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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Techno-economic analysis and life cycle assessment for the catalytic hydrogenolysis and hydrocracking of polyethylene

Catalytic hydrogenolysis and hydrocracking are promising technologies for the conversion of polyolefin waste into hydrocarbons. Here, to explore the economic and environmental viability of these approaches, we conducted techno-economic analysis and life cycle assessment of polyethylene hydrogenolysis and hydrocracking processes that produce fuel-range products or olefins, respectively. Relative to primary production, the minimum selling price (MSP) of alkanes for linear-chain naphtha was estimated to be 1.8-fold higher, whereas branched-chain naphtha and propylene were shown to be cost competitive. Environmental impacts showed similar trends across scenarios, with propylene production by hydrocracking exhibiting greenhouse gas emissions comparable with conventional propylene due to relatively low hydrogen demand and high yield. Together, these results suggest that innovations in catalysis and reaction engineering will be required to make viable products that are scale matched with today's plastics, such as light olefins for closed-loop recycling.

09 BIOMASS FUELS↗
DOE OSTI2021

Chemical and Biological Catalysis for Plastics Recycling and Upcycling

Plastics pollution is causing an environmental crisis, prompting the development of new approaches for recycling, and upcycling. Here, we review challenges and opportunities in chemical and biological catalysis for plastics deconstruction, recycling, and upcycling. We stress the need for rigorous characterization and use of widely available substrates, such that catalyst performance can be compared across studies. Where appropriate, we draw parallels between catalysis on biomass and plastics, as both substrates are low-value, solid, recalcitrant polymers. Innovations in catalyst design and reaction engineering are needed to overcome kinetic and thermodynamic limitations of plastics deconstruction. Either chemical and biological catalysts will need to act interfacially, where catalysts function at a solid surface, or polymers will need to be solubilized or processed to smaller intermediates to facilitate improved catalyst–substrate interaction. Overall, developing catalyst-driven technologies for plastics deconstruction and upcycling is critical to incentivize improved plastics reclamation and reduce the severe global burden of plastic waste.

28 EE - Advanced Manufacturing Office (EE-5A)↗
DOE OSTI2021

Development of Enabling Technologies for a Pressurized Dry Feed Oxy-Coal Reactor

Researchers at Brigham Young University (3 faculty, 9 graduate students, and 35 undergraduate students) completed this 5-year research program with the main objective to build and test a 100 kWth pressurized dry-feed oxy-coal combustor (POC). This objective was achieved through the development and testing of a unique pressurized dry coal fluidization feed system that operates in conjunction with a pressurized oxycoal combustor. The project included a series of R&D tasks, including design, modeling, bench-scale testing, construction, safety reviews, and reactor testing which are detailed in this report. BYU researchers were supported in some modeling tasks by project partners Reaction Engineering International (REI) and CPFD Software.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Characterizing Impacts of Dry Coal Feeding in High Pressure Oxy-Coal Combustion Systems

Reaction Engineering International (REI) has managed a team of experts from the University of Utah, Southeast University (SEU) in Nanjing, China, Electric Power Research Institute (EPRI), Corrosion Management Ltd. (C-M), Praxair, and Brigham Young University (BYU) to investigate dry pulverized coal feeding for pressurized oxy-coal combustion. Dry feed firing systems for entrained flow, pressurized, oxy-coal combustors have not been well developed, although related technologies have been used in the Shell Gasification Process and for pressurized fluid bed combustion. DOE-funded research recently completed at REI and the University of Utah focused on characterizing impacts of high temperatures and pressures in oxy-coal combustion systems. For high pressure combustion, that research used a coal slurry feed into a 17 bar pressurized combustor. As a consequence of that research, it was identified that fuel feeding and firing system flexibility are challenges that require attention. Based on that experience, the approach of using a coal slurry feed system leads to challenges in producing consistent atomization of the slurry, which causes burnout problems, especially at high pressures. In addition, slurry atomization processes may be difficult to scale to sizes appropriate for practical commercial use. Dry pressurized coal burner systems, on the other hand, have the potential to yield efficiency gains, improve flexibility and facilitate applications at larger scales. Experimental work was conducted at the University of Utah Industrial Combustion and Gasification Research Facility as well as the 100 kW pressurized oxy-coal combustor (POC) facility at Brigham Young University. Mechanism development and CFD-based combustion and dense-phase flow modeling were performed at REI. Successful completion of the project objectives has resulted in the following key deliverables: 1) Design and prototype of a pressurized pulverized coal feeding and oxy-firing system 2) Data from a 100kW, pressurized (15 bar) entrained flow reactor with a dry feeding delivery and burner system that describes flame characteristics, radiative heat flux profiles, carbon burnout, along with characteristics of ash aerosols, fouling, and slagging. 3) Validated and transportable models that describe the relevant conditions in pressurized oxy-combustion systems and that can be used for scale-up and optimization. 4) Principles to guide design of high pressure, pilot-scale and full-scale coal oxy-firing systems. 5) Assessment of pressurized oxy-combustion impacts on key parameters relevant to oxy-coal fired utility boilers such as coal devolatilization, char oxidation, mineral matter transformation, deposition, and corrosion. The experimental data, pressurized oxy-firing system principles, and process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess the use of high temperature and high pressure oxy-combustion in current research and to guide development of new oxy-coal boiler designs.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Characterizing Impacts of Dry Coal Feeding in High Pressure Oxy-Coal Combustion Systems

Reaction Engineering International (REI) has managed a team of experts from the University of Utah, Southeast University (SEU) in Nanjing, China, Electric Power Research Institute (EPRI), Corrosion Management Ltd. (C-M), Praxair, and Brigham Young University (BYU) to investigate dry pulverized coal feeding for pressurized oxy-coal combustion. Dry feed firing systems for entrained flow, pressurized, oxy-coal combustors have not been well developed, although related technologies have been used in the Shell Gasification Process and for pressurized fluid bed combustion. DOE-funded research recently completed at REI and the University of Utah focused on characterizing impacts of high temperatures and pressures in oxy-coal combustion systems. For high pressure combustion, that research used a coal slurry feed into a 17 bar pressurized combustor. As a consequence of that research, it was identified that fuel feeding and firing system flexibility are challenges that require attention. Based on that experience, the approach of using a coal slurry feed system leads to challenges in producing consistent atomization of the slurry, which causes burnout problems, especially at high pressures. In addition, slurry atomization processes may be difficult to scale to sizes appropriate for practical commercial use. Dry pressurized coal burner systems, on the other hand, have the potential to yield efficiency gains, improve flexibility and facilitate applications at larger scales. Experimental work was conducted at the University of Utah Industrial Combustion and Gasification Research Facility as well as the 100 kW pressurized oxy-coal combustor (POC) facility at Brigham Young University. Mechanism development and CFD-based combustion and dense-phase flow modeling were performed at REI. Successful completion of the project objectives has resulted in the following key deliverables: 1) Design and prototype of a pressurized pulverized coal feeding and oxy-firing system 2) Data from a 100kW, pressurized (15 bar) entrained flow reactor with a dry feeding delivery and burner system that describes flame characteristics, radiative heat flux profiles, carbon burnout, along with characteristics of ash aerosols, fouling, and slagging. 3) Validated and transportable models that describe the relevant conditions in pressurized oxy-combustion systems and that can be used for scale-up and optimization. 4) Principles to guide design of high pressure, pilot-scale and full-scale coal oxy-firing systems. 5) Assessment of pressurized oxy-combustion impacts on key parameters relevant to oxy-coal fired utility boilers such as coal devolatilization, char oxidation, mineral matter transformation, deposition, and corrosion. The experimental data, pressurized oxy-firing system principles, and process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess the use of high temperature and high pressure oxy-combustion in current research and to guide development of new oxy-coal boiler designs.

pressurized oxy-coal combustion, sub-micron ash ae↗
DOE OSTI2022

Characterizing Impacts of Dry Coal Feeding in High Pressure Oxy-Coal Combustion Systems

Reaction Engineering International (REI) has managed a team of experts from the University of Utah, Southeast University (SEU) in Nanjing, China, Electric Power Research Institute (EPRI), Corrosion Management Ltd. (C-M), Praxair, and Brigham Young University (BYU) to investigate dry pulverized coal feeding for pressurized oxy-coal combustion. Dry feed firing systems for entrained flow, pressurized, oxy-coal combustors have not been well developed, although related technologies have been used in the Shell Gasification Process and for pressurized fluid bed combustion. DOE-funded research recently completed at REI and the University of Utah focused on characterizing impacts of high temperatures and pressures in oxy-coal combustion systems. For high pressure combustion, that research used a coal slurry feed into a 17 bar pressurized combustor. As a consequence of that research, it was identified that fuel feeding and firing system flexibility are challenges that require attention. Based on that experience, the approach of using a coal slurry feed system leads to challenges in producing consistent atomization of the slurry, which causes burnout problems, especially at high pressures. In addition, slurry atomization processes may be difficult to scale to sizes appropriate for practical commercial use. Dry pressurized coal burner systems, on the other hand, have the potential to yield efficiency gains, improve flexibility and facilitate applications at larger scales. Experimental work was conducted at the University of Utah Industrial Combustion and Gasification Research Facility as well as the 100 kW pressurized oxy-coal combustor (POC) facility at Brigham Young University. Mechanism development and CFD-based combustion and dense-phase flow modeling were performed at REI. Successful completion of the project objectives has resulted in the following key deliverables: 1) Design and prototype of a pressurized pulverized coal feeding and oxy-firing system 2) Data from a 100kW, pressurized (15 bar) entrained flow reactor with a dry feeding delivery and burner system that describes flame characteristics, radiative heat flux profiles, carbon burnout, along with characteristics of ash aerosols, fouling, and slagging. 3) Validated and transportable models that describe the relevant conditions in pressurized oxy-combustion systems and that can be used for scale-up and optimization. 4) Principles to guide design of high pressure, pilot-scale and full-scale coal oxy-firing systems. 5) Assessment of pressurized oxy-combustion impacts on key parameters relevant to oxy-coal fired utility boilers such as coal devolatilization, char oxidation, mineral matter transformation, deposition, and corrosion. The experimental data, pressurized oxy-firing system principles, and process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess the use of high temperature and high pressure oxy-combustion in current research and to guide development of new oxy-coal boiler designs.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Catalyst Development to Overcome Barriers for Commercialization of Synthetic High-Octane Hydrocarbons: Cooperative Research and Development (Final Report)

In recent years, researchers at the National Renewable Energy Laboratory (NREL) and the University of California Berkeley (UC Berkeley) have independently developed catalysts that convert methanol and dimethyl ether into alkylate-like hydrocarbons with a high-octane value, and both have developed intellectual property around these chemical transformations. Both UC Berkeley and NREL wish to see their technologies commercialized to address a number of domestic and international energy challenges. The technologies developed by NREL and UC Berkeley are complimentary but neither have moved beyond the laboratory scale due to remaining challenges with the catalyst activity and selectivity, and/or with the reaction engineering associated with maximizing the yield of the high-value product. NREL and UC Berkeley wish to collaboratively through a shared resources CRADA to solve issues related to the scale-up and process integration of their high-octane hydrocarbon technologies, thus enabling future licensing of the technology to an industry partner.

10 SYNTHETIC FUELS↗
DOE OSTI2026

Final Report: Process Intensification of Hydrogen Production through Sorption-Enhanced Gasification of Biomass

The University of Utah, in partnership with Idaho National Laboratory (INL), evaluated Sorption-Enhanced Gasification (SEG) as a transformative pathway for producing hydrogen with the potential for negative CO 2 emissions. SEG integrates gasification, water-gas shift, and in-situ carbon capture within a dual fluidized bed reactor to enable efficient clean hydrogen production. Key challenges related to biomass variability and process complexity were addressed through feedstock engineering, reaction optimization, and process validation. A co-pelletized biomass–limestone feedstock was developed to simplify feeding and introduction of makeup limestone. Kinetic and sorbent studies identified optimal operating conditions and confirmed the suitability of low-cost limestone, while catalysts were developed to reduce tar formation. Reactor modeling and techno-economic analysis indicated that SEG can achieve competitive hydrogen production costs, particularly when combined with carbon incentives, supporting its potential for scale-up and carbon-negative operation.

08 HYDROGEN↗
DOE OSTI2020

Catalytic Hydrogen Production from Methane: A Review on Recent Progress and Prospect

Natural gas (Methane) is currently the primary source of catalytic hydrogen production, accounting for three quarters of the annual global dedicated hydrogen production (about 70 M tons). Steam–methane reforming (SMR) is the currently used industrial process for hydrogen production. However, the SMR process suffers with insufficient catalytic activity, low long-term stability, and excessive energy input, mostly due to the handling of large amount of CO 2 coproduced. With the demand for anticipated hydrogen production to reach 122.5 M tons in 2024, novel and upgraded catalytic processes are desired for more effective utilization of precious natural resources. In this review, we summarized the major descriptors of catalyst and reaction engineering of the SMR process and compared the SMR process with its derivative technologies, such as dry reforming with CO 2 (DRM), partial oxidation with O 2 , autothermal reforming with H 2 O and O 2 . Finally, we discussed the new progresses of methane conversion: direct decomposition to hydrogen and solid carbon and selective oxidation in mild conditions to hydrogen containing liquid organics (i.e., methanol, formic acid, and acetic acid), which serve as alternative hydrogen carriers. We hope this review will help to achieve a whole picture of catalytic hydrogen production from methane.

08 HYDROGEN↗
DOE OSTI2023

2.2.3.106 - Lignin-First Biorefinery Development

The Lignin-First Biorefinery Development (LigFirst) project aims to develop a cost-effective, and scalable biomass fractionation strategy based on reductive catalytic fractionation (RCF). The RCF process uses a protic solvent, hydrogen gas or a hydrogen donor, and a metal catalyst in the presence of intact biomass to produce a stable, depolymerized lignin oil and a polysaccharide pulp, which can both be converted to value-added products in parallel processes. RCF is a promising strategy to enable the use of woody feedstocks in biochemical conversion processes and is also promising as a means to valorize lignin with equal emphasis to biomass carbohydrates. Guided by techno-economic analysis and life cycle assessment and in collaboration with industry partners, we are actively developing RCF methods to 1) avoid the need for exogenous hydrogen gas, 2) substantially reduce reactor pressure via use of low vapor pressure solvents, 3) separate the lignin solvolysis and catalytic processes through reaction engineering solutions, 4) reduce solvent loading below what can be achieved in typical batch reactors, and 5) avoid or minimize the use of organic solvents. The LigFirst project also collaborates closely with the Lignin Utilization and Lignin Conversion-to-SAF projects for critical substrate handoffs and analytics. Overall, the LigFirst project is enabling new approaches that ultimately can enable RCF to be a feedstock-agnostic method to valorize both polysaccharides and lignin.

BIOMASS FUELS↗
DOE OSTI2023

Rewiring cell-free metabolic flux in E. coli lysates using a block—push—pull approach

Abstract Cell-free systems can expedite the design and implementation of biomanufacturing processes by bypassing troublesome requirements associated with the use of live cells. In particular, the lack of survival objectives and the open nature of cell-free reactions afford engineering approaches that allow purposeful direction of metabolic flux. The use of lysate-based systems to produce desired small molecules can result in competitive titers and productivities when compared to their cell-based counterparts. However, pathway crosstalk within endogenous lysate metabolism can compromise conversion yields by diverting carbon flow away from desired products. Here, the ‘block—push—pull’ concept of conventional cell-based metabolic engineering was adapted to develop a cell-free approach that efficiently directs carbon flow in lysates from glucose and toward endogenous ethanol synthesis. The approach is readily adaptable, is relatively rapid and allows for the manipulation of central metabolism in cell extracts. In implementing this approach, a block strategy is first optimized, enabling selective enzyme removal from the lysate to the point of eliminating by-product-forming activity while channeling flux through the target pathway. This is complemented with cell-free metabolic engineering methods that manipulate the lysate proteome and reaction environment to push through bottlenecks and pull flux toward ethanol. The approach incorporating these block, push and pull strategies maximized the glucose-to-ethanol conversion in an Escherichia coli lysate that initially had low ethanologenic potential. A 10-fold improvement in the percent yield is demonstrated. To our knowledge, this is the first report of successfully rewiring lysate carbon flux without source strain optimization and completely transforming the consumed input substrate to a desired output product in a lysate-based, cell-free system.

59 BASIC BIOLOGICAL SCIENCES↗