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DOE OSTI2023

Research and Development of Advanced Superconducting Radiofrequency (SRF) Accelerator Technology and Components for Scientific and Industrial Applications

The purpose of this CRADA is to provide for the joint conduct of research and development (R&D) investigations between Fermi Research Alliance, LLC (Contractor), as operator of the Fermi National Accelerator Laboratory (Fermilab) and Euclid TechLabs, LLC (Participant) related to Research and Development of Advanced Superconducting Radiofrequency (SRF) Accelerator Technology and Components for Scientific and Industrial Applications.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Compact, High-Power Superconducting Electron Linear Accelerators for MW Industrial Applications

Fermilab has developed a novel concept for an industrial electron linac using Nb₃Sn coating technology and conduction cooling. We will show the range of multi-cavity linac designs targeted toward various applications. We will also discuss technology development status with results on conduction cooling of SRF cavities based on cryocoolers, which removes the need for liquid Helium, thus making SRF technology accessible to industrial applications. These conduction-cooled linacs can generate electron beam energies up to 10 MeV in continuous-wave operation and can reach higher power (>=1 MW) by combing several modules. Compact and light enough to mount on mobile platforms, our machine is anticipated to enable new in-situ environmental remediation applications such as waste-water treatment for urban areas, X-ray medical device sterilization, and innovative pavement applications. We also show cost-economics and key R&D areas that much be addressed for a practical machine.

43 PARTICLE ACCELERATORS↗

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 OSTI2023

Human and Technology Integration Evaluation of Advanced Automation and Data Visualization

While the existing United States (U.S.) light water reactors are highly reliable, safe, and provide a significant proportion of carbon-free electricity, the cost of operating and maintaining them has become less competitive compared to other electricity generating sources. The reason for the gap in operating and maintenance (O&M) costs can be at least in part attributed to the advent of new digital technologies that other electricity generating industries are currently using. Advanced capabilities including digital instrumentation and control (I&C) systems, advanced automation and analytics, and greater span of data integration (i.e., connectedness) across these non-nuclear plants has transformed the way work is performed and ultimately given them a competitive advantage in terms of the cost required for operating, maintaining, and supporting them. To reduce O&M cost and address obsolescence of the aging I&C infrastructure of the existing U.S. light water reactors, the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program Plant Modernization Pathway is conducting targeting multidisciplinary research that 1) delivers a sustainable business model to enable a cost-competitive U.S. nuclear industry and 2) is developing technology modernization solutions that address aging and obsolescence challenges. The work described in this report supports these two objectives and describes the demonstration of human and technology integration across recent industry collaborations to support their large-scale digital I&C modifications. This technical report describes the demonstration of the human and technology integration methodology in performing full-scale performance-based human-in-the-loop tests to evaluate plant-specific advanced automation and data visualization applications within these collaborators’ digital modifications. This technical report also documents future applications of human and technology integration that expand beyond main control room modernization and digital I&C upgrades, which have been a central focus to date. Thus, this technical report discusses how to implement human and technology integration across new business opportunities and how to develop an evaluation plan that defines measures and criteria, and documents key assumptions to support full plant modernization.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Technology Feasibility of High-Temperature Heat Pumps for Industrial Drying Process in the US

High-temperature heat pumps are a prospective technology for electrifying and decarbonizing industrial drying processes. This study investigates the technological potential of HTHPs in replacing fossil-fuel burners or steam boilers in industrial spray dryers. The performance of HTHPs with three configurations was investigated, including high high-temperature heat pump boosted with an electric air heater, a steam-generating high-temperature heat pump with multi-stage mechanical vapor compressions, and transcritical high-temperature heat pumps. R1336mzz(Z) is used as the refrigerant in both subcritical and transcritical high-temperature heat pumps, and R717 is used as the working fluid in the mechanical vapor recompression and the heat transfer fluids. Thermodynamic models are built to evaluate the energy efficiency of HTHPs. A case study was carried out on an industrial spray dryer integrated with a waste heat recuperator, where the HTHPs are used to recover precooled air with a dew point of 40℃ and supply heat for drying air at 200℃. For a high-temperature heat pump boosted with an electric air heater, a higher system-level COP is achieved with a high supply temperature from high-temperature heat pump. For a high-temperature heat pump with mechanical vapor recompressions, larger temperature drops in the flashing tank provide higher heat capacities but almost constant values of the coefficient of performance. For a transcritical high-temperature heat pump, an optimum discharge pressure exists for the temperature profiles within the gas cooler and the coefficient of performance. The transcritical high-temperature heat pump provides the best energy efficiency among the three configurations. The theoretical results prove the technical feasibility of high-temperature heat pumps in industrial air-drying applications. .

Wang, Pengtao↗

DOE OSTI2025

Staying Competitive in Clean Manufacturing: Insights on Barriers from Industry Interviews

While industrial emissions research has historically focused on energy-intensive sectors like steel, cement, and chemicals, this study addresses a critical gap by examining barriers across all the manufacturing industry in the U.S. Sectors like food processing, retail, plastics, and transportation face unique challenges distinct from heavy industry, operating on thin margins with limited bargaining power while experiencing heightened consumer and stakeholder pressure for improved environmental responsibility. Through structured interview data collection process and using quantitative ratings and qualitative analysis, this research identifies and categorizes emission reduction barriers across four key themes: financial, technical, organizational, and regulatory. Unlike energy-intensive industries that may pursue hydrogen or carbon capture technologies, discrete manufacturing industry like automotive, electrical and electronics, and machine manufacturers typically focus on energy efficiency, electrification of thermal processes, and alternate fuel switching, solutions better aligned with their lower-temperature processes and distributed facility profiles. The study’s primary contribution lies in documenting specific barrier manifestations within organizations and identifying proven mitigation strategies that companies have successfully implemented or observed among peers.

business competitiveness↗

DOE OSTI2023

Targeted Particle Fractionation Technologies: Proof of Concept

Most methods of particle-size analysis involve particle fractionation which, is often done by filtration or the use of screens. This paper provides proof of concept testing for new in-pipe particle fractionation technologies that can be used at laboratory to industrial scales. These technologies are extensions of recent advancements in bump arrays as well as testing of new inline angled-to-the-flow slats, and advanced boycott-based Avalanche separation technologies. Experiments were conducted for three targeted particle fractionation technologies to evaluate the in-pipe removal of oversized sands in Newtonian slurries prior to the introduction of bump arrays. The mesofluidic system uses an array of staggered posts as configured in a bump array for Newtonian slurry conditions. The methods and results of these experiments are described in this paper. This information could be applied in most industrial and laboratory systems to rapidly remove oversized particles from a flowing slurry.

slurry, solids removal, particle fractionation, bu↗

DOE OSTI2025

CSP Systems Analysis 2022-2024 (Final Technical Report)

The CSP Systems Analysis project estimates the current market cost of CSP subsystems and technologies for use by the DOE Program and within NREL analysis tools. The project addresses upgrades to NREL's System Advisor Model (SAM) related to CSP, as well as development of new modules within SAM to expand the types of CSP systems that can be simulated and new tools for evaluating CSP subsystem performance or optimizing CSP system layouts, for example, SolarPILOT and SolTrace. The project evaluates the potential cost and performance of new CSP-relevant technologies and generally includes assessment of CSP technologies in support of the DOE subprogram. A primary goal of the CSP System Analysis project is to provide timely and accurate cost data to the DOE to assess the current state of CSP technologies as well as predict performance and cost for pre-commercial and emerging technologies that may impact the industry. Prior work in this task has produced technology cost reports and roadmaps for DOE and highlighted promising research paths that could reduce overall CSP cost, such as the supercritical CO2 power cycle and molten-salt trough systems. CSP Systems Analysis produces modeling tools to evaluate the performance of CSP systems, subsystems, or components, and journal articles, conference papers, technical reports and databases to disseminate information to the CSP industry. CSP technology costs are estimated and tracked using these tools as well as analysis of literature and industry sources. The CSP modeling tools and NREL analysis results are used by researchers; government, financial, and industry analysts; and other CSP stakeholders. The purpose of this final technical report is to summarize the key accomplishments of the past three years of this project. The project was divided into seven separate tasks, and in what follows, we describe the background, objectives, key accomplishments, and path forward for each task within the project, with one section of this report summarizing each task.

14 SOLAR ENERGY↗

DOE OSTI2023

FOR-868 Microreactor Applications Research Validation and Evaluation (MARVEL) Project

The Microreactor Applications Research Validation and Evaluation (MARVEL) reactor will offer experimental capabilities that are not currently available at DOE’s national laboratories. The test bed will perform R&D on the fundamental features, operations, and behaviors of microreactor technologies and help industry partners quickly test, develop, and demonstrate their technologies. The liquid- metal cooled microreactor will produce energy using small amounts of high- assay, low-enriched uranium (HALEU) from available research materials. Its design is primarily based on existing technology and will be built using off-the- shelf components to the extent practical. The reactor will be built inside the Transient Reactor Test (TREAT) Facility Micro-Reactor Experiment Cell (T- REXC), a separate project governed by the requirements of FOR-684, “Transient Reactor Test (TREAT) Facility Micro-Reactor Experiment Cell (T REXC),” and outside the scope of this document.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Ensuring Safe, Effective, and Reliable Use of Artificial Intelligence-Based Applications for Nuclear Electricity Generation through a Systems Approach

There is a significant potential to reduce operating and maintenance cost at nuclear power plants using artificial intelligence (AI) and machine learning (ML). For instance, AI/ML has the potential to significant improve work management processes, condition reporting, and plant surveillance activities. However, the nuclear industry has been slow in adopting AI/ML due to several multifaceted barriers discussed in this paper. This work presents such multidisciplinary approach intended to 1) accelerate industry adoption of AI/ML-based applications at nuclear power plants and 2) ensure their safe, reliable, and effective use. This approach is discussed further in this work and will be used to address overarching challenges associated with AI deployment at scale to provide industry guidance that support accelerated adoption of AI/ML technologies throughout the industry.

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Adapting the Technology Performance Level Integrated Assessment Framework to Low-TRL Technologies Within the Carbon Capture, Utilization, and Storage Industry, Part I

With the urgent need to mitigate climate change and rising global temperatures, technological solutions that reduce atmospheric CO 2 are an increasingly important part of the global solution. As a result, the nascent carbon capture, utilization, and storage (CCUS) industry is rapidly growing with a plethora of new technologies in many different sectors. There is a need to holistically evaluate these new technologies in a standardized and consistent manner to determine which technologies will be the most successful and competitive in the global marketplace to achieve decarbonization targets. Life cycle assessment (LCA) and techno-economic assessment (TEA) have been employed as rigorous methodologies for quantitatively measuring a technology's environmental impacts and techno-economic performance, respectively. However, these metrics evaluate a technology's performance in only three dimensions and do not directly incorporate stakeholder needs and values. In addition, technology developers frequently encounter trade-offs during design that increase one metric at the expense of the other. The technology performance level (TPL) combined indicator provides a comprehensive and holistic assessment of an emerging technology's potential, which is described by its techno-economic performance, environmental impacts, social impacts, safety considerations, market/deployability opportunities, use integration impacts, and general risks. TPL incorporates TEA and LCA outputs and quantifies the trade-offs between them directly using stakeholder feedback and requirements. In this article, the TPL methodology is being adapted from the marine energy domain to the CCUS domain. Adapted metrics and definitions, a stakeholder analysis, and a detailed foundation-based application of the systems engineering approach to CCUS are presented. The TPL assessment framework is couched within the internationally standardized LCA framework to improve technical rigor and acceptance. It is demonstrated how stakeholder needs and values can be directly incorporated, how LCA and TEA metrics can be balanced, and how other dimensions (listed earlier) can be integrated into a single metric that measures a technology's potential.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Innovations in Sustainable Passive Wastewater Treatment - 20236

Sustainable water treatment systems, engineered to mimic natural processes and utilize natural materials, yield economic and environmental benefits through reductions in long term operational inputs, including: power, chemicals, and labor. Golder is an industry leader in the development and implementation of sustainable technologies at operating and closed mines. We continue to innovate these technologies and customize solutions to meet client needs by applying past experience and focused research. Sustainable (or passive) water treatment systems include ponds, wetlands, flow-through natural media beds, and limestone drains. These systems can blend in with a natural environment, are highly cost-effective for long-term water treatment, and can outcompete traditional active treatment technologies. Application of sustainable technologies relative to active technologies can be influenced by the influent water matrix, effluent limitations, flow rate of water requiring treatment, and available land area. In this presentation, four Golder-developed systems are reviewed as case studies, demonstrating our continued progressive approach to advancing sustainable water treatment technologies to meet industry needs. These case studies focus on design innovations and operational performance from data collected from the operational systems. Resources (power, chemicals, labor) required for the operation of each case study are compared with those that would be required for operation of their active treatment technology alternatives. - Case Study 1 presents an anaerobic biochemical reactor (BCR), a technology typically implemented for metals treatment and acid neutralization, for the treatment of sulfate to low concentrations (<250 mg/L). Active treatment via reverse osmosis (RO) membrane filtration is typically required for treatment of sulfate to similar concentrations, this innovation provides potential for sustainable treatment to replace the need for energy, chemical, labor, and waste (brine) intensive RO treatment for specific applications. Magnetite waste rock materials from the site were upcycled for use in this system to provide sequestration of the sulfide generated in the BCR. - Case Study 2 examines another novel application of the conventional BCR, modified for the removal of radionuclides and metals (uranium, radium, and selenium) at a closed uranium mine. - Case Study 3 presents implementation of sustainable treatment for mine drain water from a historic mine site, now a state park with around 100,000 visitors per year. The system includes a pond, wetland, and manganese removal bed surrounded by public trails designed to maintain the character of the park. The system treats for arsenic, iron, and manganese at relatively high flows (up to 1,200 gpm), with large seasonal fluctuations in flow and quality. - Case Study 4 is a unique project for which Golder is currently designing a sustainable treatment system, with no energy input, to treat nitrate in mine water post-closure at a site near the arctic circle. In this unprecedented application, climate, management of freshet, and space availability presented substantial technical challenges. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Development of 250 kW Ammonia and Hydrogen Industrial Burner Test Facility at the National Energy Technology Laboratory

In an effort to investigate the viability of ammonia and hydrogen as fuels in the industrial heating sector, the Department of Energy’s National Energy Technology Laboratory is developing a 250 kW burner test facility. The pursuit of a decarbonized industrial heating sector requires innovative approaches to convert existing assets to alternative fuels while maintaining adequate radiative heat transfer and limiting NOx. This new capability will leverage NETL’s experience and prior investments in ammonia and hydrogen combustion, to advance atmospheric pressure industrial combustion systems for industries such as cement kilns and glass factories. The intention in coming years is to collaborate with burner manufacturers and heavy industry partners to study, develop, and validate strategies for converting existing hardware from carbon-based fuels to next-generation clean ammonia and hydrogen technologies.

May, Kristyn Johnson↗

DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy (Workshop Report)

The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector. The US industrial sector accounts for 32% of the nation’s primary energy use (including feedstocks), and refining, chemicals, pulp and paper, iron and steel, and food products represent the top energy-consuming sectors. Thermal processing or process heating represents the largest energy use category; it accounts for 63% of all energy use in manufacturing. Additionally, thermal processing is the largest contributor of carbon dioxide (CO2) generation, resulting from combustion of fuels and process related chemical reactions, such as in the case of cement and lime production. The challenge of achieving net-zero industrial GHG emissions is colossal considering the established industrial base that depends mainly on carbon-based processes and energy sources; the time frame and cost to replace carbon-based energy sources and feedstocks; and the long-term outlook for development with large-scale adaptation of alternative non carbon–based technologies. The goals of the DOE Advanced Manufacturing Office Thermal Process Intensification Workshop were as follows: (1) Identify R&D gaps and opportunities to facilitate transformative improvement in industrial thermal processes beyond current technologies and allow for entirely new methods for processing materials; (2) Gain insight into new and innovative approaches to thermally intensify processes, reduce heat demand, harness waste heat, and use fuels and hydrocarbon feedstocks more efficiently; (3) Identify the R&D pathways to thermal process intensification (TPI) with the highest potential for impact and adoption by the industrial sector; (4) Define areas of research, development, and demonstration (RD&D) activities to accelerate development and application of emerging and transformative technologies to intensify thermal processes in industry. The scope and focus of the workshop were defined to meet these goals. Based on the available data for energy use and GHG emissions, the industries that collectively use more than 80% of the total process heating energy consumption were selected as primary focus areas. The chosen industries were combined into the following four groups based on similarities in their thermal processes: high-temperature metal processing (iron and steel industry, alumina-aluminum industry); high-temperature nonmetal and mineral processing (cement and glass industry); medium- to low-temperature thermal processing (food processing and pulp and paper industry as part of forest products sector); and hydrocarbon processing (petroleum refining and chemical industry). Furthermore, all potential TPI technologies associated with the processes defined were considered as part of the workshop. Different types of TPI technologies possible in industrial in the document.

42 ENGINEERING↗

DOE OSTI2020

Integrating Commercial Ready Autonomous Robotic Platforms to Enhance Worker Safety and Efficiency - 20053

This paper will explore the challenges and triumphs of implementing advanced robotic systems and the supporting technology for the waste management industry. Deployment-ready solutions for autonomous robotic platforms are new to the radioactive waste management industry and have been slow to implement across the complex. Specifically, it will explore Hanford Tank Operations Contractor's implementation of ground-based autonomous robotic platforms to enhance workforce safety and efficiency. The first objective of the project is to demonstrate safe operation of autonomous instrumented robots, followed by a scaling up of capabilities for the platform to meet any additional requests of internal stakeholders. Autonomous robotics platforms offer a fantastic range of capabilities that will aid in decreasing long-term liability of radioactive waste management industry by enhancing clean-up efforts and worker safety. Over the past five years, deployment-ready solutions for autonomous robotic platforms have come a long way. Autonomous robotic platforms are increasingly available to purchase from many vendors, often for prices under $100,000. Additionally, the vendors who produce these products are efficient in accommodating customized solutions to unique challenges, such as those often found in the radioactive waste management industry. However, the newness of this technology to the radioactive waste management industry and has resulted in a slow implementation across the complex. This paper will explore the challenges and triumphs of implementing advanced robotic systems and supporting technology for the waste management industry. Specifically, it will explore Hanford Tank Operations Contractor's implementation of ground based autonomous robotic platforms to enhance workforce safety and efficiency. While the company has utilized robots in many parts of the tank farms mission, this was first attempted in the deployment of an autonomous platform that required no operator with only minor maintenance and created challenges not yet encountered. These challenges included stakeholder buy-in, operational safety, procurement uncertainties, adaption of 'off the shelf products, overcoming the 'Fukushima complexity' perception, security concerns, and the initial criteria down select. Hanford Tank Operations Contractor's management identified the need for a workforce protecting low cost robotics solution in the fall of 2017. The project scope generated was part of the response to the Tank Vapor Assessment Team recommendation to enhance the safety of the workforce by utilizing new technology. Since the projects inception, it has been incorporated into the Tank Stewardship Plan. This project was unique to Hanford Tank Operations Contractor, as the company does not frequently incorporate advanced technology for field deployment quickly. The project was also progressive to the Hanford Tank Operations Contractor as it functions as a partnership project with a local university. The first objective of the project is to demonstrate safe operations of autonomous instrumented robotics, monitoring and collecting data, and the wireless transmission of data to a central computing system. Following the completion of this first objective, the project will scale up capabilities of the platform to meet the requests of additional internal stakeholders throughout the tank farms - including completion of specific in-field tasks. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Evaluating the industrial potential of emerging biomass pretreatment technologies in bioethanol production and lipid recovery from transgenic sugarcane

The selection of pretreatment methods is critical to achieving high product yields during bioconversion of lignocellulosic biomass. Hydrothermal, soaking-in-aqueous ammonia, and ionic liquid pretreatment methods are viable candidates for minimizing sugar decomposition, permitting the effective hydrolysis of structural carbohydrates, and producing a fermentable substrate suitable for achieving industrial ethanol titers and yields. In this study, the effect of these three pretreatment methods on non-modified sugarcane cultivar CP88-1762 and two transgenic lipid-accumulating sugarcane lines, oilcane 1565 and oilcane 1566, were investigated and compared in terms of lipid recovery, sugar yield, and ethanol yields within the lignocellulosic biomass conversion pipeline. Fed-batch enzymatic hydrolysis at high solid loading yielded hydrolysates capable of supporting industrial bioethanol titers across all conditions. The highest sugar yields were obtained on ammonia-pretreated biomass hydrolysate (253.73 g L −1 ), followed by hydrothermally pretreated hydrolysate (213.10 g L −1 ) and ionic liquid-pretreated hydrolysate (154.20 g L −1 ). Commercially viable ethanol titers of 100.62 g L −1 , 64.47 g L −1 , and 52.95 g L −1 were achieved from ammonia, hydrothermal, and ionic liquid pretreated hydrolysate with the corresponding ethanol productivities of 2.08 g L −1 h −1 , 0.53 g L −1 h −1 , and 0.36 g L −1 h −1 . The lower acetic acid concentration in ammonia-pretreated hydrolysate may have enhanced its fermentability relative to the hydrothermal pretreatment condition, as indicated by the differences in ethanol titer and productivity. Lower sugar yields and ethanol productivities under the ionic liquid conditions likely resulted from the inhibitory effect of cholinium lysinate. Oilcane 1565 and oilcane 1566 bagasse accumulated over 16- and 3 times higher lipids than the non-modified sugarcane CP88-1762. The total fatty acid content in the oilcane samples was reduced in ammonia and ionic liquid-pretreated bagasse relative to the hydrothermal pretreatment condition. While all pretreatment techniques tested are industrially viable, the observed differences in titer, productivity, and lipid content indicate that careful selection and validation of upstream processing methods can contribute to improved economic and environmental outcomes.

09 BIOMASS FUELS↗

DOE OSTI2025

Data for "Evaluating the industrial potential of emerging biomass pretreatment technologies in bioethanol production and lipid recovery from transgenic sugarcane"

The selection of pretreatment methods is critical to achieving high product yields during bioconversion of lignocellulosic biomass. Hydrothermal, soaking-in-aqueous ammonia, and ionic liquid pretreatment methods are viable candidates for minimizing sugar decomposition, permitting the effective hydrolysis of structural carbohydrates, and producing a fermentable substrate suitable for achieving industrial ethanol titers and yields. In this study, the effect of these three pretreatment methods on non-modified sugarcane cultivar CP88-1762 and two transgenic lipid-accumulating sugarcane lines, oilcane 1565 and oilcane 1566, were investigated and compared in terms of lipid recovery, sugar yield, and ethanol yields within the lignocellulosic biomass conversion pipeline. Fed-batch enzymatic hydrolysis at high solid loading yielded hydrolysates capable of supporting industrial bioethanol titers across all conditions. The highest sugar yields were obtained on ammonia-pretreated biomass hydrolysate (253.73 g L−1), followed by hydrothermally pretreated hydrolysate (213.10 g L−1) and ionic liquid-pretreated hydrolysate (154.20 g L−1). Commercially viable ethanol titers of 100.62 g L−1, 64.47 g L−1, and 52.95 g L−1 were achieved from ammonia, hydrothermal, and ionic liquid pretreated hydrolysate with the corresponding ethanol productivities of 2.08 g L−1 h−1, 0.53 g L−1 h−1, and 0.36 g L−1 h−1. The lower acetic acid concentration in ammonia-pretreated hydrolysate may have enhanced its fermentability relative to the hydrothermal pretreatment condition, as indicated by the differences in ethanol titer and productivity. Lower sugar yields and ethanol productivities under the ionic liquid conditions likely resulted from the inhibitory effect of cholinium lysinate. Oilcane 1565 and oilcane 1566 bagasse accumulated over 16- and 3 times higher lipids than the non-modified sugarcane CP88-1762. The total fatty acid content in the oilcane samples was reduced in ammonia and ionic liquid-pretreated bagasse relative to the hydrothermal pretreatment condition. While all pretreatment techniques tested are industrially viable, the observed differences in titer, productivity, and lipid content indicate that careful selection and validation of upstream processing methods can contribute to improved economic and environmental outcomes.

biomass analytics↗