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DOE OSTI2025

Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report

The Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report outlines key insights and actionable recommendations for accelerating the scale-up of disruptive chemical manufacturing technologies. Convened in October 2024, the workshop brought together approximately fifty experts from academia, industry, national laboratories, and government agencies to address the barriers and solutions for maturing technologies from proof-of-concept to commercialization. The report identifies seven critical themes for enabling faster scale-up. These themes were explored through general discussions and breakout sessions focused on three specific chemical manufacturing technologies—electrochemical, thermochemical, and biological conversion processes. The findings emphasize the importance of interdisciplinary collaboration, robust funding mechanisms, and shared resources to overcome technical barriers and accelerate technology deployment. The report also highlights technology-specific challenges and opportunities, including the need for advanced materials, scalable manufacturing processes, and integrated testing environments. For electrochemical manufacturing processes, durability and material optimization are key priorities, while thermochemical processes require novel reactor designs and better supply chain integration. Biological conversion processes face hurdles in strain engineering, reactor design, and process integration. Across all technologies, the workshop emphasized the importance of leveraging computational tools, standardized protocols, and collaborative networks to address knowledge gaps and technical barriers. By acting on these insights, stakeholders can reduce the timeline for scaling up critical chemical manufacturing technologies, ensuring their timely impact on manufacturing competitiveness, and environmental sustainability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Electrochemical Pathways for Sustainable Chemical Manufacturing

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Prajapati, Aditya [Lawrence Livermore National Lab↗

DOE OSTI2025

Propane Activation on Pt Electrodes at Room Temperature: Quantification of Adsorbate Identity and Coverage

Abstract C−H bond activation is the first step in manufacturing chemical products from readily available light alkane feedstock and typically proceeds via carbon‐intensive thermal processes. The ongoing emphasis on decarbonization via electrification motivates low‐temperature electrochemical alternatives that could lead to sustainable chemicals production. Platinum (Pt) electrocatalysts have shown activity towards reacting alkanes; however, little is known about propane electrocatalytic activation and conditions suitable for enabling selective oxidation to valuable products. Herein, we utilize a combination of electrochemical mass spectrometry (ECMS) and density functional theory (DFT) calculations to elucidate the potential dependence of propane activation on Pt electrocatalysts. Results show a strong dependence of adsorption on the applied potential in room‐temperature aqueous acidic electrolyte, with a maximum coverage of propane‐derived adsorbates at 0.30 V vs RHE. Using charge deconvolution and deuterated experiments, the mechanism of adsorption was elucidated, and C 3 H 2 * was determined as the average dehydrogenated propane‐derived adsorbate species. DFT calculations further corroborate these results, showing that the formation of deeply dehydrogenated species is energetically accessible at room temperature. The combined theoretical and experimental findings yield insights for selective activation of paraffinic C−H bonds at room temperature, aqueous conditions—a critical step towards decarbonized chemical manufacturing.

Chemistry↗

DOE OSTI2025

Self‐Standing Carbon Nanofibers@Carbon Felt Electrodes to Boost Electrolyzer Productivity: Application to the Electro‐Manufacturing of trans ‐3‐Hexenedioic Acid and Adipic Acid

The industrial implementation of electrosynthesis for chemical manufacturing remains constrained by the limited surface area of conventional electrodes. Herein, this challenge is addressed by designing a carbon nanofiber@carbon felt (CNF@CF) electrode platform that combines the high conductivity, flexibility, and ease of handling of commercial carbon felts (CF) with the large surface area and tunable surface chemistry of carbon nanofibers (CNFs). CNFs are deliberately grown onto the CF scaffold to form a sword-in-sheath structure, where entangled nanofibers wrap the felt macrofibers to provide excellent mechanical stability and electrical conductivity without binders. CNF@CF is evaluated both as an electrode and as a catalyst support for the electrochemical hydrogenation of cis,cis-muconic acid (ccMA), a biobased platform molecule key to the production of performance polyamides and renewable Nylon 6,6. As a noncatalytic electrode for the partial hydrogenation to trans-3-hexenedioic acid, CNF@CF achieves a threefold increase in both cumulative productivity and Faradaic efficiency (FE) compared to bare CF. A similar boost in catalytic activity and energy efficiency is observed using Pd/CNF@CF for the hydrogenation of ccMA to adipic acid. These results highlight the opportunities of the CNF@CF platform for electro-organic synthesis and sustainable chemical manufacturing.

electrochemical hydrogenation↗

DOE OSTI2026

Data for High Yield Production of 3-Hydroxypropionic Acid Using Issatchenkia orientalis

Biomanufacturing provides a more sustainable alternative to fossil-based chemical manufacturing. 3-Hydroxypropionic acid (3HP) is a top Department of Energy value-added chemical and precursor to bioplastics, yet cost-effective microbial production remains elusive. Here, we establish the acid-tolerant yeast Issatchenkia orientalis as a robust host for low-pH 3HP biosynthesis. Genome-scale modeling identifies the β-alanine pathway as optimal, offering the highest theoretical yield and lowest oxygen requirement. Thermodynamic analysis confirms its favorability under acidic conditions. Using sequence similarity network analysis, we discover highly active aspartate 1-decarboxylase (PAND), β-alanine-pyruvate aminotransferase (BAPAT), and 3HP dehydrogenase (YDFG), which significantly improve the pathway efficiency. Next, to further elevate the production, pathway optimization through multi-copy PAND integration, byproduct elimination (knockouts of pyruvate decarboxylase and glycerol-3-phosphate dehydrogenase), and reinforcement of aspartate flux by overexpression of pyruvate carboxylase and aspartate amino transferase improves the titer to 29 g/L in shake flasks. Fed-batch fermentation at pH 4 with low-cost corn steep liquor medium further increases the production to 92 g/L with 0.7 g/g yield and 0.55 g/L/h productivity. Techno-economic analysis indicates that such performance could potentially enable a financially viable process for sustainable acrylic acid production. This work establishes I. orientalis as a next-generation platform for cost-effective 3HP production and paves the way toward industrial commercialization.

Bioproducts↗

DOE OSTI2025

Merging the computational design of chimeric type I polyketide synthases with enzymatic pathways for chemical biosynthesis

Synthetic biology offers the promise of manufacturing chemicals more sustainably than petrochemistry. Yet, both the rate at which biomanufacturing can synthesize these molecules and the net chemical accessible space are limited by existing pathway discovery methods, which can often rely on arduous literature searches. Here, we introduce BioPKS pipeline, an automated retrobiosynthesis tool combining multifunctional type I polyketide synthases (PKSs) and monofunctional enzymes via two complementary tools: RetroTide and DORAnet. Monofunctional enzymes are valuable for carefully decorating a substrate’s carbon backbone while PKSs are unique in their ability to iteratively catalyze carbon-carbon bond formation reactions, thereby expanding carbon backbones in a predictable fashion. We evaluate the performance of BioPKS pipeline using a previously reported set of 155 biomanufacturing candidates, achieving exact synthetic designs for 93 compounds and generating chemically similar pathways for most remaining targets. Furthermore, BioPKS pipeline can propose pathways for the complex therapeutic natural products cryptofolione and basidalin.

Chainani, Yash↗

DOE OSTI2026

Dynamic Electric Field Assisted CO 2 Methanation

Energy-efficient advanced chemical reactions are essential for accelerating the growth of hydrocarbon economy. Sabatier reaction stands out for its potential to effectively transform carbon dioxide into valuable hydrocarbons and is an asset for long-duration Mars missions. This study explores a novel catalytic approach that harnesses electric field-assisted catalysis to substantially enhance the efficiency of the Sabatier reaction. Application of a dynamically perturbed electric field at 1000 Hz resulted in remarkable enhancements, increasing methane formation rates by over 100% at 350 °C and by 74% at 400 °C. Post-reaction catalyst characterization further revealed reduced blockage of active catalytic surface area under the applied electric field, emphasizing improved catalytic longevity and sustained activity. These results underscore the potential of tailored electric field waveforms to dynamically modulate elementary reaction kinetics and surface processes, positioning electric field-assisted catalysis as a transformative strategy for energy-efficient, cost-effective chemical manufacturing and energy conversion technologies.

42 - ENGINEERING↗

DOE OSTI2025

A physiologically based pharmacokinetic (PBPK) model to align dosimetry of the isobutyl metabolic series in rats and humans

Here, we developed a physiologically based pharmacokinetic (PBPK) model in rats and humans for the isobutyl metabolic series including isobutyl acetate, isobutanol, isobutyraldehyde, and isobutyric acid. Chemical manufactures routinely use these compounds as solvents, for chemical synthesis, as potential biofuels, de-icing fluids, and additives for food and/or fragrance in consumer products. Human exposure to isobutyl compounds can occur through inhalation or oral routes. We previously developed a PBPK model for the propyl metabolic series and utilized it as a framework to create the isobutyl PBPK model due to the chemical similarities between the two series. To support model development, we measured in vitro metabolism of isobutyl acetate in rat and human blood and liver S9 fractions. Compared to rats, humans demonstrated faster isobutyl acetate hydrolysis in liver S9 fractions, while the hydrolysis rates in blood were similar between the two species. We used concentrations of isobutyl compounds measured in air and blood from rats exposed to isobutyl acetate and isobutanol as well as other published data to further parameterize the model. Following exposure to either isobutyl acetate or isobutanol, we observed isobutanol concentrations highest among the isobutyl compounds in the blood of rats. Overall, the model accurately predicts measured time course concentrations of isobutyl acetate, isobutanol, and isobutyric acid in available data in rats and humans. Sensitivity analyses identified alveolar ventilation rates, isobutyl metabolism rates, and cardiac output as the most sensitive parameters affecting concentrations of isobutyl compounds in blood. The isobutyl PBPK model enables comparisons of internal dose metrics across various isobutyl compound exposures and species and allows for calculation of equivalent external exposures that result in the same dose metric. Regulators can employ this PBPK model to predict and align internal dose metrics of isobutyl compounds for risk assessment purposes.

2-methyl-1-propanol↗

DOE OSTI2026

High yield production of 3-hydroxypropionic acid using Issatchenkia orientalis

Biotechnology↗

DOE OSTI2026

NH 3 -Mediated Reactive Capture and Conversion: Integrating CO 2 Absorption from Flue Gas with CO Production via NH 4 HCO 3 Electrolysis

Efficient carbon capture and utilization require strategies that minimize energy penalties of CO 2 regeneration and compression. Reactive capture and conversion (RCC) address this challenge by integrating capture with direct electrochemical conversion. Here, we show an NH3-mediated tandem RCC system that couples capture of CO 2 from simulated flue gas (10% v/v CO 2 in N 2 ) with electroreduction of NH 4 HCO 3 to CO over a Ni single-atom catalyst (Ni-SAC). Speciation modeling and capture experiments revealed that a deep CO 2 capture with C/N ratio of 0.65 was achieved using 2.5 M NH 3 from simulated flue gas. Electrolysis of the resulting NH 4 HCO 3 on the Ni- SAC delivered an 85% CO Faradaic efficiency at 100 mA/cm 2 with excellent tolerance to NH 3 /NH 4 + as confirmed by DFT calculations and ab initio molecular dynamics (AIMD) simulations. Further, the technoeconomic analysis established a levelized total cost of CO manufacturing of $25.43/kmol, gauging the practical viability. Overall, this study holds great potential to decarbonize the chemical manufacturing industry while reducing synthetic production costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Bioreactor Optimization through Multi-Phase Flow Models (CRADA Final Report)

Chemical manufacturing uses 29% of energy in the United States and produces 925 million metric tons of CO2 annually. Biomanufacturing offers the potential to leverage America’s rich agricultural resources to produce critical chemicals such as lubricants, pharmaceutical precursors, and components of energetic materials that today are sourced extensively from overseas. The bioreactors used in biomanufacturing applications, such as one developed by Capra Biosciences, involve multiphase flow of biofilm-coated solid support particles that are continuously circulated in a fluidized state within the reactor along with a constant supply of oxygen via an aeration mechanism. In this project, Capra Biosciences and LBNL developed a multiscale modeling framework to simulate the multiphase flows of solid particles in a liquid-gas bubble mixture that occurs in the bioreactor using the current MFIX-Exa software, an opensource multiphase flow solver developed and maintained at LBNL and NETL. By leveraging HPC capabilities, this high-fidelity multiscale model was used to inform design decisions for bioreactor architecture to make them operationally efficient.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Supply Chain Energy and Greenhouse Gas Analysis Using the Materials Flows Through Industry (MFI) Tool: Examination of Alternative Technology Scenarios for the U.S. Chemical Sector

Chemical manufacturing is a large and diverse sector of the U.S. economy, with products, fuels, and a wide assortment of materials used daily by both the public and businesses. Currently, several of the largest volume chemicals produced in the United States rely on fossil fuels as a feedstock, energy source, or both. The list of chemicals includes steam cracking products such as ethylene, propylene, benzene, and xylenes as well as products such as ammonia and methanol. The focus for this work is on platform chemicals that are both produced in the largest volume and have a high potential for subsequent processing into more specialized products. In this study, we explore several new pathways that reduce the overall energy consumption and greenhouse gas (GHG) emissions for each product. These pathways include energy efficiency measures applied to existing production methods, the use of bio‐based fuels and/or feedstocks as new production methods, and electrification of high‐energy‐input stages within current production methods. Scenarios for energy demand and GHG reduction were conducted with the National Renewable Energy Laboratory's Materials Flows through Industry tool. Projections of the energy demand and GHG emissions in 2030 and 2050 are included, using grid composition projections from the NREL ReEDS model. The alternative scenarios selected showcase the effect of realistic changes the industry could make, focusing on technologies with a high level of technical readiness.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2026

Technoeconomic Analysis of a Novel Microwave Process to Produce Ethylene from Methane

Ethylene is a critical feedstock in industrial processes, serving as a raw material in the petrochemical industry to produce plastics and commodity chemicals. Conventional ethylene production routes are energy-intensive and contribute substantially to the carbon footprint of chemical manufacturing. In this study, an industrial-scale novel microwave process was simulated using ASPEN Plus to assess its economic viability. Technoeconomic analysis confirmed the economic competitiveness of the novel microwave process, with a levelized cost of ethylene of USD 0.51/kg compared to USD 0.56/kg for the conventional base case. Key economic drivers of the process were identified, and sensitivity analyses were conducted to evaluate their impact on project economics. Furthermore, 87.7% of the total utility consumption in the novel microwave process is electricity, highlighting its potential to contribute to the electrification of the chemical industry. The findings of this study confirm the economic feasibility of both industrial-scale microwave reactors and modular plant configurations for the production of ethylene from methane, offering a promising alternative to conventional processes.

electromagnetic radiation↗

DOE OSTI2026

Biomanufacturing and Scale-Up: Pathways to Biochemicals, Biofuels, and Biomaterials

Advancing the bioeconomy requires the development of large-scale microbial bioprocesses capable of converting waste carbon streams into biofuels, biochemicals, and biomaterials at industrially relevant scales. While biomanufacturing has been successfully demonstrated at the laboratory scale for a wide range of chemicals, only a few have reached industrial-scale production. This is partly due to the inherent complexity of microbial systems, which rely on living cells with intricate metabolic pathways that are highly sensitive to environmental changes, making large-scale production difficult to optimize and predict. As a result, scaling-up bioprocesses remains a high-stakes challenge that requires deeper exploration. This involves integrating feedstock and microbial selection, upstream and downstream processes, and computational modelling, among other research efforts. Bulk and specialty chemicals derived from biological processes also face competition from fossil-based production routes, which have been refined through decades of technological advancements. While biologically derived molecules may offer more environmentally friendly production pathways than traditional chemical manufacturing, their widespread adoption depends on achieving cost parity-or superiority-relative to fossil-based methods. This emphasizes the importance of holistic research, including techno-economic analyses and life cycle assessments, to ensure both economic viability and environmental sustainability. This editorial and special issue explores state-of-the-art strategies for converting waste carbon sources into valuable products. It discusses how enzymes, single microbes (e.g., extremophiles), and microbiomes (e.g., through division of labor) can be integrated with upstream and downstream process innovations-such as consolidated bioprocessing and in situ product recovery-to improve the efficiency and scalability of biomanufacturing. The editorial further highlights the role of computational modelling in understanding, predicting, and controlling bioprocess performance across scales, and concludes by emphasizing the importance of techno-economic modelling to identify technologies that can move to market.

09 BIOMASS FUELS↗

DOE OSTI2026

The Relationship Between Catalyst and Solvent in Hydrogenation via Condensed Phase Heterogeneous Catalysis

To understand a system is to understand its components and their sum. Cascading interactions between catalyst, solvent, and reagent create a complex web of influences when heterogeneous catalysis meets the condensed phase. Due to the importance of heterogeneous catalysis in chemical manufacturing, and the present and growing potential of condensed phase chemistries, the understanding of these interactions is of paramount importance. To develop condensed phase heterogeneous catalysis, the field needs to develop understanding of the role of solvent in heterogeneous catalytic hydrogenation. While no small feat, fields such as biofuel and petroleum refining have established certain applicable generalities that can bridge the knowledge gap in emerging technologies such as integrated carbon capture and conversion to materials (IC 3 M). In this review, we thoughtfully probe the current paradigm of condensed phase catalysis by challenging the idea that catalyst and solvent are independent reaction design choices. Challenges such as lack of experimental stability studies and poor resolution on our conceptualization of the condensed phase environment are discussed. Parameters such as viscosity and the dielectric constant, and their role on reaction activity and stability are explored. Knowledge gained from established biomass and petroleum processes is discussed and used to anticipate behavior in novel processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Impact of anion-exchange membrane degradation on long-term CO 2 electrolysis to ethylene

Electrochemical CO 2 reduction (eCO2R) to ethylene offers a unique opportunity to diversify domestic supply chains for chemical manufacturing. Large-scale deployment of eCO2R to ethylene reactors is currently limited by low energy efficiencies and poor durability. Herein, we demonstrate >100 h of continuous electrolysis at an industrially relevant current density of 200 mA cm −2 in a 25 cm 2 geometric area zero-gap reactor with a full-cell voltage <3.1 V and ethylene Faradaic efficiency >30%. Incorporating expanded polytetrafluoroethylene (PTFE)-supported electrodes into zero-gap reactors allows for durable electrode catalysts that are resistant to flooding, and this enables wider ranges of operating parameters not typically accessible in CO 2 electrolysis. Finally, we identify membrane degradation, evidenced by a loss of membrane ion-exchange capacity, as the leading cause of performance loss over 144 h of electrolysis.

Energy - Conversion↗

DOE OSTI2026

A Robust Methodology to Elucidate Kinetics of Room Temperature Electrochemical Propane Adsorption on Platinum

Electrocatalytic activation of alkanes can further decarbonize chemical manufacturing by leveraging affordable renewable electricity and readily available shale gas reserves in the United States. Earlier works have identified the unique role of Pt in adsorbing and activating alkanes, like propane, at room temperature in acidic, aqueous electrolytes, revealing spontaneous formation of deeply dehydrogenated propane-derived surface species with an intact C 3 - backbone. Although an adsorption mechanism was hypothesized, it has not been explicitly investigated to date, preventing the quantification of kinetic rate parameters. A robust methodology to investigate and benchmark propane adsorption kinetics on Pt is critical for the rational design of electrocatalysts that exhibit higher selectivity toward desired partially oxidized products. Herein, we analyze an oxidative current transience that appears during the adsorption of propane on Pt in aqueous electrochemical conditions and develop a methodology that elucidates the adsorption mechanism and enables quantification of rate parameters such as order dependences and apparent activation barriers. This method yields an expected first-order dependence with respect to propane concentration at low coverage and reveals a second-order dependence with respect to the concentration of surface active sites. Additionally, the apparent activation barrier for propane adsorption was calculated using an Arrhenius analysis of the current transience under temperature control. The experimentally measured activation barrier of 35 kJ mol –1 is in excellent agreement with the theoretical barrier calculated by density functional theory (DFT). The kinetic analysis was extended, via the use of transition state theory, to extract entropy and enthalpy of activation, yielding consistent results with the proposed two-step adsorption mechanism and DFT calculations. These results demonstrate reliable quantification of kinetic parameters for electrocatalytic activation of C–H bonds in alkanes that can be employed for rational catalyst development for a versatile range of electrocatalytic conditions.

alkane activation↗

DOE OSTI2025

Upcycling of polyethylene terephthalate to high-value chemicals by carbonate-interchange deconstruction

Condensation thermoplastics have become ubiquitous. The emergence of chemical upcycling could transform them into valuable feedstocks for chemical manufacturing at their end-of-life. However, current solvolysis processes suffer equilibrium limitations due to the liberation of reactive byproducts. We report a carbonate interchange deconstruction (CID) methodology for poly(ethylene terephthalate) (PET), where carbonates act as both latent nucleophiles and byproduct sequestering agents. High product selectivity (>95%) is achieved regardless of the targeted terephthalate product, originating from removal of ethylene glycol from the reaction equilibrium via its conversion into various oligoethers. CID is robust to the impurities present in post-consumer waste plastics and significantly reduces solvent demand, with just 10 mL of dimethyl carbonate successfully converting ca. 5 g of mixed PET waste into highly pure dimethyl terephthalate in excellent isolated yield (92%). CID opens a new upcycling paradigm wherein CO2, embedded in carbonates, is leveraged to choreograph the selectivity of an otherwise equilibrium-controlled polymer upcycling process.

Galan, Nick [ORNL]↗