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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Modular Adaptive Packing for Integrally Cooled Absorbers

Process intensification is one cornerstone in ION Clean Energy’s (ION) efforts to lowering CO2 capture cost. ION has modeled, designed, and fabricated an innovative gas-liquid contactor known as Modular Adaptive Packing (MAP). During two successful SBIR Phase I and II projects entitled: “Rapid Design and Testing of Novel Gas-Liquid Contacting Devices for Post-Combustion CO2 Capture via 3D-printing”, ION developed and proved this new technology at bench scale. MAP, a 3D-printed lattice-structured packing, combines the absorber gas/liquid contactor with an innovative in-situ heat-exchanger. Thanks to the capabilities of 3D-printing, the lattice structure of MAP contains hollow channels through which coolant water can be pumped to remove the heat of reaction from CO2 absorption. ION refers to this novel method of heat exchange as intracooling. After 25.4 cm (10 in) diameter MAP modules were fabricated, ION built and tested a packing characterization rig at its pilot facility in Boulder, Colorado, U.S.A. To provide baseline results for the characterization rig, ION tested Sulzer’s Mellapak™ 250Y (MP250Y) as a standard structured packing. ION’s MAP was then compared directly to the baseline MP250Y packing to evaluate key indicators including pressure drop, liquid hold-up, and effective area. MAP has a higher pressure drop than MP250Y at the same gas velocities in addition to greater liquid holdup. However, ION found that MAP displays a higher wetting coverage of 93% compared to 65% for MP250Y and reduces shearing forces that result in undesirable droplet formation. Using Optimized Gas Treating’s (OGT) rate-based simulation software ProTreat®, a conceptual evaluation of MAP was modeled for a CO2 absorber using 30 wt% MEA solvent over a range of lean loadings at 90% CO2 capture from a coal-fired power plant. ION modeled a 25-meter column absorber for both the standard MP250Y packing and a hybrid column. The hybrid absorber contained 10 m of MP250Y packing at the top and bottom with the middle 5 meters comprised of MAP. Compared to a traditional intercooled absorber, MAP can remove 22% more heat and increase overall MEA carrying capacity by 4% without increasing overall pressure drop.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform - CRADA 387 (Final Report)

Modular chemical process intensification (MCPI) is an emerging field where chemical processing is performed using small-scale modular equipment instead of conventional large centralized chemical plants. Conventional chemical plants benefit from economies of scale that encourage scale-up to ever larger plants. A goal of MCPI is to develop technology that intensifies processing so that equipment can be dramatically smaller and integrated into modular systems. Scale-up occurs by adding more modules in parallel rather than making the equipment larger. A key concept is that equipment and modules can ultimately be cheaper by leveraging economies of mass production, analogous to the automotive industry, in manufacturing the equipment. This project made significant progress toward this outcome by meeting the RAPID institute metric to reduce equipment cost by 20% for each doubling in manufacturing volume. The MCPI application was thermochemical technology that is being commercialized by STARS Technology Corporation, one of the CRADA partners. The technology converts solar and renewable power to chemical energy to produce renewable hydrogen, fuels, and chemicals. The benefit to the public is reduction in greenhouse gases that are contributing to climate change. The project transitioned the steam methane reforming (SMR) reactor from conventional fabrication methods to additive manufacturing (AM) direct metal laser sintering (DMLS) process. This is projected to reduce the cost of making a reactor by 58% when producing 100 reactors per year. Innovations in the DMLS process produced a patented design that reduces reactor weight by 60%. Reductions in material costs and processing time extend the DMLS advantage to higher production volumes. The new design promises to be 38% cheaper than the conventional processes at 1000 units per year. The resulting 87% reduction in the steam methane reforming (SMR) module cost in scaling from current costs meets the RAPID metric. The project was successful in producing and testing the first ever additively manufactured SMR reactors. A reactor achieved over 82% efficiency in converting electric power to chemical energy, which is a world record for an inductively heated SMR. The project has contributed to the design and assembly of a first demonstration plant that is headed to a hydrogen bus filling station in Thousand Palms, CA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

A novel approach for produced water treatment: Supercritical water oxidation and desalination

Produced water generated from oil and gas operations contains significant quantities of environmentally hazardous hydrocarbons, organic chemicals, and inorganic salts. Environmental regulations with impaired water disposal mandates produced water treatment and desalination. Industry standard desalination technologies are energy-intensive and mandate extensive produced water pre-treatment including removal of hydrocarbons constituents for efficient operations. Herein this study investigates a novel process intensification approach integrating supercritical water oxidation (SCWO) unit operation with a supercritical water desalination (SCWD) process for energy efficient produced water treatment and desalination. The coupled SCWD-SCWO process is found to be very energy-efficient and cost effective than existing industry standard desalination technologies. For energy efficient operation, the heat generated from the SCWO of hydrocarbons present in the produced water is used for power generation using a high efficiency and low-cost re-heat Rankine cycle process. The cost of treating produced water with proposed SCWO-SCWD process is independent of the salt concentration. The proposed process has the potential to offer step-change improvements over conventional processes in both the efficiency and cost of produced water treatment: for example, a cost and energy saving of 70% and 100% is calculated for the treatment of produced water containing 250 g/l salt and 10.6 g/l hydrocarbon.

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

Recent Advances and Future Perspectives of Low-Concentration CO 2 Enrichment and Emerging Applications

Low-concentration carbon dioxide (LCCO 2 ) streams, ranging from ambient air to industrial flue gas, represent a significant yet underutilized carbon resource. This review examines recent advances in technologies for enriching LCCO 2 and enabling its integration into a wide range of applications. It covers emerging materials and processes for CO 2 capture, including immobilized amines, metal oxides, polymers, porous carbons, and zeolites, with a focus on performance metrics, regeneration strategies, and process intensification. Beyond capture, the review explores the direct utilization of LCCO 2 through reactive capture pathways enabled by novel catalysts and processes, as well as nonreactive applications, such as greenhouse cultivation, enhanced weathering, and sustainable agriculture. Additionally, this review highlights the role of LCCO 2 in enhancing critical metal recovery. Finally, the review outlines crucial future research directions necessary to fully realize LCCO 2 enrichment’s potential within circular carbon economies and critical material supply chains, paving the way toward a more energy-innovative and resource-resilient industrial sector. The findings are significant for researchers in academia, industry, and government, as well as the public interested in extending the value of LCCO 2 .

atmospheric chemistry↗
DOE OSTI2025

Reaction Pathways over ZnZrO 2 -Based Catalysts and Catalytic Sorbents

Reactive capture and conversion (RCC) is a process intensification approach that integrates CO 2 capture and hydrogenation within a single unit, removing the CO 2 purification and storage steps of traditional process flow schemes. This alters the catalytic step from a traditional steady-state (SS) flow process to a transient capture and conversion cycle, which could lead to product distributions distinct from those observed in conventional SS experiments. Such differences are investigated in the combined capture and hydrogenation of carbon dioxide to methanol over a ZnZrO 2 catalyst and a ZnZrO 2 + NaNO 3 /Mg 3 AlO x catalytic sorbent (CS) using fixed-bed kinetic measurements, in situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS), and steady-state isotopic transient kinetic analysis-DRIFTS (SSITKA-DRIFTS). Under SS conditions, ZnZrO 2 produced methanol through sequential hydrogenation of HCOO* and CH 3 O* intermediates. On the contrary, CO was attributed primarily to CO 2 dissociation at oxygen vacancies, as supported by isotopic shifts and measured reaction orders. For the CS, isotopic switching experiments suggested that monodentate carbonate species (CO 3 2− , abbreviated as m-CO 3 2− ) act as active intermediates that can be hydrogenated to HCOO* and subsequently to CH 3 O. Under RCC conditions, in situ DRIFTS and isotopic experiments reveal that m-CO 3 2− species formed during the CO 2 capture step follow two competing routes upon H 2 exposure: (i) direct hydrogenation to methane on the sorbent domain or (ii) migration of m-CO 3 2− to the ZnZrO 2 domain, where they are hydrogenated to methanol through the HCOO pathway. Overall, RCC enables carbonate hydrogenation routes not observed under SS cofeed conditions. Thus, the reaction pathways and rates during RCC can be different from operation under conventional SS conditions, and the product distribution is determined here by competition between carbonate hydrogenation on sorbent sites and migration to ZnZrO 2 for methanol synthesis.

CCUS↗
NASA NTRS2011

APR-2 Tropical Cyclone Observations

The Second Generation Airborne Precipitation Radar (APR-2) participated in the Genesis and Rapid Intensification Processes (GRIP) experiment in August and September of 2010, collecting a large volume of data in several tropical systems, including Hurricanes Earl and Karl. Additional measurements of tropical cyclone have been made by APR-2 in experiments prior to GRIP (namely, CAMEX-4, NAMMA, TC4); Table 1 lists all the APR-2 tropical cyclone observations. The APR-2 observations consist of the vertical structure of rain reflectivity at 13.4 and 35.6 GHz, and at both co-polarization and crosspolarization, as well as vertical Doppler measurements and crosswind measurements. APR-2 normally flies on the NASA DC-8 aircraft, as in GRIP, collecting data with a downward looking, cross-track scanning geometry. The scan limits are 25 degrees on either side of the aircraft, resulting in a roughly 10-km swath, depending on the aircraft altitude. Details of the APR-2 observation geometry and performance can be found in Sadowy et al. (2003).The multiparameter nature of the APR-2 measurements makes the collection of tropical cyclone measurements valuable for detailed studies of the processes, microphysics and dynamics of tropical cyclones, as well as weaker systems that are associated with tropical cyclone formation. In this paper, we give a brief overview of how the APR-2 data are processed. We also discuss use of the APR-2 cross-track winds to estimate various quantities of interest in in studies of storm intensification. Finally, we show examples of the standard products and derived information.

radar↗
DOE OSTI2025

Decision-Model Supported Algal Cultivation Process Enhancement (DMSACPE) (Final Technical Report)

This project was proposed in response to the FY19 Bioenergy Technologies Office Multi-Topic Funding Opportunity Announcement DE-FOA-0002029, Area of Interest Subtopic 1 (AOI1): Cultivation Intensification Processes for Algae. The main challenge identified by the FOA was “in translating results between laboratory research systems and larger-scale outdoor (or mass culture) systems. These difficulties limit reliable experimental durations, adequate and representative experimental volumes of material, and results that can be reproduced reliably. By overcoming the challenge in translating results between laboratory and mass cultures, the objective of AOI 1 is to increase the harvest yield, robustness, and quality of algae cultivation for biofuels and bioproducts”. This report marks the final technical deliverable of this project and reviews all the major findings of the research program.

09 BIOMASS FUELS↗
NASA NTRS2012

Calibration and Image Reconstruction for the Hurricane Imaging Radiometer (HIRAD)

The Hurricane Imaging Radiometer (HIRAD) is a new airborne passive microwave synthetic aperture radiometer designed to provide wide swath images of ocean surface wind speed under heavy precipitation and, in particular, in tropical cyclones. It operates at 4, 5, 6 and 6.6 GHz and uses interferometric signal processing to synthesize a pushbroom imager in software from a low profile planar antenna with no mechanical scanning. HIRAD participated in NASA s Genesis and Rapid Intensification Processes (GRIP) mission during Fall 2010 as its first science field campaign. HIRAD produced images of upwelling brightness temperature over a aprox 70 km swath width with approx 3 km spatial resolution. From this, ocean surface wind speed and column averaged atmospheric liquid water content can be retrieved across the swath. The calibration and image reconstruction algorithms that were used to verify HIRAD functional performance during and immediately after GRIP were only preliminary and used a number of simplifying assumptions and approximations about the instrument design and performance. The development and performance of a more detailed and complete set of algorithms are reported here.

Ruf, Christopher↗
DOE OSTI2025

Efficient Synthetic Natural Gas Production from Direct Air Capture Using Titania-Based Dual Function Materials

Converting atmospheric CO2 into methane offers a compelling pathway to store intermittent renewable electricity and enhance energy security using existing natural gas infrastructure. However, current CO2 utilization approaches remain energy- and capital-intensive, largely due to the need for separate capture, purification, and conversion steps. Integrating CO2 capture with catalytic methanation represents a transformative strategy for process intensification on both the unit operation and molecular levels. We report a series of Ru-Na/TiO2 dual function materials (DFMs) for a reactive carbon capture (RCC) process consisting of simulated direct air capture and subsequent CO2 methanation (DACM). Superior methane desorption purity was observed on TiO2-based DFMs (>94 %) relative to state-of-the-art Al2O3-supported DFMs (77 %). Modifying the process to begin CO2 adsorption immediately following the methanation stage, rather than beginning adsorption near ambient temperature, resulted in >97 % methane desorption purity, suitable for injection into the natural gas pipeline without additional CO2 separation steps.

organic↗
NASA NTRS2012

Airborne Wind Profiling With the Data Acquisition and Processing System for a Pulsed 2-Micron Coherent Doppler Lidar System

A pulsed 2-micron coherent Doppler lidar system at NASA Langley Research Center in Virginia flew on the NASA's DC-8 aircraft during the NASA Genesis and Rapid Intensification Processes (GRIP) during the summer of 2010. The participation was part of the project Doppler Aerosol Wind Lidar (DAWN) Air. Selected results of airborne wind profiling are presented and compared with the dropsonde data for verification purposes. Panoramic presentations of different wind parameters over a nominal observation time span are also presented for selected GRIP data sets. The realtime data acquisition and analysis software that was employed during the GRIP campaign is introduced with its unique features.

Beyon, Jeffrey Y.↗
NASA NTRS2012

Retrieval of Ocean Surface Windspeed and Rainrate from the Hurricane Imaging Radiometer (HIRAD) Brightness Temperature Observations

The Hurricane Imaging Radiometer (HIRAD) is a new airborne synthetic aperture passive microwave radiometer capable of wide swath imaging of the ocean surface wind speed under heavy precipitation e.g. in tropical cyclones. It uses interferometric signal processing to produce upwelling brightness temperature (Tb) images at its four operating frequencies 4, 5, 6 and 6.6 GHz [1,2]. HIRAD participated in NASA s Genesis and Rapid Intensification Processes (GRIP) mission during 2010 as its first science field campaign. It produced Tb images with ~70 km swath width and 3 km resolution from a ~ 20 km altitude. From this, ocean surface wind speed and column averaged atmospheric liquid water content can be retrieved across the swath. The column averaged liquid water then could be related to an average rain rate. The retrieval algorithm (and the HIRAD instrument itself) is a direct descendant of the nadir-only Stepped Frequency Microwave Radiometer that is used operationally by the NOAA Hurricane Research Division to monitor tropical cyclones [3,4]. However, due to HIRAD s slant viewing geometry (compared to nadir viewing SFMR) a major modification is required in the algorithm. Results based on the modified algorithm from the GRIP campaign will be presented in the paper.

Biswas, Sayak K.↗
DOE OSTI2022

Sustainable hydrogen manufacturing via renewable-integrated intensified process for refueling stations

The widescale consumer adoption of hydrogen fuel cell electric vehicles (HFCEVs) is currently hindered by the high cost of small-scale hydrogen generation and the lack of extensive hydrogen refueling infrastructure. Natural gas-based hydrogen is cheaper when produced in large volumes but is also associated with high CO 2 emissions. To counter these challenges, we propose a hybrid approach where both natural gas and renewables are integrated in a synergistic manner using a dynamic process intensification technology that can be deployed on-site for meeting local demands of refueling stations. The technology is based on sorption enhanced steam methane reforming (SE-SMR) that utilizes a combination of reaction with in-situ CO 2 adsorption for enhancing process modularity, productivity and efficiency thereby outperforming conventional SMR at small scale. We develop a mixed integer linear programming (MILP)-based optimization framework for simultaneous design and scheduling of the SE-SMR process. The simultaneous optimization provides a synergistic combination whereby the renewables allow sustainable hydrogen manufacturing and the dynamic SE-SMR allows optimal use of the intermittency of the renewables. The U.S. nationwide analysis indicates that for futuristic renewable prices and a hydrogen production capacity of 2 ton/day, hydrogen can be produced at 50% less cost compared to the current cost of small-scale hydrogen generation. Finally, the city-wise analysis with varying hydrogen demand shows that even with just 5% HFCEV market penetration level, hydrogen production cost less than $3/kg can be obtained at small scales across the United States with even cheaper hydrogen for large cities.

08 HYDROGEN↗
NASA NTRS2010

Development of the Data Acquisition and Processing System for a Pulsed 2-Micron Coherent Doppler Lidar System

A general overview of the development of a data acquisition and processing system is presented for a pulsed, 2-micron coherent Doppler Lidar system located in NASA Langley Research Center in Hampton, Virginia, USA. It is a comprehensive system that performs high-speed data acquisition, analysis, and data display both in real time and offline. The first flight missions are scheduled for the summer of 2010 as part of the NASA Genesis and Rapid Intensification Processes (GRIP) campaign for the study of hurricanes. The system as well as the control software is reviewed and its requirements and unique features are discussed.

Beyon, Jeffrey Y.↗
NASA NTRS2010

Data Acquisition and Processing System for Airborne Wind Profiling with a Pulsed, 2-Micron, Coherent-Detection, Doppler Lidar System

A data acquisition and signal processing system is being developed for a 2-micron airborne wind profiling coherent Doppler lidar system. This lidar, called the Doppler Aerosol Wind Lidar (DAWN), is based on a Ho:Tm:LuLiF laser transmitter and 15-cm diameter telescope. It is being packaged for flights onboard the NASA DC-8, with the first flights in the summer of 2010 in support of the NASA Genesis and Rapid Intensification Processes (GRIP) campaign for the study of hurricanes. The data acquisition and processing system is housed in a compact PCI chassis and consists of four components such as a digitizer, a digital signal processing (DSP) module, a video controller, and a serial port controller. The data acquisition and processing software (DAPS) is also being developed to control the system including real-time data analysis and display. The system detects an external 10 Hz trigger pulse and initiates the data acquisition and processing process, and displays selected wind profile parameters such as Doppler shift, power distribution, wind directions and velocities. Doppler shift created by aircraft motion is measured by an inertial navigation/GPS sensor and fed to the signal processing system for real-time removal of aircraft effects from wind measurements. A general overview of the system and the DAPS as well as the coherent Doppler lidar system is presented in this paper.

Beyon, J. Y.↗
DOE OSTI2024

Fiber Sorbents – A Versatile Platform for Sorption-Based Gas Separations

Increasing demand for high-purity fine chemicals and a drive for process intensification of large-scale separations have driven significant work on the development of highly engineered porous materials with promise for sorption-based separations. While sorptive separations in porous materials offer energy-efficient alternatives to longstanding thermal-based methods, the particulate nature of many of these sorbents has sometimes limited their large-scale deployment in high-throughput applications such as gas separations, for which the necessary high feed flow rates and gas velocities accrue prohibitive operational costs. These processability limitations have been historically addressed through powder shaping methods aimed at the fabrication of structured sorbent contactors based on pellets, beads or monoliths, commonly obtained as extrudates. These structures overcome limitations such as elevated pressure drops commonly recorded across powder adsorption beds but often accrue thermal limitations arising from elevated particle density and aggregation, which ultimately cap their maximum separation performance. Furthermore, the harsh mechanical strain to which powder particles are subjected during contactor fabrication, in the form of extrusion/compression forces, can result in partial pore occlusion and framework degradation, further limiting their performance. Here, we present the development of porous fiber sorbents as an alternative sorbent contactor design capable of addressing sorbent processability limitations while enabling an array of performance-maximizing heat integration capabilities. This new sorbent form factor leverages pre-existing know-how from hollow fiber spinning to produce fiber-shaped sorbent contactors through the phase inversion of known polymers in a process known as dry-jet/wet quenching. The process of phase inversion allows microporous sorbent particles to be latched onto a macroporous polymer matrix under mild processing conditions, thus making it compatible with soft porous materials prone to amorphization under traditional pelletization conditions. Sorbent fibers can be created with different geometries through control of the spinning apparatus and process, offering the possibility to produce monolithic and hollow fibers alike, the latter of which can be integrated with thermalization fluid flows. In this Account, we summarize our progress in the field of fiber sorbents from both design and application standpoints. We further guide the reader through the evolution of this field from the early inceptive work on zeolite hollow fibers to recent developments on MOF fibers. We highlight the versatile nature of fiber sorbents, both from the composition, fabrication and structure points of view, and further demonstrate how fiber sorbents offer alternative paths in tackling new and challenging chemical separation challenges like direct air capture (DAC), with a final perspective on the future of the field.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Integrated Radio Frequency and Ultrasonics with Conventional Processes for Efficient Water Removal in Pulp and Paper and Other Biomaterial Applications

Conventional drying processes used in the pulp and paper industry primarily involve lengthy, surface based, multi-cylinder conductive and convective drying with low thermal efficiencies and often use some fossil-based energy. Integration of cross cutting, electrically-powered, volumetric drying process intensification technologies based on Radio Frequency (RF) and acoustics (Ultrasonics) (US) will directly impart energy into the biomaterials resulting in improved energy efficiency and throughput. Integration of RFUS-based drying technology is expected to enable U.S. manufacturing industry to reduce capital and operating costs, energy consumption, and carbon emissions while increasing energy efficiency and throughput, improving product quality and sustainability, and helping preserve U.S. manufacturing jobs. The hybrid drying approach incorporates directed radio frequency (RF) and ultrasonic (US) energy with conventional conduction, diffusion and convective heat and mass transfer overcoming the limitations of the conventional drying processes and that meets/exceeds the minimum goals. We have shown the effective removal of free and bound water in the biomaterials by leveraging the synergies of RF and US technologies integrated with conventional manufacturing processes.

42 ENGINEERING↗
DOE OSTI2022

Enhanced Pool Boiling of Low-Pressure Refrigerants on Round Tubes- An Experimental Evaluation

Pool boiling heat transfer is one of the most effective heat transfer methos and crucial for several energy conversion processes such as electronic cooling, steam generation, water purification and thermal management. Enhancing boiling heat transfer around the tubes enables higher heat flux, which can improve the efficiency and lead to compact heat exchangers. Delaying the onset of critical heat flux (CHF) allows for higher CHFs and protects equipment during anomalous transient conditions. Growing interest in process intensification and delayed CHF has motivated the current study. An experimental approach has been deployed to investigate a potential technique to enhance the pool boiling performance around small diameter tubes by open cell metal foams. The findings for nucleate pool boiling of Novec HFE 7000 on the externally enhanced and smooth tubes are reported. The enhanced tube comprised of compressed aluminum foam brazed around. All the samples were horizontally oriented, and the experiments were performed under ambient pressure conditions. The heat transfer measurements for the smooth tubes were compared with several existing correlations and established the baseline. The preliminary results showed that the aluminum foam effectively enhanced the heat transfer coefficient and delayed the onset of critical heat flux. In addition, the pool boiling process around the round tube sample was visualized from both side and front views to comprehend the heat transfer mechanisms underlying substantial enhancement observed during experiments.

Yang, Cheng-Min↗
DOE OSTI2023

Cell Free and Immobilization Technologies (CFIT)

Today, several key factors negatively impact the production of fuels and chemicals from renewable sources. Common hindrances in the biological production of biochemicals are: (1) end-product or intermediate toxicity to the microbial biocatalyst, (2) the diversion of carbon to biomass formation, and (3) co-production of undesired byproducts. A particularly attractive alternative is to eliminate the biocatalyst entirely and instead operate the desired metabolic pathways in isolation, thus circumventing the roadblocks of biological toxicity, lower yields, and lack of specificity. However, cell-free enzyme systems still suffer from low productivities owing in part to the effects of free diffusion of intermediates, lack of long term enzyme stability, cofactor cost or inefficient recycling rates, and finally, the cost of enzyme production/purification. This project represents a new effort to propose innovative and cost competitive routes to producing biochemicals from a variety of feedstocks using cell free approaches. These routes will help reduce the current risk and cost associated with classical cell free production. Cell free technologies show promise for application to the production of toxic/inhibitory products or products difficult to separate from microbial growth media and can help reduce the production barriers in multiple areas of biological conversion of feedstocks to biochemicals. More specifically, we are developing new technologies and routes that could be used to produce high value biochemicals such as 2,3 BDO and terpenes (among many others) from biomass derived C5/C6 sugars or lignin but also from waste byproducts such as glycerol. This project will lead to significant innovation and also lead to new concepts and rational design of pathways and enzymes. Within this project, we will develop new metabolic enzyme cascades that will represent natural or artificial combinations of enzymes to produce the desired biochemicals from a variety of feedstocks. We are also developing basic design principals for constructing synthetic metabolons, using fusion proteins and synthetic protein scaffolds, to promote substrate channeling and stability while conserving peak activity. Additionally, our efforts include a techno economic analysis (TEA) of cell free approaches to provide the sensitivities of the process to enzyme loading, activity, pH, reactor volumes, cofactor recycling rates. Finally, we are focusing on further increasing stability, operating lifetime and efficiency of the pathway enzymes by immobilization on support surfaces. We are also focus on immobilizing pathway enzymes or combinations of enzymes on several different conducting polymers and evaluate the effect on stability and operating lifetime. As more combinations become available we will conduct a more systematic study of the means of immobilizing these enzymes. This preliminary work will enable the in-depth study of cofactor recycling at these interfaces using mediators for electron transfer. Taken together, these approaches will enable process intensification, continuous operation, lower capital and separations costs and end-product flexibility, and thus has the potential to contribute significantly to BETO's goals of cost competitive biofuels and bioproducts. To date we have demonstrated 1) the conversion of pyruvate to 2,3 BDO (4 enzymes with cofactor recycling, no additional cofactors needed) at >100g/L (>3g/L/h) using our enzyme tethering approach, 2) Generated mutants of a key redox enzyme with >180- fold improvement in NADH utilization over WT to >85% of NADPH utilization. 3) Produced mevalonate at >10g/L from glucose, limonene at >10g/L from mevalonate and more than >5g/L from glucose with crude enzyme preparations and complete cofactor recycling. 4) successfully generated fully active cross-linked aggregates (CLEAs) of NOX, a cofactor-regenerating water-forming oxidase that is key to our process with increased stability 5) Engineered and identified enzymes able to use the biomimetic cofactor NMN and synthesized new synthetic cofactors.

biocatalysis↗