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DOE OSTI2021

Specialty chemicals production case study: Economic analysis of modular chemical process intensification versus conventional stick‐built approaches

Abstract The beneficial synergies of chemical process intensification and plant modularization present a unique step‐wise advancement opportunity for many chemical manufacturers, but economic case studies are needed to raise awareness of such opportunities. The primary objective of this case study is to better understand the business case economics of a specialty chemical plant using modular chemical process intensification (MCPI), by comparing it with that of a conventional stick‐built (CSB) plant that produces the same product at the same production capacity. When comparing MCPI against CSB approaches for a plant project strategy decision, analysts should thoroughly understand and model the differences and similarities in scope bases. The MCPI approach for this case study benefitted from dramatic reductions in capital expenditures (CAPEX). A sizeable reduction in plant spatial volume likely explains some of these reductions. Sizeable operational expenditure (OPEX) reductions with the MCPI plant appear to be associated with the reduced operator staffing required from converting a labor‐intensive batch process into an automated, continuous flow process. Traditional project investment economic measures strongly favored the MCPI case for the design, construction, and operation of the specialty chemical plant. The net present value for the MCPI case was nearly twice that for the CSB case over a ten‐year period, and the payback period for the CSB case was nearly five times longer than that of the MCPI case. The opinion‐based perspective of the study participant identified significant contributors to superior MCPI economic performance for this case study. With the two conditions of low MCPI CAPEX and high product profit margin, economic analysis indicates that incorporation of a backup MCPI train, for operational redundancy when downtime occurs, is a very beneficial strategy.

O'Connor, James T.↗

DOE OSTI2020

Anthraquinone Redox Relay for Dye‐Sensitized Photo‐electrochemical H 2 O 2 Production

Abstract Anthraquinone (AQ) redox mediators are introduced to metal‐free organic dye sensitized photo‐electrochemical cells (DSPECs) for the generation of H 2 O 2 . Instead of directly reducing O 2 to produce H 2 O 2 , visible‐light‐driven AQ reduction occurs in the DSPEC and the following autooxidation with O 2 allows H 2 O 2 accumulation and AQ regeneration. In an aqueous electrolyte, under 1 sun conditions, a water‐soluble AQ salt is employed with the highest photocurrent of up to 0.4 mA cm −2 and near‐quantitative faradaic efficiency for producing H 2 O 2 . In a non‐aqueous electrolyte, under 1 sun illumination, an organic‐soluble AQ is applied and the photocurrent reaches 1.8 mA cm −2 with faradaic efficiency up to 95 % for H 2 O 2 production. This AQ‐relay DSPEC exhibits the highest photocurrent so far in non‐aqueous electrolytes for H 2 O 2 production and excellent acid stability in aqueous electrolytes, thus providing a practical and efficient strategy for visible‐light‐driven H 2 O 2 production.

Sun, Jiaonan↗

DOE OSTI2021

Immobilization of transgenic plant cells towards bioprinting for production of a recombinant biodefense agent

Abstract Transgenic rice cells ( Oryza sativa ) producing recombinant butyrylcholinesterase (BChE) as a prophylactic/therapeutic against organophosphate nerve agent poisoning, cocaine toxicity, and neurodegenerative diseases like Alzheimer's were immobilized in a polyethylene glycol‐based hydrogel. The cells were sustained for 14 days in the semi‐solid matrix, undergoing a growth phase from days 0–6, a BChE production phase in sugar‐free medium from days 6–12, and a growth/recovery phase from days 12–14. Throughout this period, the cells maintained similar viability to those in suspension cultures and displayed analogous sugar consumption trends. The rice cells in the hydrogel also produced a significant amount of active BChE, comparable to the levels produced in liquid cultures. A considerable fraction of this BChE was secreted into the media, allowing for easier product separation. To the best of our knowledge, this proof‐of‐concept is the first report of immobilization of recombinant plant cells for continuous production of high‐value heterologous proteins. This work serves as a foundation for further investigation towards plant cell bioprinting and the development of a simple, efficient, robust, modular, and potentially field‐deployable bioreactor system for the manufacture of biologics.

Varma, Anika↗

DOE OSTI2023

Enzyme selection, optimization, and production toward biodegradation of post–consumer poly(ethylene terephthalate) at scale

Poly(ethylene terephthalate) (PET) is one of the world's most widely used polyester plastics. Due to its chemical stability, PET is extremely difficult to hydrolyze in a natural environment. Recent discoveries in new polyester hydrolases and breakthroughs in enzyme engineering strategies have inspired enormous research on biorecycling of PET. This study summarizes our research efforts toward large-scale, efficient, and economical biodegradation of post-consumer waste PET, including PET hydrolase selection and optimization, high-yield enzyme production, and high-capacity enzymatic degradation of post-consumer waste PET. First, genes encoding PETase and MHETase from Ideonella sakaiensis and the ICCG variant of leaf-branch compost cutinase (LCC ICCG ) were codon-optimized and expressed in Escherichia coli BL21(DE3) for high-yield production. To further lower the enzyme production cost, a pelB leader sequence was fused to LCC ICCG so that the enzyme can be secreted into the medium to facilitate recovery. To help bind the enzyme on the hydrophobic surface of PET, a substrate-binding module in a polyhydroxyalkanoate depolymerase from Alcaligenes faecalis (PBM) was fused to the C-terminus of LCC ICCG . The resulting four different LCC ICCG variants (LCC, PelB-LCC, LCC-PBM, and PelB-LCC-PBM), together with PETase and MHETase, were compared for PET degradation efficiency. A fed-batch fermentation process was developed to produce the target enzymes up to 1.2 g L –1 . Finally, the best enzyme, PelB-LCC, was selected and used for the efficient degradation of 200 g L –1 recycled PET in a well-controlled, stirred-tank reactor. Furthermore, the results will help develop an economical and scalable biorecycling process toward a circular PET economy.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Domesticating a food spoilage yeast into an organic acid–tolerant metabolic engineering host: Lactic acid production by engineered Zygosaccharomyces bailii

Lactic acid represents an important class of commodity chemicals, which can be produced by microbial cell factories. However, due to the toxicity of lactic acid at lower pH, microbial production requires the usage of neutralizing agents to maintain neutral pH. Zygosaccharomyces bailii, a food spoilage yeast, can grow under the presence of organic acids used as food preservatives. This unique trait of the yeast might be useful for producing lactic acid. With the goal of domesticating the organic acid!tolerant yeast as a metabolic engineering host, seven Z. bailii strains were screened in a minimal medium with 10 g/L of acetic, or 60 g/L of lactic acid at pH 3. The Z. bailii NRRL Y7239 strain was selected as the most robust strain to be en- gineered for lactic acid production. By applying a PAN!ARS!based CRISPR!Cas9 system consisting of a transfer RNA promoter and NAT selection, we demonstrated the targeted deletion of ADE2 and site!specific integration of Rhizopus oryzae ldhA coding for lactate dehydrogenase into the PDC1 locus. The resulting pdc1::ldhA strain produced 35 g/L of lactic acid without ethanol production. Here, this study de- monstrates the feasibility of the CRISPR!Cas9 system in Z. bailii, which can be applied for a fundamental study of the species.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Genome‐wide CRISPR‐Cas9 screen reveals a persistent null‐hyphal phenotype that maintains high carotenoid production in Yarrowia lipolytica

Abstract Yarrowia lipolytica is a metabolic engineering host of growing industrial interest due to its ability to metabolize hydrocarbons, fatty acids, glycerol, and other renewable carbon sources. This dimorphic yeast undergoes a stress‐induced transition to a multicellular hyphal state, which can negatively impact biosynthetic activity, reduce oxygen and nutrient mass transfer in cell cultures, and increase culture viscosity. Identifying mutations that prevent the formation of hyphae would help alleviate the bioprocess challenges that they create. To this end, we conducted a genome‐wide CRISPR screen to identify genetic knockouts that prevent the transition to hyphal morphology. The screen identified five mutants with a null‐hyphal phenotype— ΔRAS2 , ΔRHO5 , ΔSFL1 , ΔSNF2 , and ΔPAXIP1 . Of these hits, only ΔRAS2 suppressed hyphal formation in an engineered lycopene production strain over a multiday culture. The RAS2 knockout was also the only genetic disruption characterized that did not affect lycopene production, producing more than 5 mg L −1 OD −1 from a heterologous pathway with enhanced carbon flux through the mevalonate pathway. These data suggest that a ΔRAS2 mutant of Y. lipolytica could prove useful in engineering a metabolic engineering host of the production of carotenoids and other biochemicals.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2024

Acetaminophen production in the edible, filamentous cyanobacterium Arthrospira platensis

Abstract Spirulina is the common name for the edible, nonheterocystous, filamentous cyanobacteriumArthrospira platensisthat is grown industrially as a food supplement, animal feedstock, and pigment source. Although there are many applications for engineering this organism, until recently no genetic tools or reproducible transformation methods have been published. While recent work showed the production of a diversity of proteins inA. platensis, including single‐domain antibodies for oral delivery, there remains a need for a modular, characterized genetic toolkit. Here, we independently establish a reproducible method for the transformation ofA. platensisand engineer this bacterium to produce acetaminophen as proof‐of‐concept for small molecule production in an edible host. This work opensA. platensisto the wider scientific community for future engineering as a functional food for nutritional enhancement, modification of organoleptic traits, and production of pharmaceuticals for oral delivery.

Biotechnology & Applied Microbiology↗

DOE OSTI2024

Endogenous Production and Vibrational Analysis of Heavy-Isotope-Labeled Peptides from Cyanobacteria

Stable isotope labeling is an extremely useful tool for characterizing the structure, tracing the metabolism, and imaging the distribution of natural products in living organisms using mass-sensitive measurement techniques. In this study, a cyanobacterium was cultured in 15 N/ 13 C-enriched media to endogenously produce labeled, bioactive oligopeptides. The extent of heavy isotope incorporation in these peptides was determined with LC–MS, while the overall extent of heavy isotope incorporation in whole cells was studied with nanoSIMS and AFM-IR. Up to 98 % heavy isotope incorporation was observed in labeled cells. Three of the most abundant peptides, microcystin-LR (MCLR), cyanopeptolin-A (CYPA), and aerucyclamide-A (ACAA), were isolated and further studied with Raman and FTIR spectroscopies and DFT calculations. This revealed several IR and Raman active vibrations associated with functional groups not common in ribosomal peptides, like diene, ester, thiazole, thiazoline, and oxazoline groups, which could be suitable for future vibrational imaging studies. More broadly, this study outlines a simple and relatively inexpensive method for producing heavy-labeled natural products. Finally, manipulating the bacterial culture conditions by the addition of specific types and amounts of heavy-labeled nutrients provides an efficient means of producing heavy-labeled natural products for mass-sensitive imaging studies.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Vanadium (II) Sulfate for the Reductive Leaching of Chalcopyrite: Replacing Smelting with Electrolysis for Copper Production

The demand for copper is expected to outpace supply in the coming decades due in part to the emergence of wind and solar technologies, which require about five times as much copper as traditional energy sources. This work introduces a potentially transformative hydrometallurgical process to extract copper from chalcopyrite, and thereby sustain a high rate of copper production throughout the 21 st century. Chalcopyrite is reacted with vanadium (II) sulfate for the first time to enable the rapid, clean, and complete recovery of copper. Reactions between 39 g/L copper concentrate, 1 M vanadium (II) sulfate, and various concentrations of sulfuric acid yielded a final product of solid copper sulfate, which was characterized by X-ray diffraction (XRD) and scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDS) analysis. The solid products were leached in a subsequent step to demonstrate copper yields ranging from 95–99%. The vanadium (II) ion may be regenerated by an electrolysis unit that leverages advances in vanadium flow battery technologies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Semi‐Continuous Ex Situ Carbon Dioxide Mineralization in Produced Water for Calcite Production

ABSTRACT The mineralization of carbon dioxide (CO 2 ) to stable carbonate products is a desirable process for carbon capture utilization and storage (CCUS). However, improving the process economics through creative use of available reactants is necessary to develop a scalable mineralization process. This study details the development of a semi‐continuous CO 2 mineralization process that uses flue gas as a point CO 2 source, produced water (PW) as an alkaline source of Ca 2+ , and NaOH effluent (potentially sourced from integration with the chlor‐alkali process. Operating at a controlled pH allowed for both complete reaction of available Ca 2+ (100% carbonation potential or 9.9 g CO 2 .L –1 PW brine) and for reproducible control of the produced calcium carbonate (CaCO 3 ) product. A full factorial design of experiments was implemented to study the effects of reaction temperature, pH, and gaseous CO 2 concentration on the mineralization and CO 2 capture rates as well as product crystalline structure and morphology. A maximum CO 2 capture rate of 0.315 ± 0.007 kg.L –1 .d –1 was achieved at 25°C and 25% CO 2 . CO 2 gas to liquid phase mass transport is believed to be the rate limiting step. With improved reactor design and optimization, the proposed semi‐continuous mineralization process shows promise for scaling to a pilot scale CO 2 capture technology.

Bennett, Quinn [Institute for Sustainable Energy &↗

DOE OSTI2025

Implications of Changes in Water Stress and Precipitation Extremes for Cocoa Production in Côte D'ivoire and Ghana

ABSTRACT Climate change induces high variability in drought patterns and extreme precipitation indices in rainfed cocoa farming, impacting cocoa production. This study evaluated water stress, meteorological and agricultural drought conditions, and critical extreme precipitation indices in the world's two largest cocoa‐producing nations from 1981 to 2022. The results revealed a significant reduction in total annual precipitation (PRCPTOT), in the last three decades, with the greatest decline in the 1991–2000 and 2011–2022 periods. Ghana experienced the most significant reduction up to 15% (200 mm/year) in the last decade, attributed to a substantial decrease in wet days number (RR1) up to 25 days per year, a reduction in maximum consecutive wet days (CWD) up to 6 days per year, and an increase in maximum consecutive dry days (CDD) up to 15 days per year. Moreover, there was a notable decline in the Simple Daily Intensity Index (SDII), with reductions of up to 4 mm/day in certain areas, contributing to increased drought frequency, severity, and duration. In the most recent decade (2011–2022), particularly during the extremely dry years of 2013 and 2015, cocoa‐growing regions in Ghana (GHA) and eastern Côte d'Ivoire (CIV) experienced prolonged agricultural drought expressed by soil moisture deficit, typically extending from May to September. Additionally, large portions of central and eastern Ghana, as well as northeastern Côte d'Ivoire experienced sustained water stress, with over three consecutive months of total monthly precipitation falling below 100 mm, negatively impacting cocoa productivity. The decrease in the yield in the range of 2.5% to 37% was noted in the dry years and the following years, varying according to the country depending on the severity of the drought. Sensitivity analysis highlights cocoa yield's responsiveness to drought and water stress, particularly in specific years when water stress occurred, such as 1984,1985, 1989, 1995, 1999, 2000, and 2008. Considering the observed trends in precipitation patterns and their impact on cocoa production, it is crucial to acknowledge the inherent uncertainty of future precipitation patterns due to climate change. To address this challenge effectively, our study underscores the importance of identifying and closely monitoring regions currently facing water stress, as determined by precipitation and drought indicators. Over the analysed period (1981–2022), we have noted shifts in the distribution of water‐stressed areas, highlighting the dynamic nature of this issue. Consequently, we advocate for a targeted approach to implement cocoa supplementary irrigation in consistently water‐stressed regions.

Obahoundje, Salomon [International Water Managemen↗

DOE OSTI2023

Long‐term changes in soil carbon and nitrogen fractions in switchgrass, native grasses, and no‐till corn bioenergy production systems

Cellulosic bioenergy is a primary land-based climate mitigation strategy, with soil carbon (C) storage and nitrogen (N) conservation as important mitigation elements. Here, we present 13 years of soil C and N change under three cellulosic cropping systems: monoculture switchgrass (Panicum virgatum L.), a five native grasses polyculture, and no-till corn (Zea mays L.). Soil C and N fractions were measured four times over 12 years. Bulk soil C in the 0–25 cm depth at the end of the study period ranged from 28.4 (± 1.4 se) Mg C ha −1 in no-till corn, to 30.8 (± 1.4) Mg C ha −1 in switchgrass, and to 34.8 (± 1.4) Mg C ha −1 in native grasses. Mineral-associated organic matter (MAOM) ranged from 60% to 90% and particulate organic matter (POM) from 10% to 40% of total soil C. Over 12 years, total C as well as both C fractions persisted under no-till corn and switchgrass and increased under native grasses. In contrast, POM N stocks decreased 33% to 45% across systems, whereas MAOM N decreased only in no-till corn and by less than 13%. Declining POM N stocks likely reflect pre-establishment land use, which included alfalfa and manure in earlier rotations. Root production and large soil aggregate formation explained 69% (p < 0.001) and 36% (p = 0.024) of total soil C change, respectively, and 60% (p = 0.020) and 41% (p = 0.023) of soil N change, demonstrating the importance of belowground productivity and soil aggregates for producing and protecting soil C and conserving soil N. Differences between switchgrass and native grasses also indicate a dependence on plant diversity. Soil C and N benefits of bioenergy crops depend strongly on root productivity and pre-establishment land use.

09 BIOMASS FUELS↗

DOE OSTI2020

Measuring Biomass-Derived Products in Biological Conversion and Metabolic Process

Biomass can be converted to various types of products in biological and metabolic processes. For an in-depth understanding of biomass conversion, quantitative and qualitative information of products in these conversion processes are essential. Here we introduce analytical techniques including high-performance liquid chromatography (HPLC), gas chromatography (GC), gas chromatography-mass spectrometry (GC-MS), and nuclear magnetic resonance (NMR) for biomass-based products characterization in biological and metabolic processes.

Yoo, Chang Geun↗

DOE OSTI2022

$\mathrm{Z}$ero-jettiness resummation for top-quark pair production at the $\mathrm{LHC}$

We study the resummation of the 0-jettiness resolution variable $\mathcal{T}_o$ for the top-quark pair production process in hadronic collisions. Starting from an effective theory framework we derive a factorisation formula for this observable which allows its resummation at any logarithmic order in the $\mathcal{T}_o$→ o limit. We then calculate the $\mathcal{O}(a_s)$ corrections to the soft function matrices and, by employing renormalisation group equation methods, we obtain the ingredients for the resummation formula up to next-to-next-to-leading logarithmic (NNLL) accuracy. We study the impact of these corrections to the 0-jettiness distribution by comparing predictions at different accuracy orders: NLL, NLL', NNLL and Approximate NNLL' (NNLL$^{'}_{a}$). We match these results to the corresponding fixed order calculations both at leading order and next-to-leading order for the $t\bar{t}$+jet production process, obtaining the most accurate prediction of the 0-jettiness distribution for the top-quark pair production process at NNLL$^{'}_{a}$+NLO accuracy.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Production of light (anti)nuclei in pp collisions at $ \sqrt{s} $=13 TeV

Understanding the production mechanism of light (anti)nuclei is one of the key challenges of nuclear physics and has important consequences for astrophysics, since it provides an input for indirect dark-matter searches in space. In this paper, the latest results about the production of light (anti)nuclei in pp collisions at $\sqrt{s}$ = 13 TeV are presented, focusing on the comparison with the predictions of coalescence and thermal models. For the first time, the coalescence parameters B 2 for deuterons and B 3 for helions are compared with parameter-free theoretical predictions that are directly constrained by the femtoscopic measurement of the source radius in the same event class. A fair description of the data with a Gaussian wave function is observed for both deuteron and helion, supporting the coalescence mechanism for the production of light (anti)nuclei in pp collisions. This method paves the way for future investigations of the internal structure of more complex nuclear clusters, including the hypertriton.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Measurement of $χ_{c1}$(3872) production in proton-proton collisions at $\sqrt{s}$ = 8 and 13 TeV

The production cross-section of the $χ_{c1}$(3872) state relative to the $ψ(2S)$ meson is measured using proton-proton collision data collected with the LHCb experiment at centre-of-mass energies of $\sqrt{s}$ = 8 and 13 TeV, corresponding to integrated luminosities of 2.0 and 5.4 fb -1 , respectively. The two mesons are reconstructed in the $J/ψπ^+π^-$ final state. The ratios of the prompt and nonprompt $χ_{c1}$(3872) to $ψ(2S)$ production cross-sections are measured as a function of transverse momentum, $ρ_T$, and rapidity, y, of the $χ_{c1}$(3872) and $ψ(2S)$ states, in the kinematic range 4 < $ρ_T$ < 20 GeV/c and 2.0< y < 4.5. The prompt ratio is found to increase with $ρ_T$, independently of y. For the prompt component, the double ratio of the $χ_{c1}$(3872) and $ψ(2S)$ production cross-sections between 13 and 8 TeV is observed to be consistent with unity, independent of $ρ_T$ and centre-of-mass energy.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Impact of fully coherent energy loss on heavy meson production in pA collisions

Hadron production in proton-nucleus (pA) collisions was previously shown to be suppressed by medium-induced fully coherent energy loss (FCEL). We show that the quenching of D and B mesons in pPb collisions at the LHC due solely to FCEL is, at least, on par with other nuclear effects such as gluon shadowing or saturation. This is consistent with previous findings for both quarkonium and light hadron production in pA collisions, emphasising that FCEL effects need to be included for a reliable understanding of hadron production measurements in pA collisions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Measurement of inclusive charged-particle b-jet production in pp and p-Pb collisions at $\sqrt{s_{\mathrm{NN}}}$ = 5.02 TeV

A measurement of the inclusive b-jet production cross section is presented in pp and p-Pb collisions at $\sqrt{s_{NN}}$ = 5.02 TeV, using data collected with the ALICE detector at the LHC. The jets were reconstructed in the central rapidity region |η| < 0.5 from charged particles using the anti-k T algorithm with resolution parameter R = 0.4. Identification of b jets exploits the long lifetime of b hadrons, using the properties of secondary vertices and impact parameter distributions. The p T -differential inclusive production cross section of b jets, as well as the corresponding inclusive b-jet fraction, are reported for pp and p-Pb collisions in the jet transverse momentum range 10 ≤ p T,ch jet ≤ 100 GeV/c, together with the nuclear modification factor, $R^{b-jet}_{pPb}$. The analysis thus extends the lower p T limit of b-jet measurements at the LHC. The nuclear modification factor is found to be consistent with unity, indicating that the production of b jets in p-Pb at $\sqrt{s_{NN}}$ = 5.02 TeV is not affected by cold nuclear matter effects within the current precision. The measurements are well reproduced by POWHEG NLO pQCD calculations with PYTHIA fragmentation.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗