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

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At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Mechanical separations of corn stover anatomical fractions in an integrated feedstock preprocessing system: An experimental and data-driven modeling study

High variabilities of material attributes in lignocellulosic biomass present risks for biofuel and biochemical productions and must be mitigated via preprocessing. Since almost no mechanical device is originally designed for processing biomass, how to operate existing apparatuses with efficient performance has not been investigated extensively. This work presents a study on an integrated screening and air classification to separate cobs and stalks from husks and leaves in corn stover. Prototype machine learning models were developed to assess the feasibility of predicting the process outcome based on the measurable parameters. The models trained upon limited experimental data rendered decent predictive accuracy of yield and purity. The experimental data and modeling results collectively suggest decreasing throughput leads to a higher purity. To the contrary, if throughput increases, a lower purity is likely. A possible trade-off between yield and purity of the separated streams indicates the need for optimal combinations of feedstock size, moisture, and throughput to achieve optimized separations. The results of this study also suggest the need to further improve model predictability by developing more accurate formulations for physics governing the integrated unit operations. To accomplish this, additional experimental data needs to be generated for model training.

09 - BIOMASS FUELS↗
DOE OSTI2026

Host analysis-guided selection and targeted engineering (HASTE) of Lipomyces tetrasporus for the conversion of CO2-derived feedstocks

Efficient and cost-competitive bioproduction calls for utilizing CO2-derived feedstocks, such as products from electro-reduction of CO2 and hydrolysate from lignocellulosic biomass. However, efficiently using all their carbon components, including acetate, glucose, and xylose, remains a challenge. Here, we characterize Lipomyces tetrasporus, a novel, robust yeast strain capable of effectively assimilating these carbon sources. We used an integrated systems biology approach combining ¹³C metabolic flux analysis, dynamic labeling experiments, and RNA sequencing. We conducted the first metabolic flux analysis for glucose, xylose, and acetate catabolism in this species. Dynamic labeling revealed a highly active TCA cycle during acetate metabolism, evidenced by rapid citrate and malate accumulation. The strain demonstrated strong NADH/NADPH production and acetyl-CoA synthase activity. Using insights and gene targets from this analysis, we engineered L. tetrasporus for malate production. The engineered strain produced 7.5 g/L malic acid (0.25 g/g yield) in shake flasks with glucose-acetate media and 28.8 g/L malic acid at a yield of 0.20 g/g in fed-batch mode with corn-stover hydrolysate. Together, these insights and rational strain engineering establish L. tetrasporus as a versatile, Crabtree-negative platform that is an energy-CO2-bioproduction nexus for channeling CO2 carbon into value-added bioproducts.

Xiao, Zhengyang↗
DOE OSTI2023

The effect of powder feedstock and heat treatment on the thermal and mechanical properties of binder jet printed ZrC

In this study, zirconium carbide (ZrC) disks were fabricated using binder jet printing to study the effect of powder feedstock, print parameters, and heat treatment on flowability and final materials properties. A median volumetric particle size smaller than 10 μm was shown to cause the powder to stop flowing during printing. Disks were printed using ZrC with suitable flowability and then heat-treated at temperatures between 1800°C and 2200°C for 1 or 5h. The density, part shrinkage, thermal diffusivity, and fracture strength all increased with increasing temperature and time. The heat-treated disks were then heated to 2200°C for 5h and the properties converged for disks of the same particle size, indicating the hottest temperature and longest time of exposure dictates the final properties. Lastly, it was shown that larger particles produce lower density materials with worse thermal diffusivity, most likely because of poor connectivity between particles after heat treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Evaluation of coal-associated sediments, wastes, and AMD sludge in the Southern Appalachian Basin as feedstock materials for REE and Li recovery

Critical minerals (CM) such as rare earth elements (REE+) and Lithium (Li) are essential to technological innovation, energy transitions, global economic and defense security, necessitating the search for unconventional resources and efficient recovery methods to avert supply chain disruptions. Here, this study evaluates coal-associated sediments (underclay and roof rock) and wastes from the Pennsylvanian Pottsville Formation of the Southern Appalachian Basin (SAB) as potential feedstocks for CM recovery. A total of 34 samples (15 underclays, 12 roof rocks, 5 Acid Mine Drainage (AMD) sludges, and 2 coal mining wastes) were characterized using XRD, XRF, ICP-MS, and μ-XRF analytical methods. The REE+ and Li concentrations of these materials ranged from 46.8 to 334.4 ppm and from 11.1 to 519 ppm, respectively, with one underclay sample (Hendrix 3456) yielding the highest values for both. Bulk mineralogy for all samples was dominated by aluminosilicate clay phases, particularly illite and kaolinite. All samples exhibited REY def, rel% values >26% and C outl indices that ranged from 0.69 to 0.94, classifying their REE ore potential as Category II (Promising) as defined by Seredin and Dai (2012). Extractability tests (EPA method 3051 A) yielded low REE+ and Li recoveries, with maximum values of 3.3% and 3.6%, respectively, suggesting associations with resistant minerals like clay and phosphates. Elemental mapping indicates that REE+ is associated with phosphate, whereas statistical analysis suggests that REE+ are associated with aluminosilicates, suggesting heterogeneous associations or minimal phosphate contribution. Li also correlated positively with Al 2 O 3 , indicating an aluminosilicate host. This study highlights the potential of coal-associated sediments in the SAB.

Clay minerals↗
DOE OSTI2023

Optimization under uncertainty of a hybrid waste tire and natural gas feedstock flexible polygeneration system using a decomposition algorithm

Market uncertainties motivate the development of flexible polygeneration systems that are able to adjust operating conditions to favor production of the most profitable product portfolio. However, this operational flexibility comes at the cost of higher capital expenditure. A scenario-based two-stage stochastic nonconvex Mixed-Integer Nonlinear Programming (MINLP) approach lends itself naturally to optimizing these trade-offs. This work studies the optimal design and operation under uncertainty of a hybrid feedstock flexible polygeneration system producing electricity, methanol, dimethyl ether, olefins or liquefied (synthetic) natural gas. A recently developed C++ based software framework (named GOSSIP) is used for modeling the optimization problem as well as its efficient solution using the Nonconvex Generalized Benders Decomposition (NGBD) algorithm. Two different cases are studied: The first uses estimates of the means and variances of the uncertain parameters from historical data, whereas the second assesses the impact of increased uncertain parameter volatility. The value of implementing flexible designs characterized by the value of the stochastic solution (VSS) is in the range of 260–405 M$ for a scale of approximately 893 MW of thermal input. Increased price volatility around the same mean results in higher expected net present value and VSS as operational flexibility allows for asymmetric exploitation of price peaks.

42 ENGINEERING↗
DOE OSTI2022

Bioenergy crops as alternative feedstocks for recovery of anthocyanins: A review

Anthocyanins are plant-based pigments known for their wide range of industrial applications. Berries, grapes, purple yam, purple corn, and black rice are among the chief dietary sources of anthocyanins. However, these sources have a well-established market in the food sector and cannot be diverted completely for the extraction of anthocyanins. Hence, there is a need to identify alternative sources of these natural colorants. In this review, color-bearing bioenergy crops with high productivity such as miscanthus, sorghum, and sugarcane have been proposed as potential feedstocks for the recovery of anthocyanins as co-products. The role of genetic modification in the biosynthesis of anthocyanins in these crops has been discussed. A consolidated bioprocessing approach has been proposed for the recovery of anthocyanins from bioenergy crops along with the production of bioethanol and lignin-based chemicals. Such an integrated process could make the overall process for the production of biofuels cost-effective.

09 BIOMASS FUELS↗
DOE OSTI2018

FT-ICR MS analysis of blended pine-microalgae feedstock HTL biocrudes

Fourier transform ion cyclotron resonance mass spectrometry (FT-ICR MS) is utilized for direct comparison of the chemical composition of biocrudes generated from the hydrothermal liquefaction of 100% pine, 100% algae, 75:25 pine:algae, and 50:50 pine:algae feedstocks. This analysis reveals that the of the 72:25 and 50:50 pine:algal HTL biocrudes is essentially a composite of the two parent feeds (i.e., pine and algae) with a lower relative abundance of Ox species and a higher relative abundance of nitrogen-containing species than the pine HTL biocrude. Alternatively, the biocrude blends have a lower relative abundance of nitrogen-containing species where N>2 than the algal HTL biocrude. The 75:25 pine:algal HTL biocrude has more elemental formulae in common with the pine HTL biocrude than the 50:50 blend; however, both blends have more elemental formulae in common with the algal HTL biocrude. Interestingly, >20% of the elemental formulae assigned to monoisotopic peaks within the 75:25 and 50:50 biocrude blends are species not present in either the pine or algal HTL biocrudes. The highest relative abundance of these new species belong to the N2O4-6 classes, which correspond to heteroatom classes with a moderate number of nitrogen atoms and higher number of oxygen atoms per molecules than the species within the pure algal HTL biocrude. Compositionally, the novel species have the same structural motif but are of higher DBE and carbon numbers than the species within the algal HTL biocrude. These original species are most likely generated from reactions between molecules from both feeds, which results in compounds wotj higher oxygen content than typically seen in the algal HTL biocrude but also higher nitrogen contents than observed in the pine HTL biocrude.

FT-ICR↗
DOE OSTI2022

Effect of secondary gas-phase reactions (SGR) in pyrolysis of carbon feedstocks for anisotropic carbon materials production – 1: Controlling SGR to modify intermediate coal tar species to improve pitch anisotropy

To meet the increasing demand for graphitizable carbon products, such as needle coke and carbon fiber, more carbon feedstocks capable of forming anisotropy should be utilized. Non-coking coals are widely available but are not typically suitable for producing anisotropic carbons due to lacking proper coal chemistry. This work used secondary gas-phase reactions (SGR) during coal pyrolysis to improve the coal tar chemistry of a non-coking coal for anisotropic carbon production. SGR pyrolysis temperatures and residence times were varied (T = 800–900°C and τ = 0–2.5 s), and analysis of the intermediate coal tar products showed that as these SGR pyrolysis conditions increased, the oxygen and aliphatic concentrations decreased, whereas aromatic contents and molecular weights increased. Without any SGR, microscopy of the thermally-treated coal tar pitch product revealed that the coal tar pitch was isotropic; however, upon using increased SGR pyrolysis conditions, the resulting coal tar pitch samples substantially increased in the percentage and quality of anisotropy formation. Further, the products' analyses show clear trends of modified chemical properties in the intermediate coal tar and improved anisotropy results. Thus, the results presented in this work show that by controlling the SGR during pyrolysis of a non-coking coal, this approach can modify the coal tar chemistry towards a precursor more suitable for quality anisotropic carbon material production.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Effect of secondary gas-phase reactions (SGR) in pyrolysis of carbon feedstocks for anisotropic carbon materials production – 2: Effects of SGR on tars produced from varying ranks of coal

Herein, this work explores the extent to which secondary gas-phase reactions (SGR) in pyrolysis can be used to modify coal tar chemistries from coals of different ranks in favor of improved anisotropy formation in their respective pitches. Pyrolysis was performed on four different coals of varying bituminous rank (Utah Sufco, Wyoming PRB Black Thunder, Illinois #6, and West Virginia Flying Eagle), with SGR temperatures ranging from 800 to 900° C and nominal SGR gas-phase residence times from 1 to 2.5 s. The oxygen content, aliphatic content, and molecular weight distributions of the coal tar samples were measured to indicate the changes with increasing levels of SGR, and microscopy was also used to measure changes in anisotropy formation in the resulting pitch samples. Generally, for all coals tested, increased levels of pyrolysis SGR led to decreased oxygen and aliphatic content, increased molecular weight sizes, and improved anisotropy formation. However, it was clear that the extent of these property changes depended on the chemistry and rank of the starting coal feedstock. Despite the relatively high rank of the Illinois #6 coal, its respective pitch samples performed poorly in improving anisotropy formation, due to its high sulfur content. The PRB, Sufco, and Flying Eagle coals performed better in their anisotropy formation than Illinois #6, depending on their respective coal ranks. Statistical analysis (analysis of variance, ANOVA) performed on the sample characterization data also suggests that SGR temperature is consistently the most dominant and significant effect on the resulting coal products.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Effect of secondary gas-phase reactions (SGR) in pyrolysis of carbon feedstocks for anisotropic carbon materials production – 3: Modifying non-coking coal tar through co-pyrolysis of coal with linear low-density polyethylene and high-impact polystyrene

Herein, this work focuses on co-pyrolysis experiments of Utah Sufco coal with linear low-density polyethylene (LLDPE) and high-impact polystyrene (HIPS). These two plastic types have differing pyrolysis chemistries and have different hydrogen transfer behavior. Similar to earlier work in this series of papers, controlled secondary gas-phase reactions during pyrolysis were used to induce cracking and condensation reactions among the pyrolytic tar species. Co-pyrolysis tests were performed with feed plastic percentages ranging from 10-20 wt% and pyrolysis SGR temperatures ranging from 800-900°C. Analyses of the intermediate tar products showed that oxygen contents and aromaticity were substantially different, depending on the plastic, and resulting pitch softening points and mesophase contents also varied greatly depending on the starting plastic feedstock used. Most of the synergies observed in the co-pyrolysis results were negative, except for the oxygen content. Oxygen contents were higher than expected when LLDPE was used, resulting in reactive pitches with softening points > 350°C. On the other hand, oxygen contents were lower than expected when HIPS was used, resulting in less reactive pitches. Ultimately, only the HIPS/coal samples created at the SGR temperature of 900°C had reasonable softening points at or under 350°C, making them the only samples created in this work potentially suitable for mesophase pitch-based carbon fiber production. The success in creating fusible mesophase pitches from co-pyrolyzing HIPS with Utah Sufco coal is likely attributed to the fact that polystyrene is a stronger hydrogen acceptor rather than donor, which should facilitate more cracking rather than stabilizing tar oxygen functional groups, making the tar species ultimately less reactive during thermal conversion to mesophase pitch.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2019

Investigation of sol-gel feedstock additions and process variables on the density and microstructure of UN microspheres

The kernel of fully ceramic microencapsulated (FCM) fuel requires a material with high fissile density. For that reason, among others, UN is the appropriate chemical state for low enriched U fuel. The UN kernels are spheres ~800 μm in diameter made using a sol-gel process. The effect of additives on the chemistry and density of the UN microspheres are investigated in this work. Gadolinium nitrate hexahydrate, Gd 2 O 3 , B, SiO 2 and SiC were incorporated into the sol-gel broth in varying concentrations. It was found that Gd can serve as both a sintering aid and burnable poison when added to the sol-gel broth as a Gd(NO 3 ) 3 6H 2 O. However, even with the increased theoretical density of the UN microspheres, the U density was still too low for the FCM design that replaces UO 2 pellets in a commercial light water reactor. Silicon carbide and B were also successfully added but produced a lower density final product. Other sol-gel processing variables were investigated. In conclusion, the pour density of the sol-gel feedstock was found to influence the final converted UN kernel density.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Predicting sintering window during supersolidus liquid phase sintering of steels using feedstock analysis and CALPHAD

Binder jet 3D printing results in carbon pickup from the binder at the inter-particle regions during binder burnout. The excess carbon lowers the solidus temperature of the green part locally during supersolidus liquid phase sintering (SLPS). Currently, thermodynamic calculations rely on the use of bulk powder compositions to predict the sintering window. This can overestimate the sintering temperature since the local increase in carbon on powder surfaces is not accounted for, that can locally lower the solidus temperature during SLPS. Here we show that using the inputs from feedstock and binder analysis, the excess carbon and hence the sintering window for the alloy can be predicted using CALPHAD. We present a case study on applying the proposed approach for pressureless sintering of binder jet additive manufactured (BJAM) of H13 steel via SLPS.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Advancing hydrogen production: A comprehensive review of wastewater reforming techniques, feedstocks, and opportunities

Wastewater is produced across nearly all human activities and requires treatment to safeguard human health and the natural environment. Treatment of wastewater often requires a large amount of thermal energy, resulting in wasted heat after the treatment process. Because hydrocarbon reforming needs both water and heat, the integration of wastewater treatment with hydrocarbon reforming, a process that produces synthesis gas rich in hydrogen, offers an excellent opportunity to utilize this waste heat and the impurities in wastewater to produce valuable hydrogen gas, to minimize waste from industrial processes, and to integrate water treatment with the hydrogen economy. Yet, no comprehensive literature review has been conducted to examine the integration of reforming and wastewater. To address this lack, we summarize the variety of catalytic reforming techniques available in the open literature and review the current literature on wastewater reforming with these techniques. Subsequently, we conduct a review of common types of wastewater contaminants and their possible effects on reforming catalyst performance and life. Lastly, three underexamined wastewater sources are identified, namely, oilfield wastewater, geothermal water, and mining and mineral processing wastewater, and their potential for future study as a reforming feedstock is examined.

08 HYDROGEN↗
DOE OSTI2017

Engineering high-level production of fatty alcohols by Saccharomyces cerevisiae from lignocellulosic feedstocks

Fatty alcohols in the C12-C18 range are used in personal care products, lubricants, and potentially biofuels. These compounds can be produced from the fatty acid pathway by a fatty acid reductase (FAR), yet yields from the preferred industrial host Saccharomyces cerevisiae remain under 2% of the theoretical maximum from glucose. Here we improved titer and yield of fatty alcohols using an approach involving quantitative analysis of protein levels and metabolic flux, engineering enzyme level and localization, pull-push-block engineering of carbon flux, and cofactor balancing. We compared four heterologous FARs, finding highest activity and endoplasmic reticulum localization from a Mus musculus FAR. After screening an additional twenty-one single-gene edits, we identified increasing FAR expression; deleting competing reactions encoded by DGA1, HFD1, and ADH6; overexpressing a mutant acetyl-CoA carboxylase; limiting NADPH and carbon usage by the glutamate dehydrogenase encoded by GDH1; and overexpressing the Δ9-desaturase encoded by OLE1 as successful strategies to improve titer. Our final strain produced 1.2 g/L fatty alcohols in shake flasks, and 6.0 g/L in fed-batch fermentation, corresponding to ~ 20% of the maximum theoretical yield from glucose, the highest titers and yields reported to date in S. cerevisiae. We further demonstrate high-level production from lignocellulosic feedstocks derived from ionic-liquid treated switchgrass and sorghum, reaching 0.7 g/L in shake flasks. Together, our work represents progress towards efficient and renewable microbial production of fatty acid-derived products.

09 BIOMASS FUELS↗
DOE OSTI2025

Feedstock-efficient conversion through hydrogen and formate-driven metabolism in Escherichia coli

Product yields for biomanufacturing processes are often constrained by the tight coupling of cellular energy generation and carbon metabolism in sugar-based fermentation systems. To overcome this limitation, we engineered Escherichia coli to utilize hydrogen gas (H 2 ) and formate (HCOO - ) as alternative sources of energy and reducing equivalents, thereby decoupling energy generation from carbon metabolism. This approach enabled precise suppression of decarboxylative oxidation during acetate growth, with 86.6 ± 1.6 % of electrons from hydrogen gas (via soluble hydrogenase from Cupriavidus necator H16) and 98.4 ± 3.6 % of electrons from formate (via formate dehydrogenase from Pseudomonas sp. 101) offsetting acetate oxidation. Hydrogen gas supplementation led to a titratable and stoichiometric reduction in CO 2 evolution in acetate-fed cultures. Metabolomic analysis suggests that this metabolic decoupling redirects carbon flux through the glyoxylate shunt, partially bypassing two decarboxylative steps in the TCA cycle. Here, we demonstrated the utility of this strategy by applying it to mevalonate biosynthesis, where formate supplementation during glucose fermentation increased titers by 57.6 % in our best-performing strain. Flux balance analysis further estimated that 99.0 ± 2.8 % of electrons from formate were used to enhance mevalonate production. These findings highlight a broadly applicable strategy for enhancing biomanufacturing efficiency by leveraging external reducing power to optimize feedstock and energy use.

Biomanufacturing↗
DOE OSTI2020

Eudicot Nutshells: Cell-Wall Composition and Biofuel Feedstock Potential

Nutshells are the recalcitrant and membranous layers that encompass and provide protection to the seed of a fruit. Rich in lignin, these are often waste products of the food industry and are a potential energy-dense feedstock for biorefineries to convert to biofuels. Here, assessing their potential requires an understanding of the relative amounts of cellulose, hemicelluloses, and lignin, the composition and structure of the lignin, and a saccharifiability assessment, all provided here. In the context of understanding the general character of phylogenetically diverse eudicot species, we provide a chemical analysis of the lignin in the shells of commonly eaten nuts and detail the chemical composition of their lignins. Particularly striking observations include the >40% levels of Klason lignins in the nutshells from macadamia, pecan, and Brazil nut and lignin compositions ranging from <1% syringyl (S) in macadamia to 77% S in pistachio and essentially 0% p-hydroxyphenyl (H) in mango to as high as 7.5% H in walnut. Novel units in the lignin polymer (such as the hydroxystilbenes recently discovered in macaúba and coconut shell lignins) were not evident in any of the samples, but the series provided such a range of compositions that it aided more detailed assignment.

NMR↗
DOE OSTI2017

Recovery of Rare Earth Elements from Low-Grade Feedstock Leachates Using Engineered Bacteria

The use of biomass for sorption of rare earth elements (REEs) for bioremediation and biomining applications has been the subject of many recent investigations. However, REE adsorption by bioengineered systems has been scarcely documented, and rarely tested with complex natural feedstocks. In this study, we engineered E. coli cells for enhanced cell surface-mediated extraction of REEs. Using Lpp-OmpA as an anchor, up to 16 copies of a Lanthanide binding tag (LBT) per OmpA protein were displayed on the E. coli cell surface, resulting in a 2-fold increase in Tb adsorption capacity compared to control cells. To test the efficacy of engineered E. coli cells to extract REEs from complex source materials, biosorption was performed with leachates from two mine tailings and two rare earth deposits. Although control E. coli cells exhibited preferential adsorption of REEs over most metals, functionalization of the cell surface with LBT yielded several notable advantages. First, the efficiency of REE adsorption from all tested leachates was enhanced with distribution coefficients for individual REEs increased by 2-10 fold. Second, although, Cu, Al, Ga and Pb were found to be the best competitors for REE binding to the E. coli cell surface, LBT-display enhanced the cell surface affinity for REEs over all non-REEs except Cu. Third, LBT-display systematically enhanced the affinity of the cell surface for REEs as a function of decreasing atomic radii, providing a means to separate high value HREEs such as Dy and Tb from more common LREEs such as La. Altogether, our results demonstrate that REE biosorption of high efficiency and selectivity can be achieved by engineering the native bacterial surface.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

At-Line Sampling and Characterization of Pyrolytic Vapors from Biomass Feedstock Blends Using SPME-GC/MS-PCA: Influence of Char on Fast Pyrolysis

Solid-phase microextraction (SPME) coupled with GC-MS analysis was used for at-line sampling of pyrolytic vapors produced during fast pyrolysis of biomass. The pure and binary blends of switchgrass (SWG) and pine harvest residues (PT6) were used as feedstock. Sequential SPME sampling allowed for monitoring of changes in the pyrolysis vapors as char accumulated in the fluid bed. The concentration and composition of the vapors desorbed from the SPME fibers were investigated using GC-MS, and the data sets were then analyzed using principal component analysis (PCA) to compare the composition of the pyrolysis vapors over the course of the pyrolysis run. The chemical composition of both carbohydrate and lignin fragments varied as the char builds up in the reactor bed. Fragments derived from cellulose and xylan included anhydrosugars, furans and light oxygenated compounds. Lignin fragments included methoxyphenols, phenolic ketones and aldehydes, low molecular weight aromatics. The composition of the carbohydrate fragments changed more than the lignin fragments as the char build-up in the fluid bed. This combination of SPME-GC/MS-PCA were a novel, easy and effective method for measuring the composition and changes in the composition of pyrolysis vapors during the fast pyrolysis process. Here, this work also highlighted the effect of char build-up on the composition of the overall pyrolysis vapors.

09 BIOMASS FUELS↗