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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

CO2ROpt (Feedstock Allocation Optimization Model) [SWR-22-13]

Reducing greenhouse gas emissions remains a critical challenge for the transportation and chemical sectors. The electrochemical reduction of carbon dioxide is a potential pathway for production of fuels and chemicals that uses atmospheric carbon dioxide as a feedstock. Here we present an analysis of the potential for carbon dioxide captured from point sources and via direct air capture to be utilized in electrochemical reduction under different market scenarios. Using a numerical optimization framework and national data sets, scenarios for nationwide production of ethylene, formate, and carbon monoxide are evaluated at scales comparable to current production of these molecules in the United States. We show that developing a network for production of these products at scale requires capture and utilization of significant portions of the carbon dioxide that is currently emitted from large stationary point sources. Because carbon dioxide point sources are spatially and compositionally variable, their use for carbon dioxide reduction depends on electricity prices, capture cost, and location. If the power sector in the United States is decarbonized, carbon dioxide supply decreases significantly, increasing the importance of utilizing other carbon dioxide streams, and increasing the likelihood that direct air capture plays a role in supplying carbon dioxide feedstocks. These findings provide a first insight into the feedstock and energy constraints for carbon dioxide reduction.

Badgett, Alex↗
DOE OSTI2023

Dynamic Modeling of a Solar-To-Hydrogen Flexible High Temperature Steam Electrolysis Plant

Sustainble hydrogen production for use as a renewable combustible fuel and clean chemical feedstock is an important objective as the world moves towards a renewable energy future. High temperature steam electrolysis is a promising hydrogen production technology due to its reduced electric input that is offset by heat input into steam generation and steam superheating. An option to provide this heat is to use concentrating solar thermal technology that can sustainably provide heat input while renewable electricity is used for the electrolysis reaction. In this work, a solar-to-hydrogen high temperature steam electrolysis plant is designed and dynamically modeled, showing continuous hydrogen production by utilizing supplemental heating and efficient recuperative heating from the electrolysis product streams. Through this design, over 90% of the required heat input for the process can by met by a combination of solar and recuperative heat. Additionally, the plant can flexibility operate by ramping down hydrogen production and through flexible heat integration, which intelligently integrates solar heat based on solar conditions. Smooth operation with flexible hydrogen production is demonstrated which decreases electrical input during on-peak grid times and also decreases the total supplemental heat load over the course of a day from 26.1% to 24.5%. In addition, by using flexible heat integration, the plant can increase its solar heat usage by 4.1% relative to a base case. Both options for flexibility show efficient use of solar thermal energy to sustainably and continuously produce hydrogen.

Immonen, Jake (ORCID:0000000341231625)↗
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 OSTI2024

Abstract for CRADA between National Energy Technology Laboratory and American Institute of Chemical Engineers dba RAPID Manufacturing Institute

NETL and RAPID Manufacturing will develop advanced electromagnetic (EM) reactors and catalysts to produce light olefins from alternative feedstocks using CO2 soft oxidation. Light olefins are the building blocks for many plastic products, in addition to synthetic fibers, rubbers, and polymers. This project has the potential to produce high-value light olefins from alternative feedstocks with reduced energy consumption (50-70%), carbon intensity (50-70%), and production cost (15-25%) compared to the traditional olefin production processes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

A Novel Framework to Evaluate the Costs and Potential of Bioenergy in Decarbonization of the U.S. Economy

The long-term strategy of the United States targets reaching economy-wide net-zero emissions by 2050 and a carbon-neutral electricity grid by 2035 (U.S. Department of State and U.S. Executive Office of the President, 2021). Meeting these targets would require considerable changes to the energy system. Some key characteristics of illustrative net-zero energy systems include increased penetration of renewable energy and carbon sources, use of CO2 capture and storage (CCS) in hard-to-abate sectors, and a greater role for energy carriers such as electricity and hydrogen (Davis et al, 2018). Another common feature of such energy systems is the need for carbon dioxide removal (CDR) approaches (Horowitz et al, 2022). Across all these characteristics of net-zero energy systems, bioenergy and biomass feedstock is anticipated to play an important role. Biomass feedstock serves as a renewable carbon source. This can enable conversion of such feedstock into fuels and energy carriers for hard-to-abate sectors such as aviation. Indeed, the U.S. Government has a target to meet all jet fuel demand by 2050 from sustainable aviation fuel (SAF), where biofuel pathways are likely to have an important role (EERE, 2020). Bioenergy is also highly versatile with the possibility to convert feedstock into electricity, hydrogen, liquid fuels, heat or high-value products, based on biomass type, demand and technology availability (Clarke et al, 2022). Combination of bioenergy with CCS can also nominally deliver CDR (Fuhrman et al, 2023). As such, the share of bioenergy is expected to grow by at least five time across scenarios studied for the long-term strategy of the U.S. between 2020 and 2050 (Horowitz et al, 2022). Notwithstanding the role of bioenergy in the energy systems, its deployment, costs and scalability are influenced by a number of factors. Some of these factors pertain to policy interventions such as imposition of a binding decarbonization target either at an economy-wide level or the sectoral level. Resource availability and type of biomass feedstock also varies considerably across regions. From a technological perspective, the readiness of bioenergy conversion pathways is subject to high variability. This influences the costs of deployment. Moreover, the sourcing of feedstock, grid carbon intensity, and co-product handling approaches all affect the life cycle efficacy of bioenergy. The latter, in turn, is particularly important in determining the extent to which bioenergy with CCS or BECCS can effectively deliver CDR (Fajardy and Mac Dowell, 2017).

air emission↗
DOE OSTI2023

Redox Mediators in Homogeneous Co-electrocatalysis

Homogeneous electrocatalysis has been well studied over the past several decades for the conversion of small molecules to useful products for green energy applications or as chemical feedstocks. However, in order for these catalyst systems to be used in industrial applications, their activity and stability must be improved. In naturally occurring enzymes, redox equivalents (electrons, often in a concerted manner with protons) are delivered to enzyme active sites by small molecules known as redox mediators (RMs). Inspired by this, co-electrocatalytic systems with homogeneous catalysts and RMs have been developed for the conversion of alcohols, nitrogen, unsaturated organic substrates, oxygen, and carbon dioxide. In these systems, the RMs have been shown to both increase the activity of the catalyst and shift selectivity to more desired products by altering catalytic cycles and/or avoiding high-energy intermediates. However, the area is currently underdeveloped and requires additional fundamental advancements in order to become a more general strategy. Furthermore, we summarize the recent examples of homogeneous co-electrocatalysis and discuss possible future directions for the field.

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

Enhanced Feedstock Characterization and Modeling to Facilitate Optimal Preprocessing and Deconstruction of Corn Stover (Final Report)

This project addresses the challenge of processing corn stover by fractionating this biomass feedstock to both streamline processing and generate new potential co-products. Additionally, the project developed new field-deployable analytical tools that can be coupled with empirical models that were used to predict feedstock properties and processing performance. The overall scope of this project was: (1) identify conditions for optimal corn stover fractionation using a two- stage physical fractionation, (2) assess how physical fractionation impacts properties, partitioning of biomass, and response to processing, (3) further adapt, develop, and validate several advanced characterization tools for assessing biomass properties that can be linked to processing behavior, and (4) develop and validate predictive models based on measurements that can be performed “in the field” or “at the biorefinery gate” to predict feedstock processing behavior (preprocessing and deconstruction). The first objective employed pre-separation processing (size reduction) which was next subjected to enhanced separations to yield fractions enriched or depleted in select compositional components or properties. For the second objective, fractions were screened for their response to post-separation processing (pretreatment and enzymatic hydrolysis). Detailed characterization profiles were developed and dynamic image analysis to assess distribution of particle size and morphology. For the final objective, we utilized these tools to develop empirical models to assess the relative abundance of tissue type in order to assess fractionation efficacy and to predict fraction performance during pretreatment and enzymatic hydrolysis.

09 BIOMASS FUELS↗
DOE OSTI2023

Assessing the economic viability of unconventional rare earth element feedstocks

Sourcing rare earth elements (REEs) from unconventional feedstocks has substantial environmental and societal-economic benefits, but its economic viability remains unclear. Here, we propose a framework for assessing the economic viability of unconventional REE feedstocks. Here, we first develop a database of capital and operating expenses for REE recovery and establish consistent process unit costs for common stages in the conventional supply chain. We then use market prices to develop well-defined methods for determining diverse product values. Finally, we report the effects of economies of scale and feedstock purity on capital and operating costs. These tools can reduce the uncertainty in the assessment of the economic viability of producing REE from unconventional feedstocks, determine the value of innovative pathways for REE production from diverse sources, and inform research priorities across a wide range of REE product development stages, contributing to a sustainable REE supply.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Simple and Scalable Process for Nanocellulose Production from Residues and Waste (CRADA Final Report)

This project successfully developed an innovative, cost-effective, and scalable method for converting low-cost agricultural waste feedstocks into nanocellulose—a sustainable material with wide-ranging industrial applications. It addressed the critical challenges of high production costs and limited global supply, which have hindered the widespread adoption of nanocellulose in industry. Through this work, significant advancements were made in optimizing resource use, improving process efficiency, and reducing costs. Notable achievements included a 50% reduction in water usage, 30% lower chemical consumption, and 20% energy savings, all while maintaining high-quality product standards. The technical feasibility of the process was further validated at a 10L scale in collaboration with the Advanced Biofuels and Bioproducts Development Unit (ABPDU), demonstrating scalability and replicability. Key challenges in reducing nanocellulose production costs were addressed by utilizing low-cost biomass feedstocks and implementing low-temperature conversion reactions, leading to lower capital and operating expenses. The project also mitigated financial risk by generating critical data on the feasibility, adaptability, and scalability of the conversion technology, paving the way for its commercial implementation. Public benefits include advancing the circular bioeconomy, reducing environmental impact, fostering job creation, and enabling a shift toward biobased materials as sustainable alternatives to fossil-based products. These outcomes align closely with national goals to reduce greenhouse gas emissions and promote sustainable technological innovation.

09 BIOMASS FUELS↗
NASA NTRS1983

Development of a Polysilicon Process Based on Chemical Vapor Deposition of Dichlorosilane in an Advanced Siemen's Reactor

Dichlorosilane (DCS) was used as the feedstock for an advanced decomposition reactor for silicon production. The advanced reactor had a cool bell jar wall temperature, 300 C, when compared to Siemen's reactors previously used for DCS decomposition. Previous reactors had bell jar wall temperatures of approximately 750 C. The cooler wall temperature allows higher DCS flow rates and concentrations. A silicon deposition rate of 2.28 gm/hr-cm was achieved with power consumption of 59 kWh/kg. Interpretation of data suggests that a 2.8 gm/hr-cm deposition rate is possible. Screening of lower cost materials of construction was done as a separate program segment. Stainless Steel (304 and 316), Hastalloy B, Monel 400 and 1010-Carbon Steel were placed individually in an experimental scale reactor. Silicon was deposited from trichlorosilane feedstock. The resultant silicon was analyzed for electrically active and metallic impurities as well as carbon. No material contributed significant amounts of electrically active or metallic impurities, but all contributed carbon.

Arevidson, A. N.↗
DOE OSTI2023

Design of an Integrated Solids Handling System to Maximize Syngas Process Reliability (Cooperative Research and Development Final Report)

The National Renewable Energy Laboratory (NREL), in partnership with Wonderful Renewable Energy (WRE) and Idaho National Laboratory (INL), plans to develop a general methodology for designing integrated biorefinery solids preprocessing, handling, and feeding systems based on the chemical, physical, and mechanical attributes of the starting biomass material. This attribute-driven approach will include detailed feedstock property measurements, iterative computational modeling, and bench-scale testing to design systems for preprocessing, handling, and reactor in-feed, up to and including the selection of the conversion reactor. The initial tests and system design will be conducted using waste material from almond and pistachio growing and production operations (shells, hulls, and wood), targeting the conversion of this material to syngas for electricity production. The methodology will then be generalized to other feedstocks. The purpose of this project is to design an integrated solids handling system to maximize the process reliability of converting almond and pistachio waste to electricity. The design methodology and workflow developed from this example will then be applied to the Feedstock Conversion Interface Consortium (FCIC) benchmark loblolly pine residues, thus demonstrating the robustness of the overall design approach and providing insight and guidance for future conversion systems. V-Grid Energy Systems was brought on as a subcontractor to provide gasifiers and labor to complete gasifier runs.

09 BIOMASS FUELS↗
DOE OSTI2025

Future marine biofuels in the port of Seattle region

Marine transportation, a vital global sector, emits 3% of global annual greenhouse gas emissions, which are predicted to increase in the future. Marine biofuels derived from biomass or waste sources like wood residue, waste oil and municipal solid waste can be used for decarbonization. However, limited studies have explored if sufficient marine biofuels could be produced and supplied to major regional ports given feedstock, supply chain and technological constraints. We fill this gap by evaluating the feasibility of supplying marine biofuels to the Port of Seattle. The Regional Bio-Economy Model (RBEM) and the Freight and Fuel Transportation Optimization Tool (FTOT) are used to build scenarios for simulating marine biofuel production in the Port region. We harmonized technoeconomic assumptions for RBEM and FTOT, input FTOT feedstock utilization and routing outputs into RBEM, and modelled conversion, feedstock, and policy scenario variations in RBEM. In RBEM, overall biofuel production was constrained primarily by the biofuel cost, and then by feedstock availability. Providing policy incentives and reducing permitting time frames alleviated these constraints and spurred the buildout of a robust industry through industrial learning dynamics in the initial years. With these measures in place, the RBEM results show that 100% of fuel demand at the Port can be supplied by biofuels with policy incentives and suitable technoeconomic conditions, but the addition of transportation cost considerations using FTOT led to 27.8% of demand being able to be met by biofuels at reasonable fuel delivery cost.

09 BIOMASS FUELS↗
DOE OSTI2025

Comparison of Commercial, State-of-the-Art, Fossil-Based Ammonia Production

This NETL report provides a comprehensive techno-economic analysis of current, state-of-the-art, fossil-based ammonia production processes, explicitly utilizing natural gas as the feedstock. The study thoroughly investigates three distinct configurations: conventional Steam Methane Reforming (SMR) without carbon capture, SMR integrated with carbon capture and storage (CCS), and Autothermal Reforming (ATR) also with CCS. The analysis incorporates detailed equipment cost accounting as part of its methodology. The primary objective is to meticulously evaluate the cost and performance of these established and emerging technological pathways, considering factors such as capital expenditures, operational costs, and energy consumption. While the report acknowledges and quantifies environmental impacts, its central focus remains on the economic and technical feasibility of each process design employing these current technologies. The analysis provides a direct comparison of the Levelized Cost of Ammonia (LCOA) for each pathway, revealing how the integration of CCS within these state-of-the-art systems impacts the overall production cost. The ATR+CCS configuration, representing an advanced approach, emerged with a slightly more favorable LCOA compared to SMR+CCS. This benefit was attributed to its inherent process efficiencies, high carbon capture rates, and economy of scale advantages. The report details the energy consumption profiles for each case, including metrics like net energy consumption and thermal efficiency, which are critical for assessing the performance of these contemporary industrial processes. Sensitivity analyses further explore how variables such as natural gas price, capital costs, and capacity factors influence the LCOA across all scenarios, offering critical insights into the economic robustness and scalability of these current ammonia production technologies.

03 NATURAL GAS↗
NASA NTRS1991

Oxygen production processes on the Moon: An overview

The production of oxygen on the Moon utilizing indigenous material is paramount to a successful lunar colonization. Several processes were put forth to accomplish this. The lunar liquid oxygen (LLOX) generation schemes which have received the most study to date are those involving: (1) the reduction of ilmenite (FeTiO3) by H2, C, CO, CH4, CO-Cl2 plasma; (2) magma electrolysis, both unadulterated and fluoride-fluxed, and (3) several others, including carbo-chlorination, HF acid leaching, fluorine extraction, magma oxidation, and vapor pyrolysis. The H2 reduction of ilmenite and magma electrolysis processes have received the most study to date. At this stage of development, they both appear feasible schemes with various pros and cons. However, all processes should be addressed at least at the onset of the considerations. It is ultimatley the energy requirements of the entire process, including the acquisition of feedstock, which will determine the mode of oxygen productions. There is an obvious need for considerably more experimentation and study. Some of these requisite studies are in progress, and several of the most studied and feasible processes for winning oxygen from lunar materials are reviewed.

Taylor, Lawrence A.↗
DOE OSTI2021

Phosphorus speciation analysis of fatty-acid-based feedstocks and fast pyrolysis biocrudes via gel permeation chromatography inductively coupled plasma high-resolution mass spectrometry

Renewable feedstocks, such as lignocelulosic fast pyrolysis oils and both vegetable oil and animal fats, are becoming a viable alternative to petroleum for producing high-quality renewable transportation fuels. However, the presence of phosphorus-containing compounds, mainly from phospholipids, in these renewable feedstocks is known to poison and deactivate hydrotreating catalysts during fuel production. In this work, gel permeation chromatography (GPC) combined with inductively coupled plasma high-resolution mass spectrometry (ICP-HRMS) was used to analyze feedstocks including unprocessed soybean oil, animal fat, and pyrolysis oils from red oak and milorganite to identify phosphorus species. The results have shown the presence of a wide range of different phosphorous compounds among all the samples analysed in this work. The GPC-ICP-HRMS analyses of a vegetable oil and two animal fats have shown different fingerprints based on the molecular weight of each of the samples, highlighting the structural differences among their corresponding phosphorus-containing compounds. While the presence of low-molecular-weight species, such as phospholipids, was expected, several high-molecular-weight species (MW > 10 000 Da) have been found, suggesting that high-molecular-weight micelles or liposomes might have been formed due to the high concentration of phospholipids in these samples. Results obtained through the hydroxylation of a mix of phospholipids (asolectin) and its posterior GPC-ICP-HRMS agree with this hypothesis. With respect to the lignocellulosic catalytic fast pyrolysis oil samples, the GPC-ICP-HRMS results obtained suggest that either aggregation or polymerization reactions might have occurred during the pyrolysis process, yielding phosphorus-containing compounds with an approximate molecular weight above 91 000 kDa. In addition, an aggregation phenomenom has been observed for those phosphorus species present within the fast pyrolysis oils after being stored for 3 months, especially for those pyrolysis oils contaning pre-processed feedstocks, such as milorganite.

09 BIOMASS FUELS↗
DOE OSTI2021

BETO 2021 Peer Review - Waste Carbon Gas Upgrading via Acetogens 2.3.2.106

Waste carbon gas represents a large and diverse set of feedstocks that could be captured and turned into useful products. This includes waste gas emitted from industrial activity, syngas from burned plant biomass or processed municipal waste, and electrochemical reduction of CO2. Currently, carbon gas is being microbially converted to ethanol as a main product. However, ethanol is a lower value product with a limited market size. While these microbes can make other higher value products, there are no commercial processes for generating these other products, leaving a gap in understanding potential implementation for commercialization. Expanding the products microbially produced from waste carbon gas requires several steps before commercial implementation. We are studying the acetogen Clostridium ljungdahlii as a biocatalyst to convert waste carbon gas to the chemical 3-hydroxybutyrate (3HB), a plastic monomer and fuel precursor. For that, we are studying and engineering microbial characteristics for novel 3HB product formation from waste gas streams. This includes metabolic characterization, genetic engineering, gas fermentation scaling, as well as technoeconomic and life cycle analysis.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Wire arc additive manufactured A36 steel performance for marine renewable energy systems

Additive manufacturing has established itself to be advantageous beyond small-scale prototyping, now supporting full-scale production of components for a variety of applications. Despite its integration across industries, marine renewable energy technology is one largely untapped application with potential to bolster clean energy production on the global scale. Wave energy converters (WEC) are one specific facet within this realm that could benefit from AM. As such, wire arc additive manufacturing (WAAM) has been identified as a practical method to produce larger scale marine energy components by leveraging cost-effective and readily available A36 steel feedstock material. The flexibility associated with WAAM can benefit production of WEC by producing more complex structural geometries that are challenging to produce traditionally. Additionally, for large components where fine details are less critical, the high deposition rate of WAAM in comparison to traditional wrought techniques could reduce build times by an order of magnitude. In this context of building and supporting WEC, which experience harsh marine environments, an understanding of performance under large loads and corrosive environments must be understood. Hence, WAAM and wrought A36 steel tensile samples were manufactured, and mechanical properties compared under both dry and corroded conditions. Here, the unique microstructure created via the WAAM process was found to directly correlate to the increased ultimate tensile and yield strength compared to the wrought condition. Static corrosion testing in a simulated saltwater environment in parallel with electrochemical testing highlighted an outperformance of corroded WAAM A36 steel than wrought, despite having a slighter higher corrosion rate. Ultimately, this study shows how marine energy systems may benefit from additive manufacturing components and provides a foundation for future applications of WAAM A36 steel.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Experimental and theoretical investigations of rotating algae biofilm reactors (RABRs): Areal productivity, nutrient recovery, and energy efficiency

Microalgae biofilms have been demonstrated to recover nutrients from wastewater and serve as biomass feedstock for bioproducts. However, there is a need to develop a platform to quantitatively describe microalgae biofilm production, which can provide guidance and insights for improving biomass areal productivity and nutrient uptake efficiency. Here, this paper proposes a unified experimental and theoretical framework to investigate algae biofilm growth on a rotating algae biofilm reactor (RABR). Experimental laboratory setups are used to conduct controlled experiments on testing environmental and operational factors for RABRs. We propose a differential–integral equation‐based mathematical model for microalgae biofilm cultivation guided by laboratory experimental findings. The predictive mathematical model development is coordinated with laboratory experiments of biofilm areal productivity associated with ammonia and inorganic phosphorus uptake by RABRs. The unified experimental and theoretical tool is used to investigate the effects of RABR rotating velocity, duty cycle (DC), and light intensity on algae biofilm growth, areal productivity, nutrient uptake efficiency, and energy efficiency in wastewater treatment. Our framework indicates that maintaining a reasonable light intensity range improves biomass areal productivity and nutrient uptake efficiency. Our framework also indicates that faster RABR rotation benefits biomass areal productivity. However, maximizing the nutrient uptake efficiency requires a reasonably low RABR rotating speed. Energy efficiency is strongly correlated with RABR rotating speed and DC.

09 BIOMASS FUELS↗