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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Sustainable aviation fuel from ethanol: Techno-economic analysis and life cycle analysis

Sustainable aviation fuel (SAF) is crucial for improving energy security, enhancing domestic production, and reducing carbon emissions in the aviation sector. Among various SAF production technologies, the ethanol-to-jet (ETJ) pathway is a promising option due to its economic viability and technological maturity. This study integrates a techno-economic analysis (TEA) and a life cycle analysis (LCA) to evaluate emissions reduction strategies for SAF production via the ETJ pathway, considering use of ethanol derived from both corn grain and corn stover. Conventional corn grain-derived ETJ fuel reduces greenhouse gas (GHG) emissions by 22 % compared to fossil jet fuel, with potential reductions of 26 %–96 % when incorporating renewable energy sources, with a 6 %–32 % increase in the minimum fuel selling price (MFSP). Corn stover-derived ETJ achieves a 77 % GHG reduction but with higher MFSPs compared to corn grain ETJ. Carbon capture and storage (CCS without considering the cost for piping and sequestration, only compression) reduces the emissions of corn grain-derived ETJ by up to 32 gCO 2 e/MJ and enables negative emissions for corn stover-derived ETJ, with MFSP increases ranging from 1 % to 22 %. While carbon capture and utilization (CCU) increase ethanol yield by 47 %, it raises MFSPs by 54 % due to high electricity demand. Sustainable farming practices provide only limited carbon intensity (CI) reductions individually but do offer cumulative benefits when combined. These findings highlight the trade-offs between cost and environmental impact, providing insights to optimize SAF production strategies and support aviation sector goals for emissions reduction.

09 BIOMASS FUELS↗
DOE OSTI2022

A combination of deep eutectic solvent and ethanol pretreatment for synergistic delignification and enhanced enzymatic hydrolysis for biorefinary process

Here, a novel pretreatment system containing deep eutectic solvents and ethanol (DES-E) for synergistic carbohydrate conversion and delignification was reported in this study. The DES-E pretreatment resulted in an enhanced glucose yield compared to individual DES and ethanol pretreatment for the three tested biomass, including Broussonetia papyrifera, corn stover and pine. To further explore the delignification mechanism, the solubilized lignin and residual lignin from Broussonetia papyrifera was recovered and extracted, then thoroughly characterized. The highest total OH content was found in the DES-E solubilized lignin, which could be used as antioxidant. The presence of ethanol in pretreatment liquor could protect the β-O-4 substructure from breakage and reduce lignin condensation, which favors the subsequent enzymatic hydrolysis. Comparable glucose yield and delignification performance was achieved by recycled DES. DES-E pretreatment offers a promising method for lignin isolation and cellulose digestibility improvement simultaneously.

09 BIOMASS FUELS↗
DOE OSTI2022

Low temperature ethanol steam reforming: Selectivity control with lithium doping of Pt/m-ZrO 2

Lithium promoted 2%Pt/m-ZrO 2 catalysts previously observed to exhibit higher rates for the low temperature water-gas shift (LTS) were tested for the ethanol steam reforming with the aim of exploring the potential tuning of the selectivity. Characterization of catalysts having optimized Li content (0.5–0.75%Li) for LTS exhibited (a) weakened C—H bonding of formate, a proposed intermediate in the LTS mechanism, as shown by a shift in the ν(CH) band to lower wavenumbers, (b) a relatively low extent of blocking of Pt, as measured by the ν(CO) band intensity of Pt-CO, (c) increased basicity as measured by CO 2 temperature-programmed desorption with mass spectrometry, but not so high as to strongly inhibit CO 2 product removal, and finally (d) no evidence of electron transfer from Li to Pt. Here, for this study, the same catalysts were tested for ethanol steam reforming (ESR). Results show that Li could likewise weaken the C—C bond of the acetate intermediate, the analog of formate in LTS, and facilitate decarboxylation over decarbonylation altering the selectivity in favor of methanation. This trend was confirmed by fixed bed reaction testing, in-situ infrared spectroscopy experiments of transient ESR, and temperature-programmed ESR using MS. The Li-doped catalysts may be used to pre-reform ethanol prior to feeding to a methane steam reformer to increase the overall H 2 selectivity of the process. DRIFTS of steady state ESR revealed that deactivation occurs through losses in the Pt-support interface, thereby hindering the turnover of the acetate intermediate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Kinetic model development for single step ethanol to butene rich olefin process over Cu-Y/Beta catalysts

Here, this study presents the first intrinsic kinetic model for the single-step conversion of ethanol to butene-rich olefins over bifunctional Cu-Y/Beta catalysts, addressing a critical gap in the design and scale-up of Sustainable Aviation Fuel (SAF) processes. The reaction network comprises ten global steps involving dehydrogenation, aldol condensation, hydrogenation, and dehydration reactions, distributed across Cu and rare-earth (Y) active sites. The model incorporates dual-site functionality (Cu and Y site) and explicitly accounts for key intermediates such as crotonaldehyde and butanal. Reaction rates are formulated using Langmuir–Hinshelwood–Hougen–Watson (LHHW) kinetics. Kinetic parameters are extracted by fitting the model to lab-scale packed-bed reactor data across a wide range of temperatures and space velocities, demonstrating strong agreement in ethanol conversion and product selectivity. The reaction kinetics developed in this work provide a foundational basis for constructing reactor models that enable process optimization and scale-up of ethanol-to-jet fuel technologies.

Cu-Y/Beta catalyst↗
DOE OSTI2020

Reprint of "Selective conversion of CO into ethanol on Cu(511) surface reconstructed from Cu(pc): Operando studies by electrochemical scanning tunneling microscopy, mass spectrometry, quartz crystal nanobalance, and infrared spectroscopy"

A polycrystalline copper, surface-terminated by a well-defined (511)-oriented facet, was electrochemically generated by a series of step-wise surface reconstruction and iterations of mild oxidative-reductive processes in 0.1 M KOH. The electrochemical reduction of CO on the resultant stepped surface was investigated by four surface-sensitive operando methodologies: electrochemical scanning tunneling microscopy (STM), electrochemical quartz crystal nanobalance (EQCN), differential electrochemical mass spectrometry (DEMS), and polarization-modulation infrared spectroscopy (PMIRS). The stepped surface catalyzed the facile conversion of CO into ethanol, the exclusive alcohol product at a low overpotential of -1.06 V (SHE) or - 0.3 V (RHE). Additionally, the chemisorption of CO was found to be a necessary prelude to ethanol production; i.e. the surface coverages, rather than solution concentrations, of CO and its surface-bound intermediates primarily dictate the reaction rates (current densities). Contrary to the expected predominance of undercoordinated step-site reactivity over the coordination chemistry of vicinal surfaces, vibrational spectroscopic evidence reveals the involvement of terrace-bound CO adsorbates during the multi-atomic transformations associated with the production of ethanol.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Rational design of septenary high-entropy alloy for direct ethanol fuel cells

Promoting C–C bond cleavage of ethanol by a complete 12-electron (12e) ethanol oxidation reaction (EOR) is a grand challenge for the development of highly efficient direct ethanol fuel cells (DEFCs). Most state-of-the-art catalysts only implement the EOR in an incomplete 4e or 2e pathway because of the poisoning of the catalysts by strongly adsorbed CO, leading to the poor output performance and low cell efficiency of DEFCs. Herein, a septenary PtPdFeCoNiSnMn high-entropy alloy (PtPd HEA) with a PtPd-rich surface but super-low platinum group metals loading was developed. We identified and proved the functions of each element in the PtPd HEA. The DEFCs assembled with the PtPd HEA (0.12 mg PtPd ∙cm -2 ) achieved a maximum power density of 0.72 W cm -2 and a durable operation for 1,200 h, which outperforms state-of-the-art catalysts for DEFCs. This work will be a design principle for nanostructured alloy development for renewable energy and sustainability applications.

25 ENERGY STORAGE↗
DOE OSTI2025

Techno-economic analysis of sugarcane bagasse and straw conversion into cellulosic ethanol via consolidated bioprocessing

Cellulosic biofuels offer a sustainable alternative to fossil fuels and a means to mitigate climate change. Consolidated bioprocessing (CBP) featuring engineered thermophilic bacteria, combined with mechanical disruption during fermentation (cotreatment), has potential to lower production costs compared to featuring thermochemical pretreatment and added cellulase. A techno-economic analysis was conducted (230 million L ethanol/year) from sugarcane bagasse and straw at stand-alone facilities generating electricity from residues. Three scenarios were evaluated: Conventional, featuring hydrothermal pretreatment, fungal cellulase, and yeast fermentation (current commercial standard); Mid-term CBP, relying on bagasse solubilization without pretreatment or cotreatment; and Mature CBP, incorporating cotreatment but no pretreatment. Results for these scenarios in this order were: fixed capital investment (CapEx) $\$$589M, $\$$658M, and $\$$472M; net annual revenue (EBITDA) $\$$56M, $\$$96M, and $\$$94M; and minimum ethanol selling price 0.73, 0.61, and 0.48 US$\$$/L. Payback periods were 10.5, 6.9, and 5.1 years, while all scenarios showed <5 years at European prices for scales >100M L/year. Sensitivity and risk analysis highlighted ethanol price as the most critical variable. It is notable that Mid-term CBP had shorter payback times and better overall economic feasibility compared to Conventional. Our results underscore opportunities for research-driven innovation on low-cost cellulosic ethanol technologies in Brazil and elsewhere.

Consolidated bioprocessing↗
DOE OSTI2020

Experimental and Kinetic Modeling Study of Laminar Burning Velocities of Cyclopentanone and Its Binary Mixtures with Ethanol and n-Propanol

Cyclopentanone is a promising biofuel that can enable more efficient engine operation and increase the fuel economy of the light duty fleet over current and planned technology developments. While the ignition of cyclopentanone has been investigated in detail, more studies on the laminar burning velocities of cyclopentanone are called for. In this work, the laminar burning velocities of cyclopentanone (C 5 H 8 O) have been measured using the heat flux and spherical flame methods at 1 atm, equivalence ratios from 0.7 to 1.6, and initial temperatures of 328, 353, and 428 K. To further investigate the relationship between the molecular structure and laminar burning velocity, identical experiments were also performed for binary mixtures of cyclopentanone with ethanol and n-propanol at 1:1 (mol). The consistency between the experimental data sets obtained in this work and literature data sets has been evaluated. Here, a recently published mechanism of cyclopentanone was used for simulation after adopting the submechanism of n-propanol. Good agreement has been seen between experimental and simulated results for all flames. To qualitatively explain the characteristics of the laminar burning velocity of cyclopentanone and the differences with those of ethanol and n-propanol, sensitivity analysis and reaction pathway analysis have been performed to compare the chemistry of the fuels under flame conditions, which revealed how the molecular structure of cyclopentanone could affect its laminar burning velocity. Compared to ethanol and n-propanol, cyclopentanone does not have primary carbon atoms in its molecule, leading to lower production of methyl radicals. Meanwhile, the carbonyl group in the cyclopentanone molecule is mostly released as CO in the decomposition of multiple intermediates accompanied by the production of unsaturated C 2 and C 4 species, especially C 2 H 4 and C 2 H 3 . Both features contribute to the high laminar burning velocity of cyclopentanone.

09 BIOMASS FUELS↗
DOE OSTI2023

Modeling Ethanol-Blend Fuel Sprays under Direct-Injection Spark-Ignition Engine Conditions

Computational modeling of fuel-injection and fuel-impingement processes was carried out to provide insight into previous experimental results obtained from a direct-injection spark-ignition research engine operated with various ethanol and aromatic fuel blends. Seven model fuels were evaluated using both single- and split-injection strategies. Model results showed that droplet vaporization enriched the concentrations of aromatic species in the liquid phase, especially those with low vapor pressure, and ethanol-containing fuels altered droplet sizes and led to increased liquid-phase mass in the cylinder. For the spray-modeling conditions studied, most of the injected fuel remained in the liquid phase, which would be expected to result in more fuel impingement on cylinder or piston surfaces. Fuel impinging on lower cylinder-temperature surfaces was found to create wall films that could interact with the piston during the compression stroke. Fuel impinging on hotter piston-temperature surfaces vaporized more readily, but for fuels with high ethanol and aromatic content, wall films remained and were highly concentrated with lower vapor pressure and aromatic compounds. These films could lead to pool fires during combustion and therefore significant particulate matter emissions.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗
DOE OSTI2021

Upgrading of Ethanol to n-Butanol via a Ruthenium Catalyst in Aqueous Solution

In this work, the upgrading of ethanol to n-butanol via the Guerbet reaction in aqueous media has been developed. This system allows for the upgrading of ethanol to n-butanol in up to a 28% yield and 57% selectivity, at only 80 °C. This system is also able to tolerate the same feedstock ratio found in fermentation broth (water to ethanol ratio of 90:10), albeit a decrease in yield and selectivity (20% yield of n-butanol, 48% selectivity). Smaller amounts of longer-chain alcohols are also formed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Predicting the Activity and Selectivity of Bimetallic Metal Catalysts for Ethanol Reforming using Machine Learning

Machine learning is ideally suited for the pattern detection in large uniform datasets, but consistent experimental datasets on catalyst studies are often small. Here we demonstrate how a combination of machine learning and first-principles calculations can be used to extract knowledge from a relatively small set of experimental data. The approach is based on combining a complex machine-learning model trained on an extensive computational library of transition-state energies with simple linear regression models of experimental catalytic activities and selectivities from the literature. Using the combined model, we identify the key C–C bond scission reactions involved in ethanol reforming and perform a computational screening for ethanol reforming on monolayer bimetallic catalysts with architectures TM-Pt-Pt(111) and Pt-TM-Pt(111) (TM = 3d transition metals). The model also predicts four promising catalyst compositions for future experimental studies. In conclusion, the approach is not limited to ethanol reforming but is of general use for the interpretation of experimental observations as well as for the computational discovery of novel catalytic materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Valorization of Ethanol: Ruthenium-Catalyzed Guerbet and Sequential Functionalization Processes

We report a ruthenium-catalyzed tandem Guerbet–alkylation strategy for the valorization of ethanol. The products of ethanol upgrading (higher-order alcohols) undergo subsequent C–C bond forming reactions with four carbon pronucleophiles and one ylide. Studies into catalyst design led to the development of ClRu(5-Mebpi)(PPh 3 ) 2 (bpi = 1,3-bis(2'-pyridylimino)isoindolate) as a highly efficient catalyst for producing biofuels and value-added chemicals from ethanol via Guerbet and tandem Guerbet reactions. Furthermore, this catalyst affords 65% higher-order alcohols in short reaction times (2 h), providing the highest TON (155,890) and TOF (12,690 h –1 ) for a homogeneous catalyst reported to date.

09 BIOMASS FUELS↗
DOE OSTI2021

Deconstruction of Woody Biomass via Protic and Aprotic Ionic Liquid Pretreatment for Ethanol Production

Ionic liquids (ILs) have emerged as important solvents for conversion of lignocellulosic feedstocks to fuels and chemicals due to their ability to enable efficient biomass deconstruction and fractionation. Woody biomass derived from forest and agricultural residues has the potential to be used for production of biofuels and its removal from forests can help mitigate disastrous wildfires in fire-prone states like California. This study evaluated woody biomass types (pine, almond, walnut, and fir) from California as potential biofuel feedstocks. The feedstocks were pretreated with the ILs cholinium lysinate ([Ch][Lys]) and ethanolamine acetate ([EOA][OAc]), followed by enzymatic hydrolysis and fermentation of lignocellulosic sugars to produce ethanol. Under optimal conditions, [EOA][OAc] pretreatment and enzymatic hydrolysis generated glucose and xylose yields in the range of 24-82 and 14-80%, respectively, while glucose and xylose yields for the [Ch][Lys] ranged between 28-83 and 23-80%, respectively. Maximum fermentable sugar was released from almond wood, and the lowest amount was from pine and fir. Further, blends of feedstocks were also explored, and a blend with a mass ratio of 2/2/1 (almond/walnut/pine) resulted in maximum glucose and xylose (>90%) yields using [Ch][Lys]. Fermentation of this hydrolysate using a C5-utilizing strain of Saccharomyces cerevisiae resulted in a maximum ethanol concentration of 17.9 g/L for mixture biomass hydrolysate, corresponding to 60.8% fermentation efficiency. This study represents the first demonstration of the use of these ILs for pretreatment of woody biomass blends that resulted in a high overall conversion efficiency for ethanol production.

09 BIOMASS FUELS↗
DOE OSTI2021

Cesium-Induced Active Sites for C–C Coupling and Ethanol Synthesis from CO 2 Hydrogenation on Cu/ZnO(000$\bar{1}$) Surfaces

The efficient conversion of carbon dioxide, a major air pollutant, into ethanol or higher alcohols is a big challenge in heterogeneous catalysis, generating great interest in both basic scientific research and commercial applications. Here, we report the facilitated methanol synthesis and the enabled ethanol synthesis from carbon dioxide hydrogenation on a catalyst generated by codepositing Cs and Cu on a ZnO(000$\bar{1}$) substrate. A combination of catalytic testing, X-ray photoelectron spectroscopy (XPS) measurements, and calculations based on density functional theory (DFT) and kinetic Monte Carlo (KMC) simulation was used. The results of XPS showed a clear change in the reaction mechanism when going from Cs/Cu(111) to a Cs/Cu/ZnO(000$\bar{1}$) catalyst. The Cs-promoting effect on C–C coupling is a result of a synergy among Cs, Cu, and ZnO components that leads to the presence of CH x and CH y O species on the surface. Furthermore, according to the DFT-based KMC simulations, the deposition of Cs introduces multifunctional sites with a unique structure at the Cu–Cs–ZnO interface, particularly being able to promote the interaction with CO 2 and thus the methanol synthesis predominantly via the formate pathway. More importantly, it tunes the CHO binding strongly enough to facilitate the HCOOH decomposition to CHO via the formate pathway, but weakly enough to allow further hydrogenation to methanol. The fine-tuning of CHO binding also enables a close alignment of a CHO pair to facilitate the C–C coupling and eventually ethanol synthesis. Our study opens new possibilities to allow the highly active and selective conversion of carbon dioxide to higher alcohols on widely used and low-cost Cu-based catalysts.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Selective Chloride-Mediated Neat Ethanol Oxidation to 1,1-Diethoxyethane via an Electrochemically Generated Ethyl Hypochlorite Intermediate

Selective primary alcohol oxidation to form aldehydes products without overoxidation to carboxylic acids remains a key chemistry challenge. Using simple alkylammonium chloride as the electrolyte with a glassy carbon working electrode in neat ethanol solvent, 1,1-diethoxyethane (DEE) was prepared with >95% faradaic efficiency (FE). DEE serves as a storage platform protecting acetaldehyde from overoxidation and volatilization. UV–vis spectroscopy shows that the reaction proceeds through an ethyl hypochlorite intermediate as the sole chloride oxidation product, and that this intermediate decomposes unimolecularly (rate constant k = (6.896 ± 0.516) × 10 –4 s –1 ) to form HCl catalyst and acetaldehyde, which undergoes rapid nucleophilic attack by ethanol solvent to form the DEE product. As a result, this indirect oxidation mechanism enables ethanol oxidation at much less positive potentials due to the fast kinetics for chloride anion oxidation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Spin Polarization Enhanced Ethanol Selectivity in Electrocatalytic CO 2 Reduction on the Paramagnetic CuO Surface

We report an electrochemical CO 2 reduction reaction catalyzed by a paramagnetic and conductive CuO/Cu interface with spins polarized by a moderate external magnetic field (MF) of similar to 800 gauss, achieving a similar to 30% increase in CO 2 -to-C 2+ Faradaic efficiency (FE) compared to that in the absence of the MF in a flow cell electrolyzer. At a current density of 400 mA/cm 2 , the CO 2 -to-C 2+ FE reached 86.7 ± 2.7% with 47.9 ± 1.4% cathodic energy efficiency (EE) in contrast to the CO 2 -to-C 2+ FE of 67.6% with 36.4% of EE in the absence of MF. Notably, ethanol production exhibits a much higher response to the MF (similar to 55.6% increase in FE) than ethylene (similar to 6.4% increase in FE) at 400 mA/cm 2 . In situ surface-enhanced Raman spectroscopy (SERS) captured magnetic-field-enhanced *CO coverage and ethanol-forming C 2 intermediates on CuO/Cu, providing direct spectroscopic evidence of spin-modulated pathway selection. Here, computational study suggests that the enhancement of ethanol selectivity is due to the reduced reaction kinetic barrier under MF, while the ethylene selectivity is less affected, mainly due to the insensitivity of the kinetic barriers under MF.

10 SYNTHETIC FUELS↗
DOE OSTI2023

Interface synergism and engineering of Pd/Co@N-C for direct ethanol fuel cells

Direct ethanol fuel cells have been widely investigated as nontoxic and low-corrosive energy conversion devices with high energy and power densities. It is still challenging to develop high-activity and durable catalysts for a complete ethanol oxidation reaction on the anode and accelerated oxygen reduction reaction on the cathode. The materials’ physics and chemistry at the catalytic interface play a vital role in determining the overall performance of the catalysts. Herein, we propose a Pd/Co@N-C catalyst that can be used as a model system to study the synergism and engineering at the solid-solid interface. Particularly, the transformation of amorphous carbon to highly graphitic carbon promoted by cobalt nanoparticles helps achieve the spatial confinement effect, which prevents structural degradation of the catalysts. The strong catalyst-support and electronic effects at the interface between palladium and Co@N-C endow the electron-deficient state of palladium, which enhances the electron transfer and improved activity/durability. The Pd/Co@N-C delivers a maximum power density of 438 mW cm -2 in direct ethanol fuel cells and can be operated stably for more than 1000 hours. This work presents a strategy for the ingenious catalyst structural design that will promote the development of fuel cells and other sustainable energy-related technologies.

25 ENERGY STORAGE↗
DOE OSTI2020

Highly selective electrocatalytic CO 2 reduction to ethanol by metallic clusters dynamically formed from atomically dispersed copper

Direct electrochemical conversion of CO 2 to ethanol offers a promising strategy of lowering CO 2 emission while storing energy from renewable electricity. However, current electrocatalysts offer only limited selectivity toward ethanol. Here we report a copper catalyst synthesized by a unique Cu-Li amalgm method over a commercial carbon support that achieved Faradaic efficiency (FE) higher than 91% at -0.7 V (RHE) and the active potential as low as -0.4 V (RHE) during direct electrocatalytic CO 2 -to-ethanol conversion. The catalyst also demonstrated stability over an extended period of operation. A strong correlation between the catalytic selectivity and the initial Cu atoms dispersion was found and Operando X-ray absorption spectroscopy identified a dynamic and reversible transformation from atomically dispersed copper atoms to Cu n (n = 3 and 4) under the electrochemical reaction. Frist-principles calculations further elucidate the possible catalytic mechanism of CO 2 reduction over Cu n .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗