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All sources NASA NTRS DOE OSTI

DOE OSTI2026

Interfacial Chemistry Involved in Selective Separation of NMC/LMO and LCO/LMO Binary Cathode Materials by Froth Flotation Using Oleic Acid

The variability in cathode compositions within recycled lithium-ion battery (LIB) feedstocks poses a significant challenge to efficient downstream refining processes. This study demonstrates the feasibility of using froth flotation with oleic acid as a collector to selectively separate lithium nickel-manganese-cobalt oxide (NMC) and lithium cobalt oxide (LCO) from lithium manganese oxide (LMO) materials. Laboratory-scale flotation tests achieved an 80% separation efficiency in a single stage, producing a froth product with >90% purity of NMC/LCO at approximately 90% yield. Concurrently, the LMO materials were enriched in the sink product with ∼90% purity and ∼90% yield. This approach was further validated using recycled cathode materials, confirming its applicability to realistic feedstocks. The underlying mechanism governing the selective separation of NMC/LCO from LMO was investigated using ζ-potential measurements, contact angle measurements, bubble-particle attachment experiments, and X-ray photoelectron spectroscopy (XPS) analysis. Both contact angle and bubble-particle attachment results confirmed that oleic acid adsorption rendered NMC and LCO surfaces hydrophobic, thereby enhancing flotation recovery. At pH 5, oleic acid adsorbed preferentially onto NMC and LCO surfaces via electrostatic interactions, while exhibiting minimal adsorption on LMO surfaces. However, separation efficiency deteriorated at higher pH, which was attributed to the co-flotation of LMO materials caused by oleate chemisorption on MnOH + species. This work establishes froth flotation as a viable cathode/cathode separation strategy, providing a low-cost, scalable pathway to preconcentrate and enrich nickel-rich and cobalt-rich cathode active materials from incompatible cathode chemistries for direct recycling or hydrometallurgical processing. Furthermore, this study reveals, for the first time, the mechanism of oleate adsorption on the surface of different cathode materials.

PH↗

DOE OSTI2025

NEWTS Economic Data Dashboard: Critical Materials for Energy

The NEWTS Economic Data Dashboard: Critical Materials for Energy is an economic screening tool for assessing the concentration and potential value of the 18 critical materials for energy in fossil energy-related wastewater across the United States. Datasets used to develop the dashboard and complete economic calculations are available as supplementary downloads. These resources were developed primarily using geochemical composition and volume data from the NEWTS Integrated dataset (version 1.0). Energy-related wastewater types presented in the dashboard include produced water (PW), brackish groundwater (BW), acid mine drainage (AMD), coal combustion residual leachate (CCRL), power plant flue gas desulfurization wastewater (FGD), and geothermal fluids. The concentrations of the following critical minerals were included in the analysis, when available: Al, Co, Cu, Dy, F, Ga, Ge, C, Ir, Li, Mg, Mn, Nd, Ni, Pt, Pr, Si, Tb. This economic screening tool was built to support identification of promising critical mineral feedstocks and economic research targets.

Critical Minerals; Critical Minerals and Materials↗

DOE OSTI2024

Aluminum Ultra-conductors for Energy-Efficient Aerospace Busbar Applications (Abstract)

In this project, we will develop aluminum ultra-conductors with graphene additives demonstrating enhanced electrical conductivity at 90 °C compared to electric grade aluminum alloy AA1100 (43% IACS at 90 °C). While ultra-conductivity has been developed in copper and copper alloys, it is yet to be reported extensively in aluminum-based materials. This project will scale initial work done at PNNL on aluminum ultra-conductors using shear-assisted processing and extrusion (ShAPETM), a novel solid phase processing technique. Ultra-conductors are an emerging class of composites, comprised of a metal substrate with small quantities of nanocrystalline additives such as graphene or carbon nanotubes that demonstrate enhanced conductivity at relevant operating temperatures. Aluminum ultra-conductors can improve efficiency and power density while reducing the demand for copper in a wide range of applications, such as power transmission cables and electric motors. Busbars are an important component in aerospace systems that require lightweight and high-current power distribution including both future electric vertical take-off and landing (eVTOL) aircrafts and current aircraft electrical systems. We will accelerate aluminum ultra-conductor composite formulation development using combinatorial synthesis and testing methods aided by process/microstructure modeling, developed previously at PNNL. Eaton will test the properties of the ShAPE aluminum ultra-conductor feedstock (used to make the busbars) in relevant operating conditions (20 – 90 °C), predict the improvement in busbar performance when manufactured with ultra-conductors over commercial conductors (such as AA1100), and perform technoeconomic analysis to evaluate the potential for commercialization of ShAPE aluminum ultra-conductors. The project is expected to have a budget of $\$375$K, with $\$300$K in federal funding and $\$75$K in-kind cost-share contribution from Eaton over a period of performance of 24 months. Of the $\$300$K of federal funds, $\$140$K is allocated for CRADA activities that generate intellectual property (IP), and the remaining $\$160$K is reserved for modeling, material testing, characterization, travel, and reporting-related activities.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Coupled CVD and Float Zone Reactor for Lower Cost, Higher Efficiency Si Boules (Final Technical Report)

This project modeled a new type of photovoltaic (PV) Si production reactor with the promise to reduce the cost, increase the efficiency, and reduce the energy required to manufacture Si wafers. The production of photovoltaic (PV) grade Si is well established, based on the pulling of single crystalline Si boules from polycrystalline Si created from trichlorosilane using the Siemens process. However, these processes are very energy intensive, and manufacturing of PV Si occurs almost entirely in China. To disrupt this paradigm and on-shore production of this critical material and provide benefits to the public, a substantial technological leap is required to move past incumbent technology. This study evaluated a new float zone chemical vapor deposition (Fz-CVD) concept in which trichlorosilane (TCS), the feedstock for polysilicon in the Siemens process, is injected directly into a float zone crystallizer to continuously deposit the feed rod for the boule pulling process through a combination of multiphysics modeling and technoeconomic analysis.

14 SOLAR ENERGY↗

NASA NTRS2001

Nanotubes in Nanoelectronics: Transport, Growth and Modeling

Carbon nanotube (CNT) baud nanotechnology appears to be promising for future Theoretical analysis and results for the ballistic current carrying capacity of nanotube wires am presented. Aspects of metal-nanotube coupling are examined. Results am also presented for chemical vapor deposition of CNT from hydrocarbon feedstock.

Anantram, M.↗

NASA NTRSDate not supplied

Microstructural Characterization of Laser Powder Bed Fusion (L-PBF) Additively Manufactured Inconel 718 for Aerospace Application

Alloy 718 (Inconel 718) is used for aerospace applications because of its excellent corrosion resistance and mechanical properties. This alloy is particularly applicable in manufacturing components subjected to high temperatures in rocket engines, aero-engines, and gas turbines. Properties for this alloy when processing on systems from similar and different Laser Powder Bed Fusion (L-PBF) machines provide subtle differences due to process parameters, feedstock, and machine configurations. A series of sixteen L-PBF AM Inconel 718 geometric feature build plates have been evaluated for microstructure using optical microscopy. This study presents the details of the microstructure analysis concerning geometry and different machine platforms. Microstructural investigations of these samples included average grain width measurement for all the X-Y and Y-Z build layers and are accompanied by process parameters and powder characterization. The present work concludes with a discussion on the importance of captured differences among builds to understand the practical limitations among AM platforms.

Additive Manufacturing↗

DOE OSTI2024

Sustainable co-production of plant lipids and cellulosic sugars from transgenic energycane at an industrially relevant scale: A proof of concept for alternative feedstocks

Development of sustainable and scalable technologies to convert lignocellulosic biomass to biofuels is critical to achieving carbon neutrality. The potential of transgenic bioenergy crops as a renewable source of sugars and lipids has been demonstrated at bench-scale. However, scaling up these processes is important for holistic analysis. Here proof-of-concept for chemical-free hydrothermal pretreatment of transgenic energycane-oilcane line L13 at an industrially relevant scale to recover vegetative lipids along with cellulosic sugars is presented. Here, pilot-scale processing of 97 kg of transgenic energycane-oilcane L13 stems and high solids pretreatment of bagasse enhanced the recovery of cellulosic glucose and xylose by 5-fold as compared to untreated bagasse and helped in the enrichment of vegetative lipids in the biomass residues which allowed its recovery at the end of the bioprocess. Palmitic and oleic acids were the predominant fatty acids (FAs) extracted from stems and leaves. The processing did not affect lipid composition. The efficiency of lipid recovery from untreated biomass was 75.9% which improved to 88.7% upon pretreatment. The vegetative tissues of transgenic energycane-oilcane L13 contained 0.42 metric tons/hectare of lipids. Processing vegetative tissues yielded 0.38 metric tons/hectare of lipids. This approaches an oil yield similar to soybean (global average 0.44 metric tons/hectare) and is almost twice as high as the oil yield from sugarcane engineered to hyperaccumulate lipids (0.20 metric tons/hectare). The study suggests that further optimization by state-of-the-art metabolic engineering and biomass processing can establish transgenic bioenergy crops for commercial drop-in fuel production.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

Superstructure Optimization of Waste Plastic Pyrolysis, Integrating Thermal, Catalytic, and Plasma Technologies with Machine Learning

Global plastic waste generation exceeds 430 million tonnes per year, yet fewer than 9% are recycled in the United States. Pyrolysis offers a chemical recycling route at scale, but existing techno-economic and life cycle assessments fix product yields to single pure polymers, producing economic and environmental outputs that break down when the feed composition changes. Here, we present a superstructure optimization framework that addresses this by embedding a composition-aware random forest yield predictor, trained on 566 pyrolysis experiments, within a full-scale process simulation. Product distributions update automatically as feed allocation shifts across four reactor chemistries: conventional thermal, catalytic (HZSM-5), thermal oxo-degradation, and nonequilibrium CO2 plasma. The optimal superstructure achieves minimum selling prices of −0.56 to −0.76/kg feed and global warming potentials of −0.276 to −0.322 kg CO2-eq/kg feed across four commodity price scenarios, confirming profitable, carbon-negative operation without tipping fees. Carbon abatement costs of $\$$0.46 to $\$$1.25/kg CO2-eq are competitive with direct air capture. Sensitivity analysis shows that the catalytic-plasma split fraction is the single largest driver of both economic and climate performance, while hydrocracking allocation in the wax upgrading stage is emission-neutral across the full variable range. Mixed plastic waste streams, evaluated as composition-variable feedstocks rather than pure resins, are profitable and carbon-negative across realistic market conditions. These results give a quantitative basis for reactor selection, circular economy investment, and policy design targeting chemical recycling on a large scale.

Life cycle assessment↗

DOE OSTI2024

In‐mold rheology and automated process control for injection molding of recycled polypropylene

Abstract Manufacturing plastic parts with secondary feedstocks has risen to the forefront of importance in recent years. However, the variation in molecular weight and rheology of secondary feedstock can lead to inconsistent part quality. This work evaluates the effectiveness of a novel closed‐loop adaptive process control system that adjusts nozzle pressure in response to in‐mold pressure data. Five different recycled polypropylene blends, with a broad distribution of flow properties, were evaluated to determine the effectiveness of the control system at reducing processing variation. The experimental results show that the process control strategy reduced the variation within the mold, as seen by in‐mold pressure curves and calculated in‐mold viscosity values. Additionally, the parameters that control the automated process adjustments were investigated, showing the importance of optimization. The analysis of the correlation between in‐mold rheology and mechanical properties showed a slight variation in the mechanical properties and parts weight with a coefficient of variation of under 5%. Overall, the results demonstrate the ability of pressure‐controlled molding and automated viscosity adjustment to reduce the variability when molding a secondary feedstock. Highlights Pressure‐controlled injection molding of recycled polypropylene. Automated closed‐loop adaptive process control methodology. Methodology resulted in a reduction in pressure variation during molding. Changes in mechanical properties and in‐mold viscosity were investigated. Results show the potential of pressure‐controlled molding at reducing variation.

Krantz, Joshua↗

DOE OSTI2026

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

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

09 BIOMASS FUELS↗

DOE OSTI2025

Unveiling Feedstock Variability: Insights into Corn Stover Conversion - Part I: Physicochemical Properties and Self-Degradation

Transforming agricultural waste into biofuels and bioproducts is crucial to advancing a low-carbon bioeconomy. However, the inherent variability in the composition and quality introduces uncertainties in the conversion efficiency and poses challenges in process development. Through integrating a high-throughput conversion system, material characterization techniques, and advanced data analysis tools, this study investigates the variability of corn stover and its subsequent impacts on carbohydrate conversion. The findings reveal that indoor storage substantially reduces the moisture and ash content and soil contamination, while other properties remain largely unchanged. Self-degradation due to microbial activity during storage decreases the carbohydrate content of corn stover but enhances glucose and xylose yields. A negative correlation is observed between sugar yields and lignin content across samples with varying ash and moisture content. The inhibitory effect of lignin diminishes in self-degraded samples likely due to the disrupted cell wall structure. Although self-degradation slightly increases cellulose crystallinity, no strong correlation was observed between the crystallinity and sugar yield. Hot water pretreatment under mild conditions effectively mitigates inherent variability, consistently improving the sugar yield from corn stover by up to 50%. By elucidating the feedstock variability and its impact on convertibility, these findings offer valuable insights into appropriate feedstock handling and management, highlighting potential strategies to address variability challenges.

09 BIOMASS FUELS↗

DOE OSTI2022

Comparing in planta accumulation with microbial routes to set targets for a cost-competitive bioeconomy

Plants and microbes share common metabolic pathways for producing a range of bioproducts that are potentially foundational to the future bioeconomy. However, in planta accumulation and microbial production of bioproducts have never been systematically compared on an economic basis to identify optimal routes of production. A detailed technoeconomic analysis of four exemplar compounds (4-hydroxybenzoic acid [4-HBA], catechol, muconic acid, and 2-pyrone-4,6-dicarboxylic acid [PDC]) is conducted with the highest reported yields and accumulation rates to identify economically advantaged platforms and breakeven targets for plants and microbes. The results indicate that in planta mass accumulation ranging from 0.1 to 0.3 dry weight % (dwt%) can achieve costs comparable to microbial routes operating at 40 to 55% of maximum theoretical yields. These yields and accumulation rates are sufficient to be cost competitive if the products are sold at market prices consistent with specialty chemicals ($20 to $50/kg). Prices consistent with commodity chemicals will require an order-of-magnitude-greater accumulation rate for plants and/or yields nearing theoretical maxima for microbial production platforms. This comparative analysis revealed that the demonstrated accumulation rates of 4-HBA (3.2 dwt%) and PDC (3.0 dwt%) in engineered plants vastly outperform microbial routes, even if microbial platforms were to reach theoretical maximum yields. Their recovery and sale as part of a lignocellulosic biorefinery could enable biofuel prices to be competitive with petroleum. Muconic acid and catechol, in contrast, are currently more attractive when produced microbially using a sugar feedstock. Ultimately, both platforms can play an important role in replacing fossil-derived products.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

Decision Support System

Forest-based value chains involve decisions that begin at the landscape level and extend through processing, product manufacturing, and end-use markets. However, these decisions are often made independently across sectors, with limited visibility into how upstream resource conditions, incentives, and land management choices influence downstream production systems. In forested regions of the United States, wildfire risk, fragmented ownership, and uncertain markets for low-value residues complicate efforts to align extraction, processing, and utilization decisions. Without tools that link these stages, stakeholders may overlook opportunities to improve resource utilization or inadvertently shift impacts elsewhere in the value chain. This repository introduces a decision support system (DSS) that applies a system-impact-analysis approach to forest biomass residues and co-products. The framework integrates forest inventory data, geospatial resource assessments, and economic modeling to evaluate how biomass extraction decisions influence downstream product pathways. By linking regional feedstock avail- ability with market incentives and processing options—such as fuels, wood products, or soil amendments like biochar—the tool allows decision-makers to compare value chain outcomes across multiple utilization strategies.

Davis, Maggie [Oak Ridge National Laboratory (ORNL↗

DOE OSTI2020

Techno-Economic Impact of Diesel Fuel, Labor, and Interest Rates on Bulk-Format and Round Bale Logistics Expenses for Switchgrass

Highlights System-wide sensitivity of bulk-format and round bale logistics responded to different degrees of expense inputs. Biomass size-reduction expenses for bulk-format were consistently less than round-bale chopping. Stack/reclaim operations with high-density-capacity equipment for bulk-format were the highest expenses. Clean-sheet design of stacker/reclaimer and self-compacting bulk trailer may significantly reduce expenses. Abstract . Deterministic cost analyses were conducted for a harvest, storage, preprocessing, and supply system providing 371,870 dry Mg (dMg) year-1 of milled switchgrass (SG) to a biorefinery from 21,929 ha of production fields within 72 km of the biorefinery. Varied input costs of diesel fuel, labor, and interest rate were input into a highly detailed cost analysis for bulk-format and baseline round bale logistics. These operational input factors, potentially reflecting an evolving economic climate or paradigm shift, were examined to provide insight into the cost to deliver preprocessed biomass feedstock for centralized commercial-scale conversions. Total annual costs per dry unit of SG were determined for all combinations of diesel fuel prices of $0.53 L-1, $0.92 L-1, and $1.32 L-1; total labor costs of $20.00 h-1, $28.85 h-1, and $40.00 h-1 singly and uniformly applied across all labor inputs; and three representative interest rates of 6%, 8%, and 12%. Increases in total cost most depended on increases in diesel fuel cost, followed by labor rate, and finally interest rate. Increases in fuel costs from $0.53 L-1 to $1.32 L-1 yielded a total cost increase of about $11.56 dMg-1 and $13.36 dMg-1 for bulk-format and round bale logistics, respectively, for all combinations of labor and interest rates. The overall increase in labor rate ($20.00 h-1 to $40.85 h-1) resulted in increased total costs of about $10.32 dMg-1 for bulk-format logistics and $9.94 dMg-1 for round bale logistics for all fuel and interest rates. The overall increase in interest rate (6% to 12%) resulted in increased total costs of about $6.72 dMg-1 for bulk-format logistics and $4.21 dMg-1 for round bale logistics for all fuel and labor rates. Increases in total costs for combined increases in fuel cost, labor rate, and interest rate were $28.60 dMg-1 and $27.48 dMg-1, yielding maximum total costs of $87.87 dMg-1 and $86.53 dMg-1 for bulk-format and round bale logistics, respectively. Costs were determined for existing equipment systems, including novel use of waste compaction and ejector semi-trailers. The highest potential for cost reductions may require clean-sheet equipment designs specifically tailored for SG, such as forage harvesters that direct-cut standing SG, mobilized stacker-reclaimer technology to not inhibit stack-area footprint, self-compacting ejector trailer technology, and bale grinding technology incorporating controlled mass feeding and shear failure elements. Keywords: Bales, Bioenergy, Bulk-format, Densification, Field chop, Logistics, Transportation

Agriculture↗

DOE OSTI2022

Mining Nontraditional Water Sources for a Distributed Hydrogen Economy

Securing decarbonized economies for energy and commodities will require abundant and widely available green H 2 . Ubiquitous wastewaters and nontraditional water sources could potentially feed water electrolyzers to produce this green hydrogen without competing with drinking water sources. Herein, we show that the energy and costs of treating nontraditional water sources such as municipal wastewater, industrial and resource extraction wastewater, and seawater are negligible with respect to those for water electrolysis. We also illustrate that the potential hydrogen energy that could be mined from these sources is vast. Based on these findings, we evaluate the implications of small-scale, distributed water electrolysis using disperse nontraditional water sources. Techno-economic analysis and life cycle analysis reveal that the significant contribution of H 2 transportation to costs and CO 2 emissions results in an optimal levelized cost of hydrogen at small- to moderate-scale water electrolyzer size. The implications of utilizing nontraditional water sources and decentralized or stranded renewable energy for distributed water electrolysis are highlighted for several hydrogen energy storage and chemical feedstock applications. Finally, we discuss challenges and opportunities for mining H 2 from nontraditional water sources to achieve resilient and sustainable economies for water and energy.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Pathways of bio-jet adoption in the US aviation industry with implications for the overall transportation and energy sectors: an integrated, multi-sectoral analysis of future scenarios

Bio-jet adoption has emerged as an attractive option to complement and supplement the use of refined fossil liquid fuels in the aviation industry in the US. However, there are significant uncertainties surrounding the costs of bio-jet including but not limited to costs of feedstock, transformation costs and the competition with co-products of bio-jet that may be demanded elsewhere in the transportation or energy sectors. This study models alternative trajectories of bio-jet adoption in the US aviation industry by 2050 through the use of a global integrated multi sector dynamics model. Three bio-jet production and consumption pathways are presented- soybean oil to jet, corn ethanol to jet (ETJ) and Fisher–Tropsch-based bio-jet, with each pathway explicitly considering the co-production of renewable diesel and renewable gasoline alongside the bio-jet. Without explicit actions or technology changes to offset the technology cost of bio-jet, scenarios where bio-jet displaces refined liquids result in higher aviation fuel prices (ranging from a 25% increase to 120% increase by mid-century) and lower demand (ranging from −14% to −43%). Corn ethanol will play an important role in the US if large scale amounts of bio-jet are to be produced with smaller effects on demand and prices. While scenarios with high levels of bio-jet availability without the availability of ETJ in the US can significantly reduce emissions in the aviation sector, these reductions are achieved more through the reduction in overall aviation fuel demand rather than technology adoption.

09 BIOMASS FUELS↗

DOE OSTI2022

Transcriptome and metabolome integration in sugarcane through culm development

Abstract Sugarcane (Saccharum sp.) is a tropical and subtropical C4 plant with a high photosynthetic and carbon assimilation efficiency that stores sucrose. Culm biomass is also composed of bagasse fibre, a by‐product of the sugarcane industry. This high‐yielding grass, high in sucrose and lignocellulosic biomass, is considered an optimal feedstock as an alternative to fossil fuels and to produce a broad range of high‐value biomaterials. The ideal sugarcane production system would optimise the relative production of sugar and these new products. Multi‐omics correlation analysis was used to generate a global view of the essential metabolic pathways identifying critical genes involved in carbon partitioning during different stages of development. This research employed an unprecedented metabolic and transcriptomic dataset of 360 samples from a selection of 1440 culms of 24 genotypes at five different development stages. Chemical composition and metabolome analysis showed an increase through the culm development of lignin, sucrose, carbon, and amino acids such as aspartic acid, serine, alanine, methionine, threonine 3‐cyano‐L‐alanine, and citric acid. Transcriptome analysis revealed functionalities such as transcription, nucleotide transport and metabolism, and the biosynthesis of amino acids that are highly activated during the immature stage and highly down‐regulated during the most mature age.

Perlo, Virginie↗

DOE OSTI2026

SAF: a promising approach to meet growing jet fuel demand

SAF provides a promising approach to aid the rising jet fuel demand from increased travel around the world and reduce the lifecycle emissions from the aviation sector. Although the feasibility of SAF pathways has been demonstrated through economic and environmental metrics quantification, the models used to quantify these variables have a high degree of variability in terms of accuracy and thereby reliability. To understand how to adopt and commercialize SAF, we need to harmonize these process models and assess metrics and technical limitations related to their production technologies. We find the production cost of SAF using hydro processed fatty acids and esters (HEFA), Fischer-Tropsch (FT), and alcohol-to-jet (ATJ) to be $\$$3-$\$$6/gallon gasoline equivalent (gge) and life cycle emissions to be lower than Jet A, except for ATJ using corn grain (≤25%). HEFA utilizing oil feedstocks has the lowest production cost (~$\$$2.9/gge) and highest jet yield (>150 gge/dry ton), while FT has the largest emission reduction (94%) compared to fossil jet. A unique contribution of this study is a comparative analysis of metrics related to SAF processes across technical, economic, and sustainability aspects. A cross-comparison of these metrics shows HEFA using fats, oils, and grease have the most favorable ratings, while HEFA using algae and ATJ using corn stover have more neutral and unfavorable ratings, respectively. These ratings can be improved by implementing the right combination of practical and technological advancements.

09 BIOMASS FUELS↗