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DOE OSTI2016

Life-cycle analysis of energy use, greenhouse gas emissions, and water consumption in the 2016 MYPP algal biofuel scenarios

The Department of Energy (DOE) Bioenergy Technologies Office (BETO) Multi-year Program Plan (MYPP) describes the bioenergy objectives pursued by BETO, the strategies for achieving those objectives, the current state of technology (SOT), and a number of design cases that explore cost and operational performance required to advance the SOT towards middle and long term goals (MYPP, 2016). Two options for converting algae to biofuel intermediates were considered in the MYPP, namely algal biofuel production via lipid extraction and algal biofuel production by thermal processing. The first option, lipid extraction, is represented by the Combined Algae Processing (CAP) pathway in which algae are hydrolyzed in a weak acid pretreatment step. The treated slurry is fermented for ethanol production from sugars. The fermentation stillage contains most of the lipids from the original biomass, which are recovered through wet solvent extraction. The process residuals after lipid extraction, which contain much of the original mass of amino acids and proteins, are directed to anaerobic digestion (AD) for biogas production and recycle of N and P nutrients. The second option, thermal processing, comprises direct hydrothermal liquefaction (HTL) of the wet biomass, separation of aqueous, gas, and oil phases, and treatment of the aqueous phase with catalytic hydrothermal gasification (CHG) to produce biogas and to recover N and P nutrients. The present report describes a life cycle analysis of energy use and greenhouse gas (GHG) emissions of the CAP and HTL options for the three scenarios just described. Water use is also reported. Water use during algal biofuel production comes from evaporation during cultivation, discharge to bleed streams to control pond salinity (“blowdown”), and from use during preprocessing and upgrading. For scenarios considered to date, most water use was from evaporation and, secondarily, from bleed streams. Other use was relatively small at the level of fidelity being modeled now.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2016

Life-Cycle Analysis of Energy Use, Greenhouse Gas Emissions, and Water Consumption in the 2016 MYPP Algal Biofuel Scenarios

09 BIOMASS FUELS↗

DOE OSTI2022

Water Power Technologies Office: Multi-Year Program Plan

The U.S. Department of Energy’s Water Power Technologies Office (WPTO) has released its first Multi-Year Program Plan (MYPP), which outlines the Office’s research priorities and plans through 2025. Cover of the WPTO MYPP 2022. The MYPP serves as both a strategic vision and an operational guide to help WPTO manage and coordinate its activities, as well as a vehicle to communicate WPTO’s mission, goals, and plans to water power stakeholders and the public. It details WPTO’s research, development, demonstration, and commercial activities across both hydropower and marine energy for the coming years and outlines how these efforts can help meet the nation’s energy and sustainability goals. The MYPP features key performance goals for 2025, as well as additional objectives running through 2030. All outlined goals contribute to the overarching mission of WPTO to enable research, development, and testing of new technologies to advance marine energy and hydropower systems for a flexible, reliable grid.

13 HYDRO ENERGY↗

DOE OSTI2018

Final Report: Scale-up of Algal Biofuel Production Using Waste Nutrients

Renewable fuels can be more environmentally friendly than conventional fuels and can be produced locally, supporting energy independence. Liquid renewable fuels are of special interest due to their high energy density. Algae are a promising prospective feedstock for low carbon intensity liquid biofuels, due to their high productivity and potential for high lipid or carbohydrate content. Their ability to grow on wastewater and waste nutrients and on non-arable land are cost and sustainability advantages. The organic matter content of wastewater promotes mixotrophic and/or heterotrophic growth of both algae and bacteria, boosting biomass productivity further. However, economic and technologic challenges persist that prevent the scale-up of algal biofuels to commercial relevance. These challenges include algal harvesting, drying, dewatering, and the conversion of algal biomass to usable fuels (Hannon et al 2010, Dunlap and Shaw 2009, Pienkos et al. 2009). The US Department of Energy (DOE) Bioenergy Technologies Office (BETO) supports research to overcome these challenges and outlines the research and development goals for algal biofuels in their Multi-Year Program Plan (MYPP). The long-term goals of the MYPP for algal biofuels research are briefly as follows: develop the domestic ability to produce algal biofuels at a scale of 5 billion gallons per year (BGY) by 2030 and demonstrate technologies that produce biofuel intermediates from algae at a cost of $3/gallon of gasoline equivalent (GGE) by 2022 (BETO MYPP 2016). This research reported herein was funded to investigate methods of meeting an intermediate milestone of 2,500 gallons of biofuel intermediate per acre per year for a non-integrated process by improving algal productivity, harvesting efficiency, and conversion to biofuel intermediates. Use of wastewater and wastewater nutrients was a key distinguishing characteristic of this project. In pursuit of 2,500 gallons of biofuel intermediate (BFI) per acre per year, California Polytechnic State University, San Luis Obispo (Cal Poly) sought to develop the capability to produce biofuel intermediates from microalgae grown on municipal wastewater at a 20-acre algae-based wastewater treatment facility in Delhi, California (37.43° N), which includes 7 acres of raceway ponds. Coupling algal biofuel production with wastewater treatment capitalizes on the abundant waste nutrients and carbon present in wastewater and reduces use of clean water in algal biorefinery systems. In this research, the performance of the full-scale wastewater treatment plant was characterized by measuring productivity, wastewater treatment performance, hydraulic characteristics, and energy consumption. Nine 1,000-L pilot raceways with CO2 addition were used in experiments to maximize productivity. Low-cost, energy-efficient algae bioflocculation and settling were monitored. Population genetics were monitored in an attempt to correlate taxa with superior productivity and/or settling. Algae-bacterial biomass was converted to biofuel intermediates via bench-scale hydrothermal liquefaction (HTL), and the resulting fuel quality was characterized. To develop rapid strain screening capabilities, a climate simulating photobioreactor (“LEAPS”) was developed and validated against outdoor raceways. A techno-economic analysis (TEA) and a lifecycle assessment (LCA) were performed to model process economics and sustainability. The major outcomes of this research included demonstration of 33 g/m2-day annual average algal-bacterial productivity in pilot raceways, and a biofuel intermediate yield of 0.35 g intermediate/g algae biomass via HTL, for a yield of 4,100 gallons BFI per acre per year, assuming a 90% harvest efficiency and ignoring other minor losses. This exceeded the project goal of 2,500 gallons of BFI per acre per year and nearly met the 2030 program goal, highlighting the promise of integrating wastewater treatment and biofuels production. The biocrude BFI produced by the process is refined to diesel and naphtha fuels. These fuels are normalized to the energy content of gasoline (gallons gasoline equivalent, GGE, for comparison to other fuels). Results from the TEA of the this complete “well-to-wheel” process demonstrated that, at a 400-ha scale, a minimum fuel selling price (MFSP) of $12.55/GGE, which could be decreased 57% to $7.14/GGE when including revenue from coupling the biofuel production with the co-products of wastewater treatment services and low carbon fuel credits from California and Federal programs. Due mainly to the high capital costs of thickener centrifuges and hydrothermal processing equipment, the fuel cost is sensitive to scale, with significantly lower costs expected for larger farms. In this research project, significant advances were made in improving raceway algal productivity and fuel production from algae biomass, while also improving process economics. These outcomes brought the algal biofuel technology closer to being a sustainable and marketable process. The remainder of this executive summary is organized into the following six primary project tasks: (1) to optimize biomass productivity for a selected strain at Delhi, (2) to maximize algal productivity and harvesting efficiency in Delhi pilot ponds, (3) a full-scale raceway hydraulic characterization, (4) biomass processing to biofuel intermediates, and (5) scale-up engineering analysis, modeling, and planning.

09 BIOMASS FUELS↗

DOE OSTI2022

GTO Multi-Year Program Plan FY 2022-2026

The GTO Multi-Year Program Plan (MYPP), building on the findings of the GeoVision analysis, outlines a 5-year plan of activities GTO will pursue to support the growth and long-term contribution of geothermal energy to the U.S. electricity grid and American homes and buildings. The MYPP outlines GTO’s vision and mission and presents a high-level technology plan for key areas of GTO research starting in Fiscal Year (FY) 2022 and running through the end of FY 2026.

15 GEOTHERMAL ENERGY↗

DOE OSTI2012

Efficient Light Extraction from Organic Light-Emitting Diodes Using Plasmonic Scattering Layers (Final Report)

Our project addressed the DOE MYPP 2020 goal to improve light extraction from organic light-emitting diodes (OLEDs) to 75% (Core task 6.3). As noted in the 2010 MYPP, “the greatest opportunity for improvement is in the extraction of light from [OLED] panels”. There are many approaches to avoiding waveguiding limitations intrinsic to the planar OLED structure including use of textured substrates, microcavity designs and incorporating scattering layers into the device structure. We have chosen to pursue scattering layers since it addresses the largest source of loss which is waveguiding in the OLED itself. Scattering layers also have the potential to be relatively robust to color, polarization and angular distributions. We note that this can be combined with textured or microlens decorated substrates to achieve additional enhancement.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2016

Bioenergy Technologies Office Multi-Year Program Plan. March 2016

The Bioenergy Technologies Office is one of the 10 technology development offices within the Office of Energy Efficiency and Renewable Energy at the U.S. Department of Energy. This Multi-Year Program Plan (MYPP) sets forth the goals and structure of the Bioenergy Technologies Office (the Office). It identifies the research, development, and demonstration (RD&D), and market transformation and crosscutting activities the Office will focus on over the next five years and outlines why these activities are important to meeting the energy and sustainability challenges facing the nation. This MYPP is intended for use as an operational guide to help the Office manage and coordinate its activities, as well as a resource to help communicate its mission and goals to stakeholders and the public.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2011

Light Duty Efficient, Clean Combustion (Final Report)

Cummins has successfully completed the Light Duty Efficient Clean Combustion (LDECC) cooperative program with DoE. This program was established in 2007 in support of the Department of Energy's Vehicles Technologies Advanced Combustion and Emissions Control initiative to remove critical barriers to the commercialization of advanced, high efficiency, emissions compliant internal combustion (IC) engines for light duty vehicles. Work in this area expanded the fundamental knowledge of engine combustion to new regimes and advanced the knowledge of fuel requirements for these diesel engines to realize their full potential. All of the following objectives were met with fuel efficiency improvement targets exceeded: (1) Improve light duty vehicle (5000 lb. test weight) fuel efficiency by 10.5% over today's state-of-the-art diesel engine on the FTP city drive cycle; (2) Develop and design an advanced combustion system plus aftertreatment system that synergistically meets Tier 2 Bin 5 NOx and PM emissions standards while demonstrating the efficiency improvements; (3) Maintain power density comparable to that of current conventional engines for the applicable vehicle class; and (4) Evaluate different fuel components and ensure combustion system compatibility with commercially available biofuels. Key accomplishments include: (1) A 25% improvement in fuel efficiency was achieved with the advanced LDECC engine equipped with a novel SCR aftertreatment system compared to the 10.5% target; (2) An 11% improvement in fuel efficiency was achieved with the advanced LDECC engine and no NOx aftertreamtent system; (3) Tier 2 Bin 5 and SFTP II emissions regulations were met with the advanced LDECC engine equipped with a novel SCR aftertreatment system; (4) Tier 2 Bin 5 emissions regulations were met with the advanced LDECC engine and no NOx aftertreatment, but SFTP II emissions regulations were not met for the US06 test cycle - Additional technical barriers exist for the no NOx aftertreatment engine; (5) Emissions and efficiency targets were reached with the use of biodiesel. A variety of biofuel feedstocks (soy, rapeseed, etc.) was investigated; (6) The advanced LDECC engine with low temperature combustion was compatible with commercially available biofuels as evaluated by engine performance testing and not durability testing; (7) The advanced LDECC engine equipped with a novel SCR aftertreatment system is the engine system architecture that is being further developed by the Cummins product development organization. Cost reduction and system robustness activities have been identified for future deployment; (8) The new engine and aftertreatment component technologies are being developed by the Cummins Component Business units (e.g. fuel system, turbomachinery, aftertreatment, electronics, etc.) to ensure commercial viability and deployment; (9) Cummins has demonstrated that the technologies developed for this program are scalable across the complete light duty engine product offerings (2.8L to 6.7L engines); and (10) Key subsystems developed include - sequential two stage turbo, combustions system for low temperature combustion, novel SCR aftertreatment system with feedback control, and high pressure common rail fuel system. An important element of the success of this project was leveraging Cummins engine component technologies. Innovation in component technology coupled with system integration is enabling Cummins to move forward with the development of high efficiency clean diesel products with a long term goal of reaching a 40% improvement in thermal efficiency for the engine plus aftertreatment system. The 40% improvement is in-line with the current light duty vehicle efficiency targets set by the 2010 DoE Vehicle Technologies MYPP and supported through co-operative projects such as the Cummins Advanced Technology Powertrains for Light-Duty Vehicles (ATP-LD) started in 2010.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2012

Development of a commercial enzymes system for lignocellulosic biomass saccharification

DSM Innovation Inc., in its four year effort was able to evaluate and develop its in-house DSM fungal cellulolytic enzymes system to reach enzyme efficiency mandates set by DoE Biomass program MYPP goals. DSM enzyme cocktail is uniquely active at high temperature and acidic pH, offering many benefits and product differentiation in 2G bioethanol production. Under this project, strain and process development, ratio optimization of enzymes, protein and genetic engineering has led to multitudes of improvement in productivity and efficiency making development of a commercial enzyme system for lignocellulosic biomass saccharification viable. DSM is continuing further improvement by additional biodiversity screening, protein engineering and overexpression of enzymes to continue to further lower the cost of enzymes for saccharification of biomass.

09 BIOMASS FUELS↗

DOE OSTI2013

Determine metrics and set targets for soil quality on agriculture residue and energy crop pathways

There are three objectives for this project: 1) support OBP in meeting MYPP stated performance goals for the Sustainability Platform, 2) develop integrated feedstock production system designs that increase total productivity of the land, decrease delivered feedstock cost to the conversion facilities, and increase environmental performance of the production system, and 3) deliver to the bioenergy community robust datasets and flexible analysis tools for establishing sustainable and viable use of agricultural residues and dedicated energy crops. The key project outcome to date has been the development and deployment of a sustainable agricultural residue removal decision support framework. The modeling framework has been used to produce a revised national assessment of sustainable residue removal potential. The national assessment datasets are being used to update national resource assessment supply curves using POLYSIS. The residue removal modeling framework has also been enhanced to support high fidelity sub-field scale sustainable removal analyses. The framework has been deployed through a web application and a mobile application. The mobile application is being used extensively in the field with industry, research, and USDA NRCS partners to support and validate sustainable residue removal decisions. The results detailed in this report have set targets for increasing soil sustainability by focusing on primary soil quality indicators (total organic carbon and erosion) in two agricultural residue management pathways and a dedicated energy crop pathway. The two residue pathway targets were set to, 1) increase residue removal by 50% while maintaining soil quality, and 2) increase soil quality by 5% as measured by Soil Management Assessment Framework indicators. The energy crop pathway was set to increase soil quality by 10% using these same indicators. To demonstrate the feasibility and impact of each of these targets, seven case studies spanning the US are presented. The analysis has shown that the feedstock production systems are capable of simultaneously increasing productivity and soil sustainability.

09 BIOMASS FUELS↗

DOE OSTI2013

Development and Utilization of Host Materials for White Phosphorescent Organic Light-Emitting Diodes

Our project was primarily focused on the MYPP 2015 goal for white phosphorescent organic devices (PhOLEDs or phosphorescent organic light-emitting diodes) for solid-state lighting with long lifetimes and high efficiencies. Our central activity was to synthesize and evaluate a new class of host materials for blue phosphors in the PhOLEDs, known to be a weak link in the device operating lifetime. The work was a collaborative effort between three groups, one primarily responsible for chemical design and characterization (Chen), one primarily responsible for device development (Tang) and one primarily responsible for mechanistic studies and degradation analysis (Rothberg). The host materials were designed with a novel architecture that chemically links groups with good ability to move electrons with those having good ability to move “holes” (positive charges), the main premise being that we could suppress the instability associated with physical separation and crystallization of the electron conducting and hole conducting materials that might cause the devices to fail. We found that these materials do prevent crystallization and that this will increase device lifetimes but that efficiencies were reduced substantially due to interactions between the materials creating new low energy “charge transfer” states that are non-luminescent. Therefore, while our proposed strategy could in principle improve device lifetimes, we were unable to find a materials combination where the efficiency was not substantially compromised.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Approach to Low-Cost High-Efficiency OLED Lighting. Building Technologies Solid State Lighting (SSL) Program Final Report

This project developed an integrated substrate which organic light emitting diode (OLED) panel developers could employ the integrated substrate to fabricate OLED devices with performance and projected cost meeting the MYPP targets of the Solid State Lighting Program of the Department of Energy. The project optimized the composition and processing conditions of the integrated substrate for OLED light extraction efficiency and overall performance. The process was further developed for scale up to a low-cost process and fabrication of prototype samples. The encapsulation of flexible OLEDs based on this integrated substrate was also investigated using commercial flexible barrier films.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Sustainability of the U.S. Manufacturing Sector: Use of the United Nations Sustainable Development Goals

The United Nations' 17 Sustainable Development Goals (SDGs) aim to improve health and education, reduce inequality, and encourage economic growth, while also preserving or improving the conditions of our oceans and forests. Pursuing these SDGs would mean $12 trillion in economic opportunities for companies, while also improving the lives of all people and bettering the planet. Some manufacturing companies are already focusing on sustainability, but not all. In 2019, almost 30% of National Association of Manufacturers members did not have a sustainable policy, goals, or program in place. Business drivers for sustainability and the SDGs are similar, with focuses on economic growth and consumer demands. Despite the shortcomings of the SDGs, they represent an opportunity for manufacturing companies to further improve energy, material efficiency, and productivity. This report evaluates the SDGs and the manufacturing sector. The manufacturing sector was analyzed using the technology assessments (TAs) introduced in the 2015 Quadrennial Technology Review (QTR) review, which focused on concepts, challenges, and solutions to meet the United States' energy needs. Annual or sustainability reporting of companies performing work in one of those TAs were analyzed for mentions of the SDGs. The call-out boxes throughout this report provide examples of companies making progress toward the SDGs. The possible overlap between the SDGs and the Advanced Manufacturing Office (AMO) was also evaluated. The TAs in the 2015 QTR Review were furthered with detailed targets in the draft Multi-Year Program Plan (MYPP) for Fiscal Years 2017-2021. Direct and likely relationships between the SDGs and the TAs were established. Positives, challenges, SDG-related literature, and future steps are also discussed in this report.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Improved Light Extraction by Engineering Molecular Properties of Square Planar Phosphorescent Emissive Materials

The ultimate objective of this project was to develop a cost-effective technology which could significantly improve the light outcoupling efficiency up to 70% and higher and the key tasks were listed as follows: (i) improving light extraction efficiency through a better control of horizontally aligned emitting dipoles of square planar phosphorescent emitters; (ii) fabricating high-efficiency monochromic and amber OLED in the device settings; (iii) fabricating high-efficiency white OLED in the device settings. With both materials innovation and device structure optimization, we realized OLEDs with an EQE of 66% with a LT 95 lifetime of over 100 khrs at a brightness of 1,000 cd/m 2 . This proposed research is a high impact project which could potentially revolutionize OLED lighting technology and expedite the commercialization process of OLED technology for solid state lighting. This project outcomes contributed to meet the targeted performance of organic solid state lighting set in the DOE MYPP.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Detecting and Characterizing Fracture Zones Using a Convolutional Neural Network

This project directly supports the Geothermal Technologies Office (GTO) objectives outlined in the Multi-Year Program Plan (MYPP) by advancing two key research areas: “Exploration and Characterization” and “Data, Modeling, and Analysis.” This project has successfully demonstrated a pre-drilling ability to image and characterize the distribution and connectivity of subsurface faults and fractures, key parameters for identifying permeable pathways that enable geothermal fluids to circulate and produce energy. Specifically, we developed and implemented innovative machine learning methodologies to enhance geothermal exploration. Large-scale faults were detected using a Convolutional Neural Network (CNN), while small-scale fractures were characterized using a novel Double-Beam Neural Network (DBNN). These tools have proven both technically effective and cost-efficient by reducing reliance on expensive exploratory drilling. Through collaboration with our geothermal industry partner, this research has significantly advanced techniques for identifying hidden geothermal systems and extending the productive lifespan of existing geothermal fields. We applied our methods to two geothermal fields—Soda Lake (Nevada) and Lightning Dock (New Mexico)—to identify shallow steam-charged fracture zones and characterize deep faults at depths of 1.5-2 km. The steam zone identified at the Soda Lake geothermal field showed excellent agreement with prior drilling data, validating the effectiveness of our approaches. In addition, the analysis revealed three new prospective drilling targets for further development and verification. The outcomes of this project improve our scientific understanding of geothermal reservoir behavior, enhance exploration efficiency, extend the economic life of existing geothermal plants. Ultimately, these advancements contribute to GTO’s goal of achieving more sustainable, affordable, and data-driven geothermal energy development across the United States.

15 GEOTHERMAL ENERGY↗

DOE OSTI2018

High efficiency and stable white OLED using a single emitter

The ultimate objective of this project is to develop efficient and stable white OLEDs employing a single emissive material. To deliver this research goal, the project was focused on three main areas including: 1) the development of efficient and stable phosphorescent excimers; 2) the quick screening of phosphorescent excimers in the device settings; and 3) the incorporation of developed phosphorescent excimers in the state-of-the-art OLED settings to maximize the device efficacy and operational lifetime of single-doped WOLEDs. The successful outcome of this project has provided a potential solution to lower the fabrication cost of WOLEDs significantly by decreasing the complexity of device fabrication, increasing the robustness of materials and providing more cost-effective alternates to the state-of-the-art Iridium-based phosphorescent emitters. Moreover, a single-doped WOLED can provide a greater control of emission color by eliminating color aging. This proposed research is a high impact project which will potentially revolutionize OLED lighting technology and expedite the commercialization process of OLED technology for solid state lighting. This project outcomes will contribute to meet the targeted cost of organic solid state lighting set in the DOE MYPP.

42 ENGINEERING↗

DOE OSTI2021

BETO 2021 Peer Review - Biological Upgrading of Sugars (BUS) 2.3.2.105

The Biological Upgrading of Sugars (BUS) project directly targets the anaerobic conversion of lignocellulosic feedstocks into intermediate molecules readily upgradeable to fuel precursors. Recent efforts on the BUS project have a particular emphasis on the biological production of butyric acid, an intermediate that can be readily upgraded to sustainable aviation fuel, diesel blend-stocks, and high value chemicals. The BUS project approaches this direction through a combination of strain engineering, fermentation process engineering, development of novel separations technologies, and the design and build of pilot scale systems. Our ultimate project goal is to develop an integrated cost-effective process at pilot scale to achieve DOE's MYPP targets of $2.50/GGE. The major thrust of the BUS project over the last project cycle was on the development of integrated processes surrounding the anaerobic production of carboxylic acids using diverse Clostridium species. We developed and expanded genetic tools for several Clostridium species and rewired microbial metabolism in an attempt to maximize substrate utilization and flux towards butyric acid. We designed and built novel bioreactors with an in situ product recovery system enabling the biological production and recovery of highly purified acids. We leveraged this system to generate 100s of grams of acid from corn stover hydrolysate. In this presentation we highlight data surrounding our proposed process and accompanying results from technoeconomic and life-cycle analyses of our integrated process. Finally, we detail plans of our pilot scale reactor system that is in process and discuss our future routes towards achieving economically viable and sustainable diesel and jet blendstocks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2010

Multi-Year Program Plan - Building Regulatory Programs

This document presents DOE’s multi-year plan for the three components of the Buildings Regulatory Program: Appliance and Equipment Efficiency Standards, ENERGY STAR, and the Building Energy Codes Program. This document summarizes the history of these programs, the mission and goals of the programs, pertinent statutory requirements, and DOE’s 5-year plan for moving forward.

Appliance and Equipment Efficiency Standards↗