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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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CORSIA: The first internationally adopted approach to calculate life-cycle GHG emissions for aviation fuels

The aviation sector has grown at a significant pace in recent years, and despite improvements in aircraft efficiency, the sector's impact on climate change is a growing concern. To address this concern, the International Civil Aviation Organization (ICAO) established the Carbon Offsetting and Reduction Scheme for International Aviation (CORSIA) to help reduce aviation greenhouse gas (GHG) emissions. This paper presents a methodology agreed by the 193 ICAO member states to evaluate the life-cycle GHG emissions of sustainable aviation fuels (SAFs), in the CORSIA system. The core life-cycle assessment and induced land use change values of SAFs are presented to determine the GHG savings of certified pathways. The paper aims to present that a number of SAFs can yield significant life-cycle emission reductions compared to petroleum-derived jet fuel. This implies the potentially major role of SAFs in reducing aviation's carbon footprint.

54 ENVIRONMENTAL SCIENCES↗

Workshop on Sustainable Aviation Fuel-Use Research Opportunities

On February 15-16, 2022, the U.S. Department of Energy’s (DOE’s) Vehicle Technology Office (VTO) within Energy Efficiency and Renewable Energy (EERE) convened a workshop to assess the end-use research opportunities for Sustainable Aviation Fuels (SAF). This report summarizes the proceedings and findings of the workshop, which the U.S. Department of Energy’s Argonne National Laboratory hosted as a virtual event. During these two half-days, invited members of national laboratories, industry, government, and academia connected virtually to share perspectives on SAF research needs for improving end-use adoption.

09 BIOMASS FUELS↗

Electrification of Aircraft: Challenges, Barriers, and Potential Impacts

Small-scale aircraft are being electrified with small e-aircraft already certified to fly and with test flights underway for retrofits of existing aircraft focused on near-term deployment. Internationally, from 2018 to 2020, the number of electric aircraft projects underway increased 50%. These technologies are projected to increase operational efficiency and reduce emissions and noise from a growing aviation sector. This emerging interest in aviation electrification includes aircraft, energy supply equipment, and battery storage manufacturers. Federal agencies are currently funding a variety of efforts including technology research as well as forecasting demand and environmental impacts and state governments have also begun pushing for further investigation in this area. This paper provides an overview of the current state and potential future development of aviation electrification. To understand the types of research questions around current and future challenges for this emerging sector, we consider a case study of the potential deployment of small commercial electric aircraft for existing, under-served markets and consider operational requirements and technical challenges as well as the range of questions that will need to be addressed around charging infrastructure, grid integration, policy and regulatory requirements, and emissions impacts. This case study also outlines potential nearer-term solutions and research areas of interest that will need to be addressed in the longer term at much larger scales and highlights NREL capabilities for addressing these challenges.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

A Hybrid Pathway to Biojet Fuel via 2,3-Butanediol

Production of biomass-derived sustainable alternative jet fuels (SAJF) has been considered as an important approach to decarbonize the aviation industry but still possesses various challenges in technology advancement, particularly in achieving high carbon efficiency. Here we report a hybrid pathway to SAJF from 2,3-butanediol (2,3-BDO), integrating biologically converting biomass to 2,3-BDO with catalytically upgrading of 2,3-BDO to jet-range hydrocarbons. This pathway is demonstrated to have a high carbon recovery to liquid hydrocarbons from corn stover (25–28%) (74–82% of the theoretical maximum efficiency). The catalytic conversion steps involve 2,3-BDO to C3+ olefins, oligomerization, and hydrogenation where the first two steps are the focus of this study. Under optimum reaction conditions (523 K, 115 kPa, 1.0 h-1 weight hourly space velocity), 2,3-BDO conversion and C3+ olefin selectivity are >97% and 94–98% during 40 h time on stream, respectively. To demonstrate the adaptability of this technology with bio-derived 2,3-BDO, we also investigated the impact of water and other organic coproducts (acetoin and acetic acid) inherited from the fermentation broth on the catalyst performance and product selectivities. We have shown that the catalyst can handle a significant amount of water in the liquid feed (40 wt% water/60 wt% 2,3-BDO) and maintain catalyst stability for ~40 h. Acetoin can be converted to similar C3+ olefins as 2,3-BDO with complete conversion of acetoin. Co-feeding 10 wt% acetoin with 2,3-BDO is found to have no impact on 2,3-BDO conversion, C3+ olefin selectivity, and catalyst stability. The utilization of organic coproduct like acetoin can help to improve overall carbon conversion efficiency when using real biomass-derived 2,3-BDO. On the other hand, the presence of 10 wt% acetic acid is shown to drastically inhibit methyl ethyl ketone (MEK) hydrogenation and butene oligomerization as revealed by the increased MEK and butene selectivities, implying the importance of separating organic acids when feeding bio-derived 2,3-BDO. The formed C3–C6 olefins from 2,3-BDO are further oligomerized over Amberlyst-36 catalyst to longer-chain hydrocarbons with >70 wt% jet-range hydrocarbons including predominantly iso-olefins/iso-paraffins. The overall carbon efficiency for the jet-range hydrocarbons is 19–22%, exceeding most of the reported biojet pathways, which makes it a promising approach for SAJF production.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Aerosol-Cloud Interactions From Aviation Soot Emissions

Current models estimate global aviation contributes approximately 5% to the total anthropogenic climate forcing, with aerosol-cloud interactions having the greatest effect. However, radiative forcing estimates from aviation aerosol-cloud interactions remain undetermined. There is an expected significant increase in aircraft emissions with aviation demand expected to rise by over 4% per year. Soot may play an important role in the ice nucleation of aircraft-induced cirrus formation due to a high emission rate, but the ice nucleating properties are poorly constrained. Understanding the microphysical processes leading to atmospheric ice crystal formation is crucial for the reliable parameterization of aerosol-cloud interactions in climate models due to their impact on precipitation and cloud radiative properties. Ice nucleation of aircraft-emitted soot is potentially affected by particle morphology with condensation of supercooled water occurring in pores followed by ice nucleation. However, soot has heterogeneous properties and undergoes atmospheric aging and oxidation that could change surface properties and contribute to complex ice nucleation processes. Further, this review synthesizes current knowledge of ice nucleation catalyzed by aviation in the cirrus regime and its effects on global radiative forcing. Further research is required to determine the ice nucleation and microphysical processes of cirrus cloud formation from aviation emissions in both controlled laboratory and field investigations to inform models for more accurate climate predictions and to provide efficient mitigation strategies.

54 ENVIRONMENTAL SCIENCES↗

Production and Catalytic Upgrading of 2,3-Butanediol Fermentation Broth into Sustainable Aviation Fuel Blendstock and Fuel Properties Measurement

With the increasing demand for sustainable supplies of aviation fuel and need to address climate change, new conversion technologies are needed to efficiently process biomass, produce high quality jet fuel blendstock, and meet carbon emission targets. This study demonstrates the synthesis, conditioning, and catalytic upgrading of 2,3-butanediol (BDO) fermentation broth into a jet fuel blendstock candidate. A high-titer 2,3-BDO fermentation broth (i.e., ~90 g/L) was produced at a 100-L scale and pretreated via nanofiltration to decrease the impurities level in the broth from 4.6 to 0.6 wt%. A novel process for catalytic upgrading of aqueous 2,3-BDO into a jet fuel blendstock candidate was developed, and each step was efficiently demonstrated. The catalytic steps include 1) 2,3-BDO dehydration into methyl ethyl ketone (MEK) over AlPO4, 2) MEK conversion into olefins over Zn1Zr10Ox, 3) oligomerization of olefins over a zeolite beta, and 4) hydrogenation over platinum/carbon. Both the model feed and real 2,3-BDO fermentation broth were tested for upgrading 2,3-BDO to MEK. With the real feed, a continuous loss of conversion (i.e., >50% loss over ~140 h time-on-stream [TOS]) was partly attributed to reversible deactivation from coking species. However, the conversion remained stable with the model feed, which demonstrates the efficiency of the first step for converting aqueous 2,3-BDO (10 wt% in water). For upgrading MEK to olefins, high selectivity to olefins (i.e., 82.5%) was obtained at high conversion levels (i.e., 93-98%) with stable conditions being achieved for > 70-hours TOS. Oligomerization of light olefins, which was demonstrated for > 270 h TOS, mainly led to the formation of dimers (C8-10) and trimers (C13-14). The oligomerized product was hydrogenated and distilled to recover the jet fraction (35 mass% or 40.9% carbon based yield), which consists mostly of desired isoalkanes (31.7 wt%), n-alkanes (24.5 wt%), and cycloalkanes (29.6 wt%). While some improvement is still needed to meet ASTM D7566 specifications for viscosity and final boiling point temperature, freezing point, density, aromatics content, and sulfur content of the jet blendstock candidate were within acceptable ranges, thus highlighting the potential of this process for production of jet fuel blendstock.

ADVANCED PROPULSION SYSTEMS,BIOMASS FUELS↗

Design, optimization, and validation of a triply periodic minimal surface based heat exchanger for extreme temperature applications

Heat exchanger (HX) innovation offers potential for significant improvements in energy efficiency for a host of applications including but not limited to aviation and power generation cycles. Triply Periodic Minimal Surfaces (TPMS) have received significant attention in recent years due to their incredibly high surface area density, which makes them very attractive from a heat transfer point of view. Recent efforts have largely focused on thermal-hydraulic characterization of the many available TPMS and the testing of small-scale HX prototypes. However, practical implementation remains largely unexplored, partially due to the extreme computational cost associated with accurately simulating these complex structures. In this work, we present the design, simulation, and optimization of a TPMS-HX for high temperature (900 °C) and pressure (25 MPa) applications. Detailed analysis of HX sub-sections is conducted to define the smallest repeatable section which may be used to characterize the thermal-hydraulic performance of the entire HX, enabling rapid design and iteration with significantly reduced computational cost. Compared to preliminary results for a water-to-water experiment, calibrated heat transfer and pressure drop predictions were within ±5 % and ±10 %, respectively. Optimization results show a 10x increase in volumetric power density over the initial design, which is verified against a parametric exhaustive search of the HX design space. Furthermore, it was found that reducing the unit cell hydraulic diameter cell plays the largest role in increasing heat transfer, increasing the surface area density and enabling a more compact and efficient HX.

42 ENGINEERING↗

Biofuel Innovation: Clean Energy Solutions, Ready Today

An overview of BETO's innovations in biofuels research to enhance transportation technologies and infrastructure. With over 300 active R&D projects, BETO initiatives encourage cost-competitive, efficient, and sustainably produced biofuels.

biofuels, bioproducts, aviation, maritime↗

Airport Ground Support Equipment Infrastructure & Logistics Electrification Assessment Tool: 2025 Data Development, Modeling and Analysis for DFW

The aviation industry is increasingly turning to modernize freight facilities by integrating electric Ground Support Equipment (eGSE) to enhance operational efficiency of freight facility moving vehicles and equipment. Airports worldwide are adopting eGSE to streamline cargo movement, reduce fuel and maintenance costs, and improve logistics coordination.1 North America, with its advanced aviation infrastructure, leads this transition, leveraging Internet of things (IoT)-enabled automation and zero emission technologies to boost reliability and reduce human errors.2 Electrification of freight facility moving vehicles and equipment boosts turnaround times, improves equipment reliability, and optimizes logistics coordination, giving operators a competitive advantage. With rising fuel price volatility and the pressure to meet stringent performance benchmarks, airports are focusing on cost-effective, scalable solutions for long-term financial and operational gains. To further accelerate electrification, airports are integrating Zero Emission Vehicles (ZEVs) into rental car fleets and deploying electric baggage carts, requiring strategic investments in charging infrastructure. 3 The shift, however, presents challenges, such as limited technical expertise, high capital costs, and complex procurement processes. By forging strategic partnerships, leveraging advanced technologies, and optimizing infrastructure investments, airports can create a resilient, future-ready ecosystem that enhances the movement of people and goods through electrification-driven efficiency. Supported by the U.S. Department of Energy (DOE) Vehicle Technologies Office (VTO), this electrification effort provides a scalable, cost-effective solution to improve airport freight operations. Through targeted investments and innovation, airports enhance efficiency, reduce costs, and meet performance benchmarks while advancing toward a resilient, electrified future.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Posterior Regularized Bayesian Neural Network incorporating soft and hard knowledge constraints

Neural Networks (NNs) have been widely used in supervised learning due to their ability to model complex nonlinear patterns, often presented in high-dimensional data such as images and text. However, traditional NNs often lack the ability for uncertainty quantification. Bayesian NNs (BNNS) could help measure the uncertainty by considering the distributions of the NN model parameters. Besides, domain knowledge is commonly available and could improve the performance of BNNs if it can be appropriately incorporated. In this work, we propose a novel Posterior-Regularized Bayesian Neural Network (PR-BNN) model by incorporating different types of knowledge constraints, such as the soft and hard constraints, as a posterior regularization term. Furthermore, we propose to combine the augmented Lagrangian method and the existing BNN solvers for efficient inference. Furthermore, the experiments in simulation and two case studies about aviation landing prediction and solar energy output prediction have shown the knowledge constraints and the performance improvement of the proposed model over traditional BNNs without the constraints.

14 SOLAR ENERGY↗

Techno-Economic Evaluation of Strategies to Approach Net-Zero Carbon Sustainable Aviation Fuel via Woody Biomass Gasification and Fischer-Tropsch Synthesis

Reducing the carbon dioxide (CO2) emissions from the transportation industry is a key target for achieving global net-zero carbon goals. Wide-spread electrification, efficient engine design, and alternative fuel implementations have been introduced for light-duty vehicles and are projected to significantly reduce light-duty emissions in the near future. Conversely, the aviation sector contributes considerably towards transportation-based carbon emissions, but current projections do not show substantial reductions in carbon emissions over time. Challenges for the aviation sector include low compatibility with electrification, relative inflexibility to variations in fuel properties, and requirement of high energy density fuels. Thus, identifying pathways to decarbonize the aviation sector via liquid low- or net-zero carbon biofuels that are compatible with current aviation infrastructure is crucial. This work investigates the economic feasibility of approaching net-zero carbon sustainable aviation fuel (SAF) from woody biomass via gasification and Fischer-Tropsch synthesis. In doing so, this assessment identifies the economic opportunities and trade-offs of several carbon mitigation strategies coupled with renewable resource interventions required to approach net-zero carbon fuels via biomass. Renewable natural gas and green hydrogen utilization strategies are assessed to examine the impact of fuel yield improvements versus renewable resource cost. Additionally, both carbon capture and sequestration (CCS) and carbon capture and utilization (CCU) are considered in this analysis to help mitigate carbon loss to the atmosphere. Each scenario was assessed on cost, carbon efficiency, energy efficiency, and overall technology-readiness level (TRL). The results of this analysis show that renewable natural gas, green hydrogen, and CCS can be viewed as a low-cost, near-term carbon abatement strategies. However, in the long-term, deployment of more expensive and less technologically mature CCU technologies can make use of point sources of CO2 to boost overall fuel production.

aviation fuel↗

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↗

Power Electronics and Electric Machines for Advanced Aircraft

Power electronics and electric machines are critical components of efficient, high-performance aircraft - from fixed-wing turbine to electric vertical takeoff and landing aircraft and beyond. Improvements to these components create enormous energy efficiencies, enable cost savings, and ensure fail-safe operations. National Renewable Energy Laboratory researchers are developing innovative power electronics, electric motors, integrated electric traction drives, and thermal management systems to build highly efficient, lightweight, ultrareliable powertrains for aircraft.

42 ENGINEERING↗

Simulated moving bed-inspired method for continuous adsorptive denitrogenation of model fuel

Efficient, continuous routes for removing nitrogen-containing compounds from hydrothermal liquefaction-derived synthetic aviation fuel are needed to enable direct blending with conventional jet fuels. Here, we report a simulated moving bed-inspired process for adsorptive denitrogenation of a model fuel. Unlike conventional simulated moving bed systems, which are designed for sharp separations between similar solutes, this approach was run deliberately outside the classical separation region so that both pyridine and indole were removed together from the hydrocarbon stream. Alcohol solvents were used to regenerate the silica adsorbent, maintaining performance over extended operation and avoiding the downtime and energy demand associated with calcination. Under these conditions, the system demonstrates removal of more than 98% of nitrogen while cutting solvent use by 28% compared to batch operation. Classical modeling tools predicted column concentration profiles even in this nontraditional regime, suggesting a straightforward path to scaling. Together, these results motivate solvent-efficient, continuous denitrogenation strategies that could be integrated with biorefinery processes.

Adsorption↗

Comparative Economic Analysis Between Bioenergy and Forage Types of Switchgrass for Sustainable Biofuel Feedstock Production: A Data Envelopment Analysis and Cost–Benefit Analysis Approach

ABSTRACT The capacity to produce switchgrass efficiently and cost‐effectively across diverse environments can be pivotal in achieving the short‐ and medium‐term Sustainable Aviation Fuel targets set by the U.S. Department of Energy. This study evaluated the economic performance of forage‐ and bioenergy‐type switchgrass cultivars and their response to N fertilization under diverse marginal environments across the US Midwest that included Illinois (IL), Iowa (IA), Nebraska (NE), and South Dakota (SD). Data Envelopment Analysis (DEA) was used to evaluate the efficiency of 23 Decision‐Making Units (DMUs)—cultivar types and N fertilization rate combinations—while a cost–benefit analysis calculated their profitability over 5 years. Results showed that two energy‐type cultivars—“Independence” and “Liberty”—were superior economically to the forage cultivars. Independence performed best with the highest profit margin when fertilized at 56 kg N ha −1 , particularly in the US hardiness zone 6a (Urbana, IL). Liberty exhibited the highest profit margins in hardiness zone 5b (Madrid, IA, and Ithaca, NE) at 56 kg N ha −1 and showed exceptional profitability with 28 kg N ha −1 in hardiness zone 6b (Brighton, IL). Switchgrass cultivar “Carthage” showed better efficiency score and profitability results in hardiness zone 4b (South Shore, SD) at 56 kg N ha −1 . The profit trends observed in current study sites may indicate broader patterns across similar US hardiness zones. This study provides valuable insights for decision‐makers to optimize input strategies for biomass production of bioenergy switchgrass to meet renewable energy demands.

Arshad, Muhammad Umer [Department of Crop Sciences↗

Harnessing ketones as hydrogen acceptors for atom-efficient upgrading of oxygenates to fuels over H/ZSM-5

Heterogeneous mixtures of bio-derived oxygenates are promising feedstocks for synthetic aviation fuel (SAF), but conversion strategies for one common component—short-chain (C 5–7 ) internal ketones—are lacking. Previous work has shown that cyclization of ketones over H/ZSM-5 is limited by its high productivity of light paraffins. We study 4-heptanone upgrading over H/ZSM-5 and show that aromatics and olefins can be formed at high carbon yield when operating at up to 90% conversion. The yield of desirable products is not impacted by the introduction of a recycle stream of the unconverted 4-heptanone and other products with similar boiling points. We hypothesize, based on first-principles calculations, that the higher olefin yield is driven by the ease of hydrogen transfer to unreacted ketones as opposed to hydrogenating olefin products. We demonstrate how this ease of hydrogen transfer to ketones can be leveraged to enhance olefin selectivity in the conversion of methanol to olefins as well by co-feeding ketones. Olefinic products of the cyclization reaction are then oligomerized to a SAF blendstock to demonstrate an end-to-end ketone-to-SAF process facilitated by upgrading ketones over H/ZSM-5 at partial conversion with a recycle stream. The results of this work demonstrate a strategy to improve the carbon yield from bio-derived acids to SAF to over 75%, representing a relative improvement of more than 50% compared to previously reported data.

08 HYDROGEN↗

Thermally robust and highly stable method for splicing silica glass fiber to crystalline sapphire fiber

This research reports an advancement in splicing silica glass fiber to sapphire single-crystal optical fiber (SCF) using a specialized glass processing device, including data that demonstrate the thermal stability of the splice to 1000°C. A filament heating process was used to produce a robust splice between the dissimilar fibers. A femtosecond laser is used to inscribe a fiber Bragg gratings sensor into the SCF to measure the high-temperature capabilities and signal attenuation characteristics of the splice joint. The experimental results demonstrate that the proposed splicing method produces a splice joint that is robust, stable, repeatable, and withstands temperatures up to 1000°C with a low attenuation of 0.5 dB. Here, the proposed method allows placement of SCF-based sensors in the extreme environments encountered in various engineering fields, such as nuclear, chemical, aviation, and metals manufacturing, to enable improvements in process monitoring, product quality, and production efficiency.

36 MATERIALS SCIENCE↗

Addressing Consequence within Operational Risk (O.T. Gagnon III) 9-18-2024

Addressing Consequence within Operational Risk: Why threats and security are just not that important! When dealing with cyber or physical risk within any critical infrastructure (CI) environment, don’t concern yourself with vulnerabilities and threats, at least not at first! Also, don’t be overly fixated on “securing the systems” within the organization. The endeavor of tackling operational risk focused on consequences in any critical infrastructure environment to include the complex Aviation ecosystem is challenging even for the most resourced entity but can be advanced though a simplified approach: identifying, binning, and prioritizing the infrastructure environment. While no two entities within a single element of the 16 critical infrastructure sectors are exactly alike when it comes to risk, there is a basic process to move toward a greater understanding of operational risk through becoming more informed about the infrastructure environment in which the entity exists. The process starts with bringing internal and external stakeholders and subject matter experts together to analyze key areas such as Information Technology (IT) and Operational Technology (OT) components and points of convergence, analyzing internal and external cyber and physical dependencies, accounting for explosive growth in devices and wireless technology, and leveraging the contributions of people inside and outside the operational environment. Attaining a common understanding of the infrastructure environment as part of addressing consequences within operational risk is not easy to do or resource light, but the process outlined provides the framework to further any entity’s efforts in this space. When it comes to cyber risks, before an organization can consider vulnerabilities within and threats to its operations, it must first have a solid understanding of the consequences existing inside its infrastructure environment. Idaho National Lab’s Consequence-Driven, Cyber-Informed Engineering is offered as an example of this approach to effective and efficient cyber risk mitigation.

99 GENERAL AND MISCELLANEOUS↗