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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Experimental and statistical study on the effect of process parameters on the quality of continuous fiber composites made via additive manufacturing

Ongoing research in additive manufacturing towards structural and industrial application has led to the use of commingled roving as a manufacturing feedstock for printing high fiber volume fraction composites. The prospects of using this technology for high performance applications necessitates the need for a comprehensive experimental investigation into the effects of processing parameters on the quality of an additively manufactured composite printed from commingled roving feedstock. Here, in this work, transverse flexure and void fraction matrix pyrolysis testing are both performed to evaluate composite quality. The transverse flexure test is a testing approach that evaluates the quality of the interfacial fiber-matrix bond while the void fraction test estimates the void content in the printed composite. A full observational study consisting of 27 different test combinations is done to investigate the effects of three different process parameters namely, temperature, pressure, and print speed across three different levels. Composite samples were made from commingled roving of E-glass and amorphous PET using an in-house built continuous fiber composite digital manufacturing system. Least squares regression analysis is performed to study the main, interaction and quadratic effects of process parameters. A statistical regression model having an R2 adjusted value of 80.1% is generated from the transverse flexure study, which is used to explain main and interaction effects and also predict performance. Response surface plots are also generated and are used to optimize process parameters which can subsequently be of help in scaling up composite manufacturing. Results show that all three process parameters are highly statistically significant at the 0.01 level of significance. Pressure * Temperature and Pressure * Printspeed are significant interaction terms. Pressure plays a weightier role when print speed is increased or temperature is decreased as it closes more voids that would ordinarily have been introduced because of drop in polymer melt viscosity. Micrographic analysis is also performed.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Hydrocyclone pre-processing of wastewater algae: A strategy for inorganic ash separation

Microalgae cultivation on wastewater can provide remediation and generate valuable feedstocks for biofuel production. Wastewater algae typically have a high percentage of inorganic ash, which can reduce yield and quality of biocrude produced during hydrothermal liquefaction (HTL). Here, in this work, we evaluated the ability of hydrocyclone pre-processing to remove inorganic ash from wastewater algae. The pH of the algae slurry was adjusted to 9.5 to encourage the formation of precipitates and create a density differential between ash particles and algal cells. Hydrocyclone processing successfully concentrated ash particles in the underflow fraction and reduced the total ash percentage in the overflow fraction. Overall, hydrocyclone processing reduced the total ash by 21%, while only 8% of organics were lost. Elemental and mineral analysis showed that Mg and P were concentrated in the underflow in the form of baricite (an isomorph of vivianite). Future research should focus on improving vivianite and/or baricite formation, and therefore ash removal, by providing a reducing environment. The addition of multiple hydrocyclones in series could also improve the removal of ash. We concluded that hydrocyclone treatment of wastewater algae is a feasible method to remove inorganic ash, but further process optimization is required.

09 - BIOMASS FUELS↗
DOE OSTI2020

Evaluation of near-ambient algal biomass fractionation conditions for bioproduct development

This contribution describes an algal fractionation scheme based on cell lysing and carbohydrate hydrolysis under acidic conditions, coupled with solvent extraction, that produces algal lipids, carbohydrates, and proteinaceous solid from partially dewatered algal biomass. Here, a design of experiments analysis was employed to identify the effect of fractionation conditions on the yields of the three product streams. By selection of appropriate conditions, the process can be steered from simple lipid extraction to near complete fractionation of the biomass. Lipid purification and upgrading were respectively achieved with a low-cost adsorbent and an inexpensive Ni-based catalyst that deoxygenated the lipids via decarboxylation/decarbonylation, an approach offering several advantages over the hydrodeoxygenation-based processes typically employed to convert lipids to hydrocarbons. The proteinaceous solids obtained were found to have much lower ash content as well as higher protein content relative to the untreated algae, enhancing the suitability of this material as a feedstock for the production of bioplastics.

09 BIOMASS FUELS↗
DOE OSTI2023

Disruption of p -coumaroyl-CoA:monolignol transferases in rice drastically alters lignin composition

Grasses are abundant feedstocks that can supply lignocellulosic biomass for production of cell-wall-derived chemicals. In grass cell walls, lignin is acylated with p-coumarate. These p-coumarate decorations arise from the incorporation of monolignol p-coumarate conjugates during lignification. A previous biochemical study identified a rice (Oryza sativa) BAHD acyltransferase (AT) with p-coumaroyl-CoA:monolignol transferase (PMT) activity in vitro. In this study, we determined that that enzyme, which we name OsPMT1 (also known as OsAT4), and the closely related OsPMT2 (OsAT3) harbor similar catalytic activity toward monolignols. We generated rice mutants deficient in either or both OsPMT1 and OsPMT2 by CRISPR/Cas9-mediated mutagenesis and subjected the mutants’ cell walls to analysis using chemical and nuclear magnetic resonance methods. Our results demonstrated that OsPMT1 and OsPMT2 both function in lignin p-coumaroylation in the major vegetative tissues of rice. Notably, lignin-bound p-coumarate units were undetectable in the ospmt1 ospmt2-2 double-knockout mutant. Further, in-depth structural analysis of purified lignins from the ospmt1 ospmt2-2 mutant compared with control lignins from wild-type rice revealed stark changes in polymer structures, including alterations in syringyl/guaiacyl aromatic unit ratios and inter-monomeric linkage patterns, and increased molecular weights. Furthermore, our results provide insights into lignin polymerization in grasses that will be useful for the optimization of bioengineering approaches for the effective use of biomass in biorefineries.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Longitudinal genome-wide association study reveals early QTL that predict biomass accumulation under cold stress in sorghum

Sorghum bicolor is a promising cellulosic feedstock crop for bioenergy due to its high biomass yields. However, early growth phases of sorghum are sensitive to cold stress, limiting its planting in temperate environments. Cold adaptability is crucial for cultivating bioenergy and grain sorghum at higher latitudes and elevations, or for extending the growing season. Identifying genes and alleles that enhance biomass accumulation under early cold stress can lead to improved sorghum varieties through breeding or genetic engineering. We conducted image-based phenotyping on 369 accessions from the sorghum Bioenergy Association Panel (BAP) in a controlled environment with early cold treatment. The BAP includes diverse accessions with dense genotyping and varied racial, geographical, and phenotypic backgrounds. Daily, non-destructive imaging allowed temporal analysis of growth-related traits and water use efficiency (WUE). A genome-wide association study (GWAS) was performed to identify genomic intervals and genes associated with cold stress response. The GWAS identified transient quantitative trait loci (QTL) strongly associated with growth-related traits, enabling an exploration of the genetic basis of cold stress response at different developmental stages. This analysis of daily growth traits, rather than endpoint traits, revealed early transient QTL predictive of final phenotypes. The study identified both known and novel candidate genes associated with growth-related traits and temporal responses to cold stress. The identified QTL and candidate genes contribute to understanding the genetic mechanisms underlying sorghum's response to cold stress. These findings can inform breeding and genetic engineering strategies to develop sorghum varieties with improved biomass yields and resilience to cold, facilitating earlier planting, extended growing seasons, and cultivation at higher latitudes and elevations.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Development of the Well-to-Wake Life Cycle Assessment Model for Marine Fuels in R&D GREET 2025

The Marine analysis capabilities in the 2025 Research and Development Greenhouse gases, Regulated Emissions, and Energy use in Technologies (R&D GREET) have been updated to incorporate the latest findings from the Fourth International Maritime Organization (IMO) GHG Study.1 To support these updates and enhance user flexibility, the former single marine module used in previous R&D GREET versions has been split into two workbook tabs: The Marine_Fuel tab, which covers the fuel-cycle, and the Marine_Trip tab, which covers the trip-cycle. In the Marine_Fuel tab, fuel cycle results for 39 marine fuels are available—assuming a slow speed diesel engine—and can be seen in Appendix A. However, there are options for changing feedstocks for multiple fuels, ability to view results with or without pilot fuels for fuels such as methanol and ammonia, and carbon capture options. All these combinations make the number of total possible pathways over one hundred. For each pathway, life cycle emission results are divided into feedstock, conversion, and combustion categories, along with pilot fuel supply chain emissions for fuels used in dual fuel engines. In the newly created Marine_Trip tab, users can view the life cycle emissions of using these fuels from a trip perspective. Compared to R&D GREET 2024, 16 new types of vessels are added in R&D GREET 2025. Examples of results assuming the default size for each vessel type are available in Appendix A. Additional information categories on vessels are included such as vessel size, main propulsion type, engine power rating, combustion cycle, etc. based on the Fourth IMO GHG Study. Operational mode of the trip, fuel consumption, and load calculation were updated based on the report. The fuel consumption calculation also incorporates low-load adjustment, speed–power correction, weather correction, and fouling correction factors. Furthermore, fuel consumption in boilers or steam turbines is also added for the first time, besides fuel use in main propulsion engines and auxiliary engines. This effort makes the R&D GREET Marine capabilities more robust than before. Users will be able to estimate fuel consumption more accurately for more diverse choices of vessel categories, vessel sizes, and energy converters.

09 BIOMASS FUELS↗
DOE OSTI2023

Biomass pretreatment with distillable ionic liquids for an effective recycling and recovery approach

Ionic liquid (IL) pretreatment methods show incredible promise for the efficient conversion of lignocellulosic feedstocks to fuels and chemicals. Given their low vapor pressures, distillation-based methods of extracting ionic liquids out of biomass post-pretreatment have historically been ignored in favor of alternative methods. We demonstrate a process to distill four acetate-based ionic liquids ([EthA][OAc], [PropA][OAc], [MAEthA][OAc], and [DMAEthA][OAc]) at low pressure and high purity that overcome some disadvantages of “water washing” and “one pot” recovery methods. Out of four tested ILs, ethanolamine acetate ([EthA][OAc]) is shown to have the most agreeable conversion metrics for commercial bioconversion processes achieving 73.6% and 51.4% of theoretical glucose and xylose yields respectively and >85 % recovery rates. Our process metrics are factored into a techno-economic analysis where [EthA][OAc] distillation is compared to other recovery methods as well as ethanolamine pretreatment at both milliliter and liter scales. In conclusion, although our TEA shows [EthA][OAc] distillation underperforming against other processes, we show a step-by-step avenue to reduce sugar production cost below the wholesale dextrose price at scale.

09 BIOMASS FUELS↗
DOE OSTI2026

Understanding and Mitigating Stickiness in Biochar Produced through Acid Hydrolysis and Dehydration

Levulinic acid is a platform chemical with significant potential for conversion into a wide range of biobased chemicals and fuels. A common process for producing levulinic acid from lignocellulosic feedstocks involves acid hydrolysis and dehydration (AHDH), where hexose polymers are hydrolyzed into monomeric sugars and subsequently dehydrated to levulinic acid and formic acid in the presence of dilute sulfuric acid. However, scaling the AHDH process is challenging because of the formation of byproducts such as sticky biochar, which accumulates in continuous-flow reactors, reducing effective reaction volume and increasing process downtime. This study investigates the effect of a chemical preconditioning step on mitigating sticky biochar formation. Woody biomass was preconditioned at 170 °C with 0.26 wt % sulfuric acid for 30 min, resulting in substantial removal of hemicellulose and acid-soluble lignin. AHDH of these preconditioned solids produced biochar that did not adhere to reactor surfaces. TGA analysis confirmed that the chemical preconditioning step minimized interactions between hemicellulose-derived degradation products and lignin side chains, reducing sticky char formation. Additionally, the study observed a 6% higher yield of organic acids from softwood species compared to hardwoods, with bark content shown to negatively impact yield. These findings suggest that targeted preconditioning of lignocellulosic biomass can enhance reactor operability and improve organic acid production efficiency in AHDH processes.

biopolymers↗
NASA NTRS2014

Interstellar Organics, the Solar Nebula, and Saturn's Satellite Phoebe

The diffuse interstellar medium inventory of organic material (Pendleton et al. 1994, Pe 2002) was likely incorporated into the molecular cloud in which the solar nebula condensed. This provided the feedstock for the fo planets, and the smaller icy bodies in the region outside Neptune's orbit (transneptunian objects, or TNOs). Saturn's satellites Phoeb open a window to the composition of one class of TNO as revealed by the near-infrared mapping spectrometer (VIMS) on the Cass Phoebe (mean diameter 213 km) is a former TNO now orbiting Saturn. VIMS spectral maps of Phoebe's surface reveal a complex consisting of prominent aromatic (CH) and aliphatic hydrocarbon (CH2, CH3) absorption bands (3.2-3.6 μm). Phoebe is the source encircling Saturn, and from which particles (~5-20 μm size) spiral inward toward Saturn. They encounter Iapetus and Hyperion wh blanket the native H2O ice of those two bodies. Quantitative analysis of the hydrocarbon bands on Iapetus demonstrates that aroma abundant as aliphatic CH2+CH3, significantly exceeding the strength of the aromatic signature in interplanetary dust particles, com carbonaceous meteorites (Cruikshank et al. 2013). A similar excess of aromatics over aliphatics is seen in the qualitative analysis o itself (Dalle Ore et al. 2012). The Iapetus aliphatic hydrocarbons show CH2/CH3 ~4, which is larger than the value found in the di as Phoebe is a primitive body that formed in the outer regions of the solar nebula and has preserved some of the original nebula inv understanding the content and degree of processing of that nebular material. There are other Phoebe-like TNOs that are presently b in the organic spectral region, but JWST will open that possibility for a number of objects. We now need to explore and understand organic-bearing Solar System material to the solar nebula and the inventory of ISM materials incorporated therein.

Interstellar↗
DOE OSTI2022

Protonic Ceramics for Energy Storage & Electricity Generation with Ammonia (Final Report)

The commercial product resulting from this R&D project will enable cost-effective synthesis of the Carbon Neutral Liquid Fuel (CNLF) ammonia, a common chemical, at a small scale for energy and industrial applications using only intermittent renewable energy, water, and air as feedstocks. These products are also capable of producing electrical energy from the CNLF in a fuel cell mode of operation. Thus, the eventual commercial product enables both single direction production of either CLNF or electricity, or alternatively functions as a fully reversible, self-contained energy storage device. The renewed interest in developing electrolysis systems is driven, in part, by the burgeoning renewable, solar, and wind industries and the need for an energy conversion and storage technology that can convert intermittent solar and wind energy into the production of hydrogen. Electrolysis systems integrated into both distributed and central renewable power plants would utilize solar and wind energy as their primary power source to produce renewably generated hydrogen for local energy storage or chemical feedstock purposes. Ammonia is an excellent surrogate for hydrogen transportation. NH3 presents an attractive alternative to hydrogen as a working fluid in reversible devices towards a sustainable green energy-oriented future. Ammonia can be easily liquefied at room temperature at about 8 bar or at -33°C at ambient pressure. In contrast, the liquefaction temperature of hydrogen is -253°C at ambient pressure. NH3 has a significantly higher volumetric energy density (12.7 MJ/L) than compressed hydrogen (4.5 MJ/L at ~70 MPa) or liquefied hydrogen (8.5 MJ/L). Additionally, ammonia is a widely used raw material for agriculture fertilizer and thus has well-established storage, transport, and handling processes (about 180 million tons of ammonia are produced annually). Techno-economic analysis suggests ammonia is the least expensive fuel among hydrogen, gasoline, natural gas, liquefied petroleum gas, and methanol.

08 HYDROGEN↗
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 OSTI2020

Nonspecific phospholipase C6 increases seed oil production in oilseed Brassicaceae plants

Summary Plant oils are valuable commodities for food, feed, renewable industrial feedstocks and biofuels. To increase vegetable oil production, here we show that the nonspecific phospholipase C6 (NPC6) promotes seed oil production in the Brassicaceae seed oil species Arabidopsis, Camelina and oilseed rape. Overexpression of NPC6 increased seed oil content, seed weight and oil yield both in Arabidopsis and Camelina, whereas knockout of NPC6 decreased seed oil content and seed size. NPC6 is associated with the chloroplasts and microsomal membranes, and hydrolyzes phosphatidylcholine and galactolipids to produce diacylglycerol. Knockout and overexpression of NPC6 decreased and increased, respectively, the flux of fatty acids from phospholipids and galactolipids into triacylglycerol production. Candidate‐gene association study in oilseed rape indicates that only BnNPC6.C01 of the four homeologues NPC6s is associated with seed oil content and yield. Haplotypic analysis indicates that the BnNPC6.C01 favorable haplotype can increase both seed oil content and seed yield. These results indicate that NPC6 promotes membrane glycerolipid turnover to accumulate TAG production in oil seeds and that NPC6 has a great application potential for oil yield improvement.

Cai, Guangqin↗
DOE OSTI2022

Emerging wild virus of native grass bioenergy feedstock is well–established in the Midwestern USA and associated with premature stand senescence

The North American native prairie grass Panicum virgatum (switchgrass) is a primary bioenergy feedstock candidate. Its widespread distribution and genetic diversity enable the possibility of developing this perennial grass for high production in a variety of conditions, including on marginal lands. A critical concern in feedstock development and deployment is the risk of novel pathogen emergence. Here we investigate the landscape-scale prevalence and epidemiology of a little-studied North American virus first detected in switchgrass and other grasses in bioenergy trials in the US Midwest. Switchgrass mosaic virus (SwMV, Genus Marafivirus, Family Tymoviridae) is transmitted by leafhoppers and phylogenetically sister to Maize rayado fino virus, a significant pathogen of maize in parts of the Americas. Our goal was to determine whether SwMV is uniquely limited to specific bioenergy trials or well-established and circulating more broadly. We used molecular diagnostics to quantify naturally occurring SwMV infection in leafhoppers and switchgrass in naturalistic stands throughout a large Midwestern landscape, and quantified leafhopper abundances and stand performance. Our analysis revealed that this apparently wild virus is well-established and widespread. Infection was present at nearly all sites, across diverse landscape contexts, with prevalences ranging as high as 33%–60%. Infection appeared to accumulate and persist in stands over time. It was associated with increases in premature stand senescence but not with reductions in stand height. Although wild viruses are believed to evolve benign relationships with their natural hosts, these data suggest that SwMV has potential to impact yield components. Viruses are frequently overlooked in crop development efforts, but represent the majority of emerging plant pathogens. For SwMV, it is imperative to quantify its impact on host performance, to identify the extent of any host resistance, and to assess any risks of virus spillover to agricultural plantings of other Poaceae species, including maize and sorghum.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2026

Data for Comparison of Genotyping Assays for Detection of Targeted CRISPR/Cas Mutagenesis in Highly Polyploid Sugarcane

Sugarcane ( Saccharum spp.) is an important biofuel feedstock and a leading source of global table sugar. Saccharum hybrid cultivars are highly polyploid (2n = 100–130), containing large numbers of functionally redundant hom(e)ologs in their genomes. Genome editing with sequence-specific nucleases holds tremendous promise for sugarcane breeding. However, identification of plants with the desired level of co-editing within a pool of primary transformants can be difficult. While DNA sequencing provides direct evidence of targeted mutagenesis, it is cost-prohibitive as a primary screening method in sugarcane and most other methods of identifying mutant lines have not been optimized for use in highly polyploid species. In this study, non-sequencing methods of mutant screening, including capillary electrophoresis (CE), Cas9 RNP assay, and high-resolution melt analysis (HRMA), were compared to assess their potential for CRISPR/Cas9-mediated mutant screening in sugarcane. These assays were used to analyze sugarcane lines containing mutations at one or more of six sgRNA target sites. All three methods distinguished edited lines from wild type, with co-mutation frequencies ranging from 2% to 100%. Cas9 RNP assays were able to identify mutant sugarcane lines with as low as 3.2% co-mutation frequency, and samples could be scored based on undigested band intensity. CE was highlighted as the most comprehensive assay, delivering precise information on both mutagenesis frequency and indel size to a 1 bp resolution across all six targets. This represents an economical and comprehensive alternative to sequencing-based genotyping methods which could be applied in other polyploid species.

Genomics↗
DOE OSTI2022

Cradle-to-Grave Lifecycle Analysis of U.S. Light-Duty Vehicle-Fuel Pathways: A Greenhouse Gas Emissions and Economic Assessment of Current (2020) and Future (2030-2035) Technologies

This study provides a comprehensive life cycle analysis (LCA), or cradle-to-grave (C2G) analysis, of the cost and greenhouse gas (GHG) emissions of a variety of vehicle-fuel pathways, the levelized cost of driving (LCD) and cost of avoided GHG emissions. The C2G analysis assesses light duty midsize sedans and small sport utility vehicles (SUVs) across a variety of vehicle-fuel technology pathways, including conventional internal combustion engine vehicles (ICEVs), flexible hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs) with varying vehicle ranges, and fuel cell electric vehicles (FCEVs). Coming at a timely manner, given the marked increase, since 2016, in climate aspirations announced by governmental institutions and private firms both in the US and across the globe, this analysis builds on a previous comprehensive life cycle analysis, updating that study’s 2016 assumptions and methods (Elgowainy et al. 2016). These updates incorporate technological advances and changes in energy supply sources that have emerged during the intervening period. Utilizing these updated assumptions and methods, alongside more recent data, the present report accounts for a broader range of vehicle technologies and considers both current (2020) and expected future (2030-2035) conditions. Reflecting increased research interest in synthetic liquid fuels produced using renewable low-carbon electricity and CO 2 sources, electro-fuels (a.k.a. e-fuels) were added to the potential future fuel technologies that are evaluated. This study takes a “pathway” approach rather than a “scenario” approach; hence distinct, technically feasible, routes or sequences of processes starting with one or more feedstocks and ending with an intermediate or a final product are examined, not necessarily constrained by practical feedstock, economic, policy, and market considerations.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Comparison of genotyping assays for detection of targeted CRISPR/Cas mutagenesis in highly polyploid sugarcane

Sugarcane (Saccharum spp.) is an important biofuel feedstock and a leading source of global table sugar. Saccharum hybrid cultivars are highly polyploid (2n = 100–130), containing large numbers of functionally redundant hom(e)ologs in their genomes. Genome editing with sequence-specific nucleases holds tremendous promise for sugarcane breeding. However, identification of plants with the desired level of co-editing within a pool of primary transformants can be difficult. While DNA sequencing provides direct evidence of targeted mutagenesis, it is cost-prohibitive as a primary screening method in sugarcane and most other methods of identifying mutant lines have not been optimized for use in highly polyploid species. In this study, non-sequencing methods of mutant screening, including capillary electrophoresis (CE), Cas9 RNP assay, and high-resolution melt analysis (HRMA), were compared to assess their potential for CRISPR/Cas9-mediated mutant screening in sugarcane. These assays were used to analyze sugarcane lines containing mutations at one or more of six sgRNA target sites. All three methods distinguished edited lines from wild type, with co-mutation frequencies ranging from 2% to 100%. Cas9 RNP assays were able to identify mutant sugarcane lines with as low as 3.2% co-mutation frequency, and samples could be scored based on undigested band intensity. CE was highlighted as the most comprehensive assay, delivering precise information on both mutagenesis frequency and indel size to a 1 bp resolution across all six targets. This represents an economical and comprehensive alternative to sequencing-based genotyping methods which could be applied in other polyploid species.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Pilot Scale Testing of the Hydrophobic-Hydrophilic Separation Process to Produce Value-Added Products from Waste Coal

The primary objective of this project was to demonstrate the technical and economic feasibility of using the hydrophobic-hydrophilic separation (HHS) process to produce high-purity, value-added clean coal that could serve as feedstock for specialty carbon products from waste coal. An existing one-skid (i.e., the entire unit fits on a single tractor-trailer) HHS pilot-scale facility was used to process bituminous and anthracite waste coals to produce: 1) a clean coal containing less than 5% ash (super-clean) and 2) another containing less than 1.5% ash (ultra-clean), all of which contain single-digit moistures. Sufficient quantities of these products were to be generated to permit detailed evaluations by potential customers producing or developing new, high-value market applications. In addition, the project included the evaluation of several process improvements to reduce the capital and operating costs for a commercial HHS plant. A final objective was to complete an economic analysis, market-penetration analysis, and technology-gap analysis of the HHS technology and its products.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

An Anisotropic Yield and Damage Material Model to Improve the Contact Pressure Analysis in a Biomass Shredding System

Size reduction systems used in biomass processing break biomass into smaller pieces by utilizing the kinetic energy from the sharp rotating blades. Abrasive and/or erosive wear caused by biomass comminution results in blade wear of the sharp edged cutters, deteriorating the process efficiency. Here, this study aims to optimize the blade design and improve the system efficiency by attempting to understand the interactions between the blades and biomass particles. Since real-time monitoring of these interactions is impractical during operation, mechanical simulations offer a viable alternative for investigating the shredding process. Yet, the irregular geometry and complex mechanical properties of biomass—such as the anisotropic nature of woodchips and their nonlinear fracture behavior—pose significant challenges for accurately simulating contact pressure. In this work an anisotropic yield material model, along with a damage initiation and evolution function, is applied to the woodchip particle to study the contact pressure on shredder blade, offering a scientific basis for improved blade design and process efficiency. This approach can be extended to other biomass processing systems with similar anisotropic feedstocks, making it a valuable tool for advancing sustainable biomass utilization.

09 - BIOMASS FUELS↗