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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Integrating Oil Debris and Vibration Measurements for Intelligent Machine Health Monitoring

A diagnostic tool for detecting damage to gears was developed. Two different measurement technologies, oil debris analysis and vibration were integrated into a health monitoring system for detecting surface fatigue pitting damage on gears. This integrated system showed improved detection and decision-making capabilities as compared to using individual measurement technologies. This diagnostic tool was developed and evaluated experimentally by collecting vibration and oil debris data from fatigue tests performed in the NASA Glenn Spur Gear Fatigue Rig. An oil debris sensor and the two vibration algorithms were adapted as the diagnostic tools. An inductance type oil debris sensor was selected for the oil analysis measurement technology. Gear damage data for this type of sensor was limited to data collected in the NASA Glenn test rigs. For this reason, this analysis included development of a parameter for detecting gear pitting damage using this type of sensor. The vibration data was used to calculate two previously available gear vibration diagnostic algorithms. The two vibration algorithms were selected based on their maturity and published success in detecting damage to gears. Oil debris and vibration features were then developed using fuzzy logic analysis techniques, then input into a multi sensor data fusion process. Results show combining the vibration and oil debris measurement technologies improves the detection of pitting damage on spur gears. As a result of this research, this new diagnostic tool has significantly improved detection of gear damage in the NASA Glenn Spur Gear Fatigue Rigs. This research also resulted in several other findings that will improve the development of future health monitoring systems. Oil debris analysis was found to be more reliable than vibration analysis for detecting pitting fatigue failure of gears and is capable of indicating damage progression. Also, some vibration algorithms are as sensitive to operational effects as they are to damage. Another finding was that clear threshold limits must be established for diagnostic tools. Based on additional experimental data obtained from the NASA Glenn Spiral Bevel Gear Fatigue Rig, the methodology developed in this study can be successfully implemented on other geared systems.

Dempsey, Paula J.↗
NASA NTRS2001

Oil-Free Turbomachinery Being Developed

NASA and the Army Research Laboratory (ARL) along with industry and university researchers, are developing Oil-Free technology that will have a revolutionary impact on turbomachinery systems used in commercial and military applications. System studies have shown that eliminating an engine's oil system can yield significant savings in weight, maintenance, and operational costs. The Oil-Free technology (foil air bearings, high-temperature coatings, and advanced modeling) is being developed to eliminate the need for oil lubrication systems on high-speed turbomachinery such as turbochargers and gas turbine engines that are used in aircraft propulsion systems. The Oil-Free technology is enabled by recent breakthroughs in foil bearing load capacity, solid lubricant coatings, and computer-based analytical modeling. During the past fiscal year, a U.S. patent was awarded for the NASA PS300 solid lubricant coating, which was developed at the NASA Glenn Research Center. PS300 has enabled the successful operation of foil air bearings to temperatures over 650 C and has resulted in wear lives in excess of 100,000 start/stop cycles. This leapfrog improvement in performance over conventional solid lubricants (limited to 300 C) creates new application opportunities for high-speed, high-temperature Oil-Free gas turbine engines. On the basis of this break-through coating technology and the world's first successful demonstration of an Oil-Free turbocharger in fiscal year 1999, industry is partnering with NASA on a 3-year project to demonstrate a small, Oil-Free turbofan engine for aeropropulsion.

DellaCorte, Christopher↗
NASA NTRS2003

Oil-Free Turbomachinery Research Enhanced by Thrust Bearing Test Capability

NASA Glenn Research Center s Oil-Free Turbomachinery research team is developing aircraft turbine engines that will not require an oil lubrication system. Oil systems are required today to lubricate rolling-element bearings used by the turbine and fan shafts. For the Oil-Free Turbomachinery concept, researchers combined the most advanced foil (air) bearings from industry with NASA-developed high-temperature solid lubricant technology. In 1999, the world s first Oil-Free turbocharger was demonstrated using these technologies. Now we are working with industry to demonstrate Oil-Free turbomachinery technology in a small business jet engine, the EJ-22 produced by Williams International and developed during Glenn s recently concluded General Aviation Propulsion (GAP) program. Eliminating the oil system in this engine will make it simpler, lighter (approximately 15 percent), more reliable, and less costly to purchase and maintain. Propulsion gas turbines will place high demands on foil air bearings, especially the thrust bearings. Up until now, the Oil-Free Turbomachinery research team only had the capability to test radial, journal bearings. This research has resulted in major improvements in the bearings performance, but journal bearings are cylindrical, and can only support radial shaft loads. To counteract axial thrust loads, thrust foil bearings, which are disk shaped, are required. Since relatively little research has been conducted on thrust foil air bearings, their performance lags behind that of journal bearings.

Bauman, Steven W.↗
NASA NTRS2017

Managing Fire Risk During Drought: The Influence of Certification and El Nino on Fire-Driven Forest Conversion for Oil Palm in Southeast Asia

Indonesia and Malaysia have emerged as leading producers of palm oil in the past several decades, expanding production through the conversion of tropical forests to industrial plantations. Efforts to produce "sustainable" palm oil, including certification by the Roundtable on Sustainable Palm Oil (RSPO), include guidelines designed to reduce the environmental impact of palm oil production. Fire-driven deforestation is prohibited by law in both countries and a stipulation of RSPO certification, yet the degree of environmental compliance isunclear, especially during El Niño events when drought conditions increase fire risk. Here, we used time series of satellite data to estimate the spatial and temporal patterns of fire-driven deforestation on and around oil palm plantations. In Indonesia, fire-driven deforestation accounted for one-quarter of total forest losses on both certified and noncertified plantations. After the first plantations in Indonesia received RSPO certification in 2009,forest loss and fire-driven deforestation declined on certified plantations but did not stop altogether. Oil palm expansion in Malaysia rarely involved fire; only 5 % of forest loss on certified plantations had coincident activefire detections. Interannual variability in fire detections was strongly influenced by El Nino and the timing of certification. Fire activity during the 2002, 2004, and 2006 El Nino events was similar among oil palm plantations in Indonesia that would later become certified, noncertified plantations, and surrounding areas. However, total fire activity was 75% and 66% lower on certified plantations than noncertified plantations during the 2009 and 2015 El Nino events, respectively. The decline in fire activity on certified plantations, including during drought periods, highlights the potential for RSPO certification to safeguard carbon stocks in peatlands and remaining forests in accordance with legislation banning fires. However, aligning certification standards with satellite monitoring capabilities will be critical to realize sustainable palm oil production and meet industry commitments to zero forestation.

Noojipady, Praveen↗
DOE OSTI2020

Ultrasonic in-situ water-cut measurement using ultrasonic oil-water separation for affecting sound speed calibration

An apparatus and method for the separation of an oil-water mixture into its components are described. An acoustic radiation force moves oil droplets to the nodes of an acoustic standing wave generated in a vertical column containing the oil-water mixture. Once the droplets are sufficiently close together, attractive forces become dominant and the droplets may coalesce to form larger droplets, which have greater buoyancy, and separation of the mixture into a layer of oil and a layer of water occurs, not possible by simple gravitational separation. Acoustically-driven oil-water separation may be used for water-cut measurements in oil production wells, since separation of the oil from the water permits accurate sound speed measurements to be made for both the oil and the water, thereby allowing frequent in situ calibrations of the apparatus to determine whether sound speed measurements on the mixture are accurate in the event that one or both of the mixture constituents is changing.

02 PETROLEUM↗
DOE OSTI2021

Design Study for Bio-Oil Production from Biomass Using a Dual Fluidized-Bed Reactor

To evaluate the re-design and reconfiguration of a dual-fluidized bed (DFB) gasification system into a recirculating pyrolysis reactor, Computation Fluid Dynamic (CFD) simulations of the system were conducted. The Barracuda Virtual Reactor® computational particle fluid dynamic code was used to perform simulations of the pyrolysis process. Modeling of the chemical reaction kinetics for both gas phase and solid particle phase were included. The recirculating pyrolysis reactor shown in Fig. 1a is based on a bubbling-bed biomass pyrolyzer and a riser combustor to convert the remaining char. The operational differences in the re-configuration of the DFB gasification system into a recirculating pyrolysis system for the production of bio-oil are (1) replacement of a low-surface area inert bed material with a high-surface-area bed material that has acidic properties to provide catalytic activity for the production of bio-oil with reduced oxygen content, (2) lower temperature and residence time for bio-oil production from pyrolysis, (3) replacement of the fluidization gas in the bubbling bed pyrolyzer from steam to nitrogen, and (4) the reduction of pyrolyzer freeboard volume. The bed material used for catalytic pyrolysis is Sasol 300 (300-micron dia., bulk density 0.94 kg/l, and surface area 130 m2/g) and is a theta-alumina with mild acidity. This is in comparison with previous standard bed material Carbo HSP (430-micron dia., bulk density 2.01 kg/l, and surface area 0.03 m2/g) used for gasification. For bio-oil production, pyrolysis in the bubbling bed requires temperatures in the range of 550 C in comparison with gasification temperatures near 850 C. To attain this lower temperature requires management of the energy mass balances, with control of the bed material recirculation rate between bubbling bed pyrolyzer and riser combustor, the introduction of a nitrogen purge in the pyrolyzer, and adjusting the pressure balance between the two vessels. To extract bio-oil from the pyrolysis reactor with a snorkel, two different freeboard configurations were evaluated. In Fig. 1 b the existing high freeboard configuration is shown and in Fig. 1 c the reduced freeboard design is presented. The introduction of a nitrogen purge for the high free board configuration provided the highest bio-oil production from the CFD simulations. To decrease the bed-material circulation rate, primary and secondary air on the combustor side were reduced, and the pressure on the combustor was slightly increased. A portion of the biomass and bio-oil was observed to be transported to the combustor, leading to a smaller pyrolysis yield. The control of the pyrolyzer temperature is performed by controlling the circulation rate. Good fluidization of the bubbling bed and cascade PID control are required to keep the temperature from oscillating due to large time delay experienced when changing primary and secondary air. (a) (b) (c) Figure 1. (a) Dual Fluidized Bed pyrolysis system configuration, (b) mole fraction of nonpolar biooil in high freeboard configuration, and (c) mole fraction of nonpolar bio-oil in low freeboard configuration with nitrogen purge introduced in both configurations.

BASIC BIOLOGICAL SCIENCES,BIOMASS FUELS↗
DOE OSTI2021

Enhanced heavy oil recovery by low salinity polymer flood combined with microgel treatment

“Heavy oil resources account for a large portion of the total oil reserves around the world. The target heavy oil reservoir is located on Alaska’s North Slope (ANS). Advantages of low-salinity HPAM polymer (LSP) over high-salinity polymer (HSP) were demonstrated. LSP could recover more oil with 40% less polymer consumption. No additional oil was recovered by HSP after LSP flood. The first-ever polymer flood pilot on ANS showed remarkable success regarding water cut reduction, oil production increase, delayed breakthrough, and projected oil recovery improvement. Polymer alone was insufficient to achieve satisfactory recovery as the reservoirs were highly heterogeneous. Microgels could improve the effectiveness of polymer flood by reducing water cut and increasing oil recovery. Favorable working conditions were identified. Microgel transport behavior was studied using superpermeable sandpacks (27-221 darcies) with multiple pressure sensors. The particle-to-pore matching size ratio significantly impacted the effectiveness of the gels. A threshold differential pressure (ΔPth) and critical pressure gradient (∇Pcr) were required to push the gels to penetrate and propagate through the channels. The ΔPth and ∇Pcr revealed the underlying mechanisms of selective penetration/placement behavior of microgels in heterogeneous reservoirs. Diagrams were developed to estimate the maximum propagation distance of the gels in channels in conceptual field applications. Sandwich-like channel models and methodologies were developed to comprehensively evaluate the effectiveness of gel materials. Gel retention in the channels was quantified. Results also indicated that the retained gels were dehydrated. Fluid diversion and sweep improvement after gel treatments were evaluated by tracer tests”--Abstract, page iv.

Zhao, Yang↗
DOE OSTI2020

Surface Reactivity Analysis of the Crude Oil–Brine–Limestone Interface for a Comprehensive Understanding of the Low-Salinity Waterflooding Mechanism

Low-salinity waterflooding (LSWF) has proven to improve oil recovery in carbonate formations through rock wettability alteration, although the underlying mechanism remains elusive. Multivalent ionic exchange and calcite dissolution have usually been investigated using geochemical analysis in secondary coreflooding. In this work, coreflooding, in tertiary mode, coupled with a surface reactivity analysis approach was employed to investigate the interplay of wettability alteration mechanisms such as mineral dissolution, electrostatic bond attraction, and the effect of pH at in situ conditions. Improved oil recovery (IOR) in tertiary mode observed by coreflooding in Indiana limestone rocks showed an ionic strength dependence, that is, reducing brine ionic strength resulted in an increase in oil recovery. Coreflooding results showed that the seawater and low-salinity brines deprived of Mg 2+ ions resulted in the lowest IOR in tertiary mode, indicating the significance of Mg 2+ on IOR in limestone rocks. Similar results were observed through the contact angle measurement showing the limestone rock wettability state dependence on ionic strength and the effect of Mg2+ ions. Surface reactivity analysis showed an increase in solution pH, Ca 2+ and Mg 2+ ions concentration in the effluent solution from the coreflooding in tertiary mode using low salinity brines (about 40 and 20% increase in the effluent composition for Ca 2+ and Mg 2+ , respectively). These changes in solution composition were used to calculate the in situ oil–brine and rock–brine zeta potential using a validated surface complexation model, showing the changes of zeta potential as brine is injected into limestone rocks. The results show that using seawater-like brine in tertiary mode resulted in no mineral dissolution or ionic exchange. However, improved oil recovery (IOR) using such seawater-like brine was due to wettability alteration caused by reduced electrostatic bond attraction associated with Mg 2+ ions [from 2.6 × 10 –13 (mol/m 2 ) 2 for formation water salinity to 1.5 × 10 –13 (mol/m 2 ) 2 for seawater salinity]. Using low-salinity brines in tertiary mode improved oil recovery by mineral dissolution, resulting in oil desorption and an increase in solution pH. Finally, the increase in solution pH also resulted in reduced electrostatic bond attraction which lead to rock wettability alteration using low-salinity brines.

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2020

Experimental Investigation on Separation Behavior of Heavy-Oil Emulsion for Polymer Flooding on Alaska North Slope

The first-ever field pilot on Alaska North Slope (ANS) to validate using polymer floods for heavy-oil enhanced oil recovery is currently ongoing. One of the major concerns of the operator is the effect of polymer on oil/water-separation efficiency after polymer breakthrough. This work investigates the influence of polymer on the separation behavior of heavy-oil emulsions and evaluates the performance of emulsion breakers (EBs). In this study, two types of heavy-oil emulsions were prepared and tested at 20 and 50% water cut (WC), respectively. The bottle test method was used in the experiments, in which the separated water volume with time, the separated water quality, and the volume fraction of phases were recorded. Results showed that polymer accelerated the oil/water separation acting as an emulsion inhibitor at 20% WC but tended to impede the water separation at 50% WC. Regardless of WC, polymer resulted in poor water quality and the formation of a stable intermediate oil in water (o/w) emulsion, because of the increased viscosity of the water phase. The performance of EBs showed a complex dependency on the WC, the type of demulsifier and dosage, and the polymer concentration. Despite the varied conditions encountered in the heavy-oil/water/polymer/demulsifier system, a compound EB achieved satisfactory demulsification performance, showing the highest potential for deployment in the current ANS polymer flooding pilot. Here, we systematically studied the potential influence of polymer breakthrough on the separation behavior of heavy-oil emulsion on ANS for the first time. The findings of this study will provide practical guidance in advance for produced fluid treatment of the ongoing first-ever polymer flooding pilot on ANS.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Water Imbibition and Oil Recovery in Shale: Dynamics and Mechanisms Using Integrated Centimeter-to-Nanometer-Scale Imaging

Water imbibition, and the associated oil displacement, is an important process in shale oil reservoirs after hydraulic fracturing and in water-based enhanced oil recovery (EOR). Current techniques for water imbibition measurement are mostly “black-box”-type methods. A more explicit understanding of the water imbibition/oil recovery dynamics and geological controls is in demand. In this paper, a multiscale imaging technique that covers centimeter to nanometer scale (i.e., core to pore scale), integrating neutron radiography, microcomputed tomography (micro-CT), and scanning electron microscope (SEM) is applied to investigate the water imbibition depth and rate and the cause of heterogeneity of imbibition in shale samples. The dynamic processes of water imbibition in the 1-in. (25.4-mm) core sample were explicitly demonstrated, and the imbibition along the matrix and imbibition through microfractures are distinguished through neutron radiography image analysis. The causes of observed imbibition heterogeneity were further investigated through micro-CT and SEM image analysis for 1.5-mm diameter miniplug samples from different laminas of the 1-in. core samples. Imbibition depth and rate were calculated on the basis of image analysis as well. Estimation of oil recovery through water imbibition in shale matrix was performed for an example shale field. Here this innovative and integrated multiscale imaging technique provides a “white/gray-box” method to understand water imbibition and water-oil displacement in shale. The wide span of the length scale (from centimeter to nanometer) of this technique enables a more comprehensive, accurate, and specific understanding of both the core-scale dynamics and pore-scale mechanisms of water imbibition, oil recovery, and matrix-fracture interaction.

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2024

Roles of kaolinite-oil-gas molecular interactions in hydrogen storage within depleted reservoirs

Hydrogen is a clean alternative to fossil fuels, emitting only water vapor during combustion. In a future hydrogen economy, large-scale storage will be an important component of the supply chain. Due to its low volumetric density, conventional surface storage methods are inadequate. Underground hydrogen storage (UHS) offers a viable solution, enabling the storage of millions of cubic meters. Among potential geological sites, including salt caverns, aquifers, and depleted gas reservoirs, depleted oil reservoirs show promise. Studying hydrogen interactions with residual oil and reservoir minerals is vital for understanding the properties of hydrogen and the reservoir post-injection. In this work, we employed molecular dynamics simulations to gain molecular-level insights into these interactions. We investigated hydrogen dissolution in oil, adsorption at kaolinite/oil interfaces, the role of CO 2 as a cushion gas, and the influence of kaolinite’s hydrophobicity on H 2 behavior. The main findings include: (1) hydrogen dissolves more in oil than in water, (2) the introduction of CO 2 suppresses hydrogen dissolution in oil and reduces the interfacial tension (IFT) between oil and gas, (3) CO 2 decreases H 2 partitioning near kaolinite surfaces due to its strong affinity for the hydrophilic gibbsite surface of kaolinite, and (4) CO 2 is more effective than H 2 in reducing IFT between kaolinite and the oil–gas mixture. These findings emphasize the effectiveness of CO 2 as a cushion gas and the important role of clay hydrophobicity in UHS, providing insights that are challenging to obtain experimentally.

08 HYDROGEN↗
DOE OSTI2024

Biofuel production from palm oil deoxygenation using nickel-molybdenum on zirconia catalyst using glycerol as a hydrogen donor

The growing demand for renewable energy has generated interest in biofuels as alternatives to fossil fuels. Second-generation biofuels, derived from deoxygenating fats and oils, have garnered a higher level of interest from industry and academia due to their potential for direct replacement of diesel and jet fuels. Palm oil, mostly cultivated in Thailand and composed of C16 and C18 fatty acids, is a primary feedstock sought for biofuel production. Palm oil deoxygenation contains several pathways that may or may not require hydrogen gas. This study aimed to produce biofuels in different fuel ranges, such as gasoline, jet fuel, and diesel, through palm oil deoxygenation using glycerol as a hydrogen source. Glycerol, a low-value byproduct, was used as a hydrogen donor, whereas nickel-molybdenum-supported catalysts were chosen for their high efficiency in deoxygenation and cost-effectiveness. The study investigated the impact of reaction time, temperature, and catalyst activation method on palm oil deoxygenation. Catalyst characterization methods, including XRD, SEM, TEM, XPS, FTIR, TGA, and nitrogen-sorption, were employed to understand the role of catalysts’ activity during palm oil upgrading. Findings indicated that alkane hydrocarbons are the major components in liquid products. The presence of excess hydrogen in post reaction gaseous phase proves the hydrogen donation capability of glycerol. Increased reaction time and temperature facilitated the removal of oxygen from palm oil. Nickel-molybdenum on zirconia activated by sulfidation demonstrated higher stability than by reduction activation.

09 BIOMASS FUELS↗
DOE OSTI2024

The Roles of Oil–Water Interfaces in Forming Ultrasmall CaSO 4 Nanoparticles

In natural and engineered environmental systems, calcium sulfate (CaSO 4 ) nucleation commonly occurs at dynamic liquid–liquid interfaces. Although CaSO 4 is one of the most common minerals in oil spills and oil–water separation, the mechanisms driving its nucleation at these liquid–liquid interfaces remain poorly understood. Here, in this study, using in situ small-angle X-ray scattering (SAXS), we examined CaSO 4 nucleation at oil–water interfaces and found that within 60 minutes of reaction, short rod-shaped nanoparticles (with a radius of gyration (R g ) of 17.2 ± 2.7 nm and a length of 38.2 ± 5.8 nm) had formed preferentially at the interfaces. Wide-angle X-ray scattering (WAXS) analysis identified these nanoparticles as gypsum (CaSO 4 ·2H 2 O). In addition, spherial nanoparticles measuring 4.1 nm in diameter were observed at oil–water interfaces, where surface-enhanced Raman spectroscopy (SERS) revealed an elevated pH compared to the bulk solution. The negatively charged oil–water interfaces preferentially adsorb calcium ions, collectively promoting CaSO 4 formation there. CaSO 4 particle formation at the oil–water interface follows a nonclassical nucleation (N-CNT) pathway by forming ultrasmall amorphous spherical particles which then aggregate to form intermediate nanoparticles, subsequently growing into nanorod-shaped gypsum. These findings of this study provide insights into mineral scaling during membrane separation and can inform more efficient oil transport in energy recovery systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Limited increases in Arctic offshore oil and gas production with climate change and the implications for energy markets

Climate change impacts on sea ice thickness is opening access to offshore Arctic resources. The degree to which these resources are exploited will depend on sea-ice conditions, technology costs, international energy markets, and the regulatory environment. We use an integrated human-Earth system model, GCAM, to explore the effects of spatial–temporal patterns of sea-ice loss under climate change on future Arctic offshore oil and gas extraction, considering interactions with global energy markets and emission reduction scenarios. We find that under SSP5, a “fossil-fueled development” scenario, the effects of sea-ice loss are larger for Arctic offshore oil production than gas. Under SSP5, future extraction of Arctic offshore oil and gas through 2100 adds roughly 0.8–2.6 EJ/year to oil and gas markets but does not have large impacts on global oil and gas markets. Surprisingly, a low-carbon scenario results in greater Arctic offshore oil production to offset the more emissions-intensive unconventional oil production.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Accelerated Aging of Fast Pyrolysis Bio-Oil Using Carbonyl Titration: Laboratory Analytical Procedure (LAP)

This laboratory analytical procedure covers the accelerated aging of fast pyrolysis bio-oils. Bio-oils undergo reactions that result in physical and chemical changes over time. These changes typically result in an increase in molecular weight, decrease in some functional groups such as carbonyls, and an increase in viscosity; additionally, the aging process often leads to phase separation. Studies have shown that accelerated aging of bio-oils using this method closely mimics room temperature aging for long periods of time (over 3 years). This procedure has been developed for the accelerated aging of fast pyrolysis bio-oils only. Fast pyrolysis bio-oils are more reactive than other bio-oils (e.g., catalytic fast pyrolysis) and undergo aging much more rapidly. Therefore, this procedure should only be used for fast pyrolysis bio-oil samples.

09 BIOMASS FUELS↗
DOE OSTI2024

Engineered Water for Improved Oil Recovery from Fractured Reservoirs (Final Scientific/Technical Report)

The goal of this proposal is to field test the novel technology of engineered water (modifying ionic composition and/or adding surfactants or nanoparticles) injection to improve oil recovery from the carbonate matrix in fractured reservoirs. Carbonate reservoirs tend to be oil-wet/mixed-wet due to positively charged carbonate mineral surfaces and negatively charged acidic/asphaltic components in the oil. Many carbonate reservoirs are also highly fractured. Water injection does not work efficiently in fractured oil-wet reservoirs because water does not imbibe into the matrix. The water composition can be engineered with ionic modification, surfactants and nanoparticles which can change the wettability of carbonate rocks towards more water-wet conditions which can imbibe water into the matrix and push the oil into the fractures. The engineered water can also lower interfacial tension and minimize capillary forces so that gravity can push the oil up and out of the matrix. Wettability alteration also increases water relative permeability which can also improve oil recovery in non-fractured carbonate reservoirs. This technology, if successful, can be a game changer for West Texas carbonates.

02 PETROLEUM↗
DOE OSTI2021

Feedstock and Catalyst Impact on Bio-Oil Production and FCC Co-Processing to Fuels

NREL’s thermochemical biomass conversion research is focused on ex-situ upgrading of biomass fast-pyrolysis (FP) vapors as an efficient and economical route to completely biogenic pyrolysis-based fuel precursors, potential fuels, and value-added chemicals depending on catalyst choice and process conditions. In this approach, biomass vapors are generated via fast pyrolysis with destabilizing vapor components (char, inorganics, tar aerosols) removed by hot gas filtration to produce conditioned vapors more responsive to catalytic upgrading. A Davison Circulating Riser (DCR), a petroleum industry standard for fluidized catalytic cracking (FCC) catalyst evaluation, was coupled with a custom pyrolyzer system designed to produce consistent composition pyrolysis vapors as feed to the DCR. The coupled system is shown below (Figure 1). Pyrolysis vapors, derived from pure hardwood and softwood, were upgraded using commercially available and laboratory modified zeolite-based catalysts. Upgraded oils were analyzed via 31P and 13C NMR spectroscopy, GCxGC-TOF/MS, carbonyl and ultimate analysis (CHNO), and micro distillation to assess both oil chemistry and distillation behavior as they relate to catalyst and feedstock type for producing fungible hydrocarbon product liquids. Measured process parameters identified from technoeconomic process analysis included achieving oil oxygenate contents of 20% or less, carbon-conversion efficiencies of 30% or more, and catalyst coking rates of 10% or less. A proprietary modified zeolite catalyst from Johnson Matthey produced oils that met these requirements. Using the DCR equipped with a proprietary nozzle system, a second approach focused on reducing the carbon intensity of petroleum-derived hydrocarbon fuels by FCC co-processing these CFP oils with petroleum vacuum gas oil (VGO) to produce biogenic carbon containing fuels. The vapor-phase upgrading results demonstrated for the first time the feasibility of producing refinery-compatible hydrocarbon fuel intermediates entirely from biomass-derived fast-pyrolysis vapors using an industry-accepted DCR system for catalytic upgrading. The co-processing results demonstrated the feasibility of using CFP oils with VGO feeds in FCC refinery operations to produce biogenic carbon containing fuels.

bio-oil↗
DOE OSTI2022

Carbon Anode Material from Biomass Pyrolysis Oil

Lithium-ion batteries (LIB) are an important component of electric vehicles and sodium-ion batteries (SIB) are an attractive alternative for grid electric storage. We are investigating a novel approach to synthesizing the carbon anode materials for these batteries from biomass pyrolysis oil as part of conversion processes to produce biofuels. Graphite is used as anode material in LIB and is exclusively produced from petroleum residue or mined mineral carbon. We have synthesized drop-in graphite by coking the heavy residual oil from the distillation of catalytic fast pyrolysis oil and by catalytic graphitizing raw pyrolysis oil. XRD and Raman spectroscopies were used to verify the production of high purity crystalline graphite. Figure 1 shows typical XRD spectra of the bio-graphite compared to commercial material as well as the charge/discharge cycle. Graphite particle sizes and morphologies were adjusted to improve performance using jet milling and carbon coating. The bio-graphite delivered a high capacity (335 mAh/g) when tested in a graphite half-cell. Full cell coin cell experiments were also conducted to verify the observations from half-cell testing. The high value of graphite (>$9/kg) can positively impact the economics of biofuels production and can be an important part of a future circular carbon economy. We have also investigated synthesizing hard carbon from pyrolysis oil for use as anode material in SIB. These batteries are not commercially mature but have great promise in grid storage and use earth abundant elements. We have demonstrated that pyrolysis oil can be used to synthesize hard carbon, which was subsequently be used in SIB experiments. This material achieved a sodium-ion capacity of 250 mAh/g and a first cycle efficiency of 78%, with opportunities to further optimize this performance from optimizing the composition of the pyrolysis oil to shaping the hard carbon particles. As with graphite, hard carbon is a high value (> $10/kg) material that could facilitate biofuels production.

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