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Results for “integrated biorefineries”

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 OSTI2023

Small Business Voucher Program: Scaling-Up of Bio-Based C5 Building Block Production: Cooperative Research and Development Final Report, CRADA Number CRD-16-00611

Visolis, Inc. is an early stage industrial biotechnology company developing next generation of processes for producing building blocks for bulk polymers and fuels. The company is developing low-cost routes to the chemicals of the future in support of DOE, EERE and BETO goals to grow the U.S. bioeconomy. NREL has capabilities in scale-up of fermentation processes from bench top through pilot scales and also has expertise and technologies related to production of lignocellulosic sugars from cellulosic feedstocks. NREL's Integrated Biorefinery Research Facility (IBRF) houses multiple fermentation vessels/systems ranging in size from 0.5 to 9,000 L along with ancillary capabilities in compositional analysis, separations, and purification. NREL's role will be to scale-up the Visolis process to produce an intermediate product, mevalonic acid, from both dextrose and biomass derived sugars. The goals of the project are to: 1) transfer and reproduce one of Visolis's proprietary fermentation processes at bench top and pilot scale at NREL's IBRF using dextrose as the feedstock, 2) carry out bench-scale fermentations using Visolis's organism and cellulosic sugars, and 3) produce mevalonic acid from the bench top and pilot scale runs for catalyst lifetime testing and conversion to isoprene.

09 BIOMASS FUELS↗
DOE OSTI2020

Integrated Strategies to Enable Lower-Cost Biofuels

This report summarizes the findings of a qualitative analysis to identify integrated strategies needed for more affordable biofuels. It outlines five key strategies needed to achieve lower fuel production costs in an integrated biorefinery and provides high-level research needs across the biofuel supply chain.

09 BIOMASS FUELS↗
DOE OSTI2021

Project Liberty: Launch of an Integrated Bio-Refinery with Eco-Sustainable and Renewable Technologies. Conversion of Corn Stover Biomass to Bio-Ethanol, Final Report

POET-DSM Advanced Biofuels, in collaboration with parent companies, POET and DSM, has successfully designed, constructed, and continuously operated Project Liberty, a 770 bone-dry ton per day (tpd) nameplate capacity, 20 million gallon (cellulosic bioethanol) per year demonstration scale integrated biorefinery (IBR). The IBR produced cellulosic bio-ethanol from agriculture waste (corn stover) feedstock using next-generation pretreatment and enzymatic conversion technologies. The IBR plant was built and demonstrated operations in Emmetsburg, Iowa. The schedule for this IBR project is illustrated in Figure E1. Due to uncontrollable market factors and COVID-19 pandemic, cellulosic bioethanol production ceased near the end of 2019 and remaining operations were idled June of 2020.

09 BIOMASS FUELS↗
DOE OSTI2022

Impacts of Biologically Induced Degradation on Surface Energy, Wettability, and Cohesion of Corn Stover

The impacts of biological degradation on surface area, surface energy, wettability, and cohesion of anatomically fractionated (i.e., leaf, stalk, and cob) and bulk corn stover are presented in this study. The physical, thermal and chemical properties of corn stover are critical material attributes that not only influence the mechanical processing and chemical conversion of corn stover, but also the bulk solids handling and transport. The measured surface areas were observed to be dependent on the degree of biological degradation (mild vs. moderate vs. severe) and on the anatomical fraction. The surface area of the bulk corn stover samples increased with the degree of biological degradation. The leaf fraction was the most sensitive to biological degradation, resulting in an increase in surface area from 0.5 m 2 /g (mildly degraded) to 1.2 m 2 /g (severely degraded). In contrast, the surface area of the cob fraction remained relatively unaffected by the degree of biological degradation (i.e., mildly degraded–0.55 m 2 /g, severely degraded–0.40 m 2 /g. All biologically degraded samples resulted in significant changes to the surface chemistry (evidenced by an increase in surface energy. As a general trend, the surface energy of bulk corn stover increased with the degree of biological degradation—the same trend was observed for the leaf and stalk anatomical fractions; however, the surface energy for the cob fraction remained unchanged. Wettability, calculated from surface energy, for bulk corn stover samples did not reveal any discernable trend with the degree of biological degradation. However, trends in wettability were observed for the anatomical fractions, with wettability increasing for the stalk and leaf fractions, and decreasing for the cob fraction. Excluding the cob fraction, the work of cohesion increased with the degree of biological degradation. Understanding the impacts of biological degradation on the physical, chemical and thermal properties of corn stover offers insights to improve the overall operational reliability, efficiency and economics of integrated biorefineries.

09 BIOMASS FUELS↗
DOE OSTI2021

Upgrading of C1 Building Blocks

This project is developing the centerpiece technology for a market-responsive, integrated biorefinery concept based on the conversion of renewable C1 intermediates (e.g., syngas, CO2, methanol) to a suite of fuels and co-products with improved carbon efficiency, reduced capital expense, and control of the product distribution to meet market demand. Advanced upgrading technologies of syngas are critically needed for the successful commercialization of fuel production at a scale relevant for biomass gasification. Research tasks within this project leverage complementary catalyst and process design for the conversion of CO2-rich syngas (15-20% CO2 in syngas) to achieve high carbon yields of gasoline and jet fuels as the major products. The conversion pathways generate high quality fuels (e.g., high octane gasoline with low aromatics, desirable jet-range hydrocarbons), and potential to achieve favorable cost targets by 2022. Research progress is compared against the Mobil Olefin to Gasoline and Distillate (MOGD) process, which also offers control over the gasoline and distillate products, as an industrial benchmark. The pathway for direct conversion of CO2-rich syngas to hydrocarbon fuels seeks to exceed the carbon efficiency of biomass-sourced MOGD (31.8%). Recent catalyst and process development achievements are highlighted by improvements in carbon-selectivity to fuels and carbon yields, along with evidence of incorporation of carbon from CO2 into the hydrocarbon products.

bioenergy↗
DOE OSTI2022

Biological Lignin Valorization

Given lignin's heterogeneity, catalytic depolymerization results in aromatic compound mixtures, and conversion of this complex substrate to a single product is challenging. To that end, the Biological Lignin Valorization (BLV) project is pursuing biological funneling, wherein aromatic catabolic microbes are engineered to convert a mixture of lignin-derived compounds to a single product. Namely, we employ Pseudomonas putida and pursue atom-efficient products, such as muconic acid, which can be further converted to direct replacements or used in performance-advantaged bioproducts. Overall, biological lignin conversion can make major contributions to reduce the minimum fuel selling price of the integrated biorefinery. Early industrial efforts in this area are also leading to value-added products, including in collaboration with the BLV project. Primary challenges associated with BLV efforts include accessing bio-available monomers from lignin (with the Lignin Utilization project), enabling commercial titers, rates, and yields of bioproducts from lignin-derived compounds, and overcoming substrate and product toxicity. To date, we have 1) demonstrated 49 g/L of muconate from aromatic compounds and 4 g/L of muconate from lignin, 2) improved the toxicity tolerance of P. putida to key aromatic substrates, 3) debottlenecked biological funneling for higher rates, and 4) engineered P. putida to convert S, G, and H-type lignin-derived compounds to a single product.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗
DOE OSTI2025

Sustainability perspectives of integrated pulp and paper biorefineries – A systematic critical review

As the pulp and paper industry is impacted by changing product demand trends, an opportunity arises to utilize existing pulp and paper mills (PPMs) and byproduct biomass to produce a wide range of value-added products, i.e., by converting existing PPMs into integrated pulp and paper biorefineries (IPPBs), a form of industrial symbiosis. In addition to the conventional products that a pulp and paper mill produces, IPPBs produce bio-based products that can help generate a new income stream. This paper provides a systematic critical review of IPPBs with a focus on the types of IPPBs and sustainability perspectives. Specifically, this review's objective is to identify and discuss current and emerging types of IPPBs, provide insights into the types of value-added products produced, and the opportunities and barriers they have according to published literature. We reviewed 97 articles and proposed a robust definition for IPPBs. The results show that there is a dominance of studying bioethanol as the main value-added product and black liquor as one of the main feedstocks. Additionally, we found that there are different types of market challenges for bioproducts depending on the conventional product being replaced and that location and policies play a crucial role. This review identified the limited sustainability focus on this topic and the crucial need to invest in new research to more thoroughly cover the environmental, economic, and social impacts of IPPBs.

Biorefinery pathways↗
DOE OSTI2022

Techno-economic assessment for the production of algal fuels and value-added products: opportunities for high-protein microalgae conversion

Abstract Background Microalgae possess numerous advantages for use as a feedstock in producing renewable fuels and products, with techno-economic analysis (TEA) frequently used to highlight the economic potential and technical challenges of utilizing this biomass in a biorefinery context. However, many historical TEA studies have focused on the conversion of biomass with elevated levels of carbohydrates and lipids and lower levels of protein, incurring substantial burdens on the ability to achieve high cultivation productivity rates relative to nutrient-replete, high-protein biomass. Given a strong dependence of algal biomass production costs on cultivation productivity, further TEA assessment is needed to understand the economic potential for utilizing potentially lower-cost but lower-quality, high-protein microalgae for biorefinery conversion. Results In this work, we conduct rigorous TEA modeling to assess the economic viability of two conceptual technology pathways for processing proteinaceous algae into a suite of fuels and products. One approach, termed mild oxidative treatment and upgrading (MOTU), makes use of a series of thermo-catalytic operations to upgrade solubilized proteins and carbohydrates to hydrocarbon fuels, while another alternative focuses on the biological conversion of those substrates to oxygenated fuels in the form of mixed alcohols (MA). Both pathways rely on the production of polyurethanes from unsaturated fatty acids and valorization of unconverted solids for use as a material for synthesizing bioplastics. The assessment found similar, albeit slightly higher fuel yields and lower costs for the MA pathway, translating to a residual solids selling price of $899/ton for MA versus $1033/ton for MOTU as would be required to support a $2.50/gallon gasoline equivalent (GGE) fuel selling price. A variation of the MA pathway including subsequent upgrading of the mixed alcohols to hydrocarbon fuels (MAU) reflected a required solids selling price of $975/ton. Conclusion The slight advantages observed for the MA pathway are partially attributed to a boundary that stops at oxygenated fuels versus fungible drop-in hydrocarbon fuels through a more complex MOTU configuration, with more comparable results obtained for the MAU scenario. In either case, it was shown that an integrated algal biorefinery can be economical through optimal strategies to utilize and valorize all fractions of the biomass.

09 BIOMASS FUELS↗
DOE OSTI2024

Techno-economic and life-cycle analysis of strategies for improving operability and biomass quality in catalytic fast pyrolysis of forest residues

Many of the challenges faced by the first commercial biorefineries were associated with feedstock handling, quality, and cost. Strategies are needed to enable further expansion of biorefineries and meet the growing demand for bio-based fuels and products. Here, we examine 2 key feedstock challenges and mitigation strategies in the context of a catalytic fast pyrolysis (CFP) biorefinery: (1) the operability of the feed system, which may be improved by modifying the minimum particle size fed to the reactor, and (2) the quality of the biomass, which may be improved by employing air classification to remove undesirable material and increase fuel yields. We conduct techno-economic analysis (TEA) and life-cycle analysis for these strategies, employing a discrete event simulation model for biomass preprocessing combined with a series of correlations developed from literature data and a rigorous CFP conversion model. Our results highlight the importance of balancing increased cost and material losses from preprocessing against improved operability and fuel yields. Economics and sustainability were optimized when operating at the lowest minimum particle size, emphasizing the importance of minimizing material losses while maintaining the operability of the process. Economically, additional costs and material losses from air classification could be acceptable due to improved biomass conversion, and an optimum air classification speed was identified; however, the fuel GHG emissions were minimized when air classification was not used. Valorizing material removed during preprocessing as a coproduct could improve economics and sustainability, decreasing the burden of material losses.

09 - BIOMASS FUELS↗
DOE OSTI2026

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↗
DOE OSTI2020

Design of a Biomass Scale Cubical Triaxial Tester

The bioenergy industry is dependent on predictable and reliable feedstock handling equipment. High profile failures in the industry demonstrate the need for better modeling tools for feedstock handling, specifically tools which can model the bulk flow of biomass feedstock materials in handling equipment such as hoppers or screw conveyors. Measurement of bulk material flow characteristics is a critical component to inform modeling tools. Following examples in the soils and pharmaceuticals industries, a Cubical Triaxial Tester (CTT) was selected as a critical component to study relationships between applied stress on a bulk sample and the resulting strain on the bulk material. In cooperation with The Pennsylvania State University, Forest Concepts designed a CTT specifically to measure bulk biomass flowability characteristics. Several mechanical design constraints were identified to ensure proper scaling and repeatability. Major design constraints included sample chamber size versus particle length, volumetric strain sensing accuracy, independent axial pressure control, and sample chamber handling. This report explains how major design constraints were determined.

09 BIOMASS FUELS↗
DOE OSTI2024

Improved biomass feedstock materials handling and feeding engineering data sets, design methods, and modeling/simulation tools

Forest Concepts led a project to develop a set of tools which enable feedstock handing equipment designers to better understand and model the flowability of bulk particulate biomass materials. The work products included improved flowability mathematical models, data sets used to populate the models, and two new laboratory devices – a biomass-scale true cubical triaxial tester and a biomass-scale gas pycnometer. This work was funded in part by the US Department of Energy under contact DE-EE0008254.

09 BIOMASS FUELS↗
DOE OSTI2024

A Novel Integrated Fermentation Process with Engineered Microbial Consortia for Butanol Production from Lignocellulose Sugars without CO 2 Emission

The goal of this project was to develop a synthetic microbial consortium consisting of a lactic acid bacterium, a carboxydotrophic acetogen, and a solventogenic clostridia for the production of n butanol, an advanced biofuel and industrial chemical, from lignocellulose sugars (mainly glucose and xylose) and formate (produced from CO 2 by electrochemical reduction) in an integrated bioprocess (biorefinery), which can provide an effective solution to the technical challenges in developing energy and carbon optimized synthesis for the bioeconomy and achieve the program objectives of ARPA-E. The project focused on the design, modeling and construction of synthetic microbial consortia consisting of three bacterial species to maximize carbon conversion and butanol production with a 100% theoretical product yield from glucose and zero or negative CO 2 emission.

09 BIOMASS FUELS↗
DOE OSTI2023

2.3.2.100 - Biological Lignin Valorization (BLV)

The Biological Lignin Valorization (BLV) project develops microbial strains and associated bioprocesses to convert lignin-derived aromatic compounds into value-added bioproducts. Our main objective in the BLV project is to achieve industrially relevant bioproduction metrics that can directly contribute to the economic viability and improved sustainability of the integrated lignocellulosic biorefinery, in collaboration with complementary BETO-funded lignin valorization projects. Specifically, the BLV project works closely with the BETO-funded Lignin Utilization project, which provides bio-available aromatic compounds from chemo-catalytic lignin depolymerization. We use the robust soil bacterium, Pseudomonas putida, as our primary microbial host for the conversion of lignin-derived compounds to bioproducts. To date, we have focused on atom-efficient bioproducts that can be used as either direct replacement chemicals or performance-advantaged bioproducts, including cis,cis-muconic acid, beta-ketoadipic acid, and 2-pyrone-4,6-dicarboxylic acid. From model aromatic substrates, we have achieved titers of each of these compounds approaching 40 g/L and productivity values ranging from 0.5 to over 1 g/L/hr, all at 90% molar yield or higher. From real lignin streams, we have thus far achieved 24 g/L, 0.66 g/L/hr, and theoretical yield of beta-ketoadipic acid. A major pursuit now is to reach industrially relevant performance metrics on an expanded slate of lignin-derived streams.

BIOMASS FUELS↗