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DOE OSTI2024

ChemPren: a new and economical technology for conversion of waste plastics to light olefins

With the ever-increasing demand for plastics, sustainable recycling methods are key necessities. Here, the current plastics industry can manage to recycle only 10% of the 400 million metric tons of plastic produced globally. Waste plastics, in the current infrastructure, land up mostly in landfills. Although a lot of research efforts have been spent on processing and recycling co-mingled mixed plastics, energy-efficient sustainable and scalable routes for plastic upcycling are still lacking. Catalytic valorization of waste plastic feedstock is one of the potential scalable routes for plastic upcycling. Silica-alumina based materials, and zeolites have shown a lot of promise. A major interest lies in restricting catalyst deactivation, and refining product selectivity and yield for such catalytic processes. This article highlights ChemPren technology as a clean energy solution to waste plastic recycling. Co-mingled, mixed plastic feedstock along with spray dried, attrition resistant, ZSM-5 containing catalysts is preprocessed with an extruder to form optimally sized particles and fed into a fluidized bed reactor for short contact times to produce selectively and in high yields ethylenes, propylenes and butylenes. This techno-economic perspective indicates that the ChemPren technology can produce propylene at $\$$0.16 per lb, whereas the current selling price of virgin propylene is $0.54 per lb. This technology can serve as a platform for mixed plastic upcycling, with more advancements necessary in the form of robust and resilient catalysts and reactor operation strategies for tuning product selectivity.

25 - ENERGY STORAGE↗

DOE OSTI2025

Linking groundwater variability to ecosystem carbon and water use efficiencies across India

Carbon use efficiency (CUE) and water use efficiency (WUE) are important indicators of ecosystem health, reflecting the balance between carbon uptake and allocation, and the relationship between carbon assimilation and water loss. Although India shows large spatiotemporal variation in water table depth (WTD), and increasing groundwater stress, the influence of WTD on ecosystem functioning remains underexplored. This study uses satellite-based, modeled, and in-situ datasets to (1) quantify variations in CUE and WUE under shallow (SWTD) and deep (DWTD) WTD conditions across six homogeneous meteorological regions (HMRs), (2) evaluate temporal roles of gross primary productivity (GPP), net primary productivity (NPP), and evapotranspiration (ET) in driving these efficiencies, and (3) examine temporal responses to WTD shifts. SWTD regions generally showed 12 to 18 % higher GPP, 10 to 15 % higher NPP, and 10 to 20 % higher ET than DWTD zones, especially in semi-arid croplands and forests, leading to 8 to 12 % higher CUE and WUE. However, in humid and heavily irrigated regions such as northeastern and hilly India, CUE was up to 10 % higher in DWTD zones, possibly due to reduced respiration and better soil aeration compared to SWTD areas affected by waterlogging. During the Kharif (wet) season, DWTD croplands in humid zones had higher efficiencies, while in the Rabi (dry) season, SWTD croplands in northern India benefited from irrigation and cooler temperatures. These results highlight strong influence of WTD on carbon and water use processes and support the need for region-specific groundwater strategies.

Carbon use efficiency↗

DOE OSTI2024

Scaleup and Site-Specific Engineering Design for Global Thermostat Direct Air Capture Technology

The overall goal of the project is completion of an initial design of a commercial-scale, Carbon Capture, Utilization, and Storage Direct Air Capture (CCUS-DAC) plant design at three different sites that captures a net of at least 100,000 tonnes per year (TPY) carbon dioxide (CO 2 ) from the atmosphere and considers compression and conditioning of the captured CO 2 for purpose of pipeline transportation to different geological formation sites for deep well injection and underground storage. In addition to the leading system consisting of a scaled-up Global Thermostat DAC unit, overall plant design includes a combined Heat and Power (CHP) unit integrated with a conventional liquid amine-based carbon capture system (90% capture) and compression facilities. These are considered balance of plant (BOP) systems and are required to provide low carbon-intensity steam and power to the DAC process. A second approach involving provision of DAC units modified to directly capture emissions from the CHP unit was initially assessed as an alternative and it was determined to be less mature than considered approach and not included in the scaled-up plant design efforts. Three geographically diverse continental United States locations were selected to better understand the effect of local/regional ambient conditions on scaled-up DAC system performance and project costs: Bucks, Alabama (hot wet climate), Odessa, Texas (dry hot climate), and Goose Creek, Illinois (mid continental climate). The team focused on initial engineering design activities, including the development of project design criteria, initiation of site-specific studies and investigations, completion of DAC system process and equipment design, and definition of balance of plant (BOP) engineering. The purpose of the activities were to develop Technoeconomic Analysis (TEA), Life-Cycle Analysis (LCA), and Environmental, Health, and Safety (EH&S) analysis, and Business Case Analysis (BCA) to validate that the project engineering and scale-up plans of the DAC systems, at each of the three distinct case studies considered, are technically, economically, and environmentally feasible for commercial-scale operation.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Wetting and drying trends in the land–atmosphere reservoir of large basins around the world

Abstract. Global change is altering hydrologic regimes worldwide, including large basins that play a central role in the sustainability of human societies and ecosystems. The basin water budget is a fundamental framework for understanding these basins' sensitivity and future dynamics under changing forcings. In this budget, studies often treat atmospheric processes as external to the basin and assume that atmosphere-related water storage changes are negligible in the long term. These assumptions are potentially misleading in large basins with strong land–atmosphere feedbacks, including terrestrial moisture recycling, which is critical for global water distribution. Here, we introduce the land–atmosphere reservoir (LAR) concept, which includes atmospheric processes as a critical component of the basin water budget and use it to study long-term changes in the water storage of some of the world's largest basins. Our results show significant LAR water storage trends over the last 4 decades, with a marked latitudinal contrast: while low-latitude basins have accumulated water, high-latitude basins have been drying. If they continue, these trends will disrupt the discharge regime and compromise the sustainability of these basins, resulting in widespread impacts.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Hydrometeor Transport and the Stratiform Water Budget in Amazonian Mesoscale Convective Systems

A significant portion of precipitation falls within the stratiform regions of mesoscale convective systems (MCSs). These regions are formed from convective clouds that have either weakened and formed a horizontally stratified structure or have advected hydrometeors to form a trailing-stratiform region, with further precipitation growth promoted by in situ dynamical and microphysical processes. Green Ocean Amazon 2014/5 (GoAmazon2014/5) field campaign observations are used to quantify the stratiform water budget of six MCSs (three each from the wet and dry seasons) utilizing the framework from Leary and Houze, with an emphasis on the transfer of hydrometeors (C A ) from the convective to the stratiform regions. The storms were predominantly leading-line/trailing-stratiform MCSs, but two had embedded convection in the stratiform region, which can complicate water budget calculations. A pulse-like pattern with a mean interval of 21 min occurs in C A during each storm resulting from a lag between the initial convective updrafts and the subsequent hydrometeor transport and sedimentation in the stratiform region. Here, the peaks in C A were followed by peaks in hydrometeor growth associated with the mesoscale updraft (C mu ) in the stratiform region. Averaged over the six storms, the positive contributions of C A and C mu to the stratiform water budget were roughly equal, although storm-to-storm variations existed. Negative contributions from evaporation below cloud base in the mesoscale downdraft and detrainment from the stratiform region into the nonprecipitating anvil cloud and environment accounted for 53% and 21% of the sum of C A and C mu , respectively, resulting in a mean stratiform region precipitation efficiency of 26%.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Microwave Absorbing Perovskite Catalysts for Efficient Electrification of Syngas Production from CO2 and Methane

Microwave absorbing catalysts have the potential to make thermal reactions such as methane reforming (CH4 + CO2 + H2O → H2 + CO) into carbon negative processes when coupled with decarbonized electricity. Due to microwaves directly heating the catalyst rather than heating the reactor and gases, even high temperature reactions such as dry reforming methane (DRM, CH4 + CO2 → H2 + CO) can be achieved rapidly, efficiently, and on-demand, ideal for coupling with intermittent renewable electricity. However, microwave catalysts present unique design challenges due to the same material needing to both efficiently absorb microwaves in oxidative and reductive reaction conditions and be an efficient and stable catalyst in inherently non-isothermal reactors. We screened from over 28 catalysts in the La0.8Sr0.2(Co-Ni-Mn)O3 perovskite solid-solution family to determine promising microwave reforming catalysts and identify design principles for effective materials. The best performing catalyst candidate was able to produce syngas ratios (H2:CO) from 1-3, and scale up testing showed CO and H2 production efficiencies rivaling conventional carbon intensive steam reforming efficiencies at the liters per minute level of production.

Marin, Christopher↗

DOE OSTI2024

High performance heat exchangers for next generation hybrid cooler (CRADA NFE-19-07891 Final Report)

The evaporative cooling process has been successfully deployed in multiple energy conversion processes such as power generation, process cooling, heating, ventilation & cooling (HVAC), and commercial and industrial refrigeration. The heat exchanger is a very common yet extremely critical component of such systems. The device is important since the performance of the overall cooling system heavily relies on the thermal-hydraulic efficiency of the heat exchanger. The possible wet operation as evaporative cooling heat exchanger complicates the issue. Indeed, based on the hybrid nature of operation (fully dry, partially wet, fully wet) the efficiency can vary significantly and can cause performance variation for the whole system. Understanding the importance of the issue, Oak Ridge National Laboratory (Contractor) and Baltimore Aircoil Company (Participant) propose an activity focused on the analysis of the existing heat exchanger technology used in air and evaporative cooling processes and design, development and demonstration of a novel heat exchanger design based on porous materials. The potential candidates include metallic wire meshes and metal foams carefully designed for the proposed application. Prior research has indicated that these materials have great potential for deployment in thermal systems, particularly heat sinks and heat exchangers. It is expected that the successful completion of the project will lead to novel heat exchanger technology for hybrid systems (capable of dry and wet operation) by exploring newly emerging materials and their potential for heat transfer application. The overall goal is to develop a next generation heat exchanger technology which can be deployed in evaporative cooling systems. The impact of the such development is significant since, it will not only make the overall system highly efficient but will also, reduce the total refrigerant charge in the heat exchanger, a critical aspect for the deployment of refrigerants with lower Global Warming Potential (GWP).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Fabrication of yeast engineered porous 13X adsorbent layers for CO 2 capture

This study investigates a novel environmentally friendly coating technique using yeast fermentation to obtain super porous Zeolite 13X adsorbent layers through freeze-drying technique for CO 2 capture applications. Several mass ratios of sugar to yeast were used to control the porosity and pore sizes in the adsorbent layer. A unique peeling process was integrated to obtain foamy, hollow structures to have deeper layer accessibility of adsorbent for adsorption applications. These coated adsorbent layers were experimentally characterized as a function of the mass ratio of sugar to yeast and adsorbent solid fraction. Scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and Fourier-transform infrared spectroscopy (FT-IR) are used to analyze the coated layers. Here, the void fraction for coated samples is found to vary between 0.48 and 0.56, making the samples applicable for adsorption applications. Adsorption performance experiments are performed to test the coated samples' performance compared to 13X powder. Due to their simplistic fabrication, cost-effectiveness, rapid pore formation, and high adsorption capacity, these porous 13X layers hold potential for large-scale fabrication and CO 2 capture applications.

Adsorbent coating↗

DOE OSTI2025

p -Coumaroylated Lignins Are Natively Produced in Three Rosales Families

Carbon-rich plant cell walls contain biopolymers that, with some processing, could replace fossil fuels as a major component of the current petrochemical production. To realize this, biorefineries need to be paired with biomass that during the deconstruction and fractionation processes transforms into the desired products. One component of interest is p-coumarate that, in some species, can account for up to 1% of the biomass’ dry weight. When p-coumarate is present in eudicot cell walls, it is mostly part of the suberin (bark and root), acylates the γ-hydroxy group of the lignin, in part of the tannins, or is a metabolite. The current understanding of eudicot plant cell wall composition is that the lignin is sometimes acylated with acetate and rarely with hydroxycinnamates (p-coumarate or ferulate). This study identified a clear division in the Rosales in which three families produce p-coumaroylated lignins whereas the other six families showed no evidence of the trait.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Development of a High-Efficiency Hybrid Dry Cooler System for sCO 2 Power Cycles in CSP Applications

This project addressed a major gap in supercritical CO 2 (sCO 2 ) power cycle research by focusing on the pre-cooler, a component that had received little attention despite its significant impact on cycle efficiency and plant economics. The team developed a compact dry cooler using brazed/diffusion-bonded microchannel passages paired with formed air-side fins, advancing the technology from TRL-2 toward commercial readiness. Compared to conventional fin-tube coolers, the design cuts installation footprint by roughly half for 10+ MWth systems while achieving better heat transfer and lower approach temperatures, translating into a projected LCOE reduction from 6.04 ¢/kWh to between 5.85 and 5.94 ¢/kWh. While fabrication of an aluminum MW-scale prototype revealed brazing and sealing challenges at larger scales, lessons learned informed a subsequent 1 MWth unit that was successfully built and delivered for integration into Sandia's Gen3 Particle Pilot Plant, advancing the technology to TRL-7 with a path toward TRL-8 pending successful testing.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

High performance heat exchangers for next generation hybrid cooler (CRADA Final Report)

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Deconvoluting sources of variability in aerosol jet printing using light scattering measurements

Aerosol jet printing (AJP) is a digital additive manufacturing technique for hybrid and conformal electronics, where its contactless deposition readily enables patterning over 3D surface topography. However, the complexity of aerosol transport physics makes deposition rate sensitive to process variability, hindering widespread industry adoption. Light scattering measurements have recently been demonstrated as a capable tool for measuring deposition rate in real time, enabling closed-loop control and in-situ qualification frameworks. These inline optical measurements present further opportunity as a diagnostic tool to understand the effects of secondary process parameters affecting vapor–liquid equilibrium and heat and mass transport during deposition. Downstream of the optical measurement cell, changing the sheath gas flow rate, increasing temperature via an inline heater, and adding solvent vapor via a sheath gas bubbler were observed to alter drying physics during sheath-collimation, and thereby impaction efficiency. Further upstream, the introduction of solvent vapor via a carrier gas bubbler and liquid build-up in the printhead were seen to affect the quantitative relationship between the light scattering data and the true deposition rate. Using this information, tightened controls of meaningful secondary parameters were implemented to improve the batch-to-batch consistency for printing a dielectric ink. In addition to advancing AJP process reliability for production, this work demonstrates the capability of inline optical measurements to provide insight into process physics and deconvolute competing mechanisms that underly variability.

additive manufacturing↗

DOE OSTI2025

Co-depolymerization of lignin and plastic waste using hydrothermal liquefaction process

Sustainable valorization of underutilized lignin and plastic waste beyond incineration is critical for producing renewable fuels. Hydrothermal liquefaction (HTL) provides a promising approach to convert wet lignin and plastics into high-quality oils without the need for prior drying of wet lignin. Here, this study examines the effects of temperature (300–400 °C), residence time, and polymer molecular weight on product yield and composition during HTL of polyethylene (PE), polypropylene (PP), and lignin under subcritical and supercritical water conditions. For PE, oil yields increased with temperature, with low molecular weight (LMW) PE achieving a maximum of ∼93 % at 400 °C for 30 min, while high molecular weight (HMW) PE reached ∼86 % at 400 °C for 1 h. Lignin and PP exhibited optimal oil yields at intermediate temperatures, decreasing at higher temperatures due to secondary reactions and char formation. Lignin yielded a maximum of ∼22 % oil at 300 °C for 30 min, LMW PP ∼88 % at 375 °C for 1 h, and HMW PP ∼83 % at 400 °C for 1 h. GC–MS analysis revealed that lignin oils were rich in phenols and alkylphenols, while PE and PP oils were dominated by paraffins and olefins. Oxygenated compounds in PE decreased at higher temperatures, improving oil quality. Co-liquefaction of lignin with plastics enhanced oil yields and energy content under specific conditions, demonstrating synergistic effects dependent on plastic type, molecular weight, and HTL conditions. These findings highlight the potential of HTL to produce high-energy, value-added fuels from lignin–plastic mixtures.

09 - BIOMASS FUELS↗

DOE OSTI2026

Root Dynamics Mitigate Warm and Dry Biases over the Central United States

The central United States frequently exhibits warm and dry biases in simulations of summertime conditions, a persistent feature that remains unresolved. While previous studies linked these biases to misrepresented surface energy exchanges, the role of belowground processes remains poorly understood. Here, we demonstrate that inadequate representation of root water uptake in land surface models contributes to this bias. Using both offline Noah-MP and coupled WRF-Noah-MP simulations with static and dynamic root water uptake schemes, we show that the inclusion of dynamic root processes reduces 2-m air temperature biases and enhances precipitation, primarily by increasing the rain rate of convective systems. Offline and coupled simulations further reveal that the cooling effects and precipitation increases are amplified through positive land-atmosphere feedback, active only in the coupled model. These findings highlight an important role of root in modulating land-atmosphere interactions and underscore the need to refine root-zone processes to improve regional atmospheric simulations.

Yang, Zhao (ORCID:0000000288027130)↗

DOE OSTI2024

Cellulose Nanofibrils Dewatered with Poly(Lactic Acid) for Improved Bio-Polymer Nanocomposite Processing

Cellulose nanofibrils (CNFs) have theoretically ideal properties for bio-based composite applications; however, the incorporation of these materials into polymers is made challenging by the strong binding of water to CNFs and the irreversible agglomeration of CNFs during drying. Previous methods used “contact dewatering”, wherein the addition of wood flour (WF) to CNFs facilitated the mechanical removal of water from the system via cold pressing, which showed potential in producing dried CNF fibrils attached to wood fibers for biocomposite applications. In this work, the viability of contact dewatering with poly(lactic) acid (PLA) powder for PLA/CNF composites was evaluated. The energy efficiency of dewatering, preservation of nanoscale CNF morphology, and mechanical properties were examined by mixing wet CNFs with pulverized PLA at various loading levels, pressing water out of the system, and compression molding and shear mixing composites for testing. The most impressive results from this dewatering method were the preservation of micron-to-nanoscale fibers with high aspect ratios in PLA-CNF composites; increased strength and modulus of 1.7% and 4.2%, respectively, compared to neat PLA; equivalent or better properties than spray-dried nanocellulose at similar loading levels; and an 11-194x reduction in drying energy compared to spray-drying CNFs.

Chemistry↗

DOE OSTI2026

Fungal mat growth and leaf colonization at the TRACE warming experiment, Mar - Aug 2024, Luquillo, Puerto Rico

This data package contains processed measurements on the growth of litter mat-forming fungi and the time to leaf colonization at the Tropical Responses to Altered Climate Experiment (TRACE). Located near the Sabana Field Research Station in Luquillo, Puerto Rico, the TRACE site is located in a mature, closed-canopy tropical rainforest within the Luquillo Experimental Forest (LEF). These data quantify fungal mat growth and the time to leaf colonization of fungi species Gymnopus johnstonii and Marasmius crinis-equi. The experiment was conducted in ambient (control) and experimentally warmed plots (4°C above ambient) during spring and summer periods to assess how litter mat-forming fungi respond to a range of environmental conditions of tropical wet forests. The data files include tables of relative fungal mat growth rates, time to leaf colonization, averages of soil temperature (°C), and number of dry days before leaf attachment. The data are stored in comma-separated values (CSV) format and viewable with any text editor, spreadsheet, or statistical software (e.g., R, Python, Excel). Associated metadata describe plot identifiers, measurement descriptions, and processing steps.

Agaric fungi↗

DOE OSTI2026

Automation of Solid Oxyde Electrolyzer Cell (SOEC) & Stack Assembly

The work performed under this agreement before the No/Go decision amounted to the following: 1. Preliminary manufacturing requirements defined by business sensitivity, baseline processes & risk assessment; 2. Process & materials development, in-line gauge exploration, and preliminary automation work used to reduce risk & further refine equipment specifications; 3. “Request for Quote” issued to multiple suppliers for major equipment; 4. Application specific equipment, hardware, and fixturing will be more beneficial to fabricate inhouse; 5.Current proposals & estimates meet cycle time, capital spend, & direct labor; space is on target but requires awareness; 6. Team will continue to explore opportunities to reduce risk (dry time, traceability); 7. Go / No-Go, Purchase Orders, Equipment build & commissioning next All other future task were not completed because during the Go /No-Go decision it was confirmed this project was a "No-Go" and did not proceed past BP1; these included the following: 1. Preliminary manufacturing requirements defined by business sensitivity, baseline processes & risk assessment; 2. Process & materials development, in-line gauge exploration, and preliminary automation work used to reduce risk & further refine equipment specifications; 3. “Request for Quote” issued to multiple suppliers for major equipment; 4. Application specific equipment, hardware, and fixturing will be more beneficial to fabricate inhouse; 5. Current proposals & estimates meet cycle time, capital spend, & direct labor; space is on target but requires awareness; 6. Team will continue to explore opportunities to reduce risk (dry time, traceability) In final preparation of the termination of the Automation of Solid Oxyde Electrolyzer Cell (SOEC) & Stack Assembly, Cummins has purchased no equipment with government funds, and there is no government-owned property in Cummins possession related to this project. Minimal labor and travel were completed and paid. This acts as the Final technical report and concludes our business with DOE on this grant.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Bioinspired Dry‐Steam Superinsulation Straw Foam

Abstract Cellulosic materials offer sustainable advantages for building energy conservation. However, their development has been hindered by reduced thermal performance, often caused by structural collapse during the transition from solution to solid. Inspired by natural goose down, a bio‐based, lightweight insulation foam derived from agricultural waste straw is presented. Through in situ synthesis, bio‐silica fibers with branched structures capable of supporting hollow silica microspheres are fabricated. After steam‐mediated processing, the resulting foam exhibit low density (95 mg cm − 3 ), high porosity (95.5%), low thermal conductivity (0.03 ± 0.003 W mK −1 ), and a cyclic compressive strength of 90 kPa at 50% strain. Owing to the synergistic microstructure formed by branched bio‐fibers and hollow silica spheres, the bio‐silica foam exhibit outstanding thermal insulation performance relative to other bio‐based foams prepared by ambient drying. A passivated insulation panel is further developed by incorporating this material as the core component, achieving a thermal conductivity of 0.0275 W mk −1 and flexural strength of 6.85 MPa. The panel demonstrated durability with stable thermal performance throughout a 60‐day outdoor test. Moreover, the bio‐silica foam shows a carbon footprint of 7.50 kgCO₂ kg −1 at 70.2 wt.% silica, highlighting its promise as a sustainable insulation solution for green buildings.

Chemistry↗