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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Force-triggered, Bio-based, Sealants for Prefabricated Building Components: Towards Improved Efficiency, Performance and Sustainability

The prefabricated building construction industry has made extensive progress in expediting the manufacture of prefabricated components at offsite plants. However, this progress has not translated to the assembly of the prefabricated components at the construction site. Case in point, sealing the joints between components to prevent air leaks requires the manual application of tape, caulk, or spray foam at the jobsite, and performance is highly dependent on the skills of the installer. To reduce assembly time and improve assembly quality of prefabricated components, we developed a sealant that can be installed at the plant and triggered at the jobsite. Additionally, we used this opportunity to lower the use of fossil fuel derived feedstocks and introduced bio-based alternatives to decrease the embodied carbon of the new sealant. We evaluated a series of force-triggered, bio-based, high strength, and fast curing sealants, consisting of a one-part heterogeneous system. These sealants are derived from formulations with ≥80% of biogenic carbon, consisting of a cardanol derived diepoxy that is microencapsulated in a polymer shell and embedded in a cardanol derived amine curing agent. The microcapsule shell allows separation of the reactive species in the one part sealant allowing shelf stability to an otherwise fast curing system. When the microcapsules are broken and activated by force, the highly reactive species mix and cure, exhibiting peel strengths up to 143 ppi. The shelf stability of these sealants and the on-demand triggering of the curing reactions enable installation on prefabricated components and storage prior to delivery and assembly at a jobsite, which could result in consistent sealant application with lower installation time than tapes and caulks at the construction site.

Cortes Guzman, Karen [ORNL] (ORCID:000000028793468↗
DOE OSTI2025

Extraction, purification, and reuse of dyes from coloured polyester textiles

The removal of dyes from coloured textile waste represents a sustainable approach to textile recycling, enabling the recovery of valuable chemical, and material resources that would otherwise be discarded. Up to 40% of the greenhouse gas emissions from textiles originate from dye production, making efficient recycling of dyes a major opportunity for curbing emissions and minimizing waste in both textile manufacturing and recycling. Here, in this study, we demonstrate a process for the extraction, purification, and reuse of mixed dyes from polyester textiles using bio-based, non-hazardous solvents selected on the basis of computational predictions for polyester and dye solubilities. Extracted dyes are purified to individual compounds using counter-current chromatography and analysed via liquid chromatography-mass spectrometry. Post-extraction characterization of the extracted dyes and polymer substrate confirms dye colour retention and polyester fabric property preservation. Dye recycling is demonstrated by redyeing colour-free fabrics with the recovered dyes. We further show a potential process configuration for dye removal using a flow-through reactor packed with a textile substrate. The proposed dye removal process produces reusable, recyclable dyes, and dye-free fabrics, thus facilitating textile recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2026

ASU’s DAC polymer-enhanced cyanobacterial bioproductivity (AUDACity)

ASU’s DAC polymer-enhanced cyanobacterial bioproductivity (AUDACity) project aims to demonstrate a novel, scalable method for removing carbon dioxide (CO 2 ) directly from ambient air and delivering it to cyanobacterial cultures to produce commodity biofuel, mid-value protein for supplements, and high value phycocyanin (PC), a natural blue colorant (Figure A). This approach uses low-cost, reusable anion exchange polymers embedded in modular mesh packets, which capture CO 2 during drying cycles when exposed to ambient air, and release concentrated CO 2 into aqueous cultivation systems. The project addresses a critical challenge in energy research needed for developing sustainable, economically viable methods of Direct Air Capture (DAC) that can be integrated with bio-based systems for fuel and chemical production. AUDACity contributes to scientific understanding by integrating materials chemistry, cyanobacterial biology, and system engineering to create a distributed CO 2 delivery platform. Key insights have emerged around the design of biocompatible sorbents, optimization of CO 2 capture-release cycles, and durability of packet-based delivery systems under outdoor conditions. Notably, the team has synthesized and tested a range of polymer sorbents, identified mechanisms of material degradation and fouling, and advanced both lab- and pilot-scale cultivation systems to evaluate performance. From a technical and economic standpoint, AUDACity shows promise for achieving cost-effective CO 2 capture and delivery into aqueous media and biofuel production. Preliminary techno-economic analysis (TEA) indicates that the DAC system based on current performance can reach $\$$680/tonne CO 2 delivered into aqueous solution; with reasonable improvements to sorbent lifetime, sorbent capacity, reducing water uptake the approach could reach $\$$66/tonne by avoiding the need for energy-intensive sorbent regeneration and CO 2 compression, making it more feasible for decentralized deployment. With these costs for CO 2 and by extracting and selling high-value PC ($\$$50/kg) and mid-value protein supplement ($\$$6/kg), the remaining biomass can be hydrothermally treated into biofuel for $\$$2.50/gallon, and would support a small first-of-a-kind biorefinery capable of producing 500 barrels per day of biofuel. The project offers meaningful public benefits by advancing carbon removal technologies that are low-energy, modular, and adaptable to non-arable land and brackish water use. It aligns with national goals to develop advanced biotechnology and supports future pathways for bio-based fuels and products. By enabling direct coupling of CO 2 transfer into aqueous medium and biological carbon utilization, AUDACity lays the groundwork for effective algae cultivation without wasteful CO 2 delivery and is a promising and innovative solution for low-carbon fuel and bioproduct generation contributing to a vigorous bioeconomy.

09 BIOMASS FUELS↗
DOE OSTI2025

Self-assembly of wood-based shape memory composites triggered by solar-thermal energy

Transporting and assembling large, complex structures poses significant challenges due to their size, geometry, and cost. Additionally, the installation sites are often inaccessible or hazardous for humans, necessitating self-assembling capabilities in these structures. To mitigate these challenges, we propose using 3D printing materials with shape memory effect (SME) for both transport and construction. This approach involves developing 3D modular components into flat sheets for easier transportation, and then self-assembling into 3D structures on-site using solar energy. To gain a deeper understanding of the factors influencing material memory performance, we have chosen a composite PLA/WF, which is polylactic acid (PLA) with 20 wt% wood flour (WF) for this purpose, leveraging its high tensile modulus at 0.966 GPa, low cost, and sustainability. Printed shapes with this material can maintain a recovery ratio over 90% after 3 cycles. While traditional composites fillers (e.g. glass or carbon fiber) are added to enhance mechanical and thermal properties, the addition of bio-based fillers like WF accomplish similar goals without compromising sustainability. We conducted multiple experiments to demonstrate how environmental conditions (i.e. temperature) maximize the material’s SME. Although still at an early stage, this study provides initial insights into bridging the gap between the small-scale nature of shape memory polymers (SMPs) and their potential for large-scale additive manufacturing, addressing a critical need for efficient and sustainable construction. In the long term, we hope our study contributes to the design vision of utilizing SMPs for transportation, assembly, and deployment of complex structures, providing a new pathway for sustainable construction and transportation of large-scale structures to hard-to-access locations such as disaster-affected areas and remote deserts, etc.

4D printing↗
DOE OSTI2026

Making an s1G Self-Preserving Environmental DNA (eDNA) Filter from Sustainable Materials

Environmental DNA (eDNA) sampling of aquatic environments is a powerful new tool for resource managers to use in detecting the presence of rare and endangered species. The use of eDNA for species detection is quickly becoming an industry-standard methodology in environmental science, and the technology sector is moving quickly to create purpose-built tools for eDNA sampling. Smith-Root, Inc. pioneered the new technology of self-preserving eDNA filters that automatically preserve the DNA captured on filters by desiccating the internal filter membrane. This capability saves the sampling technician significant time in the field and drastically reduces the potential for sample contamination. One main constraint of this new technology, however, is the necessity of single-use plastics for eDNA sampling. Single-use designs are employed because sampling equipment must be devoid of potential contaminating DNA, and the time required to sterilize equipment is often not cost-effective for practitioners. Thus, this technology is creating a significant new source of plastic waste—something that eDNA practitioners, and society, would like to avoid. This project explores the use of alternative bio based polymers and composites as replacements for incumbent industrial standards for eDNA filtration systems, with an emphasis on ease of processing and biodegradable options. 8 candidate materials, 3 for the top filter housing and 5 for the bottom filter housing, were investigated to replace incumbent housing materials. Of the 8 candidates, 2 materials were identified for future investigation which met performance requirements, were bio-based and could potentially offer better disposal options like soil degradation or composting, features sought by the customers of these products. The top housing candidate, material 1, has comparable performance to the incumbent material and equally manufacturable. The bottom housing candidate, material 6, improved desiccation performance by 81% after 1 hour in comparison to the incumbent material, is 100% bio-based, compostable and can be sourced domestically throughout the U.S.A.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Sustainable, degradable and malleable low-dielectric-constant thermosets derived from biomass for recyclable green electronics

In view of their excellent thermal and chemical resistance, favorable adhesion properties, high tensile strength, and other advantages, epoxy thermosets have numerous industrial applications such as coating, adhesive, and composite material production. However, bisphenol A (BPA)-based resins, which account for a significant fraction of the above thermosets, adversely affect human health by interfering with the normal functioning of the endocrine system and cannot be easily decomposed and recycled. Herein, degradable and sustainable bio-based epoxy thermosets with crosslinked network structures are prepared by the epoxidation of isosorbide with epichlorohydrin and the curing of the produced isosorbide diglycidyl ether (ISDGE) with cyclic lactones through a cationic ring-opening reaction. The ISDGE thermosets fully decompose into soluble and recyclable products under mildly basic conditions within three days, which is ascribed to the presence of ester moieties within the polymer network structure. Compared to a representative BPA-based epoxy, ISDGE-based thermosets exhibit lower dielectric constants and are more flexible. Moreover, the glass fibers in ISDGE-based prepregs can be fully recovered after on-demand degradation. Furthermore, our work provides promising eco-friendly alternatives to conventional epoxy thermosets and paves the way for the reduction of plastic waste generation and the development of recyclable green electronics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Closed-loop recycling of mixed polyesters via catalytic methanolysis and monomer separations

A sustainable plastics future will require high recycling rates and the use of biogenic feedstocks, which together are catalyzing interest in replacing fossil fuel-derived, noncircular polyolefin packaging materials with bio-based, chemically recyclable polyesters. Here, in this study, we present a catalytic methanolysis process capable of depolymerizing both fossil fuel- and bio-based polyesters, including polyethylene terephthalate (PET), polylactic acid, polybutylene adipate terephthalate and polybutylene succinate in one reactor under mild conditions with high monomer yields. We scaled this process to 1 kg and integrated separations engineering using activated carbon, crystallization, extraction and distillation to remove contaminants and recover individual monomers from depolymerized mixed polyesters with high yield and purity. PET synthesized from monomers isolated from postconsumer materials showed comparable mechanical and thermal properties to PET from commercial monomers. Techno-economic analysis and life cycle assessment show that this process is economically viable and exhibits lower environmental impacts than primary production of respective polymers.

09 BIOMASS FUELS↗
DOE OSTI2025

In-Silico Design of Next Generation Cellulose-Derived Packaging Materials (CRADA Final Report)

Developing sustainable solutions for single-use packaging is an important objective to combat the environmental crisis of plastics pollution. Most embodiments of cellulose-based packaging materials, including CellophaneTM, are completely biodegradable in both terrestrial and marine environments. However, petroleum-derived alternatives offer some performance advantages for metrics such as moisture barriers and mechanical properties. This project leverages molecular dynamics simulation to investigate how molecular modifications to cellulose-based polymer assemblies impact their material properties. An important performance criterion for the modified materials was to retain biodegradability; thus, modifications by naturally occurring, biodegradable additives were the focus of this study. Specifically, we developed models with xylan and lignin of varying monomeric compositions into the cellulose matrix. The mechanical properties were investigated by performing stress-strain simulations, and the water barrier and hydrophobicity were investigated by simulating the water contact angle. Our findings indicate that the incorporation of xylan into the cellulose matrix tends to increase the mechanical properties with an optimal loading of ~27 wt%. We also predict that orienting the nanoscale directionality of the xylan chains such that they are perpendicular to the cellulose fibrils will dramatically increase mechanical strength. In contrast, the incorporation of lignin tends to weaken the composite at all loadings investigated. Simulations of water contact angle predicted that coating polymers on the surface of the cellulose assembly creates a more hydrophobic surface than incorporating them throughout the matrix. Of the coatings investigated, lignin resulted in the most hydrophobic surface, followed by pectin and keratin, which both imparted modest increases in hydrophobicity. Future experimental work done by Futamura will focus on designing material prototypes to capitalize on the predictions of performance enhancement obtained from molecular modeling. While substantial progress was made by the simulations performed in this project, there still exists a vast parameter space that we were unable to investigate, including branching, functional group decoration, and degree of polymerization of polymer additives. However, the methods developed in this initial investigation will facilitate more rapid evaluation of the impact of molecular characteristics on the performance of biopolymer composite materials and thereby accelerate future materials discovery efforts in this area.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Electron tomography unravels new insights into fiber cell wall nanostructure; exploring 3D macromolecular biopolymeric nano-architecture of spruce fiber secondary walls

Lignocellulose biomass has a tremendous potential as renewable biomaterials for fostering the “bio-based society” and circular bioeconomy paradigm. It requires efficient use and breakdown of fiber cell walls containing mainly cellulose, hemicellulose and lignin biopolymers. Despite their great importance, there is an extensive debate on the true structure of fiber walls and knowledge on the macromolecular nano-organization is limited and remains elusive in 3D. We employed dual-axis electron tomography that allows visualization of previously unseen 3D macromolecular organization/biopolymeric nano-architecture of the secondary S2 layer of Norway spruce fiber wall. Unprecedented 3D nano-structural details with novel insights into cellulose microfibrils (~2 nm diameter), macrofibrils, nano-pore network and cell wall chemistry (volume %) across the S2 were explored and quantified including simulation of structure related permeability. Matrix polymer association with cellulose varied between microfibrils and macrofibrils with lignin directly associated with MFs. Simulated bio-nano-mechanical properties revealed stress distribution within the S2 and showed similar properties between the idealized 3D model and the native S2 (actual tomogram). Present work has great potential for significant advancements in lignocellulose research on nano-scale understanding of cell wall assembly/disassembly processes leading to more efficient industrial processes of functionalization, valorization and target modification technologies.

3-D reconstruction↗
DOE OSTI2025

Enabling Industrial Re-Use of Large-Format Additive Manufacturing Molding and Tooling

Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling. In the past decade, the LFAM industry has seen widespread use of bio-based, glass, and/or carbon fiber reinforced thermoplastic composites which, when printed, serve as a lower-cost alternative to metallic parts. One of the highest-volume materials utilized by the industry is carbon fiber (CF)-filled polycarbonate (PC), which in out-of-autoclave applications can achieve comparable mechanical performance to metal at a significantly lower cost. Previous work has shown that if this material is recovered at various points throughout the manufacturing process for both the lab and pilot scale, it can be mechanically recycled with minimal impacts on the functional performance and printability of the material while significantly reducing the feedstock costs. End-of-life (EOL) CF-PC components were processed through industrial shredding, melt compounding, and LFAM equipment, followed by evaluation of the second-life material properties. Experimental assessments included quantitative analysis of fiber length attrition, polymer molecular weight degradation using gel permeation chromatography (GPC), density changes via pycnometry, thermal performance using dynamic mechanical analysis (DMA), and mechanical performance (tensile properties) in both the X- and Z-directions. Results demonstrated a 24.6% reduction in average fiber length compared to virgin prints, accompanied by a 21% decrease in X-direction tensile strength and a 39% reduction in tensile modulus. Despite these reductions, Z-direction tensile modulus improved by 4%, density increased by 6.8%, and heat deflection temperature (HDT) under high stress retained over 97% of its original value. These findings underscore the potential for integrating mechanically recycled CF-PC into industrial LFAM applications while highlighting the need for technological innovations to mitigate fiber degradation and enhance material performance for broader adoption. This critical step toward circular material practices in LFAM offers a pathway to reducing feedstock costs and environmental impact while maintaining functional performance in industrial applications.

additive manufacturing↗
NASA NTRS2026

Micromechanical Design of Carbon Nanotube Ribbon Reinforced Polymer Composite Materials

Lightweight materials are an important component of the design of aerospace structures. Carbon nanotube materials have been considered for this purpose due to the strength and stiffness of individual nanotubes, and the commercial availability of bulk formats such as fibers. These fibers can have a ribbon cross section which results in a different design space for their composites relative to traditional reinforcements which have a round cross section. This work applies brick-and-mortar micromechanical models and classical lamination theory with an inverse approach to investigate the design space of these composites. Using this approach, the influences of fiber geometry and axial and transverse mechanical properties are mapped. Finally, a sensitivity study is performed and the relative impacts of ±10% variations in the constituent material and geometric properties are ranked. Lamina axial moduli were found to range from a maximum of 3x to 1x minimum relative to a target quasi-isotropic laminate modulus depending on the anisotropy and shear modulus of the lamina. The fiber targets depended strongly on the fiber volume fraction in the lamina and the fiber axial modulus target was found to range from 4.8x to 3.2x the quasi-isotropic laminate target. The sensitivity analysis found that the largest driver of performance was the volume fraction, followed by the fiber axial modulus. While bio-based brick-and-mortar composites, such as nacre, can benefit from reinforcement aspect ratios above 10, for carbon nanotube ribbon (or carbon fiber)/polymer composites the sensitivity study indicated that the optimal cross-sectional aspect ratio was relatively smaller, potentially less than three.

Micromechanics↗
DOE OSTI2026

Strong and recyclable bio-derived poly(ester amide) hot-melt adhesive

Bio-based adhesives offer inherent advantages over conventional petrochemical-derived systems, including renewable sourcing, reduced environmental impact and potential degradability. However, most bio-based adhesives suffer from poor adhesion strength, limited substrate compatibility and a lack of chemical recyclability. Here, in this work, we present a bio-derived multiblock poly(ester amide) adhesive that leverages microphase segregation between different segments to reconcile mechanical robustness with strong interfacial bonding. Notably, this multiblock architecture is accessed through a one-pot, selective acceptorless dehydrogenative polymerization, obviating the need for multistep synthesis. The materials exhibit excellent adhesion across a range of substrates including metals, glass and wet wood surpassing commercial benchmarks, while also demonstrating thermal stability, tunable mechanical properties and closed-loop chemical recyclability even in the presence of other commodity plastics. Furthermore, the adhesive strength of these materials could be tuned for various potential applications through control over the chemical composition of the polymer. By integrating renewable feedstocks, high-performance functionality and efficient chemical circularity within a single platform, this work provides a viable pathway toward more sustainable adhesive technologies and contributes to advancing circular materials manufacturing.

09 BIOMASS FUELS↗
DOE OSTI2026

Simultaneous Overexpression of FERULOYL‐CoA 6′‐HYDROXYLASE 1 and COUMARIN SYNTHASE Leads to Coumarin‐Enriched Lignin and Improved Saccharification in Greenhouse‐ and Field‐Grown Poplar

ABSTRACT The urgent need for renewable resources has increased the interest in woody biomass to manufacture bio‐based products. However, lignin recalcitrance limits the enzymatic conversion of wood into fermentable sugars, posing a major challenge for biomass deconstruction. To address this problem, we aimed at incorporating the coumarin scopoletin into the lignin polymer of poplar ( Populus tremula × P . alba ) by expressing FERULOYL‐CoA 6′‐HYDROXYLASE 1 ( F6′H1 ) and COUMARIN SYNTHASE ( COSY ) in lignifying cells. Three constructs were evaluated: two bicistronic constructs, SCOP1 ( COSY followed by F6′H1 ) and SCOP2 ( F6′H1 followed by COSY ), and one monocistronic, SCOP3 (only F6′H1 ). SCOP1 poplars produced most free scopoletin without altering overall lignin, cellulose or hemicellulose content. SCOP2 poplars were overall less efficient in scopoletin production and most of these lines showed a severe biomass yield penalty, whereas SCOP3 caused plant lethality. NMR and metabolic analyses confirmed that scopoletin cross‐coupled with G and S monomers during lignification in SCOP1 lines. In addition to scopoletin, the detection of benzodioxane structures revealed the incorporation of dihydroxycoumarins. Overall coumarin incorporation in lignin amounted up to 2.3%. After alkaline pretreatment, wood from greenhouse‐grown SCOP1 poplars released up to 29% more glucose compared to the wild type upon limited saccharification. Field‐testing of three SCOP1 lines showed a 6 to 11% increase in saccharification efficiency, with the line containing the lowest scopoletin levels maintaining normal growth. These results demonstrate that engineering lignin composition in poplar can improve saccharification, and emphasize the importance of construct design, translational research and field validation.

alternative lignin monomers↗
DOE OSTI2026

Functionalized benzylamines from commercial kraft lignin

Benzylamines are key intermediates in pharmaceuticals, agrochemicals, and polymers, but their conventional production relies on benzyl chloride - a petroleum-derived compound with high toxicity and energy demands. Lignin, accounting for up to 30% of plant biomass, is the largest renewable source of aromatic carbon on Earth. However, its highly complex and recalcitrant structure poses a major barrier to efficient conversion into high-value chemicals. Here, in this study, we developed a catalytic approach to convert commercial kraft lignin into phenolic benzylamines through selective depolymerization and subsequent functionalization. We systematically evaluated the effects of three alcohol solvents, formic acid (FA), and a ruthenium-on‑carbon (Ru/C) catalyst on monophenol yield and selectivity. Up to 6.5 wt% monophenol yield was achieved using methanol (MeOH), FA, and Ru/C at 300 °C for 2 h. Quantum thermodynamic simulations based on the COSMO-RS model confirmed the superior solvation and reactivity of the MeOH + FA system, rationalizing observed product yield. The purified monophenolic products, primarily guaiacol and alkyl guaiacols, were then converted into functionalized benzylamines with >90% yield via a multicomponent Mannich reaction under mild conditions. Techno economic analysis (TEA) and life cycle assessment (LCA) underscore the importance of improving lignin depolymerization yields and expanding biorefinery scale. Solvent-only configurations outperform other options in both cost and emissions, with the methanol-only case performing the best ($\$$105 /kg and 26 kg CO 2e /kg) at a large-scale facility. This study establishes a scalable, bio-based pathway for producing benzylamines from commercial kraft lignin, advancing lignin valorization and offering a sustainable alternative to produce petrochemical-based benzylamines.

Catalytic reduction↗
DOE OSTI2023

DFO Computational Modeling Project - Catalytic Upgrading of Bio-based Furfural to 1,5-Pentanediol: A New Renewable Monomer for the Coatings Industry (Final Report)

This report summarizes the results of a collaborative effort between Oak Ridge National Laboratory (ORNL) and Pyran™ Inc. to utilize modeling capabilities developed by the CCPC (Consortium for Computational Physics and Chemistry) to assist Pyran in scaling up its proprietary process for thermocatalytic conversion of furfural to 1,5 pentanediol (PDO). Pyran’s bio-based PDO is a direct replacement for petroleum-based PDO and 1,6 hexanediol (HDO) currently used in polymers, additives, coatings, adhesives and sealants. The current market is in excess of $\$$1B/yr. According to Pyran, their production process results in 95+% reduction in fossil CO 2 at lower production costs compared to the existing petroleum-based routes for PDO & HDO. Other chemicals based on intermediates from this process have current markets in excess of $\$$10B/yr.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Catalytic Upgrading of Bio-based Furfural to 1,5-Pentanediol: A New Renewable Monomer for the Coatings Industry

This report summarizes the results of a collaborative effort between Oak Ridge National Laboratory (ORNL) and Pyran™ Inc. to utilize modeling capabilities developed by the CCPC (Consortium for Computational Physics and Chemistry) to assist Pyran in scaling up its proprietary process for thermocatalytic conversion of furfural to 1,5 pentanediol (PDO). Pyran’s bio-based PDO is a direct replacement for petroleum-based PDO and 1,6 hexanediol (HDO) currently used in polymers, additives, coatings, adhesives and sealants. The current market is in excess of $1B/yr. According to Pyran, their production process results in 95+% reduction in fossil CO 2 at lower production costs compared to the existing petroleum-based routes for PDO & HDO. Other chemicals based on intermediates from this process have current markets in excess of $10B/yr.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

SPERLU Selective Process for Efficient Removal of Lignin and Upgrading (Final Technical Report)

To meet the growing demand for bio-based chemicals and improve the profitability and efficiency of the emerging biorefinery industry, lignin is an abundant and attractive feedstock. Spero Renewables has developed a proprietary and patent-pending technology, the Selective Process for Efficient Removal of Lignin and Upgrading (SPERLU). The technology is a catalytic deconstruction and upgrading of lignin in lignocellulosic biomass or commercially available technical lignin to produce multi-functional phenol (MFP) products. The SPERLU process has been demonstrated and vetted on a lab scale to convert commercially available technical lignin to MFPs in yields of 60-90% (based on lignin). The MFP products can be separated and further upgraded through catalytic or biological means. Spero performed a detailed kinetic study of the SPERLU process and used the resulting kinetic data to design and construct a mini-pilot-scale reactor for routine production of hundreds of grams of MFP products. Spero’s lignin-based MFPs have been demonstrated for use as a drop-in replacement for bisphenol A (BPA) in the synthesis of thermoset polymers. Spero’s lignin-based thermoset polymers exhibit excellent mechanical properties and can be used in many applications. Additionally, a collaboration with the National Renewable Energy Lab (NREL) was used to evaluate the feasibility of upgrading SPERLU products through biological means into valuable chemicals. A comprehensive technoeconomic analysis (TEA) and Life-cycle analysis (LCA) have been completed and support the case for commercialization of the SPERLU technology. Through this project Spero has significantly de-risked the SPERLU technology and is actively planning larger scale pilot projects.

09 BIOMASS FUELS↗
DOE OSTI2023

2.3.4.501 - Synthesis and Analysis of Performance-Advantaged Bioproducts

This project focuses on the synthesis and analysis of performance-advantaged bioproducts (PABPs). We have established collaborations with other BETO-funded projects and academic and industrial collaborators to source new molecules that have promising manufacturing pathways and that could be serve as performance-advantaged biochemicals or biopolymers. We conduct synthesis and characterization of biochemicals and biopolymers alongside techno-economic analysis and life cycle assessment to estimate their cost and environmental impacts relative to incumbent materials. As part of the project, Profs. Linda Broadbelt and Brent Shanks are developing computational pathway prediction tools to identify optimal production pathways for bio-based compounds via biological and chemo-catalytic transformations. When coupled to the polyID tool from the Inverse Design project, these tools will ultimately enable a narrowing of design space for PABPs. From FY21-FY23, we described a framework for benchmarking PAPBs, estimated the energy and GHG emissions for commodity organic chemicals, developed performance-advantaged nylons and polyesters from beta-ketoadipic acid, and produced lignin-based plasticizers. We have shown that aromatic amines can be used in performance thermosets and that polyhydroxyalkanoates with crosslinked side chains can exhibit rubber-like properties, along with repair and degradability. We are working actively with industry partners on scale-up and validation of multiple PABPs.

BIOMASS FUELS↗