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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Failure Mode and Effects Analysis Summary Report

This report provides an overview of the development of failure modes and effects analysis (FMEA) and its implementation as a systematic criticality and risk assessment tool supporting a quality by design (QbD) approach for FCIC research. This report also provides a high-level overview of the results for the FMEA evaluation of two feedstock preprocessing system configurations: (1) generation of pine residue materials for high-temperature pyrolysis conversion and (2) generation of corn stover materials for low-temperature conversion using deacetylation and disc mechanical refining pretreatment for fermentation to hydrocarbons. For the results presented in this report, our FMEA interviews included two approaches. The first approach was to perform FMEA interviews for the entire system of unit operations giving a wholistic system level view. The second approach consisted of detailed interviews for each individual unit operation within the system allowing for a “deep dive” into the specific failures for the individual components within the configuration. These two approaches provide different resolutions of information. The FMEA results of this report were focused on failures associated with meeting critical quality attributes (CQAs) identified for the target conversion processes for each processed feedstock type. The information gathered through the FMEA interviews include estimations of risk scores for meeting each given CQA specification, identification of the impacts for not meeting a CQA specification, capturing causes associated with material attributes and process parameters for each failure, identification of current detection methods, and speculation of potential mitigation strategies for decreasing a failure’s risk score. The complete results of all FMEA interviews are provided in the Appendices of this report.

conversion↗
DOE OSTI2025

Mobilizing mine lands for biobased decarbonization strategies

Over 163 000 ha of mine lands in Pennsylvania (PA) have the potential to produce willow as a feedstock for renewable energy generation. Each year these lands could produce between 454 000 and 907 000 dry Mg of willow, which can be a feedstock for bioenergy (i.e., biopower) with carbon capture and sequestration (BECCS) or sustainable aviation fuel (SAF) production. We used a spatially explicit model to explore cost-minimized allocation of willow biomass from abandoned mine lands (AML) to be used for BECCS or SAF production and to abate carbon dioxide. The results suggest that between 454 000 and 907 000 dry Mg of biomass can be produced on AML in PA at costs from $94 to $250 per dry Mg. This AML willow biomass could be combined with other available biomass and aggregated to ten facilities to produce 17.9 TWh of power; alternatively, it could produce 958 million liters of jet fuel, 638 million liters of renewable diesel, and 1.289 billion liters of naphtha, along with 0.735 TWh of electricity. From this analysis, in PA, under the BECCS pathway, up to 36 million Mg per year of CO2 could be abated at costs of up to $134 per Mg; under the SAF pathway, up to 17.5 million Mg per year of CO2 could be abated at costs up to $150 per Mg of CO2. The use of mine land willow as a supplemental feedstock for SAF and BECCS would need strong incentive programs if costs of production are to be comparable with production on agricultural land.

Wahlstrom, Mallory [Pennsylvania State University]↗
DOE OSTI2023

Atomic Level Interactions and Suprastructural Configuration of Plant Cell Wall Polymers in Dialkylimidazolium Ionic Liquids

Ionic liquids (ILs) have been widely investigated for the pretreatment and deconstruction of lignocellulosic feedstocks. However, the modes of interaction between IL-anions and cations, and plant cell wall polymers, namely, cellulose, hemicellulose, and lignin, as well as the resulting ultrastructural changes are still unclear. In this study, we investigated the atomic level and suprastructural interactions of microcrystalline cellulose, birch wood xylan, and organosolv lignin with 1,3-dialkylimidazolium ILs having varying sizes of carboxylate anions. Analysis by 13 C NMR spectroscopy indicated that cellulose and lignin exhibited stronger hydrogen bonding with acetate ions than with formate ions, as evidenced by greater chemical shift changes. Small-angle X-ray scattering analysis showed that while both cellulose and xylan adopted a single-stranded conformation in acetate-ILs, twice as many acetate ions were bound to one anhydroglucose unit than to an anhydroxylose unit. Further, we also determined that a minimum of seven representative carbohydrate units must interact with an anion for that IL to effectively dissolve cellulose or xylan. Lignin is associated as groups of four polymer molecules in formate-ILs and dispersed as single molecules in acetate-ILs, which indicates that it is highly soluble in the latter. In summary, our study demonstrated that 1,3-dialkylimidazolium acetates displayed stronger binding interactions with cellulose and lignin, as compared to formates, and thus have superior potential to fractionate these polymers from lignocellulosic feedstocks.

13C NMR↗
DOE OSTI2025

Upcycling Mixed Spent Ni-Lean Cathodes into Ni-Rich Polycrystalline Cathodes

Sustainable battery recycling is vital for conserving resources and reducing environmental impacts. Current open- and closed-loop recycling strategies often focus on recovering individual components, making the reuse of mixed cathode materials a complex challenge. Meanwhile, the research on upcycling has been limited to using pristine cathode feedstocks and virgin materials for synthesis. Here, to address this issue, we present an upcycling approach for spent Ni-lean mixed cathode materials that integrate an upcycling hydrometallurgical recycling process with traditional hydrometallurgical methods. This strategy achieves a utilization of 92.31 mol % of recycled materials, enabling the regeneration of Ni-rich cathode materials while significantly reducing the reliance on virgin resources. The regenerated 83Ni cathode materials demonstrate physical properties comparable to those produced from virgin materials. Electrochemical evaluations using single-layer pouch cells show that both recycled and virgin cathodes exhibit initial specific capacity close to 201.1 mAh/g and maintain approximately 88 % capacity retention after 500 cycles. Additionally, 2Ah cells confirmed these findings, delivering 85 % capacity retention after about 900 cycles. Techno-economic analysis demonstrates notable environmental benefits, including reductions in greenhouse gas emissions and energy consumption, achieving 232.75 MJ/kg of product, which is 8.6 % lower than traditional methods and comparable to direct upcycling. Furthermore, the upcycling hydrometallurgical recycling process generates the highest profit, proving its economic viability. This scalable and versatile process is adaptable to varying transition metal compositions, facilitating a closed-loop recycling system that bridges mixed spent cathodes with next-generation cathode materials, and offers a sustainable solution for managing waste battery materials.

Hydrometallurgical recycling↗
DOE OSTI2024

Additive Manufacturing of Dissolvable Mandrels

ORNL collaborated with Mitsubishi Chemical America to investigate different grades of vinyl alcohol co-polymers as a potential feedstock material for large-scale material extrusion additive manufacturing (AM). Dissolvable polymers and can find potential applications in AM tooling for complex, hollow, and trapped composite structures without the need for specialized molds and tools. This CRADA Phase I work involved analysis of three different developmental grades of vinyl alcohol co-polymers for thermal and rheological properties, followed by print trials on the Big Area Additive Manufacturing (BAAM) system using these materials. Finally, printed part properties, including mechanical and thermal performance, as well as dissolvability were evaluated. The properties and performance evaluated in this phase of the project have provided guidelines to further develop these vinyl alcohol co-polymers to enable large-scale printing at high deposition rates and obtain parts that satisfy high temperature molds and dies requirements.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Final Report: Process Intensification of Hydrogen Production through Sorption-Enhanced Gasification of Biomass

The University of Utah, in partnership with Idaho National Laboratory (INL), evaluated Sorption-Enhanced Gasification (SEG) as a transformative pathway for producing hydrogen with the potential for negative CO 2 emissions. SEG integrates gasification, water-gas shift, and in-situ carbon capture within a dual fluidized bed reactor to enable efficient clean hydrogen production. Key challenges related to biomass variability and process complexity were addressed through feedstock engineering, reaction optimization, and process validation. A co-pelletized biomass–limestone feedstock was developed to simplify feeding and introduction of makeup limestone. Kinetic and sorbent studies identified optimal operating conditions and confirmed the suitability of low-cost limestone, while catalysts were developed to reduce tar formation. Reactor modeling and techno-economic analysis indicated that SEG can achieve competitive hydrogen production costs, particularly when combined with carbon incentives, supporting its potential for scale-up and carbon-negative operation.

08 HYDROGEN↗
DOE OSTI2021

Environmental and Economic Assessment of Portable Systems: Production of Wood-Briquettes and Torrefied-Briquettes to Generate Heat and Electricity

This study assessed the environmental impacts and economic feasibility of generating heat using wood-briquettes (WBs), and heat and electricity using torrefied-wood-briquettes (TWBs). WBs and TWBs were manufactured from forest residues using portable systems and delivered to either residential consumers or power plants in the United States. An integrated cradle-to-grave life-cycle assessment (LCA) and techno-economic analysis (TEA) approach was used to quantify environmental impacts and minimum-selling prices (MSPs) of heat and electricity, respectively. Results illustrated that 82% and 59% of the cradle-to-grave global warming (GW) impact of producing heat resulted from the feedstock preparation in WBs and torrefaction in TWBs, respectively. About 46–54% of total cost in the production of heat were from labor and capital costs only. The GW impact of electricity production with TWBs was dominated by the torrefaction process (48% contribution). Capital cost (50%) was a major contributor to the total cost of electricity production using TWBs. The GW impacts of producing heat were 7–37 gCO₂eq/MJ for WBs, and 14–51 gCO₂eq/MJ for TWBs, whereas producing electricity using TWBs was 146–443 gCO₂eq/kWhe. MSPs of generating heat from WBs and TWBs were €1.09–€1.73 and €1.60–€2.26/MJ, respectively, whereas the MSP of electricity from TWBs was €20–€25/kWhe. Considering carbon and pile-burn credits, MSPs of heat and electricity were reduced by 60–90% compared to the base-case.

Sahoo, Kamalakanta (ORCID:0000000277635296)↗
NASA NTRS2011

The 2010 ILSO-ISRU Field Test at Mauna Kea, Hawaii: Results from the Miniaturised Mossbauer Spectrometers Mimos II and Mimos IIA

For the advanced Moessbauer instrument MIMOS IIA, the new detector technologies and electronic components increase sensitivity and performance significantly. In combination with the high energy resolution of the SDD it is possible to perform X-ray fluorescence analysis simultaneously to Moessbauer spectroscopy. In addition to the Fe-mineralogy, information on the sample's elemental composition will be gathered. The ISRU 2010 field campaign demonstrated that in-situ Moessbauer spectroscopy is an effective tool for both science and feedstock exploration and process monitoring. Engineering tests showed that a compact nickel metal hydride battery provided sufficient power for over 12 hr of continuous operation for the MIMOS instruments.

Klingelhoefer, G.↗
DOE OSTI2020

Results of the International Energy Agency Bioenergy Round Robin on the Analysis of Heteroatoms in Biomass Liquefaction Oils

A round robin study evaluating the analysis of biomass liquefaction oils (BLOs) from fast pyrolysis and hydrothermal liquefaction (HTL) was performed, involving fifteen laboratories in seven countries in order to assess the current status of analytical techniques for the determination of nitrogen, sulfur, and chlorine content in BLOs and evaluate potential differences in origin (i.e. fast pyrolysis vs HTL). The BLOs were produced from a range of feedstocks including pine, mixed softwoods, forest residues, micro-algae, miscanthus, and wheat straw to cover a variety in nitrogen, sulfur, and chlorine content and speciation. Nine samples were distributed, comprised of eight separate BLOs and one blind duplicate produced by five producers. The samples were analyzed for water, carbon, hydrogen, nitrogen, sulfur, and chlorine content. No analytical test method was mandated; laboratories were encouraged to utilize whichever method they determined would be most applicable, relying on the existing body of BLO literature as a guide. The results of this round robin study are presented in this paper. The results of the carbon, hydrogen, and water measurements as reference analyses had relative standard deviations (2.9%, 3.5, and 5.6%, respectively) that were comparable to those found in past round robin studies on fast pyrolysis bio-oil. The analysis of nitrogen, sulfur, and chlorine showed higher levels of variability. Laboratories mostly chose the same method for water, carbon, hydrogen and nitrogen determination whereas there were a variety of methods chosen for sulfur and chlorine determination. The results suggest that specific analytical methods for the determination of nitrogen, sulfur, and chlorine should be further refined to ensure reproducible and accurate results for BLO analysis due to their importance on emissions, material selection, and catalyst activity.

Biomass, IEA Bioenergy, pyrolysis, hydrothermal li↗
DOE OSTI2022

Identification of microRNAs responsive to arbuscular mycorrhizal fungi in Panicum virgatum (switchgrass)

Background: MicroRNAs (miRNAs) are important post-transcriptional regulators involved in the control of a range of processes, including symbiotic interactions in plants. MiRNA involvement in arbuscular mycorrhizae (AM) symbiosis has been mainly studied in model species, and our study is the first to analyze global miRNA expression in the roots of AM colonized switchgrass ( Panicum virgatum ), an emerging biofuel feedstock. AM symbiosis helps plants gain mineral nutrition from the soil and may enhance switchgrass biomass production on marginal lands. Our goals were to identify miRNAs and their corresponding target genes that are controlling AM symbiosis in switchgrass. Results: Through genome-wide analysis of next-generation miRNA sequencing reads generated from switchgrass roots, we identified 122 mature miRNAs, including 28 novel miRNAs. By comparing miRNA expression profiles of AM-inoculated and control switchgrass roots, we identified 15 AM-responsive miRNAs across lowland accession “Alamo”, upland accession “Dacotah”, and two upland/lowland F 1 hybrids. We used degradome sequencing to identify target genes of the AM-responsive miRNAs revealing targets of miRNAs residing on both K and N subgenomes. Notably, genes involved in copper ion binding were targeted by downregulated miRNAs, while upregulated miRNAs mainly targeted GRAS family transcription factors. Conclusion: Through miRNA analysis and degradome sequencing, we revealed that both upland and lowland switchgrass genotypes as well as upland-lowland hybrids respond to AM by altering miRNA expression. We demonstrated complex GRAS transcription factor regulation by the miR171 family, with some miR171 family members being AM responsive while others remained static. Copper miRNA downregulation was common amongst the genotypes tested and we identified superoxide dismutases and laccases as targets, suggesting that these Cu-miRNAs are likely involved in ROS detoxification and lignin deposition, respectively. Other prominent targets of the Cu miRNAs were blue copper proteins. Overall, the potential effect of AM colonization on lignin deposition pathways in this biofuel crop highlights the importance of considering AM and miRNA in future biofuel crop development strategies.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Thermomechanical Behavior of Advanced Manufactured Parts, Subcomponents, and Their Weldments for Gen3 CSP

Generation 3 (Gen3) concentrating solar power (CSP) plants may require the use of molten chloride salt storage systems, solar receivers, and supercritical-CO 2 primary heat exchangers (PHX). The temperatures that would be expected in these parts and subcomponents could approach 760°C for hot side and 500°C for cold side at peak operating conditions. With the design limitations, highly corrosion- and creep-resistant alloys are needed for maximizing component lives. This report presents the results for the project "Thermomechanical Behavior of Advanced Manufactured Parts, Subcomponents, and their Weldments for Gen3 CSP", award number DE-EE00036334. In this project, creep enhanced ferritic alloy Grade 91, austenitic stainless-steel (SS) 304H, Ni claddings Ni201 and C22, and nickel-based superalloys Inconel 740H and Haynes 282 and 230 were evaluated for potential applications in Gen3 CSP systems. Advanced manufacturing of these parts, subcomponents and their welds, was investigated and a full technoeconomic analysis was made in comparison to conventional manufacturing techniques. The manufacturing techniques explored are explosion clad welding and combustion synthesis/combustion reaction for transfer pipes, additive manufacturing (AM) including laser-powder bed fusion (L-PBF) and electron beam AM (EBAM) with wire feedstock for PHX and solar receivers, and conventional fusion welding for similar and dissimilar joining of these various parts and subcomponents.

14 SOLAR ENERGY↗
DOE OSTI2020

Insights of Molecular Mechanism of Xylem Development in Five Black Poplar Cultivars

Black poplar (Populus deltoides, P. nigra, and their hybrids) is the main poplar cultivars in China. It offers interesting options of large-scale biomass production for bioenergy due to its rapid growth and high yield. Poplar wood properties were associated with chemical components and physical structures during wood formation. In this study, five poplar cultivars, P. euramericana ‘Zhonglin46’ (Pe1), P. euramericana ‘Guariento’ (Pe2), P. nigra ‘N179’ (Pn1), P. deltoides ‘Danhong’ (Pd1), and P. deltoides ‘Nanyang’ (Pd2), were used to explore the molecular mechanism of xylem development. We analyzed the structural differences of developing xylem in the five cultivars and profiled the transcriptome-wide gene expression patterns through RNA sequencing. The cross sections of the developing xylem showed that the cell wall thickness of developed fiber in Pd1 was thickest and the number of xylem vessels of Pn1 was the least. A total of 10,331 differentially expressed genes were identified among 10 pairwise comparisons of the five cultivars, most of them were related to programmed cell death and secondary cell wall thickening. K-means cluster analysis and Gene Ontology enrichment analysis showed that the genes highly expressed in Pd1 were related to nucleotide decomposition, metabolic process, transferase, and microtubule cytoskeleton; whereas the genes highly expressed in Pn1 were involved in cell wall macromolecule decomposition and polysaccharide binding processes. Based on a weighted gene co-expression network analysis, a large number of candidate regulators for xylem development were identified. And their potential regulatory roles to cell wall biosynthesis genes were validated by a transient overexpression system. This study provides a set of promising candidate regulators for genetic engineering to improve feedstock and enhance biofuel conversion in the bioenergy crop Populus.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS1985

Strat-trop exchange

Exchange between the stratosphere and troposphere is important to the chemical composition of both regions. The export of ozone from the stratosphere provides the troposphere with a means of initiating photochemistry. The precursor molecules originating from the planetary surface provide the stratosphere with its chemical feedstock from which the ozone-controlling HO(x), NO(x), and Cl(x) photochemistries are driven. The tropopause is defined both statistically and in a local, synoptic sense by the value P(sub theta) = .000016 K sq m/kg/s, taken from an objective analysis of 8 years of zonal, temporal mean cross sections of potential temperature, wind and potential vorticity.

Tuck, A. F.↗
NASA NTRS2014

The ISRU Field Tests 2010 and 2012 at Mauna Kea, Hawaii: Results from the Miniaturised Mossbauer Spectrometers Mimos II and Mimos IIA

The 2010 and 2012 In-Situ Resource Utilization Analogue Test (ISRU) [1] on the Mauna Kea volcano in Hawai'i was coordinated by the Northern Centre for Advanced Technology (NORCAT) in collaboration with the Canadian Space Agency (CSA), the German Aerospace Center (DLR), and the National Aeronautics and Space Administration (NASA), through the PISCES program. Several instruments were tested as reference candidates for future analogue testing at the new field test site at the Mauna Kea volcano in Hawai'i. The fine-grained, volcanic nature of the material is a suitable lunar and martian analogue, and can be used to test excavation, site preparation, and resource utilization techniques. The 2010 location Pu'u Hiwahine, a cinder cone located below the summit of Mauna Kea (19deg45'39.29" N, 155deg28'14.56" W) at an elevation of ~2800 m, provides a large number of slopes, rock avalanches, etc. to perform mobility tests, site preparation or resource prospecting. Besides hardware testing of technologies and systems related to resource identification, also in situ science measurements played a significant role in integration of ISRU and science instruments. For the advanced Mössbauer instrument MIMOS IIA, the new detector technologies and electronic components increase sensitivity and performance significantly. In combination with the high energy resolution of the SDD it is possible to perform Xray fluorescence analysis simultaneously to Mössbauer spectroscopy. In addition to the Fe-mineralogy, information on the sample's elemental composition will be gathered. The 2010 and 2012 field campaigns demonstrated that in-situ Mössbauer spectroscopy is an effective tool for both science and feedstock exploration and process monitoring. Engineering tests showed that a compact nickel metal hydride battery provided sufficient power for over 12 hr of continuous operation for the MIMOS instruments.

Klingelhoefer, G.↗
NASA NTRS2017

A Water Rich Mars Surface Mission Scenario

In an on-going effort to make human Mars missions more affordable and sustainable, NASA continues to investigate the innovative leveraging of technological advances in conjunction with the use of accessible Martian resources directly applicable to these missions. One of the resources with the broadest utility for human missions is water. Many past studies of human Mars missions assumed a complete lack of water derivable from local sources. However, recent advances in our understanding of the Martian environment provides growing evidence that Mars may be more "water rich" than previously suspected. This is based on data indicating that substantial quantities of water are mixed with surface regolith, bound in minerals located at or near the surface, and buried in large glacier-like forms. This paper describes an assessment of what could be done in a "water rich" human Mars mission scenario. A description of what is meant by "water rich" in this context is provided, including a quantification of the water that would be used by crews in this scenario. The different types of potential feedstock that could be used to generate these quantities of water are described, drawing on the most recently available assessments of data being returned from Mars. This paper specifically focuses on sources that appear to be buried quantities of water ice. (An assessment of other potential feedstock materials is documented in another paper.) Technologies and processes currently used in terrestrial polar regions is reviewed. One process with a long history of use on Earth and with potential application on Mars - the Rodriguez Well - is described and results of an analysis simulating the performance of such a well on Mars are presented. These results indicate that a Rodriguez Well capable of producing the quantities of water identified for a "water rich" human mission are within the capabilities assumed to be available on the Martian surface, as envisioned in other comparable Evolvable Mars Campaign assessments. The paper concludes by capturing additional findings and describing additional simulations and tests that should be conducted to better characterize the performance of the identified terrestrial technologies for accessing subsurface ice, as well as the Rodriguez Well, under Mars environmental conditions.

Hoffman, Stephen J.↗
NASA NTRS2017

A Water Rich Mars Surface Mission Scenario

In an on-going effort to make human Mars missions more affordable and sustainable, NASA continues to investigate the innovative leveraging of technological advances in conjunction with the use of accessible Martian resources directly applicable to these missions. One of the resources with the broadest utility for human missions is water. Many past studies of human Mars missions assumed a complete lack of water derivable from local sources. However, recent advances in our understanding of the Martian environment provides growing evidence that Mars may be more "water rich" than previously suspected. This is based on data indicating that substantial quantities of water are mixed with surface regolith, bound in minerals located at or near the surface, and buried in large glacier-like forms. This paper describes an assessment of what could be done in a "water rich" human Mars mission scenario. A description of what is meant by "water rich" in this context is provided, including a quantification of the water that would be used by crews in this scenario. The different types of potential feedstock that could be used to generate these quantities of water are described, drawing on the most recently available assessments of data being returned from Mars. This paper specifically focuses on sources that appear to be buried quantities of water ice. (An assessment of other potential feedstock materials is documented in another paper.) Technologies and processes currently used in terrestrial Polar Regions are reviewed. One process with a long history of use on Earth and with potential application on Mars - the Rodriguez Well - is described and results of an analysis simulating the performance of such a well on Mars are presented. These results indicate that a Rodriguez Well capable of producing the quantities of water identified for a "water rich" human mission are within the capabilities assumed to be available on the Martian surface, as envisioned in other comparable Evolvable Mars Campaign assessments. The paper concludes by capturing additional findings and describing additional simulations and tests that should be conducted to better characterize the performance of the identified terrestrial technologies for accessing subsurface ice, as well as the Rodriguez Well, under Mars environmental conditions.

Hoffman, Stephen J.↗