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DOE OSTI2026

Two Artificial Leaf Architectures for Solar Formate Production From CO 2 and H 2 O

Sunlight-powered artificial leaves for the production of formate from CO 2 are an attractive route to solar fuels, yet existing solar formate devices remain low in performance, and their architecture and material choices are underexplored. Herein, we report the fabrication of two distinct fully integrated, self-standing solar formate device architectures and elucidate the underlying design principles and material selection strategies. The first architecture integrates a Si photocathode with a BiVO 4 photoanode and utilizes a highly active Pd catalyst for CO 2 reduction. It represents the first artificial leaf device comprising two photoelectrodes (excluding photovoltaic [PV]-biased electrodes) for effective formate production under single-beam illumination. The second architecture employs a dark cathode and a dark anode driven by a 4-junction perovskite solar cell and uses a highly stable Bi catalyst for CO 2 reduction. This device delivers a record-high formate production rate of 174 µmol h −1 with a remarkable solar-to-formate energy efficiency of 2% among all artificial leaf devices reported to date. Finally, these results demonstrate the feasibility and outline the design principles of both PV-free and PV-assisted device architectures in solar fuel production.

electrocatalysis↗

DOE OSTI2020

Offshore Wind Project Study (Final Technical Report)

Within the Long Island electric service territory and throughout New York State there is increasing interest in and mandate for increasing clean energy technologies and renewable energy generation while reducing dependency on fossil fuels for electric production with goal of a carbon free system by 2040. This report discusses the implications of the reduction of forecasted load in the Long Island electric service territory and the impact of energy efficiency; increasing reliance of wind and other renewable resources on the transmission system; opportunities for interconnecting these resources; and reductions on the reliance of baseload fossil fueled power facilities over the coming years.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Effect of Carboxylic Acids on Corrosion of Type 410 Stainless Steel in Pyrolysis Bio-Oil

Biomass-derived oils are renewable fuel sources and commodity products and are proposed to partially or entirely replace fossil fuels in sectors generally considered difficult to decarbonize such as aviation and maritime propulsion. Bio-oils contain a range of organic compounds with varying functional groups which can lead to polarity-driven phase separation and corrosion of containment materials during processing and storage. Polar compounds, such as organic acids and other oxygenates, are abundant in bio-oils and are considered corrosive to structural alloys, particularly to those with a low-Cr content. To study the corrosion effects of small carboxylic acids present in pyrolysis bio-oils, type 410 stainless steel (SS410) specimens were exposed in bio-oils with varying formic, acetic, propionic and hexanoic acid contents at 50 °C during 48 h exposures. The specific mass change data show a linear increase in mass loss with increasing formic acid concentration. Interestingly, a mild corrosion inhibition effect on the corrosion of SS410 specimens was observed with the addition of acetic, propionic and hexanoic acids in the bio-oil.

09 BIOMASS FUELS↗

DOE OSTI2024

Applications of Thermochemical Modeling in Molten Salt Reactors

The extensively evaluated and consistent thermodynamic database, the Molten Salt Thermal Properties Database—Thermochemical (MSTDB-TC), was used along with additional thermodynamic values from other sources as examples of ways to examine molten salt reactor (MSR) fuel behavior. Relative stability with respect to halide potential and temperature for likely fuel and fission product components were mapped in Ellingham diagrams for the chloride and fluoride systems. The Ellingham diagrams provide a rich, visual means for identifying halide-forming components in proposed fuel/solvent salt systems. Thermochemical models and values from MSTDB-TC and ancillary sources were used in global equilibrium calculations to provide compositions for a close analysis of the behavior of a possible Molten Chloride Salt Fast Reactor and a Molten Salt Reactor Experiment-type system at high burnup (100 GWd/t). The results illustrated the oxidative nature of burnup in MSRs and provided information about redox behavior and possible control.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Biological upgrading of pyrolysis-derived wastewater: Engineering Pseudomonas putida for alkylphenol, furfural, and acetone catabolism and (methyl)muconic acid production

While biomass-derived carbohydrates have been predominant substrates for biological production of renewable fuels, chemicals, and materials, organic waste streams are growing in prominence as potential alternative feedstocks to improve the sustainability of manufacturing processes. Catalytic fast pyrolysis (CFP) is a promising approach to generate biofuels from lignocellulosic biomass, but it generates a complex, carbon-rich, and toxic wastewater stream that is challenging to process catalytically but could be biologically upgraded to valuable co-products. Here, we implemented modular, heterologous catabolic pathways in the Pseudomonas putida KT2440-derived EM42 strain along with the overexpression of native toxicity tolerance machinery to enable utilization of 89% (w/w) of carbon in CFP wastewater. The dmp monooxygenase and meta-cleavage pathway from Pseudomonas putida CF600 were constitutively expressed to enable utilization of phenol, cresols, 2- and 3-ethyl phenol, and methyl catechols, and the native chaperones clpB, groES, and groEL were overexpressed to improve toxicity tolerance to diverse aromatic substrates. Next, heterologous furfural and acetone utilization pathways were incorporated, and a native alcohol dehydrogenase was overexpressed to improve methanol utilization, generating reducing equivalents. All pathways (encoded by genes totaling ~30 kilobases of DNA) were combined into a single strain that can catabolize a mock CFP wastewater stream as a sole carbon source. Further engineering enabled conversion of all aromatic compounds in the mock wastewater stream to (methyl)muconates with a ~90% (mol/mol) yield. Biological upgrading of CFP wastewater as outlined in this work provides a roadmap for future applications in valorizing other heterogeneous waste streams.

(methyl)muconates↗

DOE OSTI2025

Life-cycle analysis of microalgae-based polyurethane foams

Polyurethane plastics are essential in many consumer and commercial products such as insulation, furniture, automotive interiors, and clothing. Pathways for producing polyurethane from microalgae offer an opportunity to reduce greenhouse gas emissions and other environmental impacts and can incorporate processes that avoid the use of toxic isocyanates typically used in conventional polyurethane production processes. In this study, the greenhouse gas emissions, fossil energy, and water consumption of biobased polyurethane and biobased non-isocyanate polyurethane were evaluated via life-cycle analysis using the R&D Greenhouse Gases, Regulated Emissions, and Energy Use in Technologies model. Microalgae-based polyurethane foam was found to achieve greenhouse gas emission reductions of up to 79% compared with conventional polyurethane foam production. The greenhouse gas reductions for the non-isocyanate microalgae polyurethane pathway are slightly lower at 58% compared with conventional polyurethane foam. However, it offers additional benefits by reducing toxicity potential compared to the isocyanate polyurethane pathway. The analysis also included a biorefinery-level analysis to evaluate the impact of incorporating polyurethane production into fuel-processing microalgae biorefineries. The sensitivity analyses conducted in this study reveal that improved algae cultivation strategies can lead to decreases of up to 127% and 80% in GHG emissions from the baseline process of Bio-PU and Bio-NIPU, respectively. Likewise, implementation of renewable electricity can result in up to 128% and 74% lower GHG emissions compared to the baseline production of Bio-PU and Bio-NIPU, respectively. Finally, the analysis evaluated different coproduct handling methods including displacement and allocation (based on mass, energy, and market-value). The results suggest that it is important to consider both the displacement and allocation methods as these led to significant differences in the environmental impacts.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Sooting tendencies of 20 bio-derived fuels for advanced spark-ignition engines

The sooting tendencies of 20 bio-derived fuels indicated as potential blendstocks for spark-ignition engines by the Co-Optimization of Fuels & Engines (Co-Optima) Initiative are studied. The Yield Sooting Index (YSI) is used to quantify the sooting tendencies. The Co-Optima Chemical Model is used to predict the numerical YSIs for all test fuels, and these results are compared with measurements. Experimental YSIs are newly measured for 2 furans and are taken from our previous work for the other compounds. Overall, the predicted YSIs agree well with measurements, within the experimental uncertainties, except for 2,5-dimethylfuran (2,5-DMF). It is found that Polycyclic Aromatic Hydrocarbons (PAH) growth reactions have little influence on the relative soot production from each fuel and therefore on YSI predictions. A modified sensitivity coefficient formulation is proposed to evaluate reaction sensitivities specifically for YSI. This formulation is applied to the 2,5-DMF-doped flame, and six 2,5-DMF initial decomposition reactions, which lead to different major soot precursors, are identified as the most sensitive reactions. The impact of the chemical kinetic uncertainties embedded in these reactions is quantified by randomly perturbing their reaction rates within a factor of two. The resulting prediction uncertainty in the 2,5-DMF-doped flame is found to be ± 8 YSI units (±11%), which demonstrates that the test-fuel-specific decomposition reactions indeed have considerable influence on its YSI prediction. Our research suggests that more accurate kinetic parameters for fuel initial decomposition reactions can potentially improve YSI predictions effectively, without altering the YSI predictions of other fuels with significantly different molecular structures.

09 BIOMASS FUELS↗

DOE OSTI2023

Joint Optimization for Transport and Bucket Loading Phases of Automated Wheel Loaders

This article investigates optimization of fuel-efficiency and productivity for automated wheel loaders. A control-oriented model for both the transport phase and bucket loading phase is proposed. Here, the vehicle model includes an automatic gear shift schedule that can be incorporated into the optimization problem. Based on the model, the multistage optimization problem is formulated to simultaneously consider all phases of a short cycle with physical constraints. Cycle time and fuel efficiency are used as the weighted performance indexes in a multiobjective cost function. Bucket fill factor is included as a constraint during the bucket loading phase. A nonlinear programming problem is created with collocation using MATLAB and CasADi. The optimization solver IPOPT solves the problem to obtain the optimal state and control trajectories, which can be used as a reference for automated wheel loaders or even as a driver advisory for human-driven wheel loaders.

42 ENGINEERING↗

DOE OSTI2021

Circular Bioeconomy Concepts—A Perspective

Circular economy concepts—including a circular bioeconomy—aim to transition the current, essentially linear, economic system to a more sustainable one. However, organizations and researchers currently define the circular economy concept differently, resulting in inconsistencies and difficulty in effectively implementing the framework. In this paper, we provide our perspective on the conceptual definitions of the circular economy, bioeconomy, and circular bioeconomy, outlining potential overlaps and differences and proposing a harmonized interpretation that stresses the importance of the carbon cycle. We conclude that the key goal of a circular economy is to slow, narrow, and close material resource loops, built on the foundation of renewable energy and non-toxic materials. Further, a sustainable bioeconomy goes beyond simply switching fossil resources with renewable, biological resources. It requires low-carbon energy inputs, sustainable supply chains, and promising disruptive conversion technologies for the sustainable transformation of renewable bioresources to high-value bio-based products, materials, and fuels. The bio-based circular carbon economy, in particular, stresses capturing atmospheric carbon via photosynthesis and exploiting this unique feature to the fullest extent possible. It sits at the intersection between the circular economy and the bioeconomy concept, resulting in a framework that focuses on closing the carbon cycle and stressing the opportunity to create an additional carbon sink capability in the technosphere by utilizing biogenic carbon for products and materials that are circulated in same or improved use cycles. Lastly, a sustainable circular bioeconomy transition will necessitate a set of consistent metrics that fit all products and industries.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

Life cycle analysis of a hydrogen production system based on solid oxide electrolysis cells integrated with different energy and wastewater sources

Hydrogen production via water electrolysis is a promising and evolving technology. The solid oxide electrolysis cell (SOEC) is one of the several technologies for this purpose. They are alternatives to the traditional hydrogen production from fossil fuels to enhance global energy decarbonization. However, in the bid for sustainability and a green economy, these technologies are not free from causing some environmental burdens. Using life cycle assessment (LCA), the greenhouse gas emission and degree of environmental impacts by these technologies can be identified and measured throughout their lifespan. This study addresses how to quantify these CO 2 emission impacts for an electrolytic system with different energy sources. The LCA of a novel integrated hydrogen production SOEC system with energy from solar photovoltaic and bituminous powerplant is performed using simaPro, the leading global LCA solution software. Measuring the environmental impact of the electrolytic operation in terms of weight, the bituminous powerplant poses damage which is, on average 700% more than solar PV. The thermal-to-hydrogen efficiency of the SOEC system is 56%, and a probable 28% reduction in carbon footprint with heat integration. The steam generation and the manufacturing of the SOEC have a very high environmental impact potential on the system. Here, we recommend LCA and net energy analysis is carried out for every new hydrogen technology and adequate comparison to enhance sustainable and green economy.

08 HYDROGEN↗

DOE OSTI2023

Volume 1: Introduction to the HFIR Futures - Enhanced Capabilities Series

Since it began operating at full power in 1966, the High Flux Isotope Reactor (HFIR) has contributed unparalleled neutron science capabilities to research on neutron scattering, isotope production, materials and fuels irradiation, and neutron activation analysis. HFIR is a high-performance, multi-mission research reactor operated on behalf of the US Department of Energy (DOE) at the Oak Ridge National Laboratory (ORNL). In 2020, a DOE Basic Energy Sciences Advisory Committee Subcommittee (BESAC) published a report recommending that DOE make significant investments in HFIR to enable continued operations beyond the year 2100 while also enabling new research and isotope production capabilities. ORNL organized an initiative to investigate how to specifically address the report’s key recommendations, including enabling long-term operation, brainstorming future scientific research needs, and outlining the infrastructure required to realize these future research capabilities. A multivolume series of reports has been developed to document the nonscattering enhancements. This volume, the introductory report, provides an overview of HFIR and the initiative.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Dynamic Life Cycle Assessment for Evaluating the Global Warming Potential of Geothermal Energy Production Using Inactive Oil and Gas Wells for District Heating in Tuttle, Oklahoma

Repurposing abandoned oil and gas infrastructure for geothermal energy production has great potential to reduce greenhouse gas (GHG) emissions. This study quantified the life cycle global warming potential of geothermal energy production using four inactive oil and gas wells repurposed for district heating in Tuttle, Oklahoma. A cradle-to-grave prospective life cycle assessment was performed to compare GHG emissions between the geothermal district heating system and conventional natural gas-fired heating system from 2020 to 2050. For initial implementation of the geothermal system, we investigated two approaches: 1) repurposing abandoned infrastructure from a nearby oil and gas well site, and 2) production and injection well drillings including new construction of a central heat exchange station. Environmental impacts from the geothermal system were estimated for five scenarios where a natural gas peaking boiler is incorporated to supply peak heat demand. The prospective results indicated that cumulative reduction in GHG emissions from transitioning to the geothermal district heating system increase over time as a function of future renewable resource penetration and technological advancements within electricity, fuel, and steel production. Over 30 years, the global warming potential associated with the district heating demand will have been reduced by up to 24 % with the repurposed system. These results imply that repurposing existing oil and gas infrastructure for geothermal energy systems of district heating will bring future climate benefits.

abandoned oil and gas wells↗

DOE OSTI2021

Recycled Paper as a Source of Renewable Jet Fuel in the United States

Converting biomass into jet fuel involves more than the core chemical process. The overall process includes the logistics of harvesting and transporting the biomass, handling and preparing the material for processing, and processing and disposal of waste. All of these activities contribute to cost. Controlling cost involves more than developing efficient process chemistry. Choice of feedstock also has a significant impact on process economics. We consider chemical conversion of paper from municipal solid waste as a feedstock for the production of jet fuel and diesel. Paper has a significantly higher cellulose content than raw lignocellulosic biomass such as corn stover, so it requires less pretreatment to convert it into hydrocarbons than lignocellulosic biomass. Our techno-economic analysis showed that the cost of converting paper waste into jet fuel is about $1.00/gal less than jet fuel produced from corn stover. Although the cost of recycling paper into jet fuel is less than producing it from corn stover, the process is not competitive with petroleum. We estimated a minimum selling price of $3.97/gal for paper-derived jet fuel. Our sensitivity studies indicated that the biggest economic obstacle is the cost of cellulose hydrolysis. Direct hydrogenation of paper to sugar alcohols combined with increased economy of scale could make recycling paper jet fuel competitive.

09 BIOMASS FUELS↗

DOE OSTI2024

Algal Biomass Production via Open Pond Algae Farm Cultivation: 2023 State of Technology and Future Research

The annual State of Technology (SOT) assessment is an essential activity for platform research conducted under the Bioenergy Technologies Office (BETO). It allows for the impact of research progress (both directly achieved in-house at the National Renewable Energy Laboratory [NREL] and furnished by partner organizations) to be quantified in terms of economic improvements in the overall biofuel production process for a particular biomass processing pathway, whether based on terrestrial or algal biomass feedstocks. As such, initial benchmarks can be established for currently demonstrated performance, and progress can be tracked toward out-year goals to ultimately demonstrate economically viable biofuel technologies. NREL's algae SOT benchmarking efforts historically focused both on front-end algal biomass production and separately on back-end conversion to fuels through NREL's "combined algae processing" (CAP) pathway. The production model is based on outdoor long-term cultivation data, enabled by comprehensive algal biomass production trials conducted under the Development of Integrated Screening, Cultivar Optimization, and Verification Research (DISCOVR) consortium efforts, driven by data furnished by Arizona State University (ASU) at the Arizona Center for Algae Technology and Innovation (AzCATI) testbed site. The CAP model is based on experimental efforts conducted primarily under NREL research and development projects. This report focuses on front-end algal biomass production, documenting the pertinent algal biomass cultivation parameters that were input to the NREL open pond algae farm model. Through partnerships under DISCOVR, collaborators at ASU furnished details on cultivation performance metrics including biomass productivity and harvest densities for recent growth trials done at the AzCATI site. The resulting biomass productivity was calculated at 16.7 g/m 2 /day (ash-free dry weight [AFDW], annual average) for seasonal cultivation of Picochlorum celeri TG2 and Monoraphidium minutum 26B-AM biomass strains at the ASU site. Picochlorum celeri achieved the best productivity from April to September, with Monoraphidium minutum 26B-AM being used between October and March. Tetraselmis striata LANL1001, usually part of the strain rotation in previous cultivation SOTs, was supplanted by Monoraphidium minutum 26B-AM in this year's outdoor cultivation trials. Finally, building from an industry case study presented in the 2022 SOT report, in the Appendix of this report we provide an update on further improved data furnished by an industry collaborator and resultant impacts on economics reflecting several seasonal scenarios. This case study provides a supplementary datapoint on work being performed elsewhere with a more dedicated focus on improved compositional quality, producing biomass enriched in lipids as may be more optimal for conversion upgrading to fuels and products.

09 BIOMASS FUELS↗

DOE OSTI2021

Material transfers detection with seismic observations

We are exploring the use of data from a seismic network around a research nuclear reactor and isotope production facility at Oak Ridge National Laboratory to study activity patterns related to the transfer of nuclear material. A sensor network with eight seismometers was installed around the High Flux Isotope Reactor and the Radiochemical Engineering Development Center and started operating in October 2019. These data are used to detect and characterize operational events around facility. We are using those data to extract signals related to the movement of vehicles involved in the transport of nuclear materials (e.g., transportation of reactor fuel, targets, and product isotopes). Large vehicles produce mechanical energy that can be observed as seismic signals, either as the result of sound emanating from the vehicle engine or by the generation of surface waves as a response of the ground to the load of the vehicles. In particular, the station located near the entrance gate of the facility displays a clear seismic signature as vehicles cross a metal platform on the ground. This signal is characterized by sharp energy bursts that correspond to the number of axles on the vehicle. We developed and are testing an algorithm to identify sequences of energy bursts to count and characterize vehicles of different sizes. We are also exploring the use of seismic polarization analysis to measure the degree of polarization of the observed signals. These two techniques for detection and characterization of vehicles used for nuclear material transfers will be validated with seismic data from a targeted collection using different vehicles and routes similar to the ones used in real-life scenarios at the High Flux Isotope Reactor.

Marcillo, Omar↗

DOE OSTI2021

Double-Site Substitution of Ce into (Ba, Sr)MnO 3 Perovskites for Solar Thermochemical Hydrogen Production

Solar thermochemical hydrogen production (STCH) is a renewable alternative to hydrogen production using fossil fuels. While serial bulk experimental methods can accurately measure STCH performance, screening chemically complex materials systems for new promising candidates is more challenging. Here we identify double-site Ce-substituted (Ba,Sr)MnO 3 oxide perovskites as promising STCH candidates using a combination of bulk synthesis and high-throughput thin-film experiments. The Ce substitution on the B-site in 10H-BaMnO 3 and on the A-site in -SrMnO 3 leads to 2–3 times higher hydrogen production compared to CeO 2 , but these bulk single-site substituted perovskites suffer from incomplete reoxidation. Double-site Ce substitution on both A- and B-sites in (Ba,Sr)MnO 3 thin films increases Ce solubility and extends the stability of 10H and 3C structures, which is promising for their thermochemical reversibility. This study demonstrates a high-throughput experimental method for screening complex oxide materials for STCH applications.

08 HYDROGEN↗

DOE OSTI2021

Collaboration to Enable Higher Penetrations of Solar Power Generation Using the Natural Gas Pipeline System for Energy Storage (CRADA CRD-14-00567)

This unique project explored one possible solution for photovoltaic (PV) generation to become a reliable and dispatchable energy resource similar to conventional baseload fossil fuel electricity generation. Solar power generation is a renewable resource that varies naturally from day-to-day as well as seasonally. To use solar power as a baseload generation asset requires a flexible storage system that can recover power on both a daily and seasonal basis. Converting solar power to natural gas (i.e., first to hydrogen and then to methane) and having access to utility-scale storage in the natural gas network has the potential to make solar power generation a baseload asset. This will: 1) Increase the net energy yield from solar resources by increasing the effective capacity factor and maximize the energy produced during the assets’ lifetimes. 2) Improve the economics of energy storage for solar project developers, thereby accelerating the deployment of new solar generation. 3) Reduce the impact of increasing solar penetration on congestion of the electrical transmission system by shifting power delivery in time using the gas pipeline network for long-duration storage. 4) Reduce the impact of increasing solar generation on electrical distribution system control. 5) Offer alternative revenue sources for solar power generation beyond electricity including: hydrogen (H 2 ) production for stationary fuel cells and fuel cell electric vehicles, conversion of carbon dioxide (CO 2 ) to methane (CH 4 ) as a direct drop-in replacement for fossil natural gas use, and transmission as high volumetrically-dense CH 4 for use in transportation, heating, power generation, chemical production or conversion back to H2 at the point of use. Additional work was added to this CRADA in modification 4 having a primary objective to characterize the performance of the electrolyzer, Southern California Gas (SoCalGas) bioreactor and balance of plant to demonstrate production of renewable natural gas (RNG) from renewable H 2 and CO 2 using single-cell, self-replicating organisms. The additional scope of work allowed researchers to ramp up gas flowrates and pressure of the system over the designed range to grow the cells and begin to show the load-following capabilities of this anaerobic gas fermentation process. These activities enabled the research team to predict system performance at much greater scales; namely 10’s of mega-watts (MWs) of electrolyzer nameplate capacity.

14 SOLAR ENERGY↗

DOE OSTI2026

Linking spout fluidization hydrodynamics to pyrolytic carbon deposition characteristics in a fluidized bed chemical vapor deposition reactor

Spout fluidized bed chemical vapor deposition (SFB-CVD) is the dominant method for producing pyrolytic carbon (PyC) coatings on tristructural-isotropic (TRISO) fuel particles, yet the relationship between gas injector design, fluidization hydrodynamics, and resulting coating quality remains poorly quantified. Here, in this work, three spout fluidized bed (SFB) nozzle geometries were designed and fabricated to empirically investigate how injector-driven changes in particle circulation influence PyC deposition. The geometries were first evaluated in a room temperature fluidization apparatus using time-resolved particle image velocimetry, which highlighted distinct differences in particle velocity fields, circulation pathways, and overall fluidization quality. Graphite versions of each injector geometry were subsequently implemented in a laboratory-scale SFB-CVD reactor to deposit PyC onto surrogate fuel kernels under similar conditions. Post-deposition characterization included particle morphology, coating thickness, porosity distribution, optical anisotropy, and microindentation mechanical testing. Overall, the results show clear differences in coating microstructure as a function of changing injector geometry, despite mechanical testing indicating comparable elastic modulus values across all coatings. This study provides one of the first fully experimental, quantitative mappings between SFB nozzle geometry, fluidization hydrodynamics, and resulting PyC coating structure. The framework established here supports rational injector design and offers a pathway toward improved coating control in future pilot- and production-scale TRISO fuel fabrication systems.

Coated particle fuel↗