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DOE OSTI2025

Risk assessment of wellbore leakage during underground hydrogen storage

The expansion of renewable energy sources would require large-scale energy storage options to overcome the intermittent nature of these sources. Underground hydrogen storage (UHS) in depleted hydrocarbon reservoirs offers a scalable and practical energy storage solution. These reservoirs are chosen for their availability and large capacity, but the unique properties of hydrogen raise concerns about potential leakage pathways, particularly through wellbores. In this study, we develop and apply, for the first time, reduced-order models (ROMs) specifically designed for efficient leakage risk prediction in UHS systems operating in depleted hydrocarbon reservoirs. Using 3,000 high-fidelity simulation scenarios, we examine the influence of 11 key parameters, including reservoir and aquifer depths, wellbore permeability and porosity, initial saturations of water, oil and gas fractions (hydrogen, light, intermediate, and heavy hydrocarbons), reservoir pressure multiplier, and the aquifer-to-reservoir volume ratio, to simulate leakage behavior over a 1,000-year timescale. We train ROMs using a two-step classification-regression approach, achieving R 2 values exceeding 99 % across all targets. These ROMs effectively capture the leakage evolution and identify critical controls of leakage, guiding the design of mitigation strategies. Results indicate that gas leakage occurs in about 27 % of scenarios as early as five years post-operation, reaching volumes of up to 106 ft3. Oil leakage is less frequent (~17 %) and typically begins decades later. Our findings also show that hydrogen often migrates first, owing to its smaller molecular size and higher buoyancy, followed by heavier hydrocarbons. Over time, these heavier components contribute significantly to the total leaked volume, reinforcing the need for targeted monitoring and remediation strategies. Our analysis highlights that deeper storage reservoirs, shallower aquifers, and low-permeability wellbores significantly reduce leakage risks. In conclusion, this work offers a robust framework for risk-informed UHS deployment, supporting energy security through reliable large-scale hydrogen storage while safeguarding environmental integrity.

08 HYDROGEN↗

DOE OSTI2025

Graph neural networks for mechanical property prediction of 2D fiber composites

This work investigates the ability of graph neural networks (GNNs) to homogenize 2D fiber composite microstructures. We use different inhomogeneity and anisotropy indices to motivate and show that the Volume Elements (VEs) used in ML methods should ideally be far from their Representative Volume Element (RVE) size limit and, consequently, are notably anisotropic. Hence, training only the isotropic limit properties may not be acceptable. Another aspect is the need to normalize elastic stiffness values for ML, especially when high elastic contrast ratios are encountered between composite phases or in the material set. We introduce a normalization technique based on the mean-field method (MFM) to handle such high contrast ratios and train for the entire stiffness tensor. We show that the proposed GNN approaches exhibit high accuracy and efficiency compared to traditional methods and convolutional neural networks, utilizing unstructured graphs constructed from microstructure topology. Our model successfully predicts the stiffness tensor, peak strength under bulk damage, and brittle fracture initiation strength across diverse microstructure configurations while maintaining high accuracy even for extreme material contrasts and volume fractions. We also present a method to improve prediction accuracy for small dataset sizes using Voronoi partitioning.

Brittle strength↗

DOE OSTI2022

Electrochemical, thermodynamic, and physical properties of tetradecyltrihexylphosphonium ([P 6,6, 6,14 ] + ) and methyl-propyl piperidinium containing ionic liquids and their propylene carbonate solutions

Here, the viscosity, conductivity, electrochemical window and related thermodynamic properties such as excess volume and dynamic viscosity deviation of two phosphonium ionic liquids were measured and calculated for “as-supplied” and dried neat liquids and also v/v mixtures of 99/1, 95/5, 90/10, 75/25, and 50/50 of the ionic liquids with propylene carbonate (PC). Tetradecyltrihexylphosphonium dicyanamide ([P 6,6,6,14 ] + dicyanamide), Cyphos 105, and tetradecyltrihexylphosphonium bis(trifluororomethanesulfonyl)imide (called bistriflimide) ([P 6,6,6,14 ] + bistriflimide), Cyphos 109, ionic liquids were studied. Generally speaking, there were slight differences in the measured properties of the wet and dried IL solutions which were reflected in differences if the calculated properties. The measured and calculated properties were compared with those collected and derived from a piperidinium-based ionic liquid, methyl-propyl piperidinium bistriflimide. Arrhenius plots for both the viscosity and conductivity were linear, with the linearity of the Litovitz plots being slightly higher. The viscosity and conductivity of the phosphonium solutions yielded Walden Plots that differed from Walden plots of piperidinium solutions and other ionic liquid solutions. For the phosphonium based ionic liquids, the ionicity was found to increase with increasing dilution in propylene carbonate. The electrochemical windows of the ionic liquids were determined as a function of the concentration of the ionic liquid present in the solution. The size of the window generally initially decreased and then increased with the addition of PC for the [P 6,6,6,14 ] + dicyanamide ionic liquid increasing from 3.4 V in the 95/5 v/v (volume Cyphos 105) to volume of PC solvent) to 3.7 in the 50/50 dried IL case. The electrochemical windows of the dried liquids were slightly larger 3.5 V for the 95/5 v/v and 4.2 V for the 50/50 v/v Cyphos 105/PC solutions. The electrochemical window was larger and the conductivity was higher for the piperidinium IL solutions, but since the ionicity increases with dilution, the phosphonium based IL solutions may prove favorable for processes such as electrochemical reduction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Susceptibility weighted MRI pinpoints spontaneous intracerebral hemorrhage in stroke-prone spontaneously hypertensive rats

Purpose: To find magnetic resonance imaging (MRI) precursors of spontaneous intracerebral hemorrhage in stroke-prone spontaneously hypertensive rats (SHRSP). Method: SHRSP rats were used with both a low/high salt (n = 18 or 11) Japanese diet and salty drinking water to generate spontaneous intracerebral hemorrhage (ICH). Various MRI sequences, and in particular, susceptibility weighted imaging (SWI), were used and combined with a gadolinium (Gd) contrast agent or oxygen gas to identify the rupture of the blood brain barrier (BBB) and the temporal ICH. Results: Most rats developed hypertensive ICH stroke in the high salt group during the 10–13 week period compared to only one third of rats in the low salt group during the 14–18 week period. The location of stroke for both the low/high-salt groups was highest in the striatum (58%/43%), followed by the cortex (21%/30%). The edematous enhancement on T2 weighted (T2W) imaging or Gd based T1 weighted (Gd-T1W) imaging due to the ruptured BBB preceded the striatal hemorrhages seen on SWI. The most recent bleeds were observed on temporal SWI or on oxygen-enhanced SWI. The mode of the volume of bleeds was 0.4 mm 3 . A positive correlation between susceptibility x volume and R2* x volume of the bleeds was observed. Conclusions: SHRSP rats with the high salt diet effectively generated a hypertensive hemorrhagic stroke which could be monitored by various MRI sequences. The venous dilation on SWI may precede any abnormality on T2W or Gd-T1W imaging. The edematous enhancement on T2W or Gd-T1W indicated a BBB breakdown that may precede striatal ICH by several days. This suggests the need for immediate treatment to improve outcome if this finding is observed. Here, the use of oxygen with SWI was able to help differentiate old bleeds from very recent bleeds.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

Effect of copper content on the tensile elongation of Al–Cu–Mn–Zr alloys: Experiments and finite element simulations

Microstructures of cast aluminum alloys used in automotive engine applications often consist of intermetallic particles that can impact the tensile elongation of these alloys. Here in this paper, we investigate the effect of intermetallic grain boundary particles on tensile elongation by fabricating a series of alloys with Cu content varying between 6.0 - 9.0 wt% in cast Al–Cu–Mn–Zr (ACMZ) type compositions. The tensile elongation of as-aged ACMZ alloys decreases monotonically with increase in Cu content. While the microstructure within the grains and yield stress of the alloy remains invariant with Cu content, the decrease in tensile elongation correlates well with increase in the size and volume fraction of grain boundary particles. Microstructural observations are combined with finite element simulations to explain the trend in tensile elongation with changing Cu content. Crack initiation is found to occur by brittle fracture of the grain boundary particles. Increase in particle size promotes crack initiation by reduction in size dependent particle fracture strength. Lower inter-particle spacing at higher particle volume fraction further facilitates crack initiation by increasing stress within the particles caused by the interaction between stress fields of neighboring particles. Increase in particle volume fraction also accelerates crack propagation through the formation of macro shear zones in the microstructure. The increase in Cu content of cast ACMZ alloys, therefore, decreases tensile elongation by promoting both crack initiation and crack propagation.

36 MATERIALS SCIENCE↗

DOE OSTI2023

The effects of Fe and Al on the phase transformations and mechanical behavior of β-Ti alloy Ti-11at.%Cr

Alloy composition is important for developing desired microstructures in beta-titanium (β-Ti) alloys during thermomechanical processing. In this work, the relatively low-cost alloying elements iron (Fe) and aluminum (Al) were added to a base Ti-11at%chromium (Cr) alloy and in-situ and ex-situ examination of the microstructural evolution and mechanical properties during tension, hardness, elevated temperature X-ray diffraction (XRD) and resonance ultrasound spectroscopy (RUS) were performed. The 400 °C XRD revealed that Ti-11at%Cr underwent β-to-ω and β-to-α transformations. Adding 0.85at% Fe reduced the volume fraction of the ω- and α-phases, and adding 5.3at% Al inhibited the β-to-ω transformation. The 400 °C RUS showed that the alloys containing the ω phase exhibited an increase in shear modulus (G) of ~140%, while the ω-free alloys exhibited an increase of only ~102%. The hardness and strength values of the ω-containing Ti-11Cr and Ti-11Cr-0.85Fe increased with increased ω-phase volume fraction when the ω/α ratio was greater than 0.25. The relationship between ω/α volume ratios and mechanical properties is discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Multicycle flash sintering of cubic Y 2 O 3 -stabilized ZrO 2 : An in situ energy dispersive synchrotron x-ray diffraction study with high temporal resolution

The current induced unit cell volume changes, (111) Bragg peak full width at half maximum (FWHM) and its integrated intensity in 8 % Y 2 O 3 stabilized ZrO 2 (8 %YSZ) solid state electrolyte was monitored during a triple-flash sintering experiment by in situ energy dispersive x-ray diffraction using a polychromatic synchrotron probe (max, photon energy 200 keV) with 2 second temporal resolution. The first spontaneous singularity in the unit cell volume (+0.54 %) was observed at 899 °C under 15 V/mm applied field intensity, which was associated with 13 mA/mm 2 current draw and an increase in density to 97 %. Following anelastic relaxation of the unit cell volume under open circuit conditions, the same applied field was applied twice in a row which resulted in additional induced singularities at 925 °C (+0.48 %) and 944 °C (+0.42 %). A floating baseline, which was above the thermal expansion baseline, was observed from 833 to 969 °C and was attributed to Joule heating. In conclusion, the singularity at 899 °C is associated with a sharp change in (111) FWHM and a 34 % decrease in integrated peak area that was attributed to changes in the distribution of oxygen vacancies and the changes in their concentration as induced by the applied field in the spontaneous transient stage of flash sintering.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Rationalizing nitrogen-doped secondary carbon particles for practical lithium-sulfur batteries

Nanostructured carbon host materials are widely used to improve both sulfur utilization rate and reaction kinetics in lithium-sulfur (Li-S) batteries. However, high complexity/cost of materials synthesis and difficulty in processing nano-materials into high-mass-loading electrodes are still significant barriers to the development of low-cost and high-energy Li-S batteries. In this study, we reported a generic and scalable synthesis approach to prepare nitrogen-doped secondary carbon particles. By using nitrogen-containing precursor as an integration reagent, the nanosized Ketjen Black particles were integrated into micron-size secondary ones and nitrogen-doped (NKB) simultaneously through a one-step heat treatment. With NKB as an example material, the effects of particle integration degree on the secondary particles’ structures, pore volume and connectivity, sulfur loading capability, and cell performance were studied and discussed. At an optimal integration condition, the NKB particles had significantly improved particle dimensions with well-maintained high specific surface area and pore volume. Here, contributed by the micron size and high pore volume, the NKB/S were successfully used for high-sulfur-loading cathodes (4–7 mg s /cm -2 ) and were able to deliver a specific capacity of ~1100 mAh g -1 at a low-porosity (50%) and lean-electrolyte conditions (E/S =4 µL/mg -1 ). Feasibility of the materials for practical use was validated through scaling up synthesis (40 g/batch), large-area electrode coating, and practical pouch cell (1.6 Ah) assembly and test.

25 ENERGY STORAGE↗

DOE OSTI2024

Nuclear waste attributes of near-term deployable small modular reactors

The nuclear waste attributes of near-term deployable SMRs were assessed using established nuclear waste metrics, which are the DU mass, SNF mass, volume, activity, decay heat, radiotoxicity, and decommissioning LLW volumes. Metrics normalized per unit electricity generation were compared to a reference large PWR. Three SMRs, VOYGR, Natrium, and Xe-100, were selected because they represent a range of reactor and fuel technologies and are active designs deployable by the decade’s end. The SMR nuclear waste attributes show both some similarities to the PWR and some significant differences caused by reactor-specific design features. The DU mass is equivalent to or slightly higher than the PWR. Back-end waste attributes for SNF disposition vary, but the differences have a limited impact on long-term repository isolation. SMR designs can vary significantly in SNF volume (and thus heat generation density). However, these differences are amenable to design optimization for handling, storage, transportation, and disposal technologies. Nuclear waste attributes from decommissioning vary depending on design and decommissioning technology choices. Given the analysis results in this study and assuming appropriate waste management system and operational optimization, there appear to be no major challenges to managing SMR nuclear wastes compared to the reference PWR.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Accelerated radiation transport modeling techniques for pencil beam computed tomography using gamma rays

Monte Carlo radiation transport modeling studies were performed for a compact, and high-resolution gamma-ray computed tomography system designed for imaging irradiated nuclear fuel. The system comprises a 60 Co source – chosen for its highly penetrating 1173 keV and 1332 keV gamma rays – a pair of high-aspect-ratio pencil beam collimators, and an inorganic scintillator detector. Here two acceleration methods are proposed to rapidly model a transmission type gamma-ray tomography system. The first, a variance reduction technique, is based on performing Monte Carlo simulations with a monodirectionally-biased source, sampled from a characteristic sub-volume of the full source volume. The second acceleration method is based on the deterministic calculations using the Beer–Lambert law and detector response characteristics. Comparison of simulations using acceleration approaches with analog simulations of the fully isotropic, full-volume equivalent, show that the Monte Carlo variance reduction technique gives quantitatively accurate predictions for large collimator aspect ratios while the deterministic calculations are semi-quantitative but converge close to the correct result as the collimator aspect ratio increases. As such, these techniques can be used to reduce the computational cost in generating simulated radiographs and tomographs by several orders of magnitude. Experimental validation efforts are currently underway and will be demonstrated in future work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Development of thin-gap GEM- μ RWELL hybrid detectors

Micro Pattern Gaseous Detectors (MPGDs) are used for tracking in High Energy Physics and Nuclear Physics because of their large area, excellent spatial resolution capabilities and low cost. However, for high energy charged particles impacting at a large angle with respect to the axis perpendicular to detector plane, the spatial resolution degrades significantly because of the long trail of ionization charges produced in clusters all along the track in the drift region of the detector. The long ionization charge trail results in registering hits from large number of strips in the readout plane which makes it challenging to precisely reconstruct the particle’s position using simple center of gravity algorithm. As a result, the larger the drift gap, the more severe the deterioration of spatial resolution for inclined tracks. For the same reason, the position resolution is also severely degraded in a large magnetic field, where the Lorentz E x B effect causes the ionization charges to follow a curved and longer path in the detector gas volume. In this paper, we report on the development of thin-gap MPGDs as a way to maintain excellent spatial resolution capabilities of MPGD detectors over a wide angular range of incoming particles. In a thin-gap MPGD, the thickness of the gas volume in the drift region is reduced from typically 3 mm to 1 mm or less. We present preliminary test beam results demonstrating the improvement in spatial resolution from 400 m with a standard 3 mm gap μ RWELL prototype to ~140 μ m with a double amplification GEM- μ RWELL thin-gap hybrid detector. Here, we also discuss the impact of a thin-gap drift volume on other aspects of the performance of MPGD technologies such as the efficiency and detector stability.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Elastic nucleon-pion scattering at m π = 200 MeV from lattice QCD

Elastic nucleon-pion scattering amplitudes are computed using lattice QCD on a single ensemble of gauge field configurations with N f = 2 + 1 dynamical quark flavors and m π = 200 MeV. The s-wave scattering lengths with both total isospins I = 1/2 and I = 3/2 are inferred from the finite-volume spectrum below the inelastic threshold together with the I = 3/2 p-wave containing the Δ(1232) resonance. The amplitudes are well-described by the effective range expansion with parameters constrained by fits to the finite-volume energy levels, enabling a determination of the I = 3/2 scattering length with statistical errors below 5%, while the I = 1/2 scattering length is somewhat less precisely evaluated. Systematic errors due to excited states and the influence of higher partial waves are controlled, providing a step toward future computations down to physical light quark masses with multiple lattice spacings and volumes.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

YOLO2U-Net: Detection-guided 3D instance segmentation for microscopy

Microscopy imaging techniques are instrumental for characterization and analysis of biological structures. As these techniques typically render 3D visualization of cells by stacking 2D projections, issues such as out-of-plane excitation and low resolution in the z-axis may pose challenges (even for human experts) to detect individual cells in 3D volumes as these non-overlapping cells may appear as overlapping. In this paper a comprehensive method for accurate 3D instance segmentation of cells in the brain tissue is introduced. The proposed method combines the 2D YOLO detection method with a multi-view fusion algorithm to construct a 3D localization of the cells. Next, the 3D bounding boxes along with the data volume are input to a 3D U-Net network that is designed to segment the primary cell in each 3D bounding box, and in turn, to carry out instance segmentation of cells in the entire volume. The promising performance of the proposed method is shown in comparison with current deep learning-based 3D instance segmentation methods.

3D instance segmentation↗

DOE OSTI2024

Critical mineral source potential from oil & gas produced waters in the United States

The volume of produced water, a by-product of oil & gas operations and other energy processes, has been growing across the United States (U.S.) along with the need to manage or recycle this wastewater. Produced water contains many naturally occurring elements of varying concentrations, including critical minerals which are essential to the clean energy transition. However, the current understanding of critical mineral concentrations in produced water and the associated volumes across the U.S. is limited. This study has assessed available databases and literature to gain insight into the presence and concentration of five high priority critical minerals, namely cobalt, lithium, magnesium, manganese, and nickel. The U.S. Geological Survey's National Produced Waters Geochemical Database was the main data source used for determining average critical mineral concentrations in produced water from the major oil and gas reservoirs in the U.S. The volumes of produced water for these major reservoirs were coupled with these concentrations to provide insights into where critical minerals are likely to have high abundance and therefore more recovery options. The analysis indicated the highest recovery potential for lithium and magnesium from produced water in the Permian basin and the Marcellus shale region. However, these assessments should be considered conservative due to the limited availability of reliable concentration data. Finally, it is expected more critical mineral recovery options could emerge with comprehensive characterization data from more recent and representative sources of produced water.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Surface roughness and dimensional evaluation of laser powder bed fusion additively manufactured shell and tube heat exchangers

The growing interest in additively manufactured (AM) heat exchangers drove the need to understand how this construction technique impacts heat exchanger performance. Two primary factors driven by AM that influence heat exchanger performance are surface roughness and geometry. To better understand these parameters, a range of shell and tube heat exchangers constructed using laser powder bed fusion were evaluated. Of those evaluated, the surface roughness throughout a fourteen-tube, zero-baffle heat exchanger was measured using computed tomography. Between the inner and outer tubes, the inner tube surfaces had a greater surface roughness than the outer by 8.07 μm, while the surfaces at the top of the build volume had higher surface roughness values than the bottom. Dimensionally, the inner tube diameters of this heat exchanger were 0.15% different from the design value, while the outer diameters were within a 0.84 % difference. Manual measurements across seven other heat exchangers yielded a maximum 1.15% difference between the design and measured diameters. Across the build volume for all heat exchangers studied, the tube diameters at the top were larger than at the bottom by a maximum of 1.24% difference. Inconsistent melting throughout the individual parts and the build volume, as well as particle splatter and thermal gradient variation were attributed to the surface roughness and dimensional changes seen. These results strengthen the knowledge of dimensional and surface roughness considerations when designing AM heat exchangers.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Single Entity Electrochemistry in Nanopore Electrode Arrays: Ion Transport Meets Electron Transfer in Confined Geometries

Electrochemical measurements conducted in confined volumes provide a powerful and direct means to address scientific questions at the nexus of nanoscience, biotechnology, and chemical analysis. How are electron transfer and ion transport coupled in confined volumes and how does understanding them require moving beyond macroscopic theories? Also, how do these coupled processes impact electrochemical detection and processing? We address these questions by studying a special type of confined-volume architecture, the nanopore electrode array, or NEA, which is designed to be commensurate in size with physical scaling lengths, such as the Debye length, a concordance that offers performance characteristics not available in larger scale structures. The experiments described here depend critically on carefully constructed nanoscale architectures that can usefully control molecular transport and electrochemical reactivity. We begin by considering the experimental constraints that guide the design and fabrication of zero-dimensional nanopore arrays with multiple embedded electrodes. These zero-dimensional structures are nearly ideal for exploring how permselectivity and unscreened ion migration can be combined to amplify signals and improve selectivity by enabling highly efficient redox cycling. Our studies also highlight the benefits of arrays, in that molecules escaping from a single nanopore are efficiently captured by neighboring pores and returned to the population of active redox species being measured, benefits that arise from coupling ion accumulation and migration. These tools for manipulating redox species are well-positioned to explore single molecule and single particle electron transfer events through spectroelectrochemistry, studies which are enabled by the electrochemical zero-mode waveguide (ZMW), a special hybrid nanophotonic/nanoelectronic architecture in which the lower ring electrode of an NEA nanopore functions both as a working electrode to initiate electron transfer reactions and as the optical cladding layer of a ZMW. Furthermore, while the work described here is largely exploratory and fundamental, we believe that the development of NEAs will enable important applications that emerge directly from the unique coupled transport and electron-transfer capabilities of NEAs, including in situ molecular separation and detection with external stimuli, redox-based electrochemical rectification in individually encapsulated nanopores, and coupled sorters and analyzers for nanoparticles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Electrochemical Salt Wasteform Development: A Review of Salt Treatment and Immobilization Options

Electrochemical reprocessing, also referred to as pyroprocessing, is a technique for recycling actinides from used nuclear fuel (UNF) to produce fuel for future reactors. Here, UNF is dissolved in a molten salt (e.g., LiCl-KCl eutectic) within an electrorefiner. After UNF dissolution, fission products are released into the electrolyte salt and converted to chlorides. This paper discusses wasteform options for processing the base electrolyte salt with the fission product salts as well as just the rare-earth fission products (as RECl 3 , REOCl, or REO x ) with the intent of finding optimal methods for reducing total waste salt volumes or partitioning the salt for alternate wasteform options. Furthermore, two of the more detailed partitioning options discussed herein include halide removal from the salt (dehalogenation), which accounts for more than half of the salt on a molar basis, and RE fission product removal for wasteforms with high-RE loadings. Wasteform properties are compared with emphasis on wasteform volume starting from a given amount of (1) total salt cations or (2) RE cations. Comparisons are also made of wasteform chemical durabilities, with the data available from like testing methods. A main conclusion from this work is the justification of subsequent salt processing after electrorefiner operations for achieving significant wasteform volume reduction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Pilot-Scale Continuous Plug-Flow Hydrothermal Liquefaction of Food Waste for Biocrude Production

Pilot-scale hydrothermal liquefaction (HTL) of biowaste is a critical step toward commercialization of the HTL technology. Despite many HTL studies conducted with wet biomass, including food waste, few were performed with a pilot-scale continuous plug-flow reactor (PFR), with the biocrude yield and quality analysis based on dewatering (ASTM D2892 Annex X1). This paper describes the development and performance evaluation of a mobile pilot-scale HTL continuous PFR, with a processing capacity of 60 L/h of wet feedstock and 6 L/h of biocrude production. The reactor system was designed for reaction conditions of up to 325 °C and 17.25 MPa. The reactor has a volume of 28.88 L with an additional counterflow heat exchanger volume of 18.07 L. Two types of food wastes, from a food processing plant and grocery store, were processed at 280 °C for 30 min, producing biocrude oil yields of 52.19 and 47.06 wt %, energy recoveries of 68.17 and 70.77%, and carbon recoveries of 66.91 and 64.78%, respectively. Furthermore, due to its high feedstock capacity and reaction volume, large amounts of biocrude oil and post-HTL wastewater (PHW) were obtained from this pilot-scale reactor to allow downstream research on upgrading biocrude oil for transportation fuel as well as PHW treatment and nutrient recovery.

09 BIOMASS FUELS↗