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DOE OSTI2016

Assessment of potential greenhouse gas mitigation from changes to crop root mass and architecture

Reducing (and eventually reversing) the increase in greenhouse gases (GHGs) in the atmosphere due to human activities, and thus reducing the extent and severity of anthropogenic climate change, is one of the great challenges facing humanity. While most of the man-caused increase in GHGs has been due to fossil fuel use, land use (including agriculture) currently accounts for about 25% of total GHG emissions and thus there is a need to include emission reductions from the land use sector as part of an effective climate change mitigation strategy. In addition, analyses included in the recent IPCC 5th Climate Change Assessment report suggests that it may not be possible to achieve large enough emissions reductions in the energy, transport and industrial sectors alone to stabilize GHG concentrations at a level commensurate with a less than 2°C global average temperature increase, without the help of a substantial CO 2 sink (i.e., atmospheric CO 2 removal) from the land use sector. One of the potential carbon sinks that could contribute to this goal is increasing C storage in soil organic matter on managed lands. This report details a preliminary scoping analysis, to assess the potential agricultural area in the US – where appropriate soil, climate and land use conditions exist – to determine the land area on which ‘improved root phenotype’ crops could be deployed and to evaluate the potential long-term soil C storage, given a set of ‘bounding scenarios’ of increased crop root input and/or rooting depth for major crop species (e.g., row crops (corn, sorghum, soybeans), small grains (wheat, barley, oats), and hay and pasture perennial forages). The enhanced root phenotype scenarios assumed 25, 50 and 100% increase in total root C inputs, in combination with five levels of modifying crop root distributions (i.e., no change and four scenarios with increasing downward shift in root distributions). We also analyzed impacts of greater root production on the soil-crop nitrogen balance, from the standpoint of increased need for additional N inputs and consequences for increased N 2 O flux, as well as potential impacts if more and deeper roots contributed to reduced N leaching. In the enhanced root phenotype scenarios, the implicit assumption was that increases in overall plant production could be achieved (e.g., through increased CO 2 assimilation, greater growth efficiency) without reducing the harvested yield – that is, we did not include potential leakage and land substitution effects from potential decreased crop yield in the analysis.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2017

2016 Billion-Ton Report: Advancing Domestic Resources for a Thriving Bioeconomy, Volume 2: Environmental Sustainability Effects of Select Scenarios from Volume 1

With the goal of understanding environmental effects of a growing bioeconomy, the U.S. Department of Energy (DOE), national laboratories, and U.S. Forest Service research laboratories, together with academic and industry collaborators, undertook a study to estimate environmental effects of potential biomass production scenarios in the United States, with an emphasis on agricultural and forest biomass. Potential effects investigated include changes in soil organic carbon (SOC), greenhouse gas (GHG) emissions, water quality and quantity, air emissions, and biodiversity. Effects of altered land-management regimes were analyzed based on select county-level biomass-production scenarios for 2017 and 2040 taken from the 2016 Billion-Ton Report: Advancing Domestic Resources for a Thriving Bioeconomy (BT16), volume 1, which assumes that the land bases for agricultural and forestry would not change over time. The scenarios reflect constraints on biomass supply (e.g., excluded areas; implementation of management practices; and consideration of food, feed, forage, and fiber demands and exports) that intend to address sustainability concerns. Nonetheless, both beneficial and adverse environmental effects might be expected. To characterize these potential effects, this research sought to estimate where and under what modeled scenarios or conditions positive and negative environmental effects could occur nationwide. The report also includes a discussion of land-use change (LUC) (i.e., land management change) assumptions associated with the scenario transitions (but not including analysis of indirect LUC [ILUC]), analyses of climate sensitivity of feedstock productivity under a set of potential scenarios, and a qualitative environmental effects analysis of algae production under carbon dioxide (CO 2 ) co-location scenarios. Because BT16 biomass supplies are simulated independent of a defined end use, most analyses do not include benefits from displacing fossil fuels or other products, with the exception of including a few illustrative cases on potential reductions in GHG emissions and fossil energy consumption associated with using biomass supplies for fuel, power, heat, and chemicals. Most analyses in volume 2 show potential for a substantial increase in biomass production with minimal or negligible environmental effects under the biomass supply constraints assumed in BT16. Although corn ethanol has been shown to achieve GHG emissions improvements over fossil fuels, cellulosic biomass shows further improvements in certain environmental indicators covered in this report. The harvest of agricultural and forestry residues generally shows the smallest contributions to changes in certain environmental indicators investigated. The scenarios show national-level net SOC gains. When expanding the system boundary in illustrative cases that consider biomass end use, reductions in GHG emissions are estimated for scenarios in which biomass—rather than oil, coal, and natural gas—is used to produce fuel, power, heat, and chemicals. Analyses of water quality reveal that there could be tradeoffs between biomass productivity and some water quality indicators, but better outcomes for both biomass productivity and water quality can be achieved with selected conservation practices. Biodiversity analyses show possible habitat benefits to some species, with other species showing potential adverse effects that may require additional safeguards. Increasing productivity of algae can reduce GHG emissions and water consumption associated with producing algal biomass, though the effects of water consumption are likely of greater concern in some regions than in others. Moreover, the effects of climate change on potential biomass production show gains and losses in yield among feedstocks across the continental United States. Key research gaps and priorities include actions that can enhance benefits and reduce potential for negative effects of increased biomass production. The results from this report will help DOE, the bioenergy industry, and other institutions continue important discussions on environmental effects and will help chart a path toward a more environmentally sustainable bioeconomy.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Low Temperature Geothermal Play Fairway Analysis For The Appalachian Basin: Phase 1 Revised Report November 18, 2016

Geothermal energy is an attractive sustainable energy source. Yet project developers need confirmation of the resource base to warrant their time and financial resources. The Geothermal Play Fairway Analysis of the Appalachian Basin evaluated risk metrics that communicate the favorability of potential low-temperature geothermal energy resources in reservoirs more than 1000 m below the surface. This analysis is focused on the direct use of the heat, rather than on electricity production. Four risk factors of concern for direct-use geothermal plays in the Appalachian Basin portions of New York, Pennsylvania, and West Virginia are examined individually, and then in combination: 1) thermal resource quality, 2) natural reservoir quality, 3) induced seismicity, and 4) utilization opportunities. Uncertainty in the risk estimation is quantified. Based on these metrics, geothermal plays in the Appalachian Basin were identified as potentially viable for a variety of direct-use-heat applications. The methodologies developed in this project may be applied in other sedimentary basins as a foundation for low temperature (50-150 °C), direct use geothermal resource, risk, and uncertainty assessment. Three methods with which to combine the four risk factors were used. Among these, the averaging of the individual risk factors indicates the most favorable counties within the study area are the West Virginia counties of Monongalia, Harrison, Lewis (dubbed the Morgantown–Clarksburg play fairway), Putnam, and Kanawha (Charleston play fairway), the New York counties of Chemung and Steuben plus adjacent Bradford county in Pennsylvania (Corning–Ithaca play fairway), and the Pennsylvania counties of Mercer, Crawford, Erie, and Warren, and adjacent Chautauqua county in New York (together, the Meadville–Jamestown play fairway). These higher priority regions are surrounded by broader medium priority zones. Also worthy of additional exploration is a broad region near Pittsburgh Pennsylvania, for which the available geological data are insufficient to fully analyze the geological risks but yet the population is high. First, to assess the spatial variation in the depth to which one would need to drill to obtain geothermal temperatures that are useful to a future project, the project used bottom-hole temperature data from Appalachian Basin oil and gas exploration. These bottom hole temperature data are abundant but of low quality. Second, the project examined the potential for sufficient water flow rates through rocks to harvest heat from a geothermal well field, considering only natural reservoirs. This analysis provides a very incomplete picture of spatial variability of natural reservoirs because the oil and gas reservoir data lack key properties and are spatially biased toward those locations with profitable amounts of hydrocarbons in the rock pore spaces. Third, in light of the fact that earthquake activity has been induced in several states by subsurface work related to the oil and gas industry, this project examined the potential for similar activity in the Appalachian Basin. Acknowledging that data for such a task are insufficient, we utilized what was available: records of seismic activity, regional estimates of the orientations of stress in the rocks, and locations and orientations of zones of lateral change in rock properties at depths down to several kilometers below Earth’s surface. With these data, we created a first approximation of spatially variable risks for induced earthquakes. Because no data existed with which to test the reliability of these methods, the results have a high degree of uncertainty. Fourth, we examined the spatial variability of the above-the-ground factors that contribute to the economical viability of projects to tap low-temperature geothermal resources for direct-use. We worked principally with population density as a regionally known variable that would impact the cost of district heating. The resulting maps omit the costs of producing the hot water from the ground, because the below-ground costs are directly coupled to the thermal resource risk factor and natural reservoir risk factor – later analyses of those costs will be needed. The result of the district heating analysis is highly skewed: few census locations yielded a low estimated surface cost. The team also identified more than 165 prospects for high value direct-use geothermal energy opportunities such as industrial sites, university campuses, and federal facilities, among others. At the closure of this regional analysis, the most significant technical uncertainties are 1) reservoir distribution and capacities; 2) validity of thermal resource maps, and 3) the holistic estimation of Levelized Cost of Heat for favorable geological situations.

15 GEOTHERMAL ENERGY↗
DOE OSTI2016

Design and Demonstration of an Advanced Agricultural Feedstock Supply System for Lignocellulosic Bioenergy Production

This three-year project developed and demonstrated four innovative, first-of-their-kind pieces of equipment that are aimed at significantly reducing the cost of delivered herbaceous biomass. This equipment included a Self-Propelled Baler (SPB), a Bale Picking Truck (BPT), a Self-Loading Trailer (SLT), and a Heavy Crop Header for harvesting high yielding energy crops. This equipment was designed and fabricated during the first two years of the project and demonstrated on available crops (corn stover, wheat straw, and warm season grasses) across the nation, as available. Operational performance and cost data was collected and analyzed throughout the project to measure the costs of baseline harvesting (using conventional harvesting equipment) and advanced harvesting with the newly developed equipment. This data revealed that the project met its original goal of developing equipment that is realistically capable of reducing the cost of delivered biomass by $13 per dry ton. Each machine was tested after fabrication and put to the test in one or more commercial harvesting seasons. During these tests, operational flaws were found and fixed through upgrades and improvements. The first new SPB, BPT, and two new SLTs were ready for use during the 2013 harvest season. Since then, over 40 SLTs have been ordered and are currently under fabrication. All of the equipment will be commercially available to the industry as demand increases.

09 BIOMASS FUELS↗
DOE OSTI2017

Life-Cycle Analysis of Greenhouse Gas Emissions and Water Consumption – Effects of Coal and Biomass Conversion to Liquid Fuels as Analyzed with the GREET Model

The vast reserves of coal in the U.S. provide a significant incentive for the development of processes for coal conversion to liquid fuels (CTL). Also, CTL using domestic coal can help move the U.S. toward greater energy independence and security. However, current conversion technologies are less economically competitive and generate greater greenhouse gas (GHG) emissions than production of petroleum fuels. Altex Technologies Corporation (Altex, hereinafter) and Pennsylvania State University have developed a hybrid technology to produce jet fuel from a feedstock blend of coal and biomass. Collaborating with Altex, Argonne National Laboratory has expanded and used the Greenhouse gases, Regulated Emissions, and Energy use in Transportation (GREET®) model to assess the life-cycle GHG emissions and water consumption of this hybrid technology. Biomass feedstocks include corn stover, switchgrass, and wheat straw. The option of biomass densification (bales to pellets) is also evaluated in this study. The results show that the densification process generates additional GHG emissions as a result of additional biomass process energy demand. This process coproduces a large amount of char, and this study investigates two scenarios to treat char: landfill disposal (Char-LF) and combustion for combined heat and power (CHP). Since the CHP scenarios export excess heat and electricity as coproducts, two coproduct handling methods are used for well-to-wake (WTWa) analysis: displacement (Char-CHP-Disp) and energy allocation (Char-CHP-EnAllo). When the feedstock contains 15 wt% densified wheat straw and 85 wt% lignite coal, WTWa GHG emissions of the coal-and-biomass-to-liquid pathways are 116, 97, and 137 gCO2e per megajoule (MJ) under the Char-LF, Char-CHP-Disp, and Char-CHP-EnAllo scenarios, respectively, as compared to conventional jet fuel production at 84 gCO2e/MJ. WTWa water consumption values are 0.072, -0.046, and 0.044 gal/MJ for Char-LF, Char-CHP-Disp, and Char-CHP-EnAllo, respectively, as compared to conventional jet fuel production at 0.028 gal/MJ. To reach the break-even point of 84 gCO2e/MJ, under the assumptions of constant product yields and energy demands regardless of the share of biomass and coal feedstocks, 31 wt%, 23 wt%, and 53 wt% of the feedstock blend need to be biomass under the Char-LF, Char-CHP-Disp, and Char-CHP-EnAllo scenarios, respectively.

09 BIOMASS FUELS↗
DOE OSTI2017

Systems Level Regulation of Rhythmic Growth Rate and Biomass Accumulation in Grasses

Objectives: Several breakthroughs have been recently made in our understanding of plant growth and biomass accumulation. It was found that plant growth is rhythmically controlled throughout the day by the circadian clock through a complex interplay of light and phytohormone signaling pathways. While plants such as the C4 energy crop sorghum (Sorghum bicolor (L.) Moench) and possibly the C3 grass Brachypodium distachyon also exhibit daily rhythms in growth rate, the molecular details of its regulation remain to be explored. A better understanding of diurnally regulated growth behavior in grasses may lead to species-specific mechanisms highly relevant to future strategies to optimize energy crop biomass yield. Here we propose to devise a systems approach to identify, in parallel, regulatory hubs associated with rhythmic growth in C3 and C4 plants. We propose to use rhythmicity in daily growth patterns to drive the discovery of regulatory network modules controlling biomass accumulation. Description: The project is divided in three main parts: 1) Performing time-lapse imaging and growth measurement in B. distachyon and S. bicolor to determine growth rate dynamic during the day/night cycle. Identifying growth-associated genes whose expression patterns follow the observed growth dynamics using deep sequencing technology, 2) identifying regulators of these genes by screening for DNA-binding proteins interacting with the growth-associated gene promoters identified in Aim 1. Screens will be performed using a validated yeast-one hybrid strategy paired with a specifically designed B. distachyon and S. bicolor transcription factor libraries (1000 clones each), and 3) Selecting 50 potential growth regulators from the screen for downstream characterization. The selection will be made by using a sytems biology approach by calculating the connectivity between growth rate, rhythmic gene expression profiles and TF expression profile and determine which TF is likely part of a hub and a potential regulator of plant growth. We will confirme the 50 DNA-protein interactions using transient transcriptional assays in B. distachyon and S. bicolor, and perform further testing in vivo by measuring growth parameters in transgenic loss- or gain-of-function lines for the selected transcription factors (25 B. distachyon and 3 S. bicolor lines). In 2016 the Principal Investigator relocated the laboratory to The Scripps Research Institute (TSRI) where the project has continued with an end date of 08/31/17. Accomplishments: We successfully collected large datasets of gene expression form the model grass Brachypodium. We used and developed bioinformatics analysis tools to investigate the structure, dynamics and robustness of circadian regulated gene expression in Brachypodium. Relevant Discoveries: We were able to determine that the endogenous circadian clock appears to play a much more subdued role in growth regulation in Brachypodium, that has been demonstrated in either Arabidopsis, or crop plants like Rice, Corn and Soybean. This led to our conclusion that Brachypodium unfortunately is unlikely to serve as an informative model for understanding how growth regulation in plants is under the control of circadian network circuitry. However, we were able to leverage our datasets in Brachypodium to inform us and reinforce a large collaborative study on gene networks governing cell wall deposition in Arabidopsis. This led to a major and highly cited publication relevant to improving biomass production.

09 BIOMASS FUELS↗
DOE OSTI2017

Catalytic Upgrading of Thermochemical Intermediates to Hydrocarbons: Conversion of Lignocellulosic Feedstocks to Aromatic Fuels and High Value Chemicals

The principal objective of this project was to develop a fully integrated catalytic process that efficiently converts lignocellulosic feedstocks (e.g. bagasse, corn stover, and loblolly pine) into aromatic-rich fuels and chemicals. Virent led this effort with key feedstock support from Iowa State University. Within this project, Virent leveraged knowledge of catalytic processing of sugars and biomass to investigate two liquefaction technologies (Reductive Catalytic Liquefaction (USA Patent No. 9,212,320, 2015) and Solvolysis (USA Patent No. 9,157,030, 2015) (USA Patent No. 9,157,031, 2015)) that take advantage of proprietary catalysts at temperatures less than 300°C in the presence of unique solvent molecules generated in-situ within the liquefaction processes.

09 BIOMASS FUELS↗
DOE OSTI2018

Biomass Pyrolysis to Hydrocarbon Fuels in the Petroleum Refining Context: Cooperative Research and Development Final Report, CRADA Number CRD-12-500

This work focuses on developing a thermochemical route to produce biofuels from agricultural wastes such as sugar cane bagasse, wood chips or corn stover; more specifically it intends to develop the biomass pyrolysis route, which produces bio-oils. Production of bio-oils by pyrolysis is a commercial technology. However, bio-oils are currently not being used for liquid fuels production. Although bio-oils can be produced by high-pressure liquefaction, pyrolysis is a less expensive technology. Nevertheless, bio-oils cannot be used directly as a transportation fuel without upgrading, since they are generally unstable, viscous, and acidic. Thus NREL and Petrobras intend to use their combined expertise to develop a two-step route to biofuels production: in the first step, a stable bio-oil is produced by NREL biomass pyrolysis technology, while in the second step it is upgraded by using two distinct catalytic processes under development by Petrobras. The first process converts bio-oil into gasoline, LPG, and fuel oil using the catalytic cracking process, while the second one, converts bio-oil into synthesis gas. Syngas gasification catalysts provided by both NREL and Petrobras will be tested. The work includes experiments at both sites to produce bio-oil and then biofuels, life-cycle analysis of each route, personnel training and development of analytical methods with a duration time of two years.

09 BIOMASS FUELS↗
DOE OSTI2018

Poplar Interactome: Project Final Report

The feedstock plant Poplar has many advantages over traditional crop plants. Not only Poplar needs low energy input and off season storage as compared to feedstocks such as corn, in the winter season Poplar biomass is stored on the stem/trunk, and Poplar plantations serve as large carbon sink. A key constraint to the expansion of cellulosic bioenergy sources such as in Poplar however, is the negative consequence of converting land use from food crops to energy crops. Therefore in order for Poplar to become a viable energy crop it needs to be grown mostly on marginal land unsuitable agricultural crops. For this we need a better understanding of abiotic stress and adaptation response in poplar. In the process we expected to find new and existing poplar genes and their function that respond to sustain abiotic stress. We carried out an extensive gene expression study on the control untreated and stress (drought, salinity, cold and heat) treated poplar plants. The samples were collected from the stem, leaf and root tissues. The RNA of protein coding genes and regulatory smallRNA genes were sequenced generating more than a billion reads. This is the first such known study in Poplar plants. These were used for quantification and genomic analysis to identify stress responsive genes in poplar. Based on the quantification and genomic analysis, a select set of genes were studied for gene-gene interactions to find their association to stress response. The data was also used to find novel stress responsive genes in poplar that were previously not identified in the Poplar reference genome. The data is made available to the public through the national and international genomic data archives.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

Assessment of JBEI Ionic Liquid Biomass Pretreatment Technology on POET Feedstocks

This CRADA was focused on the development, demonstration and optimization of advanced biomass conversion technologies, specifically the one-pot ionic liquid (IL) technology pioneered at the Joint BioEnergy Institute, on feedstocks that are of primary interest to POET. The aim of this study is to provide a comprehensive analysis of comparative material balance and process yields after different IL pretreatment configurations through a parametric study of the efficacy of [C 2 C 1 Im][OAc] and [Ch][Lys] for the pretreatment of corn stover in order to establish the upper and lower limits for IL pretreatment. This included evaluating the impact of solids loading, particle size, temperature and enzyme loading on both IL pretreatment and sugar yields.

09 BIOMASS FUELS↗
DOE OSTI2018

Process Design and Economics for the Conversion of Lignocellulosic Biomass to Hydrocarbon Fuels and Coproducts: 2018 Biochemical Design Case Update; Biochemical Deconstruction and Conversion of Biomass to Fuels and Products via Integrated Biorefinery Pathways

Over the past decade, NREL conducted a campaign to quantify the economic implications associated with observed and future targeted performance for the biochemical conversion of corn stover to ethanol through techno-economic modeling. This report serves as an update to the biological sugar conversion approach, reflecting modifications to underlying conversion operational strategies, as well as refinements to the techno-economic model details. In addition, the report includes a more quantitative focus on envisioned processing requirements for achieving final fuel cost goals moving further into the future, via inclusion of value-added coproducts.

09 BIOMASS FUELS↗
DOE OSTI2019

Shock Initiation Measurements of PBX 9404; Lot 10102Y, FY2018

This report details a series of 5 shock initiation experiments on PBX 9404, Lot 10102Y. These experiments cover a pressure range of 2.98-6.66 GPa, and were conducted at the LANL TA-40 Chamber 9 gun facility. 4 experiments (shot numbers 1s-1665-1668) were performed using the single-stage gas gun, and the fifth on the two- stage gun (shot number 2s-1079). A pair of cylindrical PBX 9404 30 degree wedges were assembled into a right cylinder (nominally 43 mmØ and 23 mm tall) with an embedded electromagnetic velocity (EMV) gauge pack- age glued between them. A 'stirrup' EMV gauge was also glued to the impact face of the target. The gauges consist of Al conductors sandwiched between FEP Teflon, and produce a voltage proportional to local particle velocity as they move through a static magnetic field. Gauges are nominally spaced 0.8 mm apart for the first 7.5 mm of the depth of the target. Precise gauge depths for each experiment are given in their respective small scale database entries. All glue bonds were made with Dow Corning 733 Silicone. The configuration of this experiment is shown in Fig. 1. A summary of experimental conditions explored is given in Table I.

42 ENGINEERING↗
DOE OSTI2019

Future High Performance Computing Capabilities: Summary Report of the Advanced Scientific Computing Advisory Committee (ASCAC) Subcommittee

The ASCAC Subcommittee on Future High Performance Computing (HPC) Capabilities has reviewed opportunities and challenges related to the most promising technologies that are currently planned for the post-exascale (2020's) and post-Moore (2030's and beyond) timeframes. We briefly summarize in this report the key findings and recommendations from this review, from the perspective of planning and research directions that need to be given priority to prepare for the very significant challenges that await us in the post-Moore computing era. An overarching concern that emerged from the subcommittee's deliberations is that DOE has lost considerable momentum in funding and sustaining a research pipeline in the applied math and computer science areas that should have been the "seed corn" for preparing for these future challenges, and it is therefore critical to correct this gap as soon as possible. While the subcommittee understands the paramount importance of DOE's commitment to deliver exascale capabilities, we believe that it is essential for DOE ASCR to fund research and development that looks beyond the Exascale Computing Project (ECP) horizon so as to ensure our nation's continued leadership in HPC and we were glad to learn about the ASCAC exascale transition subcommittee in this regard.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Herbaceous Feedstock 2019 State of Technology Report

The U.S. Department of Energy (DOE) promotes the 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 with this mission, Idaho National Laboratory (INL) completes an annual SOT report for biomass feedstock logistics. This report summarizes supply system impacts of Bioenergy Technologies Office (BETO)-funded research and development efforts at INL and elsewhere (such as the High-Tonnage Feedstock Logistics projects (Webb et al. 2013a, Webb et al. 2013b, Webb et al. 2013c, Webb and Sokhansanj 2014, Sokhansanj et al. 2014)) that lead to improvements in feedstock supply systems. These include improvements to and observed performance of innovative harvest and collection methods, storage technologies, transportation and handling approaches, and advanced preprocessing technologies. Biomass quality and variability, and the interface between feedstock quality and conversion performance are key drivers in addition to delivered feedstock cost. In this report, we estimate the benefits of R&D improvements to individual supply system unit operations and present the status of feedstock logistics technology development for converting biomass into biofuels. These analyses are supported by experimental data where possible and help to align the SOT relative to the cost goals defined in the Multi-Year Program Plan. The 2019 Herbaceous SOT incorporates several technology changes in feedstock preprocessing and introduces opportunities from the integrated landscape management (ILM) strategy and increased grower participation to reduce biomass access costs, while maintaining or improving grower profitability. During FY18 uneven flow from the horizontal bale grinder was identified as a significant issue limiting preprocessing system throughput. Based on FSL-funded research at INL, the 2019 Herbaceous SOT replaces the horizontal bale grinder used in the first stage size reduction with a bale processor. The improved uniformity of biomass flow entering the PDU eliminated slugging flow from the first stage size reduction and improved the throughput of downstream operations. In order to achieve moisture reduction through frictional heating during grinding (which allowed elimination of the costly rotary drum dryer in previous SOTs), the second stage grinder was changed from a rotary shear, which does not remove moisture, back to a hammer mill. Finally, the 2019 Herbaceous SOT introduces modified three-pass and two-pass corn stover supply curves derived from the BT16 resource assessment, based on FY19 modeling results (WBS 4.2.1.20) quantifying economic benefits of ILM in the supply area, together with modeling results (WBS 1.2.1.5) identifying ILM strategies to increase grower participation. The 2019 Herbaceous SOT report documents the current modeled cost of an herbaceous feedstock supply system from harvest to the pretreatment reactor throat for hydrocarbon fuel production via biochemical conversion, based on equipment and processes now available or potentially available in the near term. The modeled cost also considers both the required quality and the availability of the biomass resources. The 2019 Herbaceous SOT predicts a modeled delivered feedstock cost of $81.37 /dry ton (2016$); this is a $2.30/dry ton (2016$) decrease from the 2018 Herbaceous SOT. Technology improvements that contributed to this modeled cost reduction include reduced cost for the new preprocessing design and quantification of the opportunities of the integrated landscape management (ILM) strategy and an increased grower participation rate to reduce the grower payment portion of biomass access costs, while maintaining or improving grower profitability. A greenhouse gas emissions (GHG) assessment was completed by Argonne National Laboratory using the 2019 Greenhouse Gases, Regulated Emissions, and Energy use in Transportation model, estimating an increase of 14.89 kg CO2e/ton from the 2018 SOT (69.27 kg CO2e/ton in 2018 to 84.16 kg CO2e/ton in 2019). The increase of energy consumption during preprocessing along with higher transportation distance to access low cost biomass from further distance contributed to the increase of GHG emissions in the 2019 Herbaceous SOT. The reason for the increased transportation distances was the cost tradeoff of going farther from the biorefinery to access the cheaper ILM-derived counties (the cheaper price outweighed the cost of increased supply radius).

09 BIOMASS FUELS↗
DOE OSTI2021

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Competitive Furfural Production: Producing Additional Revenue From Waste

The competitive furfural synthesis process converts a low-value byproduct of corn ethanol production into a high-value chemical and a high-value feed residue. This easily implemented process may be incorporated alongside existing work flows to create additional revenue streams.

09 BIOMASS FUELS↗
DOE OSTI2021

Higher Throughput, Lower Cost Processing of Flexible Perovskite Solar Cells by Photonic Curing

The objectives of this SETO project are to explore whether photonic curing can be used to perform annealing in perovskite solar cell (PSC) fabrication, and if so, whether it can enable high-throughput PSC manufacturing. The successful outcome of the project will reduce manufacturing cost towards realizing the SETO goal of the Levelized cost of electricity (LCOE) $0.03/kWh by 2030. The project is a collaboration between Hsu’s group at the University of Texas at Dallas (UTD) and NovaCentrix, an Austin TX based company that pioneered the PulseForge® photonic curing tools and has expertise in applying this technology to printed electronics. Thin-film synthesis typically involves a thermal annealing step to convert from precursors to final material phases, to obtain the desired crystalline phase, or to improve materials structural or electrical properties. However, thermal annealing typically requires high temperatures that are incompatible with inexpensive plastic substrates and annealing times lasting tens-to-hundreds of minutes, making it incompatible with roll-to-roll (R2R) manufacturing at a desirable web speed. Photonic curing uses a flash Xe lamp to deliver short (20 µs to 100 ms) but high intensity (up to 50 kW/cm 2 ) pulses of broadband light (200 – 1500 nm) to the sample. It has been successfully applied to sinter printed metal nanoparticle inks into conductive patterns. This project aimed to extend the applications of photonic curing to convert halide perovskite films and transparent metal oxide transport layers. Despite the interruption by COVID-19, we have achieved significant accomplishments to establish photonic curing as a viable technology for the high-throughput manufacturing of PSCs. (1) We demonstrated that photonic curing can convert both metal oxide transport layer and halide perovskite absorber in the PSCs and successfully made flexible PSCs on Corning Willow glass® (WG)/ indium tin oxide (ITO) substrates without any thermal annealing steps. These photonically cured devices achieve performance comparable to conventional thermally annealed devices but were fabricated with a total processing time reduced by six orders of magnitude. We also show that photonic curing can achieve desirable web speed (up to 26 m/min) and large-area uniformity. (2) By establishing photonic curing processing phase spaces for the perovskite, we show that the longer pulses are more forgiving in small variation in the photonic curing conditions, making it more suitable for R2R manufacturing. (3) Our results clearly illustrated the importance of improving mechanical and optical properties of transparent electrodes on flexible substrates. (4) We also performed fundamental studies that elucidate the interactions between perovskite absorber and metal oxide transport layer that can undermine the PSC stability. Five refereed journal papers in top journals (ACS Energy Letters, npj Flexible Electronics, ACS Applied Energy Materials, Materials Advances, and Frontiers in Energy Research), one conference proceeding (PVSC-47), six conference presentations (PVSC and Materials Research Society meetings), and a Ph.D. dissertation (Trey B. Daunis) were produced under this project. Energy Materials Corporation (EMC) has forecast that with a 1.5 m wide web moving at a web speed of 30 m/min, R2R processing of PSC could provide up to 4 GW/year for a single R2R assembly line. Replacing thermal annealing with photonic curing, as demonstrated by the accomplishments of this project, is necessary to realize such an energy production goal.

14 SOLAR ENERGY↗
DOE OSTI2020

Reduction of CO 2 Emissions Through Lightweight Body Panels (Project Final Report)

Lightweight construction is an integral part of Volkswagen’s overall strategy of reducing CO 2 emissions. Due to its low cost, steel is the most commonly used material for automotive exterior body panels today. Unfortunately, steel has a high density, resulting in a relatively low specific strength. Glass fiber based sheet molding compounds (SMC) provide high properties in combination with lower density. The high specific strength of SMC offers an enormous lightweight potential. To unlock the full potential of SMC materials in combination with cutting edge manufacturing processes, Volkswagen Group of America worked together with IACMI (Institute for Advanced Composites Manufacturing Innovation) and the academic partners: University of Tennessee Knoxville, Purdue University and Michigan State University; as well as the industry partners: Ashland, IDI, Owens Corning and Continental Structural Plastics. Leveraging the expertise of all project partners, reaching over the entire supply chain the project demonstrated the potential of these materials. This report will highlight the major steps in the development process on the way to technology readiness for SMC using the example of the Volkswagen Atlas Liftgate. Over the 36-month period of the project, the work focused on three R&D areas: material development, design and simulation, and development of the manufacturing process. Material selection included alternative fibers and resin systems, and accounted for material availability, properties, and cost-efficiency. The work undertaken in the field of design and simulation has pushed the envelope of short fiber reinforced thermoset molding compound process simulation. Design iterations were virtually tested, while the final design was used to validate the simulation software against physical parts. Manufacturing development used cutting-edge technology, while experts along the supply chain were working together to ensure the best possible results. In the final stage of the project, liftgates were molded, trimmed, bonded, painted and assembled before exhaustive testing. The result is an e-coat (electrophoretic dip coating) capable Class-A SMC liftgate, which is ready for high-volume production, and can be used as a technology demonstrator. The prototypes manufactured in the scope of this work have exhibited a mass reduction for the Volkswagen Atlas liftgate of up to 35% compared to the series production steel version, without a degradation of the functionalities.

36 MATERIALS SCIENCE↗