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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 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Effect of digestate and digestate supplemented with biochar on switchgrass growth and chemical composition

Digestate, a by-product of anaerobic digestion, can be an excellent source of nutrients for bioenergy crop production, while biochar, resulting from pyrolyzing biomass, can valorize the nutrients of digestate. The objective of this study was to evaluate the nutritional value of digestate and digestate + biochar for switchgrass production. The greenhouse experiment was conducted to determine the effects of a nitrogen (N) source including 0 N (control), urea (nutrient control), sewage sludge digestate, and sewage sludge digestate + corn stover biochar on switchgrass growth and feedstock composition. Nitrogen sources were observed to significantly increase plant weight at the 32-week harvest, with weight ranging from 94.2 to 125.2 g plant -1 , depending on the N source, compared to 70.7 g plant -1 from the negative control. Moreover, switchgrass treated with digestate + biochar showed higher plant weight than samples treated only with digestate. Nitrogen application of urea, digestate, and digestate + biochar had positive effects on plant height and total leaf area in the 32-week harvests and chlorophyll content in the 8-week harvests. Feedstock quality traits including hemicellulose, cellulose, and lignin content were not affected by N sources in either the 8 or 32-week harvests with the exception of ash concentration in the 32-week harvests. Our results indicate that digestate and digestate + biochar can be a potential substitute for chemical fertilizer, resulting in increased biomass yield.

09 BIOMASS FUELS↗
DOE OSTI2024

Nth-plant scenario for blended pellets of Miscanthus, Switchgrass, and Corn Stover using multi-modal transportation: Biorefineries and depots in the contiguous U.S.

The sustainability of the biofuel industry depends on the development of a mature conversion technology on a national level that can take advantage of the economies of scale: the nth-plant. Here, this study addresses the logistic challenge of mobilizing national cellulosic feedstock supplies for a sustainable bioenergy industry. A Mixed Integer Linear Programming (MILP) model was developed and updated to deliver on-spec biomass that considers both a desired quantity and quality at the biorefinery. Our supply chain analysis includes multi-modal transport (truck and rail), varying depot and biorefinery sizes, and feedstock blends of corn stover (harvested by either a two- or three-pass method), switchgrass, and miscanthus. The following US states: Illinois, Kansas, Missouri, North Carolina, Oklahoma, Georgia, and Texas were identified as key locations for producing accessible miscanthus. Based on our most optimistic scenario, using trucks as the only transportation mode in 2040 with a cost target of $\$$79/dt, corn stover, switchgrass, and miscanthus could help meet 48% of the EPA target, 173 million dry tons that translate into 7.8 billion GGE. The addition of rail transportation for biomass delivery to biorefineries could help meet 79% of the EPA target, 283 million dry tons that translate into 12.7 billion GGE.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Life cycle analysis of dedicated energy crops for fuel production in the United States

Dedicated energy crops are promising feedstocks to make biofuels including jet fuels. This study applies life cycle analysis (LCA) to estimate direct well-to-wake (WTW) greenhouse gas (GHG) emissions (g CO 2 e/MJ) for jet fuel derived from five energy crops-biomass sorghum, miscanthus, switchgrass, poplar, and willow-via Fischer-Tropsch-to-Jet (FTJ) and Ethanol-to-Jet (ETJ) pathways. The WTW boundary includes direct emissions from biomass production, fuel production, and fuel combustion. The R&D GREET model is expanded to conduct the LCA, using national average biomass yields and farming inputs from the 2023 Billion-Ton Study. In addition, this study estimates emissions from market-mediated effects, including induced land-use change, induced other crop (non-feedstock) production changes, and induced livestock production changes using global economic and emissions factor models. On a per-dry U.S. ton basis, cultivation and harvest emissions are lowest for willow (51,565 g CO 2 e) and highest for biomass sorghum (104,488 g CO 2 e). Per-acre results show similarly high emissions for sorghum and lowest values for poplar and willow. Direct WTW emissions are substantially lower for FTJ (biomass sorghum: 5.5; miscanthus: 10.3; switchgrass: 11.7; poplar: 11.9; and willow: 8.7 g CO 2 e/MJ) than ETJ (33.2; 33.8; 34.8; 36.2; and 31.7 g CO 2 e/MJ, respectively). When market-mediated emissions are included, miscanthus exhibits the lowest total emissions across energy crop pathways. Although results are sensitive to modeling assumptions, they indicate that high-yielding perennial and woody crops, particularly when planted on marginal land, could significantly reduce WTW emissions for bio-jet fuels by combining low direct emissions with soil carbon gains and favorable market-mediated effects.

Billion-Ton Study↗
DOE OSTI2024

Policy impact on economic and environmental sustainability of anaerobic digestion: Industrial case study Insights

This paper thoroughly examines how policy incentives impact the economic and environmental sustainability of anaerobic digestion (AD) systems. It uses techno-economic and life cycle analyses, along with real industry data, to explore the entire AD process—from feedstock acceptance to digestate disposal. It evaluates the effects of various U.S. policy crediting programs on the economic viability of different AD pathways for treating sewage sludge and food waste. Furthermore, tipping fees are identified as the primary driver of profitability, while policy credits play a crucial role in enhancing economic feasibility, particularly for renewable natural gas production. However, future regulatory changes could reshape this economic landscape. All AD pathways are found to significantly reduce greenhouse gas emissions, though economic outcomes are highly sensitive to digestate disposal costs and feedstock tipping fees. Co-digestion with food waste is proposed as a strategy to reduce dependence on policy credits and improve long-term economic stability.

Anaerobic Digestion↗
DOE OSTI2025

Cradle-to-Gate greenhouse gas emissions of the production of ethylene from U.S. Corn ethanol and comparison to fossil-derived ethylene production

Conventional ethylene production heavily depends on fossil-derived feedstocks via steam cracking, a very energy- and emission-intensive process. Researchers have been exploring alternatives to reduce CO 2 emissions including producing ethylene from biobased feedstocks. This paper evaluates the cradle-to-gate greenhouse gas (GHG) emissions of bioethylene produced from U.S. corn ethanol. The analysis includes different pathways for the dehydration of corn ethanol to ethylene and co-processing routes via fluid catalytic cracking (FCC) processes. For the FCC co-processing route carbon-14 analysis is used to determine bioethanol yields. A 127% reduction in life cycle GHG emissions of bioethylene is estimated compared to fossil-derived ethylene for the base case. Additional case studies are also discussed to understand the reduction of GHG emissions due to sustainable corn farming and renewable power use, biogenic carbon capture, and fuel switch with biofuels at the ethanol plant, and its impact on bioethylene GHG emissions.

carbon footprint↗
DOE OSTI2025

pH adjustment increases biofuel production from inhibitory switchgrass hydrolysates

Biofuels derived from renewable and sustainable lignocellulosic biomass, such as switchgrass, offer a promising means to limit greenhouse gas emissions. However, switchgrass grown under drought conditions contains high levels of chemical compounds that inhibit microbial conversion to biofuels. Fermentation of drought switchgrass hydrolysates by engineered Saccharomyces cerevisiae and Zymomonas mobilis results in lower ethanol production than does fermentation of hydrolyzed switchgrass from a typical rainfall year. Here, it is demonstrated that this inhibitory effect can be alleviated by altering the pH of drought switchgrass hydrolysates produced by two different pretreatment methods: Ammonia Fiber Expansion (AFEX) and Soaking in Aqueous Ammonia (SAA). Fermentation rates and biofuel production by Saccharomyces cerevisiae and Zymomonas mobilis were higher at pH 5.8 than at pH 5.0 from all feedstock years and following both pretreatment methods. SAA pretreatment of drought switchgrass furthermore enabled increased fermentation rates and biofuel titers compared to AFEX pretreatment. A synthetic mimic of switchgrass hydrolysate was developed and identified relief from pH-dependent inhibition by lignocellulose-derived inhibitors as the cause of increased biofuel production above a pH of 5.0. These results demonstrate that SAA pretreatment and pH adjustment can significantly improve fermentation and biofuel production from inhibitory feedstocks by industrial microorganisms.

09 BIOMASS FUELS↗
DOE OSTI2025

Integrated thermal and biological conversion of microalgal proteins to lipids

Microalgal composition varies with cultivation strategy, and low-cost approaches often produce high-protein biomass. This presents challenges for biorefineries designed around static, lipid-rich feedstocks. In particular, hydrolysates from high-protein algae are nitrogen-rich and sugar-poor, limiting microbial conversion and reducing product yields. This study develops a sequential thermal conditioning and biological upgrading strategy to integrate high-protein hydrolysate processing within conventional lipid extraction and upgrading designs. Oxidative deconstruction was used to break down proteins into ammonium and short-chain carboxylates. Ammonium was subsequently removed to yield a nitrogen-depleted, carboxylate-rich medium suitable for microbial lipid production. Bioconversion trials with Cutaneotrichosporon oleaginosum showed lipid accumulation only from hydrolysates treated with both oxidative deconstruction and nitrogen removal, reaching 1.2 g/L lipids at 30 % intracellular content. This integrated approach enables protein-to-lipid conversion and improves flexibility to process variable algal feedstocks, advancing fuel-oriented microalgal biorefineries.

09 BIOMASS FUELS↗
DOE OSTI2026

Advancing Ethanol-to-Jet cost Effectiveness via direct conversion to n -Butene-Rich olefins and Co-Product Valorization

Ethanol is a promising feedstock for sustainable aviation fuel production; however, conventional routes face significant energy and cost challenges, particularly due to the ethanol dehydration step to ethylene. Here, this study leverages breakthrough experimental data to perform comprehensive techno-economic and life-cycle assessments of an innovative ethanol-to-jet process. The process employs a single-step catalytic conversion, enabled by multifunctional Cu-ZrO 2 /SBA-16 catalyst, to directly upgrade ethanol into a mixed olefin stream rich in n-butene. The single-step conversion eliminates the costly ethanol dehydration step in the conventional process. High selectivity toward n-butene offers key advantages: it simplifies downstream oligomerization into jet-range hydrocarbons and enables the co-production of renewable n-butene alongside sustainable aviation fuel. The analysis estimates a minimum fuel selling price as low as $\$$2.50 per gallon, whether using corn ethanol or cellulosic ethanol from corn stover. Life cycle CO 2 equivalent emissions are projected to be as low as 10.6 g CO 2 eq/MJ sustainable aviation fuel, representing over 70% reduction compared to conventional petroleum-based jet fuel. This one-step ethanol upgrading approach not only facilitates SAF and n-butene co-production but also provides operational flexibility. The ability to tailor product outputs allows the ethanol-to-jet process to adapt to varying feedstocks, incentive programs, and market dynamics, ultimately enhancing the economic viability of sustainable aviation fuel production.

Xu, Yiling [Pacific Northwest National Laboratory ↗
DOE OSTI2023

Coal-based graphene oxide-like materials: A comprehensive review

Coal is the most abundant energy and hydrocarbon resource in the United States which has been primarily used for power generation. With the increasing retirement of coal power plants and transition to a low-carbon emission economy, the future use of coal will likely shift to a feedstock source for production of valuable materials for different applications. In this review, the latest research reported on production of graphene-like materials in a powder form from coal is compiled and discussed. Here, this review includes: 1) brief background information on graphene and related materials (GRM); 2) relevant material, resource, economic, and socioeconomic information regarding suitability of coal as a potential feedstock for production of GRM; 3) a summary of common approaches for coal upgrading for preparation of more suitable precursors for production of GRM; 4) a compilation and analysis of the reported routes and methods for preparation of GRM from coal and coal derivatives; and 5) reported potential applications of coal-based GRM.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Diethylenetriamine-functionalized graphene oxide: Insights into ion adsorption and applications in rare earth element separation

The growing demand for critical minerals and materials requires atom- and energy-efficient, selective separations to overcome the challenges posed by the similar chemical and physical properties of the rare earth elements (REEs) and their low concentrations in unconventional domestic feedstocks. Here, in this study, we developed diethylenetriamine-functionalized graphene oxide (DETA-GO) as a membrane material for REE adsorption and separation. Synthesis conditions were optimized to maximize nitrogen incorporation while also preserving GO dispersibility for facile membrane fabrication. We investigated the mechanism of amine functionalization, the nitrogen-bonding configurations, the organization of the interlayer transport channels, and the resulting effects on ion and water transport for REE separations. Neat-GO and DETA-GO multilayer laminate membranes were fabricated by vacuum filtration onto polymer supports. To investigate the effects of amine functionalization, the membranes were characterized using scanning electron microscopy, Raman, Fourier transform infrared, and X-ray photoelectron spectroscopy, as well as grazing-incidence X-ray diffraction measurements. Ion permeation experiments with representative lanthanum (La 3+ ) and ytterbium (Yb 3+ ) solutions revealed enhanced ion adsorption and water transport through DETA-GO membranes compared to neat-GO. The strong affinity of the membranes for multivalent REEs was also validated with conductivity and inductively coupled plasma mass spectrometry measurements. Atomistic insight into the role of amine functionalization in modulating nanochannel architecture and long-term stability, optimizing adsorption sites, and regulating REE and water transport was obtained using classical molecular dynamics simulations. Collectively, our joint experimental and theoretical study demonstrates the potential of DETA-GO membranes for selective REE separations, offering insights into ion-binding mechanisms, water-transport properties, and nanochannel optimization for the recovery of critical materials from aqueous feedstocks.

Adsorbent↗
DOE OSTI2020

Oxidation kinetics of biochar from woody and herbaceous biomass

The goal of this study was to determine oxidation kinetics for biochar produced from fast pyrolysis of various biomass feedstocks. In particular, the role of inherent ash content on the oxidation rate was evaluated. Thermogravimetric analysis (TGA) and fluidized bed combustion experiments were used to explore oxidation kinetics of six fast pyrolysis produced biochars with diverse ash content. Here, the reaction rates varied by a factor of three under chemical kinetic-limited conditions, demonstrating inorganic content impacts oxidation rate. Chemical kinetic rate coefficients were proposed as a function of compositional parameters to determine overall fit and impact. Potassium content was found to have a positive correlation, best describing the differences in the oxidation kinetic rate coefficients. Additionally, feedstocks were subjected to a 1 M HCl acid wash mitigating the catalytic activity of the metals. Acid washed biochars had lower oxidation kinetic rates compared to their unwashed counterparts, indicating the removal of catalytically active metals reduced oxidation rate. Gas composition (CO/CO 2 ) was measured during fluidized bed experiments for both acid-washed and unwashed biochars, which varied between the six biochars. Formation of CO 2 was greatly affected by catalytic metals, finding potassium content to correlate well with a higher percentage of CO 2 formation as compared to CO. Comparison of oxidation rates were made between the two experimental apparatuses to measure the effect of attrition on biochar oxidation.

09 BIOMASS FUELS↗
DOE OSTI2021

Multiscale CFD simulation of biomass fast pyrolysis with a machine learning derived intra-particle model and detailed pyrolysis kinetics

Coupling particle and reactor scale models is as essential as reactor fluid dynamics and particle motion for accurate Computational Fluid Dynamic (CFD) simulations of biomass fast pyrolysis reactors due to intraparticle heat transfer and chemical reactions controlling conversion time and product distributions. Direct online coupling of a particle model with a reactor model is computationally expensive, while offline coupling is case-dependent. In this research, solutions from a series of particle pyrolysis simulations were regressed with Artificial Neural Network (ANN). Furthermoer, this machine learning-derived model predicted the same temperature and conversion profiles compared with particle resolved simulation while the isothermal approach overpredicted the temperature by 130 K and underpredicted the conversion time by 30 s. The ANN model was then integrated into CFD simulations of fluidized bed biomass fast pyrolysis with varied feedstocks via coupling PyTorch and MFiX. The averaged error of simulation predicted bio-oil yields with four feedstocks is 6.4%. This multi-scale approach provides an efficient tool for the coupled particle and reactor scale simulations of biomass pyrolysis.

09 BIOMASS FUELS↗
DOE OSTI2022

CFD-DEM Modeling of Autothermal Pyrolysis of Corn Stover with a Coupled Particle- and Reactor-Scale Framework

Autothermal operation of fast pyrolysis is an efficient process-intensification technique wherein exothermic oxidation reactions are used to overcome the heat-transfer bottleneck of conventional pyrolysis. The development of accurate, reliable modeling toolsets is imperative to generating a deeper understanding of biomass autothermal pyrolysis systems to support scale-up and industrial deployment. This modeling effort describes the development of single-particle and reactor models which incorporate detailed reaction schemes and simultaneous exothermic oxidation reactions. The particle-scale model was parameterized for corn stover feedstock with particle morphology, density, ash content, and biopolymer composition, all of which impact the emergent conversion characteristics during pyrolysis. Results were then used to parameterize a reactor-scale autothermal pyrolysis model, which was developed using a coarse-grained computational fluid dynamic-discrete element method. The simulation results compared well with experimental results, with the predicted bio-oil, light gas, and biochar yield within 3.0 wt% of the experimental yields. Further analyses were performed to test the influence of equivalence ratio, biomass injection position, and particle size distribution on autothermal pyrolysis. The analysis of the physio-chemical properties of the fluid and solid phase inside the reactor and at the reactor outlet help reveal important process interactions of autothermal pyrolysis.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗
DOE OSTI2022

Design optimization of integrated cooling inserts in modular Fischer-Tropsch reactors

Sustainable production of liquid fuels and feedstocks from atmospheric CO 2 through carbon recycling technologies is necessary to broaden decarbonization efforts and further reduce global emissions. Fischer–Tropsch (FT) reactors can address this challenge by providing storable, high-value liquid hydrocarbon fuels and feedstocks from syngas generated through reductive CO 2 utilization. FT technology, however, is most cost effective at large-scale, fixed-site plants and does not effectively address the smaller, globally distributed CO 2 point sources. Alternatively, smaller, modular reactors can be composed together to the specific scale of the emission source, yielding a flexible solution that enables more widespread deployment. In these modular reactors, thermal management using a finned cooling insert embedded within the catalyst matrix is critical to maintaining the performance and viability. Thus, in this work, topology optimization is used to determine the cooling insert geometry that maximizes reactor productivity while preventing auto-thermal runaway. Optimal designs are generated for varying number of constituent fins and over a range of maximum operating temperatures. Constraints including minimum feature length-scales and prescribed cooling insert material are imposed on the designs to enhance manufacturability. The impact of design features such as insert tapering and increased length scale hierarchy is automatically revealed by the systematic design framework employed. Here, this approach thus generates novel optimal geometries while automating, accelerating, and enhancing the design process compared to traditional heuristic approaches for cooling insert design in modular FT reactors.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Processing and mechanical characterization of short carbon fiber-reinforced epoxy composites for material extrusion additive manufacturing

Fiber-reinforced polymer composites have been extensively utilized in recent years as feedstock materials for material extrusion additive manufacturing (AM) processes to improve strength, stiffness, and functionality of printed parts over unfilled printed polymers. However, the widespread adoption of AM of fiber-reinforced polymer composites requires a deeper understanding of the process-structure-property relationships in printed components, and such relationships are not well understood yet. Fiber length is critically important to the mechanical performance of short fiber composites, but very few studies to-date have focused on how the fiber length distribution (FLD) evolves during processing of composite feedstocks and how this evolution affects printing behavior and mechanical properties in 3D-printed composites. Here, FLD is measured for carbon fiber reinforced epoxy composites over a wide range of ink compositions and shear mixing times, and the distributions are fit with a Weibull-type distribution function. The effects of FLD on the tradeoff between ink processability, ink rheology, printing behavior and mechanical properties are investigated. Furthermore, the effects of printing parameters (nozzle size and print speed) on mechanical anisotropy and fiber orientation distribution (FOD) in printed composites are explored. Mechanical properties of printed composites are characterized via 3 pt-flexural testing, and microstructure is investigated using optical and scanning electron microscopy (SEM), and x-ray computed tomography. Finally, the fitted Weibull parameters are fed into a composite model that incorporates FLD and FOD, and model predictions are found to be in excellent agreement with experimental observations.

3D printing↗
DOE OSTI2023

Recyclability of additively manufactured bio-based composites

As the flexibility, efficiency, and application space of additive manufacturing continues to grow, many have begun to investigate more sustainable feedstocks as well as options for the end of life of additively manufactured parts. This study examines the effects of mechanical recycling on additively manufactured parts from bio-based feedstock. Here, articles were printed on the Big Area Additive Manufacturing (BAAM) system at the Oak Ridge National Laboratory using poly (lactic acid)/wood flour (PLA/WF) pellets. These parts were shredded and granulated, and the granulate was fed directly back into the BAAM system for re-printing, skipping the costly and energy-intensive steps of extrusion and pelletization. The chemical, mechanical, thermal, and rheological changes to PLA/WF before and after recycling were investigated. Additionally, the energy savings from directly printing granulate on the BAAM system without extrusion and pelletization is reported. It is shown that PLA/WF is an excellent candidate for recycling of large format additively manufactured parts, and value of these parts can be reclaimed while saving cost and energy through mechanical recycling.

42 ENGINEERING↗
DOE OSTI2024

Recycling of CF-ABS machining waste for large format additive manufacturing

Large format additive manufacturing (LFAM) necessitates the use of short fiber thermoplastic composites, such as carbon fiber filled acrylonitrile butadiene styrene, to enable printing. Currently, when LFAM parts are machined into their final shape, the machining scrap (i.e., small flake like particles and offcuts) is landfilled. Previous studies have demonstrated the viability of recycling end-of-life LFAM parts by shredding and optionally re-compounding the material back into pellets. However, there is little understanding of the value and performance of recycled material made from LFAM machining scrap, which if pursued could motivate more broad recycling of this waste stream. In this study, recycled in-process machining scrap is explored as an LFAM feedstock source. Herein, it is found that the primary degradation mechanism of the recycled material is significant fiber length attrition during surface machining. While this fiber attrition negatively impacts the mechanical performance of the material in the print direction, it seems that the changes in processing behaviors and print quality, namely the surface roughness of the printed structure associated with shorter fiber lengths, is beneficial to interlayer adhesion. The tensile strength and elastic modulus of the recycled material, in the print direction, decreased 11% and 31% respectively compared to the pristine material. However, in the layer-wise direction it was found that the recycled material exhibited no significant change in elastic modulus and a significant 21% increase in tensile strength – a surprising result. In conclusion, this work indicates that machining waste could be a viable material stream for recycled LFAM feedstock materials.

42 ENGINEERING↗
DOE OSTI2020

Pollution to products: recycling of ‘above ground’ carbon by gas fermentation

Climate crisis and rapid population growth are posing some of the most pressing challenges to mankind and have intensified the need for the deployment of carbon recycling and carbon capture and utilization (CCU) technologies. Gas fermentation offers a solution using carbon-fixing chemolithoautotrophic microorganisms. After a decade of scale up, the technology has recently been commercialized with the first plant operating successfully since 2018 and additional units under construction. Gas fermentation offers unique feedstock and product flexibility when compared to other available gas-to-liquid technologies. Advancements in process technology and synthetic biology enable a broad range of feedstocks including emissions from industry or syngas generated from any biomass resource to be converted into a wide range of molecules realizing a circular economy.

09 BIOMASS FUELS↗