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Aircraft Engine Particle Emissions during the 2023 NASA-Boeing ecoDemonstrator Field Measurements

Aerosol aircraft emissions are responsible for the formation of contrail cirrus clouds which can alter Earth’s radiation and water budgets exerting substantial effects on climate. However, at present, the impact of aviation on climate forcing remaining uncertain. Recently, NASA has collaborated with Boeing ecoDemonstrator program to improve the understanding of air traffic emissions and the impact of different jet fuel compositions on contrail microphysics. As part of the program, in October 2023 the NASA DC-8 aircraft was used to sample engine exhausts emitted by a Boeing ecoDemonstrator Explorer 737-10 burning sustainable aviation fuel (SAF) and conventional jet fuel over the north western US. In this study, we present unique observations of aerosols properties relevant for contrail-cirrus cloud formation collected during the 2023 ecoDemonstrator research flights and we will discuss the variations of key microphysical contrail parameters in function of different jet fuel compositions and engine conditions.

Francesca Gallo↗
DOE OSTI2022

Catalytic Processes to Accelerate Decarbonization in a Net-Zero Carbon World

Reducing carbon dioxide emissions is one of the critical challenges to mitigate global climate change, which is having detrimental impacts on society and the environment. Fossil fuel combustion in transportation, power generation, and industrial processes is the dominant contributor to carbon emissions. Over the past decades, sustainable solutions and strategies have been investigated and developed to enable decarbonization. Catalysis plays an essential role to address this global challenge by increasing energy efficiency, reducing carbon emissions, capturing carbon dioxide, and utilizing clean energy sources to displace fossil fuels. In this Review, the role of catalysis in reducing energy demand was discussed, enhancing process efficiency, displacing carbon-intensive feedstocks and products, and therefore, reducing carbon emissions. Here, recent advances in catalyst development were summarized, focusing on applications to enhance industrial processes efficiency and enable utilization of clean energy sources. Emerging approaches in catalysis were reviewed, including the manufacture of iron and steel, direct air capture of CO 2 , production of ethylene, ammonia, and sustainable aviation fuels, plastic recycling, and the synthesis of biobased plastics. The Review was concluded with suggested research directions to achieve a carbon net-zero world.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High Performance Metal-Supported SOFC System for Range Extension of Commercial Aviation

The DOE ARPA-E REEACH program [1] has enabled this Phase 1 study that conceptualizes a commercial 154 passenger electric aircraft using renewable aviation fuel for range extension while meeting similar mission performance levels as current commercial aircraft. Commercial aviation accounts for about 2.5% of global CO2 emissions, and close to 5% of overall anthropogenic climate change due to the added accounting of contrail’s effects [2]. The sector has adopted a goal of carbon neutrality by 2050 [3]. 110 nations, and recently the new US administration, have embarked on work to address this important challenge. The US DOE has released a roadmap to enable the further development of sustainable aviation fuel (SAF) in the hopes that it could meet all of aviation’s fuel needs by 2050 [4]. However, SAF fuel price and sufficient future feedstock availability remains a concern [5]. Considering the first commercial biofuel flight demonstration 14 years ago [6] and that SAF still only comprises less than 0.1% of jet fuel use, the question arises as how it can ramp up to 100% use in the next 27 years. One option that has the potential to substantially reduce the need for SAF is to implement light-weight Solid Oxide Fuel Cells (SOFCs) that can efficiently utilize SAF or other sulfur-free hydrocarbon fuels. As opposed to lower temperature PEM (Proton Exchange Membrane) fuel cells that can use high-purity hydrogen, SOFC’s fuels are very flexible, ranging from low cost liquefied natural gas (LNG), renewable liquefied natural gas (RLNG), to SAF, to generate clean electrical power for use in aviation propulsion and auxiliary power units [7] [8]. Research progress is needed to enable SOFCs to achieve 3.0 kW/kg power density, making them viable for aviation [9]. The DOE’s Advanced Research Projects Agency – Energy (ARPA-E) has therefore initiated an aviation SOFC R&D program that is anticipated to dramatically reduce aircraft fuel use though the implementation of “Range Extenders for Electric Aviation with low Carbon and High efficiency” (REEACH) [1] for medium range commercial aircraft. This report summarizes the progress during phase 1 of the REEACH program.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Simulating competition in the US bioeconomy to produce hard‐to‐electrify transportation fuels using limited biomass resources

This study presents a novel bioeconomy optimization framework, BiOpt, designed to address critical questions regarding the strategic use of limited US biomass resources for biofuel production. By integrating detailed techno-economic analyses, life cycle assessments, and resource assessment data, BiOpt optimizes resource distributions across competing technologies to maximize economic performance and/or minimize greenhouse gas emissions. Using feedstock scenarios from the 2023 Billion Ton Study, the analysis explores optimal biomass allocations across sustainable aviation fuel, diesel, and marine biofuel conversion pathways given varying production targets and policy incentives. Results demonstrate distinct feedstock preferences and pathway utilizations when prioritizing economic returns vs. emissions reductions. For instance, fats, oils, and greases were highly favored in cost-optimized scenarios, while low-carbon feedstocks such as wet waste dominated greenhouse gas-minimized strategies. The findings underscore the pivotal role of policy incentives and technological advances in shaping biofuel supply chains and provide actionable insights for scaling sustainable biofuel production to decarbonize hard-to-electrify sectors. This framework offers a robust tool for policymakers and stakeholders to evaluate biofuel strategies that balance energy output, economic viability, and environmental impact.

09 BIOMASS FUELS↗
DOE OSTI2021

Higher Energy-Content Jet Blending Components Derived from Ethanol (CRADA 467)

This project aims to develop a new sustainable aviation fuel (SAF) that comprises favorable properties, such as high energy density, excellent thermal stability, and favorable cold fold properties. Through catalyst development, this work will provide a route to control the cycloalkane/n-alkane/iso alkane content of a next-generation fuel with minimal or no aromatic content. Combining n-alkane and iso-alkane streams (high specific energy, MJ/kg) with cycloalkanes (higher energy density, MJ/L), is expected to enable at least a 4% net increase in combined (specific (MJ/kg) and volumetric (MJ/L)) energy content without impacting ‘drop-in’ fuel requirements, such as seal swelling. PNNL and LanzaTech have already demonstrated a sustainable, non-petroleum, route to isoalkanes. However, economically attractive cycloalkane production from waste and biomass is challenged by large hydrogen requirements, preferential selectivity to aromatic compounds and low yields to jet fuel range components. Many gaps in understanding cycloalkane properties and performance in complex jet fuel mixtures remain. The close tie and integration of Purdue’s fuel property analysis, with PNNL’s process development, can lead to an economically attractive process. The fuel analysis and testing by Purdue will enable a robust understanding of the properties and behavior of the cycloalkanes produced to inform process development. Additionally, seal-swelling analysis will quantify the ability of fuel blends with zero or minimal aromatics content to satisfy the seal swell requirement of O rings. Lastly, Purdue’s system-level analysis will lead to the development of a roadmap for deployment in key regions that considers system pressures such as hydrogen, water, energy efficiency, and ease of infrastructure access.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels

Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.

09 BIOMASS FUELS↗
DOE OSTI2024

Supporting data for Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels

Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.

Li, Shuyun↗
DOE OSTI2025

Optimization for Bioenergy Systems

The Sustainable Aviation Fuel (SAF) Grand Challenge (Langholtz, 2024 ) seeks to generate 35 billion gallons of SAF each year by 2050, with corn stover, an agricultural byproduct, playing a key role as a feedstock. This study develops an optimization framework to enhance the quality and quantity of corn stover while ensuring economic and environmental viability. Using the Decision Support System for Agrotechnology Transfer (DSSAT) crop model, we simulate the effects of cover crops on rotation yield, soil moisture balance, and nitrogen cycling across diverse climates and soils. The model outputs, including yield data and soil quality changes, inform a Mixed-Integer Linear Programming (MILP) optimization model. This model aims to maximize economic and environmental returns by incorporating production costs, direct and indirect income, and environmental incentives. The optimization model evaluates 280 agriculture management plans composed of various crop management strategies, including corn stover removal rates, cover crop adoption, and fertilization practices. It seeks to identify the optimal combination of crop and tillage decisions for each subfield, maximizing profits while enhancing soil carbon sequestration and reducing greenhouse gas emissions. Outputs include detailed subfield locations, optimal management plans, and profits per hectare and per acre, allowing for comparison with literature values on farm profits. This study provides a robust optimization framework supporting the SAF Grand Challenge by proposing economically viable and environmentally sustainable strategies for corn stover utilization. The findings highlight corn stover's potential as a sustainable feedstock for SAF production, offering practical solutions to enhance its quality and quantity while maintaining soil health. Idaho is used as a case study to demonstrate the framework's applicability and effectiveness in real-world scenarios. Langholtz, M. H., Davis, M., Hellwinckel, C., De La Torre Ugarte, D., Efroymson, R., Jacobson, R., Milbrandt, A., Coleman, A., Davis, R., Kline, K. L., Badgett, A., Curran, S., Schmidt, E., Theiss, T., Fried, J., English, B., Lambert, L., Cook, H., Field, J., ... Walker, L. (2024). 2023 Billion-Ton Report: An Assessment of U.S. Renewable Carbon Resources. https://doi.org/10.2172/2441098 DSSAT Foundation. (2025). Decision Support System for Agrotechnology Transfer (DSSAT). Retrieved from https://dssat.net/

09 - BIOMASS FUELS↗
DOE OSTI2023

Direct Conversion of Delignified Biomass into Non-Volatile Products Using Thermophilic Bacteria

Butyric acid (BA) can be used as a platform intermediate for diesel and sustainable aviation fuels (SAFs) as well as a precursor for diverse commodity chemicals for the production of polymers, fibers, solvents, and preservatives. This work presents a co-culture-based bioprocess for the production of BA from corn stover by two thermophilic bacteria, Clostridium thermocellum, a well-known efficient degrader of insoluble and oligomeric cellulosic substrates, and Clostridium thermobutyricum, a highly efficient BA producer from monomeric sugars. First, we tested the capability of C. thermocellum to deconstruct three different biomass streams from the NREL pilot plant pretreatment process -raw, deacetylated, and deacetylated and mechanically refined corn stover (DMR)-, and up to 82% solids deconstruction and 91% carbohydrate utilization were obtained when using DMR solids. Then, the sugar utilization and by-product formation capabilities on various substrates by C. thermobutyricum were compared to evaluate its potential as a co-culture partner for C. thermocellum. Model carbon sources -glucose and xylose- were compared to a mixture of substrates present in soluble DMR hydrolysate streams, and the highest cell density as well as the maximum BA titer (8.3 g/L) were observed on DMR hydrolysate. Finally, clostridial co-cultivations on DMR solids were performed to investigate the inoculation time for both organisms that enhances BA production; while C. thermocellum was always inoculated at the beginning of the cultivation, C. thermobutyricum was inoculated at 0, 36, or 72h. It was found that BA production begins immediately upon inoculation of C. thermobutyricum regardless of the inoculation time. However, higher solids deconstruction and carbohydrate utilization results (83.7 and 95.6%, respectively) were obtained when both organisms were inoculated at the beginning of the fermentation. Under those conditions, up to 2.6 g/L of BA were obtained from DMR solids after 120h of cultivation. This work provides relevant information for the sustainable production of BA using thermophilic bacteria.

bacterial co-culture↗
DOE OSTI2024

Potential Availability of Alternative Fuel to Supply Maritime Activities in Pacific Northwest Ports

The international shipping sector represented 3% of global greenhouse gas emissions in 2023 (Office of Energy Efficiency & Renewable Energy 2024). International shipping has been classified as a difficult-to-decarbonize industry (IRENA 2024). In an effort to drive decarbonization, the U.S. Department of Energy has partnered with Mission Innovation to co-lead the Zero-Emission Shipping Mission, which launched in 2021(Office of Energy Efficiency & Renewable Energy 2021). In addition, the U.S. Department of State partnered with Norway to launch the Green Shipping Challenge in 2022 (Office of the Spokesperson 2022b). As part of the ZESM and Green Shipping Challenge, the United States is collaborating with the Republic of Korea (ROK) to develop a green shipping corridor (U.S. Mission Korea 2023). The United States and ROK have conducted a pre-feasibility study as the first step in developing a green shipping corridor between the countries. The ports included in the study are Seattle, Tacoma, and Everette in the U.S. Pacific Northwest (PNW) and Busan, Ulsan, and Masan in ROK. The National Renewable Energy Laboratory's role in the study was to analyze the availability and technical potential of alternative marine fuels in proximity to U.S. PNW ports. The findings show most of the existing alternative fuel capacity within the region is from renewable diesel, biodiesel, and sustainable aviation fuel facilities. The largest growth in fuel capacity in the region by 2030 is projected to be in renewable diesel and hydrogen. The overall technical readiness of non-drop-in alternative fuel production and conversion technologies is more developed than alternative-fueled ships and associated fueling infrastructure. However, much of the fuel capacity in the region is comprised of drop-in fuels, making it technically possible to use existing infrastructure for transporting and bunkering to the existing fleet. Data to inform regional alternative fuel quantity estimations were collected from an extensive review of databases, reports, announcements, and other publicly available resources. A maturity index and sector competition factor were applied to announced fuel projects to determine the quantity of alternative fuel available to the marine sector in the region by 2030. Demand data were collected from fuel bunkering logs covering the PNW seaports (State of Washington 2021). Both supply and demand data were converted to very-low sulfur fuel oil gallon equivalents (VLSFO-GE) for better comparison. Qualitative data were gathered through interviews with stakeholders, project developers, and industry experts. Total alternative fuel capacity available to the marine sector in the region is estimated to be 824 million VLSFO-GE per year by 2030. This is sufficient to cover the requirements of a green shipping corridor between the United States and ROK. The findings from this report are being used to inform detailed feasibility studies for several U.S. PNW -ROK green shipping corridors. Updates from the U.S. PNW - ROK feasibility studies will continue to be published on Mission Innovation's green corridor tracking website (Zero Emission Shipping Mission, n.d.). In addition, this report has helped to inform further work on shipping decarbonization in the U.S. PNW, including the Pacific Northwest to Alaska Green Corridor focused on cruise vessels.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Algae to HEFA : Economics and potential deployment in the United States

Abstract To reach the goals set by the US Department of Energy's Sustainable Aviation Fuel (SAF) Grand Challenge, currently available feedstocks may be insufficient. Giving priority to developing, prototyping and reducing the cost of algal feedstock before investing and lining up locations is important. As the production of algal feedstocks advances, a simplified conversion approach using more mature technologies can help reduce the investment risk for algae‐based fuels. Reducing process complexity to the steps described here [namely, conversion of lipids to HEFA (hydroprocessed esters and fatty acids) fuels and relegating the remainder of the biomass to anaerobic digestion or food/feed production] enables the near‐term production of algal SAF but presents challenging economics depending on achievable cultivation costs and compositional quality. However, these economics can be improved by present‐day policy incentives. With these incentives, the modeled algae‐to‐HEFA pathway could reach a minimum fuel selling price as low as $4.7 per gasoline gallon equivalent depending on the carbon intensity reduction that can be achieved compared with petroleum. Uncertainty about algal feedstock production maturity in the current state of technology and the future will play a large role in determining the economic feasibility of building algae‐to‐HEFA facilities. For example, if immaturity increases the feedstock price by even 10%, SAF production in 2050 is about 58% of the production which could have been achieved with mature feedstock. Additionally, growth in this conversion pathway can be notably boosted through the inclusion of subsidies, and also through higher‐value coproducts or higher lipid yields beyond the scope of the process considered here.

09 BIOMASS FUELS↗
DOE OSTI2025

Mobilizing mine lands for biobased decarbonization strategies

Over 163 000 ha of mine lands in Pennsylvania (PA) have the potential to produce willow as a feedstock for renewable energy generation. Each year these lands could produce between 454 000 and 907 000 dry Mg of willow, which can be a feedstock for bioenergy (i.e., biopower) with carbon capture and sequestration (BECCS) or sustainable aviation fuel (SAF) production. We used a spatially explicit model to explore cost-minimized allocation of willow biomass from abandoned mine lands (AML) to be used for BECCS or SAF production and to abate carbon dioxide. The results suggest that between 454 000 and 907 000 dry Mg of biomass can be produced on AML in PA at costs from $94 to $250 per dry Mg. This AML willow biomass could be combined with other available biomass and aggregated to ten facilities to produce 17.9 TWh of power; alternatively, it could produce 958 million liters of jet fuel, 638 million liters of renewable diesel, and 1.289 billion liters of naphtha, along with 0.735 TWh of electricity. From this analysis, in PA, under the BECCS pathway, up to 36 million Mg per year of CO2 could be abated at costs of up to $134 per Mg; under the SAF pathway, up to 17.5 million Mg per year of CO2 could be abated at costs up to $150 per Mg of CO2. The use of mine land willow as a supplemental feedstock for SAF and BECCS would need strong incentive programs if costs of production are to be comparable with production on agricultural land.

Wahlstrom, Mallory [Pennsylvania State University]↗
DOE OSTI2026

Engineering of 2‐ketoacid Decarboxylases for Production of Isobutanol and Other Fusel Alcohols in Saccharomyces cerevisiae

Isobutanol is a fusel alcohol that can be produced microbially for use as a biofuel or upgraded into sustainable aviation fuel (SAF). A key enzyme in the isobutanol biosynthetic pathway is 2-ketoacid decarboxylase (KDC), which irreversibly decarboxylates 2-ketoisovalerate (KIV) to yield isobutyraldehyde. However, many previously characterized KDC enzymes also act promiscuously on other 2-ketoacids, (e.g., pyruvate) to produce a related aldehyde (e.g., acetaldehyde). This unwanted side reaction is especially important when isobutanol is produced in Saccharomyces cerevisiae (S. cerevisiae) because it leads to pyruvate being diverted to ethanol. In order to make S. cerevisiae a strict isobutanologen, a KDC enzyme that is specific for KIV must be deployed. In this study, we used a combination of cell-based and in vitro enzyme assays to investigate KDC substrate specificity, characterizing a large set of homologs for KIV, pyruvate, and phenylpyruvate (PPV) activity. A diverse range of substrate specificities was discovered, and some previously uncharacterized KDCs were revealed to have high KIV activity and low pyruvate activity. Multi-site saturation mutagenesis (SSM) of one of these KDCs identified mutants with increased KIV activity, while maintaining low levels of pyruvate activity. In a KIV bioconversion experiment, bioprospected and engineered KDCs allowed similar KIV consumption to when using the previously characterized Lactococcus lactis KdcA, though with some ethanol also produced. The KDCs identified here show promise for production of isobutanol and other alcohols derived from 2-ketoacids, and the dataset of newly characterized KDCs can inform future efforts to understand and engineer substrate specificity in KDCs.

2-ketoacid decarboxylase↗
DOE OSTI2026

A Comparative Study of Ethanol Upgrading to Butadiene Over Rare Earth Elements Incorporated in Dealuminated Beta Zeolites

Copper and rare earth element-containing dealuminated Beta zeolites (CuREE/deAlBeta) are promising catalysts for the conversion of ethanol to C 3+ olefins en route to sustainable aviation fuel. Product selectivities over CuREE/deAlBeta depend on the identity of the REE. Here, in this study, a suite of La/deAlBeta catalysts of varied La loading are prepared, and their reactivities, selectivities, and apparent C-C coupling kinetics in the cascade reaction between ethanol and acetaldehyde are reported. Ex situ and in situ titrations to quantify Lewis acidic La sites quantify distinct numbers of sites, suggesting a distribution of site types. Across a series of REE/deAlBeta catalysts (REE = Y, La, Lu, Yb, Gd), the selectivity to secondary products correlates with the pyridine heats of adsorption at REE Lewis acid sites. The turnover frequency (per Lewis acid site) for C–C coupling was similar across the series of REE/deAlBeta catalysts. Y/deAlBeta and La/deAlBeta, which have the most disparate secondary product selectivities, had similar kinetics for C–C coupling. These findings demonstrate the complexity of quantifying active sites in REE/deAlBeta zeolites, and the sensitivity of the selectivity, but not the reactivity for C–C coupling, to the identity of the REE atom in REE/deAlBeta zeolites.

alcohol upgrading↗
DOE OSTI2026

Feedstock Choices for Advancing the Bioeconomy in the US and Policy Implications

Biomass feedstocks will be critical for scaling up the bioeconomy in the United States to meet multiple demands for biofuels, sustainable aviation fuel, bioproducts, and biochemicals. There is a wide range of choices of feedstocks, including a variety of dedicated energy crops and crop residues. There are substantial differences in the yields, costs of production, and carbon intensity of these feedstocks and for each feedstock across locations. These feedstocks also differ in the trade-offs they offer among multiple environmental impacts. We discuss the economic factors that will influence the production of these feedstocks and the implications of alternative biofuel and low-carbon policies for the mix of feedstocks that will be incentivized.

Khanna, Madhu (ORCID:0000000349944451)↗
DOE OSTI2026

Migration of Al within dealuminated beta extruded catalysts influences olefin distribution during ethanol upgrading

Zeolites serve as essential catalytic platforms for many industrial processes, including emerging ethanol-to-olefins (ETO) upgrading technologies. Although metal-loaded (Cu, Zn, Y) dealuminated beta (deAlBeta) zeolite powders are promising catalysts for direct ETO conversion with high selectivity to butene-rich C3+ olefins necessary for production of sustainable aviation fuels (SAF), development of these materials as shaped technical bodies through the incorporation of binders is required for scale-up and commercial viability. Here, we report the ethanol upgrading performance of Cu-Zn-Y/deAlBeta extruded catalysts formulated with either alumina or kaolin clay binders. Both extrudates exhibit high ethanol dehydration reactivity which competes with the initial ethanol dehydrogenation step in the direct ETO reaction network. Consequently, elevated selectivity to dehydration side products (ethylene, diethyl ether) at ∼100% ethanol conversion is observed on Cu-Zn-Y/deAlBeta extrudates compared to the powder catalyst, which inhibits production of desired C3+ olefins. Utilizing microscopy and spectroscopic characterizations, we attribute this to Al migration from binder to zeolite particles within the extrudates, thus re-aluminating the zeolite and generating Brønsted acid sites active for dehydration reactions. This work elucidates the effects of binder incorporation on ETO product distributions and emphasizes that binder selection must be carefully considered during design of extruded zeolite catalysts.

Jacobs, Hunter [ORNL] (ORCID:000000016190874X)↗
DOE OSTI2026

Advancing technologies for lignin-based jet fuel production in aqueous phase

Integrating lignin into a cellulosic ethanol plant for the co-production of lignin-based jet fuel (LJF) in aqueous phase offers a significant opportunity to boost operational efficiency, economic viability, carbon conversion, and the overall sustainability of biofuel and chemical production. LJF is lignin-structure-based jet fuel blendstocks primarily composed of alkyl-substituted mono-, bi-, and tri-cyclohexanes. It exhibits high energy density, potential for low emissions, and favourable blend characteristics that comply with drop-in specifications. An overview of lignin feedstock, catalytic processes, LJF chemical compositions, fuel properties tests, and techno-economic analysis (TEA) and life cycle assessment (LCA) indicate that (1) the reactivity of lignin plays a crucial role in its structure transformation to LJF molecules; (2) catalytic processing of lignin to LJF can occur through a simultaneous depolymerization and hydrodeoxygenation process, bypassing the intermediate step of producing and upgrading lignin-derived oil; (3) LJF's uniqueness molecules making it more promising for high energy content and low emission jet fuel properties for next generation sustainable aviation fuel (SAF); and (4) TEA and LCA demonstrate that LJF is not only potentially cost-effective but also offers favourable carbon footprint compared to other SAFs. In conclusion, this review highlights the most recent advancements in LJF technology, along with the challenges and opportunities that lie ahead in fulfilling its potential.

09 BIOMASS FUELS↗
DOE OSTI2026

Green pretreatment strategies for enhanced microbial lipid fermentation and synergistic high-quality lignin recovery for next-generation integrated biorefineries

Miscanthus × giganteus (Mxg) is a warm-season perennial grass being commercialized as a biomass feedstock for temperate farms. Three process strategies were compared for converting Mxg into single-cell oil and extracted lignin intermediates, as hydrothermal (HT) processing and two natural deep eutectic solvents (NADES), ChCl:LA (choline chloride:lactic acid) and ChCl:Gly (choline chloride:glycerol). Pretreatments were performed at 10% and 50% solids loading at 140 °C, 2 h; HT: 190 °C, 10 min. Enzymatic hydrolysates, generated at 10% solids using washed and unwashed biomass, were evaluated for microbial lipid production. Maximum glucose conversions from washed biomass reached 83.5% (ChCl:LA), 52.7% (ChCl:Gly), and 74.0% (HT). Remarkably, NADES-derived hydrolysates effectively replaced refined sugars for the cultivation of the oleaginous yeast Rhodotorula toruloides, achieving ∼51% higher biomass (OD 90.7) and lipid titers of 19.36 g/L within 45 h using a two-stage fermentation strategy. Lipid contents ranged from 34.5–44.5% dry weight, demonstrating reduced reliance on purified sugars. Beyond carbohydrate valorization, ChCl:LA pretreatment enabled high-purity lignin recovery (>89%) in a lignin-first strategy. Structural analyses (2D-HSQC and ³¹P NMR) showed syringyl (78.15%), guaiacyl (15.15%), and p-hydroxyphenyl (6.41%) units, with higher phenolic hydroxyl content (0.91 mmol/g) and a lower S/G ratio (0.19) than HT lignin (0.87 mmol/g, S/G 0.22). These attributes favor downstream lignin depolymerization into low-molecular-weight aromatics. Overall, NADES pretreatment simultaneously enhances microbial lipid yields and recovers high-quality lignin, advancing the economic feasibility of renewable diesel and sustainable aviation fuel (SAF) production from bioenergy crops within an integrated biorefinery framework.

2D HSQC↗