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DOE OSTI2021

Greenhouse Gas Impact of Algal Bio-Crude Production for a Range of CO2 Supply Scenarios

Refined bio-crude production from hydrothermal liquefaction of algae holds the potential to replace fossil-based conventional liquid fuels. The microalgae act as natural carbon sequestrators by consuming CO2. However, this absorbed CO2 is released to the atmosphere during the combustion of the bio-crude. Thus, the life-cycle greenhouse gas (GHG) emissions of refined bio-crude are linked to the production and supply of the materials involved and the process energy demands. One prominent raw material is CO2, which is the main source of carbon for algae and the subsequent products. The emissions associated with the supply of CO2 can have a considerable impact on the sustainability of the algae-based refined bio-crude production process. Furthermore, the diurnal algae growth cycle complicates the CO2 supply scenarios. Traditionally, studies have relied on CO2 supplied from existing power plants. However, there is potential for building natural gas or biomass-based power plants with the primary aim of supplying CO2 to the biorefinery. Alternately, a direct air capture (DAC) process can extract CO2 directly from the air. The life-cycle GHG emissions associated with the production of refined bio-crude through hydrothermal liquefaction of algae are presented in this study. Different CO2 supply scenarios, including existing fossil fuel power plants and purpose-built CO2 sources, are compared. The integration of the CO2 sources with the algal biorefinery is also presented. The CO2 supply from biomass-based power plants has the highest potential for GHG reduction, with a GHG footprint of −57 g CO2 eq./MJ refined bio-crude. The CO2 supply from the DAC process has a GHG footprint of 49 CO2 eq./MJ refined bio-crude, which is very similar to the scenario that considers the supply of CO2 from an existing conventional natural gas-based plant and takes credit for the carbon utilization.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Restoring Pre-Industrial CO2 Levels While Achieving Sustainable Development Goals

Unless humanity achieves United Nations Sustainable Development Goals (SDGs) by 2030 and restores the relatively stable climate of pre-industrial CO2 levels (as early as 2140), species extinctions, starvation, drought/floods, and violence will exacerbate mass migrations. This paper presents conceptual designs and techno-economic analyses to calculate sustainable limits for growing high-protein seafood and macroalgae-for-biofuel. We review the availability of wet solid waste and outline the mass balance of carbon and plant nutrients passing through a hydrothermal liquefaction process. The paper reviews the availability of dry solid waste and dry biomass for bioenergy with CO2 capture and storage (BECCS) while generating Allam Cycle electricity. Sufficient wet-waste biomass supports quickly building hydrothermal liquefaction facilities. Macroalgae-for-biofuel technology can be developed and straightforwardly implemented on SDG-achieving high protein seafood infrastructure. The analyses indicate a potential for (1) 0.5 billion tonnes/yr of seafood; (2) 20 million barrels/day of biofuel from solid waste; (3) more biocrude oil from macroalgae than current fossil oil; and (4) sequestration of 28 to 38 billion tonnes/yr of bio-CO2. Carbon dioxide removal (CDR) costs are between 25–33% of those for BECCS with pre-2019 technology or the projected cost of air-capture CDR.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Techno-economic analysis of cellulosic ethanol conversion to fuel and chemicals

In this paper, we describe multiple scenarios investigated to assess the techno-economic results of producing fuels from corn stover-derived ethanol and the impact of co-producing higher-value, ethanol-derived n-butanol and 1,3-butadiene to improve economic feasibility. An alternative approach that produces only chemicals from the lignocellulosic-derived ethanol while producing fuels from the residual cell mass, unconverted sugars and lignin using hydrothermal liquefaction and hydrotreating also is described. Our results indicate that the hydrothermal liquefaction pathway has cost advantages relative to pathways that burn lignin from the corn stover conversion process to make ethanol when the associated ethanol stream is used to make only chemicals.

09 BIOMASS FUELS↗

DOE OSTI2022

Economic and Environmental Analysis to Evaluate the Potential Value of Co-Optima Diesel Bioblendstocks to Petroleum Refiners

The U.S. petroleum refining sector is undergoing a period of historic transformation, catalyzed by the decarbonization of the U.S. economy. Diesel-boiling-range bioblendstocks have gained traction, owing to their superior fuel properties and environmental performance as compared to traditional petroleum fuels. This work couples refinery linear programming models with life cycle assessment to quantify the potential economic and environmental benefits, and trade-offs, of blending diesel-boiling-range bioblendstocks at petroleum refineries. Linear programming models were developed in Aspen Process Industry Modeling Systems (PIMS) for three representative petroleum refinery configurations of differing complexity. Seven diesel-boiling-range bioblendstocks: 4-butoxyheptane, 5-ethyl-4-propylnonane, soy biodiesel, sludge hydrothermal liquefaction diesel, polyoxymethylene ethers, renewable diesel, and hexyl hexanoate, were investigated to identify key fuel properties that influence refineries' economics and to track the effect of adding bioblendstocks on refinery-wide cradle-to-gate greenhouse gases (GHG) emissions. These analyses considered blending levels from 10 to 30 vol% and fuel demand projections over the period 2040 to 2050. This analysis determines that bioblendstock sulfur content and cetane number are the primary fuel attributes with the potential to provide value to refiners. Life cycle assessment results indicate that the use of diesel-boiling-range bioblendstocks can reduce cradle-to-gate refinery GHG emissions by up to ~ 40 % relative to conventional refinery operations when considering carbon uptake in the supply chain of the bioblendstock. Refinery-wide marginal GHG abatement costs range from 120 to 3,600 USD2016/metric tons carbon dioxide equivalent avoided across the scenarios evaluated. Reducing the price of bioblendstocks is identified as a key to their adoption.

ADVANCED PROPULSION SYSTEMS,BIOMASS FUELS,ENERGY P↗

DOE OSTI2026

Opportunities and challenges in thermochemical conversion of municipal solid waste: A comprehensive review

Recent advancements in thermochemical conversion processes have elucidated new pathways for converting municipal solid waste into valuable resources. This review explores the primary thermochemical conversion methods, including combustion, gasification, pyrolysis, torrefaction, hydrothermal carbonization, and hydrothermal liquefaction, emphasizing their potential roles in waste management and energy recovery. Key challenges including feedstock variability, ash behavior, and scale-up limitations are discussed alongside opportunities for hybrid systems and circular economy integration. A comparative analysis of research publications indicates a significant focus on thermochemical pathways within the broader context of municipal solid waste research, underscoring the growing interest in these technologies. Recent advancements in each thermochemical process, alongside their operational, technical, and economic challenges, are discussed. Comparative data reveal that torrefaction enhances the hydrophobicity and grindability of municipal solid waste components, though its energy densification benefits are more modest than those observed in biomass. Hydrothermal carbonization and liquefaction are highlighted for their ability to process high-moisture and heterogeneous waste streams. The review also synthesizes recent findings on reactor configurations, emissions control, and synergistic effects in co-processing municipal solid waste fractions. The findings underscore the importance of developing standardized protocols for municipal solid waste characterization and the need for innovative hybrid systems to improve efficiency.

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Assessing hydrogen supply chains: An integrated review of leakage and energy efficiency studies

This paper examines hydrogen leakage and efficiency across the supply chain for liquid, gaseous, and mixed hydrogen systems. These factors are crucial for assessing hydrogen's role in mitigating emissions and facilitating a clean energy transition. Drawing on a comprehensive review of existing literature and model-based analysis, the study compiles leakage rates and efficiency metrics at each stage of the supply chain: production, storage, transmission, distribution, and end-use. These data inform system scenarios that estimate the impact of leakage on overall performance and climate benefits. The analysis also identifies persistent data gaps, particularly for liquid and mixed system configurations, and outlines priorities for future research. A comparison of hydrogen system types shows that gaseous pathways generally achieve the highest efficiencies (28 %–39 %) and the lowest leakage rates (∼4.5 %) across the supply chain. Liquid hydrogen systems, while favorable for long-distance and high-volume transport due to their higher energy density, exhibit lower efficiency (∼28 %) and a greater leakage potential (∼12 %). Mixed systems, which combine gaseous and liquid elements (e.g., pipeline transmission followed by liquefaction and truck distribution), show compounded energy losses and moderate-to-high leakage rates (6.8 %–9.4 %), highlighting trade-offs associated with added system complexity. The study highlights opportunities for technological advancements, including optimizing liquefaction, enhancing insulation for storage and transportation, and refining refueling equipment. These improvements are crucial for maximizing the climate benefits of hydrogen. The results offer actionable insights for researchers, industry, and policymakers working to develop low-leakage, high-efficiency hydrogen infrastructure.

08 HYDROGEN↗

DOE OSTI2023

Optimization of a Packed Particle Magnetocaloric Refrigerator: A Combined Experimental and Theoretical Study

Magnetocaloric refrigeration has strong potential towards achieving high efficiency hydrogen liquefaction. Optimising parameters such as particle size and operating cycles can have a significant impact on liquefaction performance. Here, this work reports on a room temperature magnetocaloric refrigeration prototype designed with helium as the heat transfer fluid and packed particle Gd 0.8875 Ce 0.1025 Si 0.84 Cr 0.19 as the refrigerant. The temperature spans and cooling power with three different particle sizes at two different operating cycles were measured. A maximum temperature span of 16.7 K and a maximum cooling power of 8.6 W·kg –1 were obtained. Reduction of performance in the faster cycle was observed in larger particles due to insufficient thermal diffusion time and its implications for cryogenic temperatures are discussed. A numerical model was developed based on the experimentally observed variation of the temperature span and cooling power with particle size and cycle duration. This model was then used to study the competing effects of viscous dissipation and thermal diffusion for different particle sizes and cycle durations.

08 HYDROGEN↗

DOE OSTI2021

Material Interactions in Severe Accidents – Benchmarking the MELCOR V2.2 Eutectics Model for a BWR-3 MARK-I Station Blackout: Part I – Single Case Analysis

Here in this analysis, the two material interaction models available in the MELCOR code are benchmarked for a severe accident at a BWR under representative Fukushima Daiichi boundary conditions. This part of the benchmark investigates the impact of each material interaction model on accident progression through a detailed single case analysis. It is found that the eutectics model simulation exhibits more rapid accident progression for the duration of the accident. The slower accident progression exhibited by the interactive materials model simulation, however, allows for a greater degree of core material oxidation and hydrogen generation to occur, as well as elevated core temperatures during the ex-vessel accident phase. The eutectics model simulation exhibits more significant degradation of core components during the late in-vessel accident phase – more debris forms and relocates to the lower plenum before lower head failure. The larger debris bed observed in the eutectics model simulation also reaches higher temperatures, presenting a more significant thermal challenge to the lower head until its failure. At the end of the simulated accident scenario, however, core damage is comparable between both simulations due to significant core degradation that occurs during the ex-vessel phase in the interactive materials model simulation. A key difference between the two models’ performance is the maximum temperatures that can be reached in the core and therefore the maximum ΔT between any two components. When implementing the interactive materials model, users have the option to modify the liquefaction temperature of the ZrO 2 -interactive and UO 2 -interactive materials as a way to mimic early fuel rod failure due to material interactions. Through modification of the liquefaction of high melting point materials with significant mass, users may inadvertently limit maximum core temperatures for fuel, cladding, and debris components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Vented and sealed cookoff of powdered and pressed ε-CL-20

In this work, we have completed a series of vented and sealed cookoff experiments of the ε-polymorph of CL-20 in our Sandia Instrumented Thermal Ignition (SITI) apparatus using both powder and pressed pellets at nominal densities of 313 ± 8 kg/m 3 and 1030 ± 4 kg/m 3 , respectively. The boundary temperature of our aluminum confinement cylinder was ramped in 10 minutes from room temperature to a prescribed set-point temperature ranging between 448 nd 468 K and held at the set-point temperature until ignition. A universal cookoff model (UCM) has been calibrated using the ε-CL-20 SITI data to predict pressurization and thermal ignition of ε-CL-20. The ignition model was validated by using one-dimensional time-to-explosion (ODTX) ignition data from a different laboratory. We found that a thirtyfold increase in the reaction rates due to liquefaction at 520 K could explain the high temperature ODTX cookoff data. The model gives a plausible explanation of why melting is important in fast cookoff events involving CL-20. Our model also gives support to 520 K as the liquefaction point of CL-20, which has different values in the literature.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Modeling Framework for the Assessment of a Sustainable Hydrogen Production and Supply Chain Network in California

The cost-effective and sustainable deployment of hydrogen supply and demand networks, especially in large economic regions like California, can be challenging considering the spatial-temporal availability and variability of the different actors across the network such as production processes, distribution modes, and end-users. In this presentation, we will provide an overview and demonstration of a modeling framework used to assess the environmental, economic, and human health impacts of plausible hydrogen production and supply chain networks in California. Scenarios focus on green hydrogen production pathways using water electrolysis and biomass gasification. End-use applications included in the model are transit, medium and heavy-duty trucking, port authorities, and power and aviation companies that currently consume natural gas, diesel, and aviation fuel for their day-to-day operation. Representative locations for hydrogen production and end-use are based on recent projections of the hydrogen economy in California. All mass and energy flows, as well as estimated emissions, are based on H2A process model designs and projections of technology performance, literature review, and LBNL process, economic and life cycle modeling, and not on company data for the sake of this presentation. Human health impacts are included following methodologies developed for the University of California Irvine HyDeal project. Life cycle phases associated with hydrogen production include feedstock preparation (water and biomass), energy production and consumption (renewable, grid, and combination of renewable and grid electricity), maintenance (chemical utilization in electrolysis and natural gas combustion in gasification), carbon sequestration, hydrogen storage (compression and liquefaction), and distribution (truck and pipeline). We apply the framework utilizing California specific emission factors, financial data, and human health damages and explore the impact of network characteristics on results. Example variations include: the inclusion of policy incentives or not, different representations of the electricity grid and source, electrolysis versus gasification versus combinations of both for production, liquefaction versus compression based on producer capacity cutoffs, transportation truck versus pipeline based on existing infrastructure, and ultimate end use. Comparison of these different scenarios can help inform future projects by demonstrating the trade-offs among environmental, economic, and human health impacts. This model, automated in R, is a starting platform upon which new analysis, modeling capabilities, locations, and emission factors can be rapidly tested and integrated.

Zaki, Mohammed Tamim↗

DOE OSTI2021

A high solids field-to-fuel research pipeline to identify interactions between feedstocks and biofuel production

Abstract Background Environmental factors, such as weather extremes, have the potential to cause adverse effects on plant biomass quality and quantity. Beyond adversely affecting feedstock yield and composition, which have been extensively studied, environmental factors can have detrimental effects on saccharification and fermentation processes in biofuel production. Only a few studies have evaluated the effect of these factors on biomass deconstruction into biofuel and resulting fuel yields. This field-to-fuel evaluation of various feedstocks requires rigorous coordination of pretreatment, enzymatic hydrolysis, and fermentation experiments. A large number of biomass samples, often in limited quantity, are needed to thoroughly understand the effect of environmental conditions on biofuel production. This requires greater processing and analytical throughput of industrially relevant, high solids loading hydrolysates for fermentation, and led to the need for a laboratory-scale high solids experimentation platform. Results A field-to-fuel platform was developed to provide sufficient volumes of high solids loading enzymatic hydrolysate for fermentation. AFEX pretreatment was conducted in custom pretreatment reactors, followed by high solids enzymatic hydrolysis. To accommodate enzymatic hydrolysis of multiple samples, roller bottles were used to overcome the bottlenecks of mixing and reduced sugar yields at high solids loading, while allowing greater sample throughput than possible in bioreactors. The roller bottle method provided 42–47% greater liquefaction compared to the batch shake flask method for the same solids loading. In fermentation experiments, hydrolysates from roller bottles were fermented more rapidly, with greater xylose consumption, but lower final ethanol yields and CO 2 production than hydrolysates generated with shake flasks. The entire platform was tested and was able to replicate patterns of fermentation inhibition previously observed for experiments conducted in larger-scale reactors and bioreactors, showing divergent fermentation patterns for drought and normal year switchgrass hydrolysates. Conclusion A pipeline of small-scale AFEX pretreatment and roller bottle enzymatic hydrolysis was able to provide adequate quantities of hydrolysate for respirometer fermentation experiments and was able to overcome hydrolysis bottlenecks at high solids loading by obtaining greater liquefaction compared to batch shake flask hydrolysis. Thus, the roller bottle method can be effectively utilized to compare divergent feedstocks and diverse process conditions.

09 BIOMASS FUELS↗

DOE OSTI2020

Woody Feedstocks 2019 State of Technology Report

The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement with this overall mission, Idaho National Laboratory completes annual SOT reports for nth-plant biomass feedstock logistics. The purpose of the SOTs is to provide the status of feedstock supply system technology development for biomass to biofuels, based on actual data and experimental results relative to technical targets and cost goals from specific design cases. The 2019 Woody Feedstock SOT presents the State of Technology for feedstock supply to three individual thermochemical conversion pathways that utilize woody feedstocks: Indirect Liquefaction (IDL), Catalytic Fast Pyrolysis (CFP), and Algal-blend Hydrothermal liquefaction (AHTL). The 2019 reactor throat delivered feedstock costs were found to be $63.54/dry ton, $70.15/dry ton and $70.31/dry ton, respectively (2016$).

09 BIOMASS FUELS↗

DOE OSTI2020

Woody Feedstocks 2020 State of Technology Report

The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement with this overall mission, Idaho National Laboratory completes annual SOT reports for nth-plant biomass feedstock logistics. The purpose of the SOTs is to provide the status of feedstock supply system technology development for biomass to biofuels, based on actual data and experimental results relative to technical targets and cost goals from specific design cases. The 2020 Woody Feedstock SOT is separated into three separate pathways that utilize woody feedstocks: indirect liquefaction (IDL), catalytic fast pyrolysis (CFP), and algal-blend hydrothermal liquefaction (AHTL).

09 BIOMASS FUELS↗

DOE OSTI2021

Development of Low-cost Magnetocaloric Materials - CRADA 446

The overall goal of the project is to develop a faster heat-treatment process to produce low-cost high-performance magnetocaloric materials (MCM) for magnetic refrigeration technology. This research is in support of DOE-Fuel Cell Technology Office’s efforts to develop energy-efficient magnetic refrigeration technology for hydrogen liquefaction. Magnetic refrigeration offers a lower-cost and more energy-efficient alternative to traditional compression-based refrigeration technologies for liquefaction of gaseous hydrogen. Thus, PNNL is working with its industrial partner who is engaged in discovery, development and commercialization of low-cost high-performance MCM for use in magnetic refrigeration systems. Currently used MCM are typically a mixture of rare-earth and other elements. These are made in small batches and often need to be annealed for long durations, ranging from days to weeks, to obtain a good performance. Such extremely long heat-treatments add to the overall cost and increase the lead time to market of the commercial product. Therefore, this project will use recently developed innovative heat-treatment techniques at PNNL to shorten the annealing times and enhance the performance and lower the processing cost of MCM.

36 MATERIALS SCIENCE↗

DOE OSTI2024

LBNF/DUNE Nitrogen Refrigeration System Update

The Deep Underground Neutrino Experiment (DUNE) is supported by the infrastructure of the Long Baseline Neutrino Facility (LBNF). The central feature of DUNE is the liquid argon filled cryostats, which house the neutrino detector components. In order to maintain the argon in a liquid state, heat must be continuously removed. Argon condensers will remove this heat, and liquefy the argon, through the evaporation of liquid nitrogen. The supply of liquid nitrogen relies heavily on a near-industrial scale nitrogen refrigeration/liquefaction system. The nitrogen system will be a closed loop, in which the liquid nitrogen is supplied to users and, after being vaporized, is recycled to the nitrogen liquefaction units to be liquefied again. The system will also include nitrogen generation, to increase inventory in the closed loop, as well as to make up for losses. All of this will be installed nearly one mile underground (1.5km) on the 4850 level of the Sanford Underground Research Facility (SURF). The final DUNE vision requires 400kW of liquid nitrogen cooling capacity. Based on the operation modes and phased installation of the experiment, modularity of this cooling capacity is required. Nitrogen liquefaction will occur in four units which will afford a wide operational range of production (nominally 100kW each). Due to the experiment’s location deep underground in an inactive gold mine, there are unique and challenging constraints. These include limited access, footprint, and utilities. This poster describes the engineering effort, and provides an overview of the refrigeration system. The design includes a unique compressor arrangement which is covered in detail. Pictures and models are included where possible to help visualize the system.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Coal to Carbon Fibers

This report documents activities carried out by Oak Ridge National Laboratory and by Ramaco Carbon LLC under CRADA project NFE-20-08273 entitled “Coal to Carbon Fibers.” This project’s main objective was the demonstration of commercially relevant utilization of coal as a precursor for high-value-added products, such as carbon fibers. The specific objectives included the following: • Deploy a production platform for the conversion of coal into carbon fibers in a way that utilizes preexisting base technologies and accelerates the commercialization of coal to carbon fibers. • Rapid deployment and utilization of versatile conversion test beds for accommodating preexisting base technologies for both the conversion of coal-to-pitch (proven donor solvent liquefaction techniques) and conversion of pitch-to-fiber (proven melt spun and melt blown techniques). Results from the generation of an isotropic pitch from a subbituminous coal through the low severity direct coal liquefaction process are presented. Carbon fibers were produced from this isotropic pitch through melt spinning and melt blowing.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1975

Cryogenic nitrogen as a transonic wind-tunnel test gas

The test gas for the Langley Pilot Transonic Cryogenic Tunnel is nitrogen. Results from analytical and experimental studies that have verified cryogenic nitrogen as an acceptable test gas are reviewed. Real-gas isentropic and normal-shock flow solutions for nitrogen are compared to the ideal diatomic gas solutions. Experimental data demonstrate that for temperatures above the liquefaction boundaries there are no significant real-gas effects on two-dimensional airfoil pressure distributions. Results of studies to determine the minimum operating temperatures while avoiding appreciable effects due to liquefaction are included.

Adcock, J. B.↗

NASA NTRS1980

Literature survey of properties of synfuels derived from coal

A literature survey of the properties of synfuels for ground-based gas turbine applications is presented. Four major concepts for converting coal into liquid fuels are described: solvent extraction, catalytic liquefaction, pyrolysis, and indirect liquefaction. Data on full range syncrudes, various distillate cuts, and upgraded products are presented for fuels derived from various processes, including H-coal, synthoil, solvent-refined coal, donor solvent, zinc chloride hydrocracking, co-steam, and flash pyrolysis. Some typical ranges of data for coal-derived low Btu gases are also presented.

Reynolds, T. W.↗