOE OSTI2021

Overview and technology opportunities for thermochemically-produced bio-blendstocks

Global demand for transportation fuels is projected to increase 40% by 2040, and biomass-derived fuels (biofuels) play a crucial role in substituting fossil fuels and mitigating greenhouse gas emissions. Currently, biofuels are mainly consumed as blendstocks combined with petroleum-based fuels, and effective conversion technologies can address the quality challenges for offering standalone biofuels. Thermochemical conversion process is one of the most promising pathways among existing technologies for biofuel production. However, the major barriers are unwanted characteristics (e.g., thermal instability) of intermediate products, such as bio-oil, and required upgrading treatments for producing compatible fuels. Here, this study highlights the merits and critical challenges of thermochemical conversion and physicochemical upgrading technologies for bio-blendstock production from lignocellulosic biomass. The novelty of this study lies in potential directions for future research through both critical and systematic literature reviews, and the proposed intensified process for lignocellulosic-based fuel blendstocks production. It is concluded that recovery and fractionation strategies (e.g., quenching and stripping) can maximize process yields and add values in the efficient conversion pathways. Effective quenching can stop secondary free radical reactions and improve liquid yields over gas and solid yields. Stripping process can improve process yield, catalyst lifespan, and thermal stability. It is further concluded that physicochemical treatments are not as effective as thermochemical treatments, but have advantages of mild operating conditions and potential for integrated solutions in conjunction with other treatments.

09 BIOMASS FUELS↗
DOE OSTI2021

Varied farm-level carbon intensities of corn feedstock help reduce corn ethanol greenhouse gas emissions

Abstract A reduction in the overall carbon intensity (CI) of a crop-based biofuel can be achieved by cutting down the CI of the biofuel’s feedstock, which in turn correlates significantly to agricultural management practices. Proposals are being made to incentivize low-carbon biofuel feedstocks under U.S. fuel regulatory programs to promote sustainable farming practices by individual farms. For such an incentive scheme to function properly, robust data collection and verification are needed at the farm level. This study presents our collaboration with U.S. private sector companies to collect and verify the corn production data necessary for feedstock-specific CI calculation at the farm level, through a carefully designed questionnaire, to demonstrate the practicality and feasibility of data collection at scale. We surveyed 71 farms that produced 0.2 million metric tons of corn grain in 2018 in a Midwestern U.S. state to obtain information on key parameters affecting corn ethanol feedstock CI, such as grain yields, fertilizer/chemical application rates, and agronomic practices. Feedstock-specific CI was calculated in the unit of grams (g) CO 2 equivalent (CO 2 e) of greenhouse gases per kilogram (kg) of corn produced. Results showed large CI variations—from 119 to 407 g CO 2 e kg −1 of corn—due to the farm-level inventory, while the production-weighted average CI for all surveyed farms was 210 g CO 2 e kg −1 , comparable to the national average CI of 204 g CO 2 e kg −1 . The nitrogen fertilizer type applied and rate were identified as key factors contributing most to CI variations at the farm level. The estimated N 2 O emissions from fertilizer and biomass nitrogen inputs to soil accounted for 51% of the overall farm-level CI and therefore need to be better monitored at farm level with high resolution. We concluded that this feedstock-specific, farm-level CI evaluation has the potential to be used to incentivize low-carbon feedstock for biofuel production.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

A High-efficacy CRISPRi System for Gene Function Discovery in Zymomonas mobilis

Zymomonas mobilis is a promising biofuel producer due to its high alcohol tolerance and streamlined metabolism that efficiently converts sugar to ethanol. Z. mobilis genes are poorly characterized relative to those of model bacteria, hampering our ability to rationally engineer the genome with pathways capable of converting sugars from plant hydrolysates into valuable biofuels and bioproducts. Many of the unique properties that make Z. mobilis an attractive biofuel producer are controlled by essential genes; however, these genes cannot be manipulated using traditional genetic approaches (e.g., deletion or transposon insertion) because they are required for viability. CRISPR interference (CRISPRi) is a programmable gene knockdown system that can precisely control the timing and extent of gene repression, thus enabling targeting of essential genes. Here, we establish a stable, high-efficacy CRISPRi system in Z. mobilis that is capable of perturbing all genes—including essential genes. We show that Z. mobilis CRISPRi causes either strong knockdowns (>100-fold) using single guide RNA (sgRNA) spacers that perfectly match target genes or partial knockdowns using spacers with mismatches. We demonstrate the efficacy of Z. mobilis CRISPRi by targeting essential genes that are universally conserved in bacteria, are key to the efficient metabolism of Z. mobilis, or underlie alcohol tolerance. Our Z. mobilis CRISPRi system will enable comprehensive gene function discovery, opening a path to rational design of biofuel production strains with improved yields.

lignocellulosic hydrolysate↗
DOE OSTI2024

Hydrothermal conditioning of oleaginous yeast cells to enable recovery of lipids as potential drop-in fuel precursors

Abstract Background Lipids produced using oleaginous yeast cells are an emerging feedstock to manufacture commercially valuable oleochemicals ranging from pharmaceuticals to lipid-derived biofuels. Production of biofuels using oleaginous yeast is a multistep procedure that requires yeast cultivation and harvesting, lipid recovery, and conversion of the lipids to biofuels. The quantitative recovery of the total intracellular lipid from the yeast cells is a critical step during the development of a bioprocess. Their rigid cell walls often make them resistant to lysis. The existing methods include mechanical, chemical, biological and thermochemical lysis of yeast cell walls followed by solvent extraction. In this study, an aqueous thermal pretreatment was explored as a method for lysing the cell wall of the oleaginous yeast Rhodotorula toruloides for lipid recovery. Results Hydrothermal pretreatment for 60 min at 121 °C with a dry cell weight of 7% (w/v) in the yeast slurry led to a recovery of 84.6 ± 3.2% (w/w) of the total lipids when extracted with organic solvents. The conventional sonication and acid-assisted thermal cell lysis led to a lipid recovery yield of 99.8 ± 0.03% (w/w) and 109.5 ± 1.9% (w/w), respectively. The fatty acid profiles of the hydrothermally pretreated cells and freeze-dried control were similar, suggesting that the thermal lysis of the cells did not degrade the lipids. Conclusion This work demonstrates that hydrothermal pretreatment of yeast cell slurry at 121 °C for 60 min is a robust and sustainable method for cell conditioning to extract intracellular microbial lipids for biofuel production and provides a baseline for further scale-up and process integration. Graphical abstract

09 BIOMASS FUELS↗
DOE OSTI2020

Catalytic Bio-crude Production in a Novel, Short-Contact Time Reactor

RTI has developed a catalytic fast pyrolysis (CFP) process to produce biomass-based hydrocarbon replacement fuels. From a technology perspective, this advanced biofuels process produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum distribution infrastructure. From a business perspective, this technology does not face potential market limitations caused by oxygenate blend limitations for light duty vehicle applications. A promising catalyst has been developed with excellent potential for deoxygenation to produce a hydrocarbon-rich biocrude that is more suitable for upgrading with traditional hydroprocessing technology. The role of the catalyst is to control the chemistry during biomass pyrolysis to produce a biocrude in a single step that has lower oxygen content and is more thermally stable than conventional biomass fast pyrolysis oil. Catalyst properties are optimized to minimize gas and coke production and improve catalytic deoxygenation and biocrude yields. Results from this project have demonstrated that biocrudes from catalytic fast pyrolysis contain <20 wt% oxygen, with the organic fraction as low as 12% oxygen. These oxygen numbers are > 50% lower compared to traditional fast pyrolysis oils. The biocrude produced from our CFP process can be upgraded to gasoline range hydrocarbons. A very conservative approach for upgrading included a preliminary stabilization step followed by a hydroprocessing step. The oxygen content in the upgraded product was decreased by 97% (to less than 3wt %) from the oxygen content of the biocrude sample. Additionally, the acid content was reduced by 99% from the acid content of the biocrude sample. In an optimized integrated process, the CFP step and the hydroprocessing (upgrading) step need to be carefully balanced to maximize the input biomass energy that is recovered in the finished biofuels. Hydrogen utilization and carbon recovery during both catalytic biomass pyrolysis and biocrude upgrading need to be optimized to maximize energy recovery in the finished biofuel. A nominal 1 ton per day (TPD) catalytic biomass pyrolysis system was designed based on the laboratory experimental data. The system was designed to achieve the short residence times (0.5–2 sec) and high heat transfer rates required for maximum liquid biocrude yields while optimizing process integration to maintain catalyst activity by continuous regeneration. The catalytic biomass pyrolysis reactor is a continuously circulating single-loop transport reactor design that is flexible enough to allow sensitivity studies around temperature, residence time, biomass feed rate, and catalyst-to-biomass ratio (i.e., catalyst circulation rate) for process optimization. For a nominal 100 lb/hr feed rate of dry biomass, the products include ~25 lb/hr char and coke, ~20 lb/hr permanent gases, and ~55 lb/hr condensable vapors. Pyrolysis temperatures are 350–600°C, and the system is operated close to ambient pressure. Production of the catalyst developed within the project was scaled up to provide enough material (200kg) for bench-scale testing. The 1TPD bench-scale unit was fabricated, installed and commissioned with this project. Biocrude samples from wood were produced in this unit with the CFP catalyst with material balance > 90%. The intermediate biocrude yields and chemical composition compare well with previous laboratory results and a hydroprocessing strategy for upgrading the resulting biocrude was developed. The experimental results obtained within this project were used to develop a process model for a 2000 TPD commercial facility. Detailed flow sheets were developed for all major unit operations in the process and provided a basis for an economic analysis to develop capital and operating costs. Estimates of the biofuel production costs were used to develop internal rates of return for the yields and compositions measured for the current state of technology at the end of this project and for the yields anticipated for an optimized (nth plant) scenario as additional process improvements are made.

09 BIOMASS FUELS↗
DOE OSTI2022

Effect of Feedstock Variability, Feedstock Blends, and Pretreatment Conditions on Sugar Yield and Production Costs

Mass production of sustainable biofuels replacing fossil fuels will significantly reduce global greenhouse gas emissions. However, biomass feedstock variability, availability, and affordability pose significant risks for the sustainable production of biofuels in biorefinery plants. To derisk the sustainable production of biofuels, this work investigates the sugar yields and production costs of four different feedstocks as well as their blends, using different pretreatment methods: deacetylation and dilute acid pretreatment (DDA) and deacetylation and mechanical refining pretreatment (DMR). We found that not only feedstock species variability, but also feedstock harvesting techniques have large impacts on both sugar yields and production costs. Single-pass harvested corn stover (SPCS) showed higher sugar yields and lower production costs than multipass harvested corn stover, followed by sorghum and switchgrass. The highest glucose yields of 91% and 95.3%, which corresponds to the lowest sugar production costs of $0.2286/lb. and $0.2490/lb., were observed for SPCS using DDA and DMR, respectively. The difference in sugar yields and production costs due to feedstock variability can be largely mitigated by increasing deacetylation severity, especially in DMR. Higher deacetylation severity resulted in decreased sugar production costs in the case of DMR in contrast to increased costs in the case of DDA. Blending switchgrass and sorghum into corn stover, which can significantly increase the feedstock availability and sustainability, resulted in sugar yields and production costs of roughly the weighted average of those derived from constituent individual feedstocks, respectively. Thus, blending feedstocks of different biomass species is a potential successful strategy for sustainable production of biofuels to replace fossil-derived fuels.

09 BIOMASS FUELS↗