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DOE OSTI2023

Development of Nanocomposite Coatings for Future Large-Scale Time Projection Chambers

In the context of this award we tested the performance of thin high-resistivity coatings for their potential usage as field shaping systems in future large scale xenon Time Projection Chambers (TPC). A successful implementation of such thin coatings would likely simplify the design of potential future detectors, allowing to overcome some of the challenges observed with traditional systems constituted by massive discrete electrodes. We studied a wide range of materials and characterized their optical and electrical performances as functions of temperature and wavelength. The measurement campaign indicated that uniform coatings covering the full PTFE substrate (usually used as reflector in LXe TPCs) impact too severely on the light collection performance of such detectors when used with deep UV light. Despite tuning the composition and thicknesses of nanocomposite coatings, we were not able to identify a single coating, properly working at LXe temperature, that would simultaneously fulfill the resistance and optical requirements. Following the risk mitigation strategy identified in the proposal we moved the focus of the R&D to identify proper materials that, when coated with grid-like patterns on PTFE, would not alter meaningfully its optical properties (with respect to bare PTFE panels) but would still serve as effective field shaping systems, properly containing the drift field in TPC detectors. Among the various materials we identified germanium as the most promising one, providing a good adhesion to PTFE and the proper range of sheet resistivity. The Ge-patterned coating tested within a small scale LXe TPC showed good performance as a field shape system and, as desired, did not reduce the detector light yield. These results are encouraging and such technology should further be investigated as a potential alternative to more traditional field shaping electrodes. Incidentally, in the context of this R&D, we stumbled upon an unexpected behavior suggesting that some of the treatments performed on the PTFE panels, in preparation of the coatings, meaningfully boosted the PTFE reflectivity. The most probable candidate is the O2 plasma cleaning procedure. This hypothesis will be tested in the near future by operating the small scale TPC at UChicago first with regular PTFE panels and then with panels bombarded with O2 plasma (but no coatings). This finding, if confirmed, might open up the possibility of further boosting UV light collection in future large detectors by performing such a treatment on the PTFE surfaces.

36 MATERIALS SCIENCE↗

NASA NTRS1975

Summary of the recent short-haul systems studies

The results of several NASA sponsored high density short haul air transportation systems studies are reported as well as analyzed. Included are the total STOL systems analysis approach, a companion STOL composites study conducted in conjunction with STOL systems studies, a STOL economic assessment study, an evaluation of STOL aircraft with and without externally blown flaps, an alternative STOL systems for the San Francisco Bay Area, and the quiet, clean experimental engine studies. Assumptions and results of these studies are summarized, their differences, analyzed, and the results compared with those in-house analyses performed by the Systems Studies Division of the NASA-Ames Research Center. Pertinent conclusions are developed and the more significant technology needs for the evaluation of a viable short haul transportation system are identified.

Savin, R. C.↗

DOE OSTI2021

Coal-dependent Communities in Transition: Identifying Best Practices to Ensure Equitable Outcomes

The U.S. coal industry is experiencing a sharp increase in the numbers of retired and/or decommissioned coal-fired power plants across the U.S. In the years between 2010-2019, around 102 gigawatts (GW) of coal-fired generating capacity has been announced to be decommissioned, representing more than 546 coal-fired power plant units, and an additional 17 GW is planned to be decommissioned by 2025. This change in the energy production landscape presents an impact on the social, environmental, and economic prospects of coal-dependent communities. This report examined the role of communities in the coal power plant decommissioning process and provided community-identified best practices to ensure an equitable process. The experiences of four coal-dependent communities—Wise County, VA, Muskegon, MI, Anderson County, TN, and Becker, MN—are presented as case studies to understand the impacts of the decommissioning process, and associated best practices, from the communities’ perspective. The report results highlight the need to recognize that the decommissioning decision-making process must be community-based to be equitable. Each community’s input is key to the transition away from coal power because there is no one-size-fits-all development plan. In other words, each community’s trajectory through the decommissioning process—from the retirement decision-making stage to the final site redevelopment phase—is unique because each community has distinct needs and wants from the energy transition. What is best for one community may not be suited for another. Ultimately, the framework for site development and community revitalization post-decommissioning cannot be universal because each community’s profile—from a social, cultural, and economic perspective—is different. Community impacts of power plant decommissioning are not limited to job and revenue losses. Communities are likely to be impacted culturally, socially, environmentally, and have long-term health-based impacts that should be acknowledged and addressed in post-retirement plans. Commonly identified decommissioning best practices include: Early and continued engagement throughout, with a number of mediums for communication and feedback (e.g., in-person sessions, virtual meetings, written comment opportunities); Early planning of post-decommissioning projects to replace lost jobs, revenue, and economic activity; Recognition (and mitigation, if possible) of social impacts on the community due to plant closure; Transparency throughout the process, with trusted information being provided about the decommissioning process and timeline; potential impacts on the workforce, economy, and environment; and the feasibility of alternative site uses; Identification of funding sources, technical experts, and/or strategic partnerships to support decommissioning and the affected communities upfront; and, Acknowledgment of communities as stakeholders who have a role in the conversation and right to determine their futures. Three key areas for assisting coal-dependent communities affected by the energy transition: Technical assistance: assessment of site feasibility for alternative uses or to repower with new technologies; Cross-partnership engagement and collaboration: facilitate knowledge-sharing of “lessons learned” about the decommissioning process between communities and provide guidance for decision-making processes; and, Financial assistance: access to grant and/or loan programs to assist with redevelopment survey, bolster community economic security through job creation, and cover environmental clean-up costs. Technical assistance, cross-partnership engagement, and financial aid can be mobilized to help communities throughout various stages of the decommissioning process, including the retirement decision, the site reclamation phase, and eventual revitalization of the site and surrounding community.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1978

Ion beam technology applications study

Specific perceptions and possible ion beam technology applications were obtained as a result of a literature search and contact interviews with various institutions and individuals which took place over a 5-month period. The use of broad beam electron bombardment ion sources is assessed for materials deposition, removal, and alteration. Special techniques examined include: (1) cleaning, cutting, and texturing for surface treatment; (2) crosslinking of polymers, stress relief in deposited layers, and the creation of defect states in crystalline material by ion impact; and (3) ion implantation during epitaxial growth and the deposition of neutral materials sputtered by the ion beam. The aspects, advantages, and disadvantages of ion beam technology and the competitive role of alternative technologies are discussed.

Sellen, J. M., Jr.↗

NASA NTRS2006

The Use of Liquid Isopropyl Alcohol and Hydrogen Peroxide Gas Plasma to Biologically Decontaminate Spacecraft Electronics

Legitimate concern exists regarding sending spacecraft and their associated hardware to solar system bodies where they could possibly contaminate the body's surface with terrestrial microorganisms. The NASA approved guidelines for sterilization as set forth in NPG 8020.12C, which is consistent with the biological contamination control objectives of the Committee on Space Research (COSPAR), recommends subjecting the spacecraft and its associated hardware to dry heat-a dry heat regimen that could potentially employ a temperature of 110(deg)C for up to 200 hours. Such a temperature exposure could prove detrimental to the spacecraft electronics. The stimulated growth of intermetallic compounds (IMCs) in metallic interconnects and/or thermal degradation of organic materials composing much of the hardware could take place over a prolonged temperature regimen. Such detrimental phenomena would almost certainly compromise the integrity and reliability of the electronics. Investigation of sterilization procedures in the medical field suggests that hydrogen peroxide (H202) gas plasma (HPGP) technology can effectively function as an alternative to heat sterilization, especially for heat-sensitive items. Treatment with isopropyl alcohol (IPA) in liquid form prior to exposure of the hardware to HPGP should also prove beneficial. Although IPA is not a sterilant, it is frequently used as a disinfectant because of its bactericidal properties. The use of IPA in electronics cleaning is widely recognized and has been utilized for many years with no adverse affects reported. In addition, IPA is the principal ingredient of the test fluid used in ionic contamination testers to assess the amount of ionic contamination found on the surfaces of printed wiring assemblies. This paper will set forth experimental data confirming the feasibility of the IPA/H202 approach to reach acceptable microbial reduction (MR) levels of spacecraft electronic hardware. In addition, a proposed process flow in which both IPA liquid and HPGP are utilized will be presented in Section 7.0.

microbial reduction↗

DOE OSTI2024

The potential of carbon markets to accelerate green infrastructure based water quality trading

Green infrastructure solutions can improve in-stream water quality in lieu of building electricity-consuming gray infrastructure. Permitted under the United States Clean Water Act, these programs allow regulated utilities to trade point-source water quality obligations with non-point source mitigation efforts in the watershed. Carbon financing can provide an incentive for water quality trading. Here we combine data on impaired waters, treatment technologies, and life cycle greenhouse gas emissions in the Contiguous United States, and compare traditional treatment technologies to alternative green infrastructure. We find green infrastructure could save $\$15.6$ billion dollars, 21.2 terawatt-hours of electricity, and 29.8 million tonnes of carbon dioxide equivalent emissions per year while sequestering over 4.2 million tonnes CO2e per year over a 40 year time horizon. Green infrastructure solutions may have the potential to generate $\$679$ million annually in carbon credit revenue (at $\$20$ per credit), which represents a unique opportunity to help accelerate water quality trading.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1997

Replacement Technologies for Precision Cleaning of Aerospace Hardware for Propellant Service

The NASA White Sands Test Facility (WSTF) is developing cleaning and verification processes to replace currently used chlorofluorocarbon-l13- (CFC-113-) based processes. The processes being evaluated include both aqueous- and solvent-based techniques. Replacement technologies are being investigated for aerospace hardware and for gauges and instrumentation. This paper includes the findings of investigations of aqueous cleaning and verification of aerospace hardware using known contaminants, such as hydraulic fluid and commonly used oils. The results correlate nonvolatile residue with CFC 113. The studies also include enhancements to aqueous sampling for organic and particulate contamination. Although aqueous alternatives have been identified for several processes, a need still exists for nonaqueous solvent cleaning, such as the cleaning and cleanliness verification of gauges used for oxygen service. The cleaning effectiveness of tetrachloroethylene (PCE), trichloroethylene (TCE), ethanol, hydrochlorofluorocarbon 225 (HCFC 225), HCFC 141b, HFE 7100(R), and Vertrel MCA(R) was evaluated using aerospace gauges and precision instruments and then compared to the cleaning effectiveness of CFC 113. Solvents considered for use in oxygen systems were also tested for oxygen compatibility using high-pressure oxygen autogenous ignition and liquid oxygen mechanical impact testing.

Harold Beeson↗

DOE OSTI2020

Mysteries of Nuclear Fusion: How can we build a star on Earth? [Slides]

This presentation given at the Women's Physics Summer Camp focuses on nuclear fusion as an alternative to fossil fuels, renewable energy sources and nuclear fission energy. The presentation explains plasma physics and how it might be used to generate power. Current attempts and potential applications are outlined. An appeal is made for people trained in mathematics, physics, chemistry, engineering, computer science to solve these problems. If technical problems can be overcome, fusion technology will play a part in a clean, prosperous Earth and expand humanity’s reach to the stars.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Low‐PGM and PGM‐Free Catalysts for Proton Exchange Membrane Fuel Cells: Stability Challenges and Material Solutions

Abstract Fuel cells as an attractive clean energy technology have recently regained popularity in academia, government, and industry. In a mainstream proton exchange membrane (PEM) fuel cell, platinum‐group‐metal (PGM)‐based catalysts account for ≈50% of the projected total cost for large‐scale production. To lower the cost, two materials‐based strategies have been pursued: 1) to decrease PGM catalyst usage (so‐called low‐PGM catalysts), and 2) to develop alternative PGM‐free catalysts. Grand stability challenges exist when PGM catalyst loading is decreased in a membrane electrode assembly (MEA)—the power generation unit of a PEM fuel cell—or when PGM‐free catalysts are integrated into an MEA. More importantly, there is a significant knowledge gap between materials innovation and device integration. For example, high‐performance electrocatalysts usually demonstrate undesired quick degradation in MEAs. This issue significantly limits the development of PEM fuel cells. Herein, recent progress in understanding the degradation of low‐PGM and PGM‐free catalysts in fuel cell MEAs and materials‐based solutions to address these issues are reviewed. The key factors that degrade the MEA performance are highlighted. Innovative, emerging material concepts and development of low‐PGM and PGM‐free catalysts are discussed.

Du, Lei↗

NASA NTRS2026

Ultrasonic Washer–Dryer System for Space Habitats: Design Upgrades and Parabolic Flight Readiness

Clothing makes up nearly 25% of all non-food supplies sent to the International Space Station (ISS). To support sustainable human missions in deep space, NASA’s Life Support and Habitation Systems Focus Area looks to advance technologies to support and improve logistics. Our team is creating a compact ultrasonic clothing washer/dryer system that bypasses traditional limitations and is suitable for space. Thermal drying uses a lot of energy to evaporate water, while our ultrasonic drying method offers a quicker, more efficient alternative. It uses piezoelectric transducers to vibrate textiles at the micron scale, mechanically removing water as cold mist rather than evaporating it. This speeds up drying and reduces energy use, no matter the fabric makeup. This paper details recent upgrades to a full-scale ultrasonic washer–dryer system, readying it for parabolic flight testing. Improvements include an enhanced human–machine interface, better packaging, and optimized performance and control. We also present extensive pre-flight ground tests conducted to ensure reliability and identify potential risks. Collaborating with P&G, we report preliminary cleaning tests using various detergents. These results lay a crucial foundation for the laundry system designed specifically for space. By cutting clothing-related payload and waste by over 97%, this technology supports long-term human exploration missions on the ISS, the Moon, Mars, and beyond.

Ultrasonic↗

NASA NTRS2026

Ultrasonic Washer–Dryer System for Space Habitats: Design Upgrades and Parabolic Flight Readiness

Laundry↗

DOE OSTI2025

Staying Competitive in Clean Manufacturing: Insights on Barriers from Industry Interviews

While industrial emissions research has historically focused on energy-intensive sectors like steel, cement, and chemicals, this study addresses a critical gap by examining barriers across all the manufacturing industry in the U.S. Sectors like food processing, retail, plastics, and transportation face unique challenges distinct from heavy industry, operating on thin margins with limited bargaining power while experiencing heightened consumer and stakeholder pressure for improved environmental responsibility. Through structured interview data collection process and using quantitative ratings and qualitative analysis, this research identifies and categorizes emission reduction barriers across four key themes: financial, technical, organizational, and regulatory. Unlike energy-intensive industries that may pursue hydrogen or carbon capture technologies, discrete manufacturing industry like automotive, electrical and electronics, and machine manufacturers typically focus on energy efficiency, electrification of thermal processes, and alternate fuel switching, solutions better aligned with their lower-temperature processes and distributed facility profiles. The study’s primary contribution lies in documenting specific barrier manifestations within organizations and identifying proven mitigation strategies that companies have successfully implemented or observed among peers.

business competitiveness↗

DOE OSTI2025

Optimization based process modeling of an anaerobic membrane bioreactor system: Application to swine wastewater

To maintain current levels of consumption in the economy with the dwindling supply of non-renewable material and energy, alternative resource streams more traditionally viewed as waste streams must be considered. Fermentation of high-strength wastewaters is one such pathway that allows for the recovery of energy, nitrogen, phosphorus, and carbon compounds. Anaerobic membrane bioreactors (AnMBRs) are an emerging technology that allow for the digestion of wastewater in a much smaller footprint than traditional anaerobic digesters. Adoption of this technology into industry has been limited by membrane capital and cleaning costs, but these costs may be offset through the recovery of valuable products. To evaluate the viability of AnMBR technology in the context of swine wastewater treatment, an optimization-based process model built upon Anaerobic Digestion Model No. 1 (ADM1) has been developed. Modeling results show that a swine wastewater stream provides potential for net positive energy generation from the AnMBR system in most cases. Sensitivity analyses around important variables were conducted to determine focus areas for future research into AnMBR technology and evaluate the robustness of the model to microbial variables that may change with different microbial communities.

09 BIOMASS FUELS↗

DOE OSTI2020

Sodium Ion Expansion Power Block for Distributed CSP

The Sodium Ion Expansion Power Block for Distributed CSP was a three-plus-one-year effort under the Concentrating Solar Power: Advanced Projects Offering Low LCOE Opportunities (CSP: APOLLO) funding program within the U.S. Department of Energy Solar Energy Technologies Office. The primary objective of this project is to develop a dual-stage modular sodium thermal electrochemical converter (Na-TEC) heat engine power block, which can be potentially integrated with either a small-scale dish solar or large-scale heliostats and parabolic trough CSP. Na-TEC is a heat engine that generates electricity through the isothermal expansion of sodium ions. The Na-TEC is a closed system that can theoretically achieve conversion efficiencies above 45% when operating between thermal reservoirs at 1150 K and 550 K. However, thermal designs have confined previous single-stage devices to thermal efficiencies below 20%. To mitigate some of these limitations, we consider dividing the isothermal expansion into two stages; one at the evaporator temperature (1150 K) and another at an intermediate temperature (650 K –1050 K). This dual-stage Na-TEC takes advantage of regeneration and reheating, and could be amenable to better thermal management. In light of this, we first designed and developed a thermo-electrochemical model, and thermodynamically demonstrated how the dual-stage device can improve the efficiency by up to 8% points over the best performing single-stage device. We also established an application regime map for the single- and dual-stage Na-TEC in terms of the power density and the total thermal parasitic loss. Moreover, a thermal design of an axisymmetric dual-stage Na-TEC is developed to guide the scale-up and fabrication of sub-components of prototype module. A reduced-order finite-element model is used in conjunction with a Na-TEC thermodynamic model that was developed to determine the total parasitic heat loss of this dual-stage design. A number of simplifications are applied in the reduced-order model to decrease the computational time while maintaining acceptable accuracy. According to this analysis, a maximum efficiency of 29% and a maximum power output of 125 W can be achieved. Ultimately, we were able to demonstrate thermal efficiency improvements of the Na-TEC heat engine from 19% up to 40.3%, in a dual-stage (non-optimized) prototype module that we designed, fabricated, and tested with high temperature stage at 923 K. Furthermore, a cost-performance analysis for this improved dual-stage design was carried out for distributed-CSP systems. A high-level techno-economic analysis (TEA) explores four scenarios where a Na-TEC is used as the heat engine for a distributed-CSP system. Overnight capital cost and levelized cost of electricity (LCOE) are estimated for a system lifetime of 30 years, revealing that overnight capital costs in a range from $3.57 to $17.71 per We are feasible, which equate to LCOEs from 6.9 to 17.2 cents/kWh e -1 . This analysis makes a significant contribution by concurrently quantifying the efficiency and unit costs for a range of multistage configurations, and demonstrating that a Na-TEC may be a promising alternative to Stirling engines for distributed-CSP systems at residential scale of 1–5 kW e .

14 SOLAR ENERGY↗

DOE OSTI2023

Defining a compact dry cooler design to reduce LCOE contribution in a CSP facility

Concentrating solar power (CSP), when coupled with a supercritical carbon dioxide (sCO 2 ) power cycle and sensible heat storage, presents a renewable and clean alternative for utility-scale power generation. However, in order to be competitive in the current and future markets, CSP facilities must limit their levelized cost of electricity (LCOE) by minimizing capital costs and reducing operating costs over the lifetime of the plant. Targeting this goal, this study investigates the LCOE impact of the power cycle pre-cooler. This study considers a compact dry cooler with micro-channel technology on the CO 2 side and formed fin geometry on the air side, using directly-coupled centrifugal fans and a transition duct to improve air distribution across the fins as well as protect the fins from contaminants which may cause blockage, soiling, fouling, and damage. In an effort to better understand the dry cooler impact on LCOE, a sensitivity study was conducted using various combinations of end-to-end approach temperatures, air-side pressure drop values, CO 2 -side pressure drop values, fan types, cooler turndown control schemes, cooler module sizes, and design-point ambient temperatures. Furthemore, off-design cycle performance data was calculated for each dry cooler design using NPSS simulation software; cycle performance data were then input to System Advisor Model (SAM) along with the associated capital costs for LCOE prediction of a 100 MW system over a 30 year plant lifetime. Results of this study show the LCOE is most sensitive to air-side performance, followed by heat transfer effectiveness and capital cost. It was found that a power cycle with a mid- to high-performance dry cooler will produce the most competitive power-production costs. Designing at the extreme ends for approach temperature (or effectiveness), design-point ambient temperature, and compactness (footprint) produce higher LCOE values; mid-range values for these parameters balance performance, operating costs, and associated capital cost to optimize LCOE.

14 SOLAR ENERGY↗

DOE OSTI2023

JUST-R metrics for considering energy justice in early-stage energy research

We report achieving sustainable decarbonization of the energy sector requires implementing and improving energy technologies while simultaneously managing sources of social inequity in the energy system. Centering energy justice, which has "the goal of achieving equity in both the social and economic participation in the energy system, while also remediating social, economic, and health burdens on those historically harmed by the energy system," in the transition to clean energy has become an increasingly urgent priority for social scientists, policymakers, and community activists alike. However, late-stage consideration of social impacts of energy technologies may result in identifying inequities only after substantial time, money, and effort have been expended on research and development (R&D). This issue is exemplified by concerns over environmental and human health impacts related to cobalt in lithium-ion batteries, which has spurred research into alternatives only after decades of R&D and the establishment of supply chains, infrastructure, and markets for cobalt-containing chemistries. Other examples include issues with land use and resource consumption related to first-generation biofuel feedstocks as well as occupational hazards and pollution associated with photovoltaics manufacturing. In all these cases, subsequent R&D to improve technologies or processes cannot undo the effects already experienced. Incorporating energy justice from the earliest stage of R&D will enable more just technology implementation, but integrating justice considerations into early-stage research is a challenge due to a lack of tools to assess and manage them. To fill this gap, we center early-stage research to develop the Justice Underpinning Science and Technology Research (JUST-R) metrics framework - energy justice metrics specifically targeted at early-stage researchers to assess their work on an immediate timescale. By applying these metrics to a case study focused on materials for next-generation photovoltaics, we highlight potential benefits and barriers to implementing this framework in early-stage research and discuss necessary institutional and individual actions needed for researchers to effectively leverage the tool to incorporate justice-focused criteria into R&D decision making.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

A Business Case Evaluation of Gas Switching Reforming (GSR) Technology: A Promising Technology for Natural Gas Reforming with Integrated CO2 Capture

Hydrogen is essential in the transition to sustainable energy, and developing low-carbon production methods is a key research focus. Traditional steam methane reforming (SMR) dominates the hydrogen industry but contributes substantially to CO2 emissions. In response, Gas Switching Reforming (GSR) has emerged as a novel process that integrates carbon capture and utilizes process heat more efficiently. Unlike other reforming methods, GSR consolidates oxidation and reduction reactions within a single reactor, which minimizes external energy inputs and simplifies scaling. Like conventional steam methane reforming (SMR), GSR can be integrated with water-gas shift and pressure swing adsorption units for pure hydrogen production. This work presents a comprehensive business case analysis of GSR technology based on experimental results in Technology Readiness Level 3, Life Cycle Assessment (LCA) and Techno-Economic (TEA) evaluation incorporating ASPEN Plus process modeling considering different configurations and energy scenarios. The TEA incorporates data from kinetic experiments from various catalysts to evaluate the GSR process under various conditions. The goal of this work is to evaluate GSR’s potential to serve as a low-carbon alternative to SMR, focusing on global warming potential and additional impact categories to evaluate a wide spectrum of environmental impacts. Comparative assessments were conducted with SMR, chemical loop reforming (CLR), and proton exchange membrane (PEM) electrolysis to explore trade-offs across environmental metrics. The environmental impact assessment of this work encompasses the entire hydrogen production lifecycle from raw material extraction to plant decommissioning, using a cradle-to-gate boundary. Preliminary findings highlight that GSR, when integrated with low-carbon energy sources, could significantly reduce environmental impacts, making it a promising candidate for low-carbon hydrogen infrastructure. The insights from this business case evaluation aim to guide industry in scale-up and commercialization of this promising clean energy technology.

03 NATURAL GAS↗

DOE OSTI2024

Woody Feedstock 2022 State of Technology Report

The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement in this mission, Idaho National Laboratory completes an annual SOT report for n th -plant and 1 st -plant woody biomass feedstock logistics. The purpose of the SOT is to provide the status of feedstock supply system technology development for woody biomass to biofuels relative to technical targets and cost goals from specific design cases, based on data and experimental results. Conventional feedstock supply systems need to be modified to meet the demands of conversion pathways, specifically to have the ability to adjust the quality of the raw biomass materials. Advanced systems incorporate innovative methods of material handling, preprocessing and supply chain configuration. In advanced designs, variability of the raw biomass can be reduced to produce feedstocks of a uniform format, moving toward biomass commoditization. Against this backdrop, the 2022 Woody SOT for low-ash woody feedstocks utilizes feedstock fractionation by incorporating technologies that can separate the biomass into its anatomical fractions (wood, bark, needle, and extrinsic ash) to reduce impurities and attempt to maximize the retention of usable fractions that satisfy downstream quality considerations. By using a series of air classification steps, this strategy can reduce the extrinsic ash in forest residues, separate out a majority of the incoming needles (which can be supplied to alternate markets), and maximize the retention of whitewood in the usable fraction. The fractionated forest residues are then mixed with clean-pine chips in a 50-50 blend to prepare the feedstock for the desired conversion pathway. The n th -plant analysis estimated the delivered cost for the feedstock at $\$$69.23/dry ton (2016$\$$) which represents a $\$$6.64/dry ton decrease compared to the cost estimate of the 2021 Woody SOT supply system for low-ash woody feedstocks. The quality requirements in the 2022 Woody SOT were identical to those of the 2021 Woody SOT at = 1.00 wt % ash and = 50.51 wt% carbon. The cost savings derive primarily from reductions in dry matter losses during air classification. The GHG emissions for the n th -plant analysis were estimated at 178.39 kg CO2e/dry ton compared to 178.71 kg CO 2 e/dry ton in the 2021 Woody SOT, a decrease of 0.32 kg CO2e/dry ton. The small change stems from an increase in emissions attributed to preprocessing and slightly larger savings in emissions from transportation. In the 1 st -plant analysis of the 2022 Woody SOT system, the average throughput was estimated to be approximately 2,128 dry tons/day or 96.51% of the name plate capacity. During the simulation the daily throughput ranged from 1,090 dry tons/day to 2,200 dry tons/day, or 49.43% to 99.75% of the daily nameplate capacity. After the year of operation 722,403 tons of processed feedstock were produced in total without regard to quality considerations (99.64% of the annual nameplate capacity). The variability in throughput was primarily caused by equipment failures in the system. Regular failures, downtime caused by routine maintenance per manufacturer guidelines, contributed to a majority 62.50% of failures and 62.60% of downtime. Failures due to wear were the other cause of disruption within the system, impacting the rotary shear and orbital screen and accounting for 37.50% of the failures and 37.40% of the total downtime. Ultimately the system was on stream for 87.84% during the simulation period, which is only 2.16 percentage points below the nth-plant assumption for on-stream time. The production cost of the system averaged $\$$71.66/dry ton. The costs ranged from a minimum of $\$$71.23/dry ton to a maximum of $\$$2,115.30/dry ton. When dry matter losses (disposed low-quality fractions as well as other losses such as in grinders) were considered the costs increased to an average of $\$$75.11/dry ton with a minimum of $\$$74.69/dry ton and a maximum of $\$$2,136.86/dry ton...

09 BIOMASS FUELS↗