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DOE OSTI2025

Low-cost buffer storage for solar industrial steam applications

Motivation and importance: Many industrial process heat consumers operate throughout the day, and deep decarbonization with solar energy requires thermal energy storage. Thermal energy storage provides an additional operational benefit of firm delivery of steam – essential to reducing the risk of costly production interruptions. The group of process heat consumers that use steam for biofuels production for the California transportation fuels market is incentivized through the Low Carbon Fuel Standard (LCFS) to reduce their carbon intensity through the use of solar steam. Examples include ethanol and dimethyl ether production. The production of these and other fuels involves distillation driven by steam reboilers with steam pressures in the range 100-280 psig. These pressures can be delivered from the type of thermal energy storage that has been the focus of this project – a steam accumulator Sunvapor, Inc. (SVI) calls a “Bullet Steam Accumulator” or “BSA TM ”. Our project adds to the understanding of the design and integration of steam accumulators charged by solar thermal energy in a biofuels production facility, and similar facilities that consume process steam. The fuel application requires a demanding level of Process Safety Management not found in other steam applications. The type of steam accumulator SVI engineered and built integrates steam generation and storage in one vessel to reduce cost. Achieving a first of a kind permit to operate such a first device has also added to the understanding of the industrial application of such systems. Goals: The overall goal of the project has been to demonstrate the advantages that a “Bullet Steam Accumulator” (BSA™) can provide to solar steam integration with a manufacturing process. The industrial host has already been convinced of the potential of the available solar steam to lower than carbon intensity score. They have been interviewed for a number of publications such as that tout the advantages SVI’s system brings to their operations. Accomplishments: At the end of 2023 Sunvapor placed in service the country’s first industrial solar boiler with thermal energy storage. At the same time, this placement in service represents the first pilot commercial system to decarbonize biofuels production through the use of solar thermal energy. While the full technical effectiveness will be shown as soon as the customer’s plant is able to consume the available steam, the economic feasibility was indicated early in the project when the combination of costs and steam pricing required to meet investor expectations was determined. The project represents a reference pilot from which a full-scale commercial system may be expanded. This pilot is a necessary first step in providing the full potential benefits to the public, including decarbonization of transportation fuels. The decarbonization of the separation steps in fuels production may be the most cost-effective and nearest term solar fuel. Co-benefits include a reduction of air pollutants such as NOx and particulate matter, and job creation for the construction, operation and maintenance of industrial solar facilities.

14 SOLAR ENERGY↗

DOE OSTI2021

Improved Hydrogen Utilization and Carbon Recovery for Higher Efficiency Thermochemical Bio-oil Pathways

The goal of this project was to develop a novel integrated direct biomass liquefaction process with improved hydrogen utilization and better carbon efficiency compared to other thermochemical conversion technologies for advanced biofuels production. Reactive catalytic fast pyrolysis, or RCFP, combines a robust hydrodeoxygenation catalyst for in situ pyrolysis in an excess of hydrogen at atmospheric (low) pressure. RCFP was developed to leverage advantages from catalytic fast pyrolysis (process simplicity and improved bio-crude quality) and biomass hydropyrolysis (enhanced hydrodeoxygenation) to produce a thermally-stable, low oxygen containing bio-crude intermediate that can be upgraded in a single conventional hydroprocessing step to produce gasoline- and diesel-range hydrocarbons. In parallel, carbon lost to the aqueous phase was recovered as renewable methane from anaerobic digestion to offset fossil carbon required to meet the hydrogen demand of the integrated process.

09 BIOMASS FUELS↗

DOE OSTI2020

Metabolic engineering of Zymomonas mobilis for anaerobic isobutanol production

Biofuels and value-added biochemicals derived from renewable biomass via biochemical conversion have attracted considerable attention to meet global sustainable energy and environmental goals. Isobutanol is a four-carbon alcohol with many advantages that make it attractive as a fossil-fuel alternative. Zymomonas mobilis is a highly efficient, anaerobic, ethanologenic bacterium making it a promising industrial platform for use in a biorefinery. In this study, the effect of isobutanol on Z. mobilis was investigated, and various isobutanol-producing recombinant strains were constructed. The results showed that the Z. mobilis parental strain was able to grow in the presence of isobutanol below 12 g/L while concentrations greater than 16 g/L inhibited cell growth. Integration of the heterologous gene encoding 2-ketoisovalerate decarboxylase such as kdcA from Lactococcus lactis is required for isobutanol production in Z. mobilis. Moreover, isobutanol production increased from nearly zero to 100-150 mg/L in recombinant strains containing the kdcA gene driven by the tetracycline-inducible promoter Ptet. In addition, we determined that overexpression of a heterologous als gene and two native genes (ilvC and ilvD) involved in valine metabolism in a recombinant Z. mobilis strain expressing kdcA can divert pyruvate from ethanol production to isobutanol biosynthesis. This engineering improved isobutanol production to above 1 g/L. Finally, recombinant strains containing both a synthetic operon, als-ilvC-ilvD, driven by Ptet and the kdcA gene driven by the constitutive strong promoter, Pgap, were determined to greatly enhance isobutanol production with a maximum titer about 4.0 g/L. Finally, isobutanol production was negatively affected by aeration with more isobutanol being produced in more poorly aerated flasks. This study demonstrated that overexpression of kdcA in combination with a synthetic heterologous operon, als-ilvC-ilvD, is crucial for diverting pyruvate from ethanol production for enhanced isobutanol biosynthesis. Moreover, this study also provides a strategy for harnessing the valine metabolic pathway for future production of other pyruvate-derived biochemicals in Z. mobilis.

09 BIOMASS FUELS↗

DOE OSTI2023

Impacts of Fungal Disease on Algal Biofuel Systems: Using Life Cycle Assessment to Compare Control Strategies

While climate change has incentivized attention on sustainable fuel sources, algae has positioned itself as a both promising and problematic biofuel feedstock. Diseases such as fungal pathogens cause costly algal feedstock crashes, but the life cycle assessments (LCAs) used to analyze the viability of algal feedstocks for biofuel have yet to consider the impact of disease on life cycle metrics. Here, we incorporate a disease model into a well-documented LCA for algal biorefineries to compare two sustainability metrics, energy return on investment (EROI) and global warming potential (GWP). We begin by showing that failure to consider disease leads to overly optimistic LCA metric outputs. Then, we compare two leading control strategies of disease chemical and biological. Our analyses show that biological engineering of a multispecies consortium of algae has a greater positive impact on LCA metrics than chemical control of the fungal pathogen using a fungicide. We expand how and when bi-cultures might advantageously exhibit the “dilution effect” whereby differentially susceptible species exhibit compensatory dynamics that stabilize feedstock production. Furthermore, our results emphasize the impact of disease and suggest that multispecies consortia of algae can be biologically engineered to reduce greenhouse gas emissions and improve the economic viability of biofuel.

09 BIOMASS FUELS↗

DOE OSTI2025

Life-Cycle Emissions and Human Health Implications of Multi-Input, Multi-Output Biorefineries

To meaningfully broaden the supply of fuels for the transportation sector, biofuel production must be scaled up and this requires a wider array of biomass feedstocks, including agricultural residues and organic waste. Rather than pursuing conversion of lignocellulosic biomass to fuels and anaerobic digestion of wastes as separate pathways, there are economic and environmental advantages associated with integrating these processes in a single facility. However, existing research rarely goes beyond carbon footprints in quantifying the effects of such a shift in bioenergy production. In addition to CO2, CH4, and N2O, this study explores the life-cycle air pollution (NH3, volatile organic compounds, NOx, SO2, and PM2.5), marine eutrophication, acidification, and local external cost implications of biorefineries capable of taking in crop residues, food waste, and manure to produce liquid fuel, electricity, and/or other options such as renewable natural gas (RNG), hydrogen, bioplastics, and protein-rich livestock feed. Relative to a single-input, single-output baseline, biorefineries integrated with organic waste codigestion to coproduce electricity or RNG can reduce life-cycle CO2-equivalent emissions by 84-149%, and the monetized external impacts across all scenarios range from $1.07/gallon to -$0.75/gallon ethanol.

Air pollution↗

DOE OSTI2021

Study of the Synchrotron Photoionization Oxidation of Alpha-Angelica Lactone (AAL) Initiated by O( 3 P) at 298, 550, and 700 K

In recent years, biofuels have been receiving significant attention because of their potential for decreasing carbon emissions and providing a long-term renewable solution to unsustainable fossil fuels. Currently, lactones are some of the alternatives being produced. Many lactones occur in a range of natural substances and have many advantages over bioethanol. In this study, the oxidation of alpha-angelica lactone initiated by ground-state atomic oxygen, O( 3 P), was studied at 298, 550, and 700 K using synchrotron radiation coupled with multiplexed photoionization mass spectrometry at the Lawrence Berkeley National Lab (LBNL). Photoionization spectra and kinetic time traces were measured to identify the primary products. Ketene, acetaldehyde, methyl vinyl ketone, methylglyoxal, dimethyl glyoxal, and 5-methyl-2,4-furandione were characterized as major reaction products, with ketene being the most abundant at all three temperatures. Possible reaction pathways for the formation of the observed primary products were computed using the CBS–QB3 composite method.

09 BIOMASS FUELS↗

DOE OSTI2021

Overview and technology opportunities for thermochemically-produced bio-blendstocks

Global demand for transportation fuels is projected to increase 40% by 2040, and biomass-derived fuels (biofuels) play a crucial role in substituting fossil fuels and mitigating greenhouse gas emissions. Currently, biofuels are mainly consumed as blendstocks combined with petroleum-based fuels, and effective conversion technologies can address the quality challenges for offering standalone biofuels. Thermochemical conversion process is one of the most promising pathways among existing technologies for biofuel production. However, the major barriers are unwanted characteristics (e.g., thermal instability) of intermediate products, such as bio-oil, and required upgrading treatments for producing compatible fuels. Here, this study highlights the merits and critical challenges of thermochemical conversion and physicochemical upgrading technologies for bio-blendstock production from lignocellulosic biomass. The novelty of this study lies in potential directions for future research through both critical and systematic literature reviews, and the proposed intensified process for lignocellulosic-based fuel blendstocks production. It is concluded that recovery and fractionation strategies (e.g., quenching and stripping) can maximize process yields and add values in the efficient conversion pathways. Effective quenching can stop secondary free radical reactions and improve liquid yields over gas and solid yields. Stripping process can improve process yield, catalyst lifespan, and thermal stability. It is further concluded that physicochemical treatments are not as effective as thermochemical treatments, but have advantages of mild operating conditions and potential for integrated solutions in conjunction with other treatments.

09 BIOMASS FUELS↗

NASA NTRS1989

Modern biofuel cells for waste recycling in life support systems

Innovative ways of treating urea in waste water reprocessing for long duration space exploration are being considered. Urea is very stable and therefore there are few effective ways for its decomposition. The feasibility of the use of the enzyme urease is to catalyze the hydrolysis of urea to ammonia and carbon dioxide is discussed, including a methodology, potential problems, the capabilities and advantages of such a system.

Chen, L.↗

DOE OSTI2023

Lignetics CRADA closeout report

Lignetics is one of the leading domestic producers of wood pellet fuels used for domestic heating. The company also produces pellets for other applications including animal bedding. The primary feedstock used for the production of Lignetics products is woody biomass. To improve the economics of pellet production, Lignetics is evaluating advanced preprocessing technologies developed by researchers at INL. In the proposed project, INL and Lignetics will work collaboratively to assess the feasibility of integrating INL’s advanced preprocessing technologies (fractional milling, high moisture pelleting and low temperature drying) in Lignetics production facilities. The successful completion of the project relies on the integration of the fractional milling and high moisture pelleting (HMP) process and low temperature drying to improve the economics of woody biomass pellet production for use in biofuel and bioproduct applications. In the HMP process, the biomass loses some moisture during compression and extrusion through the pellet die due frictional heat developed. Also, as pellets have a definite size and shape, they can be further dried in low temperature grain or belt dryers. Belt dryers are better suited to take advantage of low-grade and waste heat because they operate at lower temperatures than rotary dryers (Tumuluru et al.) Rotary dryers, for example, typically require inlet temperatures of 260°C, but more optimally operate around 400°C. In contrast, the inlet temperature of a belt dryer, such as a commercially available vacuum dryer, can be as low as 10°C above the ambient temperature, although more typically they operate at higher temperatures, between 90°C and 200°C. Because of their lower temperature operation, fire hazards and emissions to the air are lower for belt dryers in addition to reducing drying and overall pelleting costs, INL’s technology also has potential to reduce emissions at Lignetics facilities.

09 BIOMASS FUELS↗

DOE OSTI2021

Determination of Cellulosic Glucan Content in Starch Containing Feedstocks (Laboratory Analytical Procedure)

Carbohydrates make up a major portion of biomass samples. These carbohydrates are polysaccharides constructed primarily of glucose, xylose, arabinose, galactose, and mannose monomeric subunits. One such polysaccharide is starch, which is present in certain types of biomass. Starch will contribute to the overall glucose measurement when it breaks into the glucose subunit. Starch is often a more readily accessible source of glucose than structurally bound glucose polymers. Due to the different chemical nature of the glucan species, it is often advantageous to determine the amount of cellulosic glucose separately from the starch glucan.

09 BIOMASS FUELS↗

DOE OSTI2023

Smart Preprocessing & Robust Integration Emulator

To achieve the desired particle size of biomass feedstocks during preprocessing for trouble-free handling and conversion to produce biofuels and bioproducts, the raw materials must undergo a crucial milling process. The particle size of biomass plays a critical role in subsequent biofuel manufacturing, where a larger area-to-volume ratio facilitates efficient synthesis while balancing the impact of moisture on biomass storage. To optimize biofuel production efficiency and overcome these challenges, it is imperative to accurately predict the particle size distribution (PSD) of the biomass in the design of efficient preprocessing systems. The population balance model (PBM), upon empirical calibration and validation, can provide rapid prediction of post-milling PSD of granular biomass. However, PSD has limitations related to mass conservation and the absence of moisture considerations. To overcome these drawbacks, a deep learning model called the enhanced deep neural operator (DNO+) is implemented in the code. This model not only retains the capabilities of the PBM in handling complex mapping functions but also incorporates additional factors influencing the system. By considering various experimental conditions such as sieve size and moisture content, the trained DNO+ model can effectively predict the PSD after milling for any given feed PSD. To further reduce the reliance on experimental data, the PBM is integrated into the DNO+ model, resulting in a physics-informed DNO+ (PIDNO+). The PIDNO+ model addresses the non-conservation of quality exhibited by the PBM while inheriting the advantages of the DNO+ model in considering multiple influencing factors. Moreover, the PIDNO+ model significantly reduces the amount of data required for model training. Both deep learning models, i.e., DNO+ and PIDNO+, are excellent in predictive performance, offering swift and accurate machine learning-based predictions. The use of this code that contains these models will assist in guiding the proper milling equipment selection and operational conditions to achieve the desired biomass particle sizes, ensuring the efficiency of subsequent biofuel and bioproduct production processes.

Xia, Yidong [Idaho National Laboratory (INL), Idah↗

DOE OSTI2021

Can Multiple Ions in an Ionic Liquid Improve the Biomass Pretreatment Efficacy?

we report over the last few decades, efforts to transition the global production of fuels and chemicals toward renewable carbon feedstocks have accelerated. A large portion of these efforts have focused on valorization of one of the most abundant renewable carbon sources, lignocellulose. Pretreatment of lignocellulose is the first critical step in this process. In this study, novel ionic liquid (IL) systems consisting of multiple ions known to be effective at biomass pretreatment were tested on woody and grassy biomass. Molecular simulations and experimental results established the synergistic advantages of combining specific individual components in these systems. For pine (woody) biomass, pretreatment with the combination of imidazolium, cholinium, acetate, and lysinate ions achieved 80% glucose and 70% xylose yields at high biomass loading. For sorghum biomass, an IL system comprising cholinium, lysinate, and palmitate ions not only enabled a 98% glucose yield but was also found to be biocompatible in a one-pot configuration, producing the biofuel precursor bisabolene using an engineered strain of the yeast Rhodosporidium toruloides.

09 BIOMASS FUELS↗

DOE OSTI2026

Evaluation of Bio-Intermediates and Other Biofuels for use in Marine Engines

This paper presents an overview of the DOE Marine Biofuel Feasibility Study to evaluate the potential of biofuels for ocean-going vessels. These vessels operate on low-cost residual fuel oils (also known as heavy fuel oils or HFO), which require significant heating and purification onboard vessels. The industry is looking at economical alternative fuels that can enhance performance from combustion/emissions, rheology, and other perspectives. Four U.S. national laboratories are collaborating to evaluate a variety of biofuels, including bio-intermediates (pyrolysis and hydrothermal liquefaction oils), biodiesel (fatty acid methyl esters or FAME), bio-residuals (FAME byproducts) for their suitability as fuels for marine diesel engines. Bio-intermediates in particular are of interest because large marine engines that operate on HFO can tolerate lowerquality, more viscous fuels and may be able to utilize these fuels with less upgrading than other applications, presenting economic advantages. The test fuels of interest are examined to determine the minimum level of upgrading required for blend compatibility with market HFOs containing high levels of asphaltenes as well as their impact on the viscosity, polymerization tendency, and combustion properties (particularly cetane number) of the fuel blends in preparation for future evaluation in engine studies.

Kaul, Brian [ORNL] (ORCID:0000000184813620)↗

DOE OSTI2020

The Model System Saccharomyces cerevisiae Versus Emerging Non-Model Yeasts for the Production of Biofuels

Microorganisms are effective platforms for the production of a variety of chemicals including biofuels, commodity chemicals, polymers and other natural products. However, deep cellular understanding is required for improvement of current biofuel cell factories to truly transform the Bioeconomy. Modifications in microbial metabolic pathways and increased resistance to various types of stress caused by the production of these chemicals are crucial in the generation of robust and efficient production hosts. Recent advances in systems and synthetic biology provide new tools for metabolic engineering to design strategies and construct optimal biocatalysts for the sustainable production of desired chemicals, especially in the case of ethanol and fatty acid production. Yeast is an efficient producer of bioethanol and most of the available synthetic biology tools have been developed for the industrial yeast Saccharomyces cerevisiae. Non-conventional yeast systems have several advantageous characteristics that are not easily engineered such as ethanol tolerance, low pH tolerance, thermotolerance, inhibitor tolerance, genetic diversity and so forth. Currently, synthetic biology is still in its initial steps for studies in non-conventional yeasts such as Yarrowia lipolytica, Kluyveromyces marxianus, Issatchenkia orientalis and Pichia pastoris. Therefore, the development and application of advanced synthetic engineering tools must also focus on these underexploited, non-conventional yeast species. Herein, we review the basic synthetic biology tools that can be applied to the standard S. cerevisiae model strain, as well as those that have been developed for non-conventional yeasts. In addition, we will discuss the recent advances employed to develop non-conventional yeast strains that are efficient for the production of a variety of chemicals through the use of metabolic engineering and synthetic biology.

09 BIOMASS FUELS↗

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

Supply chain optimization of sustainable aviation fuel from carinata in the Southeastern United States

We report carinata is a purpose-grown oilseed feedstock for renewable fuels, including sustainable aviation fuel (SAF) that can replace conventional aviation fuel (CAF). Given carinata is a new crop in the Southeastern United States, it is crucial to analyze its sustainability from a supply chain perspective. This study developed a mixed-integer linear programming (MILP) model and simulated it for 20 years, starting from a farm (county-level data) and ending at the airport. About 2.06 million ha in Alabama, Florida, and Georgia combined were found suitable for carinata production. Given the three-year rotation period, about 0.69 million hectares can be cultivated annually, approximately 65% of which was in Georgia. About 2.4% of the combined SAF annual demand of four major airports (about 210 thousand t) in the study area is satisfied at that level of carinata cultivation. However, all available SAF was supplied to the Atlanta airport as this decision minimizes the supply chain cost. A total of 1343 storage units, one oil extraction mill, and one biorefinery were needed to meet the overall demand. We found that SW Georgia is the top supplier of carinata seeds. The unit cost of production and carbon intensity were estimated to be $\$$0.89 L -1 (or $\$$26.79 GJ -1 ) and 0.91 kg CO 2 e L -1 (or 27.28 kg CO 2 e GJ -1 ), respectively. This carbon intensity of carinata-based SAF was 67.8% lower than that of CAF. With variations included in SAF demand, yield, and soil carbon sequestration, carbon savings remained between 66.5% and 67.8%. Given the GHG advantage of SAF over CAF, there is justification for subsidies required to make SAF competitive.

10 SYNTHETIC FUELS↗

DOE OSTI2026

Rapid Evaluation of Amine-Functionalized Solvents for Biomass Deconstruction Using High-Throughput Screening and One-Pot Enzymatic Saccharification

Efficient and sustainable pretreatment of lignocellulosic biomass is critical for biofuel and biochemical production, yet its optimization is often hindered by slow, labor-intensive experimental methods. Here, we report the first demonstration of a custom-built, miniaturized, high-throughput screening platform integrated with one-pot enzymatic saccharification, enabling parallel evaluation of solvent type, feedstock, and temperature with minimal material use and high reproducibility. As a proof-of-concept, the HTX platform was used to screen five amine-functionalized solvents, including isopropanolamine, butylamine, N-methylbutylamine, ethanolamine, and ethanolamine acetate across three bioenergy crops (sorghum, poplar, and switchgrass) and pretreatment temperatures ranging from 80 to 140 °C. Vacuum drying successfully removed more than 99% of the solvents from the pretreated biomass, eliminating the need for water washing prior to saccharification. Isopropanolamine and N-methylbutylamine yielded the highest glucose (70–80%) and xylose (58–67%) release, with trends reflecting feedstock recalcitrance. The produced hydrolysates supported robust growth of an engineered strain of the yeast Rhodosporidium toruloides, confirming biocompatibility. This high-throughput platform provides a scalable, feedstock-agnostic framework for rapid pretreatment screening, accelerating solvent–feedstock pairing and process optimization. Its ability to integrate pretreatment, solvent removal, saccharification, and microbial conversion in a miniaturized format offers significant advantages for cost-competitive biorefinery development.

Biomass↗

DOE OSTI2022

Engineering Pseudomonas putida KT2440 for chain length tailored free fatty acid and oleochemical production

Abstract Despite advances in understanding the metabolism of Pseudomonas putida KT2440, a promising bacterial host for producing valuable chemicals from plant-derived feedstocks, a strain capable of producing free fatty acid-derived chemicals has not been developed. Guided by functional genomics, we engineered P. putida to produce medium- and long-chain free fatty acids (FFAs) to titers of up to 670 mg/L. Additionally, by taking advantage of the varying substrate preferences of paralogous native fatty acyl-CoA ligases, we employed a strategy to control FFA chain length that resulted in a P. putida strain specialized in producing medium-chain FFAs. Finally, we demonstrate the production of oleochemicals in these strains by synthesizing medium-chain fatty acid methyl esters, compounds useful as biodiesel blending agents, in various media including sorghum hydrolysate at titers greater than 300 mg/L. This work paves the road to produce high-value oleochemicals and biofuels from cheap feedstocks, such as plant biomass, using this host.

59 BASIC BIOLOGICAL SCIENCES↗