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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 OSTI2021

Comparison of methodologies used to determine aromatic lignin unit ratios in lignocellulosic biomass

Abstract Background Multiple analytical methods have been developed to determine the ratios of aromatic lignin units, particularly the syringyl/guaiacyl (S/G) ratio, of lignin biopolymers in plant cell walls. Chemical degradation methods such as thioacidolysis produce aromatic lignin units that are released from certain linkages and may induce chemical changes rendering it difficult to distinguish and determine the source of specific aromatic lignin units released, as is the case with nitrobenzene oxidation methodology. NMR methods provide powerful tools used to analyze cell walls for lignin composition and linkage information. Pyrolysis-mass spectrometry methods are also widely used, particularly as high-throughput methodologies. However, the different techniques used to analyze aromatic lignin unit ratios frequently yield different results within and across particular studies, making it difficult to interpret and compare results. This also makes it difficult to obtain meaningful insights relating these measurements to other characteristics of plant cell walls that may impact biomass sustainability and conversion metrics for the production of bio-derived fuels and chemicals. Results The authors compared the S/G lignin unit ratios obtained from thioacidolysis, pyrolysis-molecular beam mass spectrometry (py-MBMS), HSQC liquid-state NMR and solid-state (ss) NMR methodologies of pine, several genotypes of poplar, and corn stover biomass. An underutilized approach to deconvolute ssNMR spectra was implemented to derive S/G ratios. The S/G ratios obtained for the samples did not agree across the different methods, but trends were similar with the most agreement among the py-MBMS, HSQC NMR and deconvoluted ssNMR methods. The relationship between S/G, thioacidolysis yields, and linkage analysis determined by HSQC is also addressed. Conclusions This work demonstrates that different methods using chemical, thermal, and non-destructive NMR techniques to determine native lignin S/G ratios in plant cell walls may yield different results depending on species and linkage abundances. Spectral deconvolution can be applied to many hardwoods with lignin dominated by S and G units, but the results may not be reliable for some woody and grassy species of more diverse lignin composition. HSQC may be a better method for analyzing lignin in those species given the wealth of information provided on additional aromatic moieties and bond linkages. Additionally, trends or correlations in lignin characteristics such as S/G ratios and lignin linkages within the same species such as poplar may not necessarily exhibit the same trends or correlations made across different biomass types. Careful consideration is required when choosing a method to measure S/G ratios and the benefits and shortcomings of each method discussed here are summarized.

09 BIOMASS FUELS↗
DOE OSTI2023

Using Life Cycle Assessment to Inform CBI Research Priorities

Life cycle assessment (LCA) is used within the Center for Bioenergy Innovation (CBI) to provide information about how feedstock agricultural practices, supply chain logistics, biorefinery operating parameters, and the slate of biofuels and products contribute to environmental impacts, and how CBI's research priorities can result in less impactful biofuel supply chains. This poster provides an overview of the LCA methodology used within CBI and focuses on data needs in general and from other CBI teams. Assumptions and simplifications within biofuel LCA studies are reviewed, including options for modeling multi-functional processes. Calculation details for life cycle environmental impacts used within CBI - global warming potential, cumulative energy demand, and the Available Water Remaining indicator - are presented, along with a discussion of carbon intensity as an alternative metric for evaluating sustainable aviation fuel and other biofuels. The process of interpreting impact results to guide research priorities is discussed, with examples drawn from CBI's upcoming manuscript on switchgrass yield and cell wall composition.

bioenergy↗
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 OSTI2022

Bioproducts from high-protein algal biomass: An economic and environmental sustainability review and risk analysis

This report has High-protein algal biomass as an important bio-commodity that has the potential to provide a new source of sustainable protein products. Herein is a critical review that identifies 1) the most relevant sustainability findings related to the processing of proteinaceous algal biomass to higher value protein products and 2) the potential pathways to improve life cycle assessment (LCA) and techno-economic analysis (TEA) metrics, including life-cycle carbon dioxide equivalent (CO 2 eq), life cycle energy, and minimum selling price (MSP) of these products. The critical review of the literature revealed a large variation in model input parameters relating to these metrics. Therefore, a Monte Carlo analysis was conducted to assess the risk associated with these input variations. To understand the uncertainties that propagate into high-protein algae to products’ systems, we reviewed more than 20 state-of-the-art unit operations for algal biomass processing., including cell disruption, protein solubilization, protein precipitation and purification, and protein concentration. We evaluated displacement of proteinaceous products by algal-bioproducts, including ruminant feed, aquaculture feed, protein tablets, and biopolymers and biopolyesters, with prices in the market ranging from 1.9 to 120 $\$$ kg -1 protein. This review realized that the MSP of ruminant and non-ruminant feed ranges from 0.65±0.56 to 2.9±1.1 $\$$ kg -1 protein, and bioplastics’ MSP ranges from 0.97 to 7.0 $\$$ kg -1 protein. Regarding LCA metrics, there is limited research on life cycle energy in proteinaceous biomass concentration and bioproduct systems, reported at 32.7 MJ kg protein -1 , for animal feed displacement. Animal feed emissions in the literature report negative fluxes, representing environmental benefits, as low as -3.7 kgCO 2 eq kg -1 protein and positive fluxes, i.e., global warming potential, as high as 12.8 kgCO 2 eq kg -1 protein. There is limited research on bioplastics life cycle emissions reported at 0.6 kgCO 2 eq kg -1 protein. In general, the studies to date of algae-derived protein bioproducts showed similar life cycle emissions to soybean meals, nylon, polymers, and polystyrenes. Our risk analysis realized that more than 50% of scenarios can result in negative-net life cycle CO 2 eq emissions. This review and risk analysis assess and demonstrate the scenarios that improve economic and environmental sustainability metrics in high-protein algal bioproducts systems.

09 BIOMASS FUELS↗
DOE OSTI2021

Do We Need a New Sustainability Assessment Method for the Circular Economy? A Critical Literature Review

The goal of the circular economy (CE) is to transition from today's take-make-waste linear pattern of production and consumption to a circular system in which the societal value of products, materials, and resources is maximized over time. Yet circularity in and of itself does not ensure social, economic, and environmental performance (i.e., sustainability). Sustainability of CE strategies needs to be measured against their linear counterparts to identify and avoid strategies that increase circularity yet lead to unintended externalities. The state of the practice in quantitatively comparing sustainability impacts of circular to linear systems is one of experimentation with various extant methods developed in other fields and now applied here. While the proliferation of circularity metrics has received considerable attention, to-date, there is no critical review of the methods and combinations of methods that underlie those metrics and that specifically quantify sustainability impacts of circular strategies. Our critical review herein analyzes identified methods according to six criteria: temporal resolution, scope, data requirements, data granularity, capacity for measuring material efficiency potentials, and sustainability completeness. Results suggest that the industrial ecology and complex systems science fields could prove complementary when assessing the sustainability of the transition to a CE. Both fields include quantitative methods differing primarily with regard to their inclusion of temporal aspects and material efficiency potentials. Moreover, operations research methods such as multiple-criteria decision-making (MCDM) may alleviate the common contradictions which often exist between circularity metrics. This review concludes by suggesting guidelines for selecting quantitative methods most appropriate to a particular research question and making the argument that while there are a variety of existing methods, additional research is needed to combine existing methods and develop a more holistic approach for assessing sustainability impacts of CE strategies.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Measuring Sustainability of Solar Modules for Energy Transition: Mass, Energy, and Circularity

Transition to a carbon-free energy system is crucial for global decarbonization and underpins Circular Economy (CE) goals. Photovoltaic (PV) technology is required for Energy Transition, but manufacturing and circular pathways can be material, energy, and carbon-intensive. Therefore, we need a prioritization of sustainability strategies for PV evolution and lifecycle management in the context of Energy Transition. This study employs a suite of quantitative metrics to compare different proposed sustainability strategies for PV modules on their ability to achieve Energy Transition. Proposals for sustainable PV range from high-yield, high-efficiency paradigms, to short-lived and fully recyclable, to long-lasting, indestructible modules. We leverage a global decarbonization deployment schedule through 2100 with the open-source PV in Circular Economy (PV ICE) tool to quantify the impacts of different evolving module design scenarios covering the range of proposed sustainability strategies. First, modules are compared on effective capacity and required replacements to meet and maintain decarbonization capacity targets through 2100. We demonstrate the effects of lifetime, degradation, and reliability on effective capacity. Next, we quantify and compare virgin material demands and lifecycle wastes, examining the impacts of lifetime and recycling rates. Finally, and critically for renewable energy technologies, we quantify the energy demands required to achieve the decarbonization capacity targets and calculate energy balance metrics (net energy, energy return on investment). These results are then summarized into a metric matrix, demonstrating tradeoffs and the importance of longevity. Our suite of mass and energy metrics provides stakeholders and decision-makers with quantitative data on circular economy choices for PV in the energy transition, enabling informed evaluation of tradeoffs of different PV module designs and CE pathways.

circular economy↗
DOE OSTI2024

PET and polyolefin plastics supply chains in Michigan: present and future systems analysis of environmental and socio-economic impacts

Many actions are underway at global, national, and local levels to increase plastics circularity. However, studies evaluating the environmental and socio-economic impacts of such a transition are lacking at regional levels in the United States. In this work, the existing polyethylene terephthalate and polyolefin plastics supply chains in Michigan were compared to a potential future (‘NextCycle’) scenario that looks at increasing Michigan’s overall recycling rate to 45%. Material flow analysis data was combined with environmental and socio-economic metrics to evaluate the sustainability of these supply chains for the modeled scenarios. Overall, the NextCycle scenario for these supply chains achieved a net 14% and 34% savings of greenhouse gas (GHG) emissions and energy impacts, when compared with their respective baseline values. Additionally, the NextCycle scenario showed a net gain in employment and wages, however, it showed a net loss of revenue generation outside of Michigan due to the avoided use of virgin resins in Michigan.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

A New Evaluation Metric for Demand Response-Driven Real-Time Price Prediction Towards Sustainable Manufacturing

Abstract The increasing industry energy demand highlights the urgency of demand response management, while the emerging smart manufacturing technologies pave the way for the implementation of real-time price (RTP)-based demand response management towards sustainable manufacturing. The demand response management requires scheduling of manufacturing systems based on RTP predictions, and thus the prediction quality can directly alter the effectiveness of demand response. However, since the general price prediction algorithms and prediction evaluation metrics are not specifically designed for RTP in demand response problems, a good RTP prediction obtained and evaluated by these algorithms and metrics may not be suitable for demand response scheduling. Therefore, in this study, the relationships between the effectiveness of demand response for manufacturing systems and evaluation results from six commonly used metrics are investigated. Meanwhile, a new metric called k-peak distance (KPD), considering the characteristics of the demand response problem, is proposed and compared with the other six metrics. Furthermore, an encoder-decoder long short-term memory recurrent neural network with KPD is proposed to provide better RTP prediction for manufacturing demand response problems. The case studies indicate that the proposed KPD metric shows a 1.8–3.6 times higher correlation with the demand response effectiveness compared to the other metrics. In addition, the production schedule based on the RTP prediction obtained from the proposed algorithm can improve the effectiveness of demand response by 23.4% on average.

Engineering↗
DOE OSTI2024

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

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

09 BIOMASS FUELS↗
DOE OSTI2024

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

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

Li, Shuyun↗
DOE OSTI2024

Avancando na Transicao Energetica: Desafios e Estrategias para a Implantacao Sustentavel de FV

As the world embarks on an ambitious journey towards global decarbonization, the spotlight turns to photovoltaic (PV) technology as a cornerstone for sustainable energy solutions. This talk delves into the current status and projections of PV for the World, US and Brasil, and the necessary considerations to do this increase in manufacturing and deployment sustainably. With the projected scale of deployment, the industry faces significant challenges related to material demand and the management of PV modules at their end of life. The principles of the Circular Economy (CE) and its associated R-Actions - Reduce, Reuse, Recycle, among others - present a promising framework to address these challenges by mitigating end-of-life management and material sourcing concerns. However, traditional CE metrics, often focused solely on mass, fall short by excluding vital energy flow considerations. In this talk, we will highlight how various metrics are needed to understand sustainable PV solutions, how continuing the search for increased efficiency can significantly reduce material demands and enhance energy metrics, while strategies around material circularity and module lifetime and reliability improvements will offer substantial reductions in both material and energy demands.

Brasil↗
NASA NTRSDate not supplied

NASA’s Space Sustainability Strategy: An Overview and a Conceptual Framework for Implementation

Space sustainability is crucial for the continuation of humanity's exploration and utilization of space. NASA recognizes the imperative of maintaining a sustainable space operating environment to safeguard the future of space activities. On April 9, 2024, NASA released its first part of an integrated Space Sustainability Strategy focused on the domain of earth orbit, with future volumes to address impacts of space operations on earth itself; cislunar space, including the Lagrange points and the lunar surface; and deep space, including other celestial bodies. This commitment extends to ensuring the safety of astronauts conducting operations in Low Earth Orbit (LEO), as well as enabling missions to the Moon and Mars. Moreover, sustainable space practices are essential for the uninterrupted operation of NASA's robotic science missions, which monitor Earth's changes and probe the mysteries of the universe. The strategy sets out a set of goals, the first of which is to establish a framework for assessing space sustainability at NASA, addressing the absence of a universally accepted framework with key metrics that promotes understanding of how metrics are interconnected. This framework will provide a basis for evaluating the sustainability of orbital activities, with metrics informed by input from the domestic and international space community. Objectives under this goal include defining key parameters affecting space sustainability, determining tolerable levels of risk, and annually publishing NASA's effect on space sustainability, including compliance with orbital debris mitigation standards. The subsequent goals build upon this foundation, identifying effective actions for enhancing space sustainability, incentivizing adoption of these actions through technology development and policy changes, and ensuring coordination with the global space community. An organizational change within NASA is also proposed to facilitate day-to-day coordination and accountability for space sustainability efforts. By pursuing these goals, NASA aims to strengthen the technical foundations of and continue to set an example for sustainable space operations. Regular evaluation of NASA mission performance in context with meeting sustainability objectives will ensure alignment with evolving challenges in the space operating environment.

Matt Forsbacka↗
DOE OSTI2024

A Multi-Dimensional Benefit Assessment of Automated Mobility Platforms (AMP) for Large Facilities

Automated Mobility Platform (AMP) is a general term for intelligently managed passenger mobility systems that leverage automation and electrification to improve system performance and sustainability through the integration of real-time data streams with advanced decision-making processes tailored for use in large facilities. Using airports as an example, the rapid growth in air travel demand has led to facility expansions and congested terminals, which directly impacts equity (e.g., increased challenges for passengers with reduced mobility [PRMs]) and sustainability - both of which are important metrics often neglected during the engineering design process. Therefore, to evaluate systems and inform critical decisions more effectively, a holistic evaluation framework is proposed that includes equity, sustainability, and infrastructure perspectives - referred to as a multidimensional benefit assessment. More specifically, the following analysis focuses on: (1) mobility, with emphasis on travel time and accessibility within an airport, contrasting existing systems with the proposed AMP system; (2) equity analysis, specifically to the PRM community, but with an eye to the whole of society; (3) energy consumption and greenhouse gas (GHG) emissions associated with intra-airport mobility, comparing and contrasting modes as well as impacts on overall airport operations efficiency; and (4) fundamental changes in building design enabled by AMPs for larger and more flexible, functional, and energy-efficient structures.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Marine Algae Industrialization Consortium (MAGIC): Combining biofuel and high-value bioproducts to meet the RFS

The Marine Algae Industrialization Consortium (MAGIC) was formed to address pressing challenges in the commercialization of microalgae as a source of biofuel. The “Marine Algae Industrialization Consortium (MAGIC): Combining biofuel and high-value bioproducts to meet the RFS” project formally addressed two US Department of Energy Bioenergy Technologies Office (BETO) goals: (1) Model the sustainable supply of 1 million metric tonnes ash free dry weight (AFDW) cultivated algal biomass and (2) Demonstrate valuable co-products produced along with biofuel intermediates to increase value of algal biomass by 30%. To achieve these goals, the project demonstrated and validated high-value co-products to drive down the cost of biofuel by increasing the value of algae “co-products” towards increasing the selling price of total algae biomass as one of the key drivers of economics and adoption. This was accomplished through five core, interdependent tasks including: (1) strain selection to identify and deliver strains for mass culture, (2) mass culture using a hybrid cultivation system and following key operating parameters for downstream applications to provide algae feedstock, (3) recovery and conversion to evaluate two alternative methods to separate dry algae biomass into oil and residuals for downstream testing, (4) product assessment to determine biofuel, aquafeed or poultry feed product efficacy using algae biomass fractions as well as to provide critical performance data for valuation and (5) commercialization to use technoeconomic and life cycle assessments (TEA/LCA) as iterative design and assessment tools including consideration of target markets, competitors, and distribution channels to guide product assessment, development and valuation. A total of 46 peer-review publications, many open-access, provide detail of much of the work carried out and the results of the tasks. Additional reports and presentations provide other technical and public engagement material. At a high level, using a variety of approaches, more than 1000 marine microalgae strains were evaluated to ultimately identify the seven winners that were down-selected to be grown in mass culture. Strain selection demonstrated that there were no ‘super strains’ and that each candidate had strengths and limitations for specific products, growth conditions or operational considerations. Mass culture growth of these seven strains at >5000 L / 29 m 2 scale found that four them were suitable for product assessment. More than 250 kg of biomass was produced across hundreds of pond runs along with thousands of cultivation entries on the growth and biomass characteristics as well as environmental parameters. In the process, dozens of standard operating procedures were generated as was custom software to process and analyze cultivation data. Recovery and conversion of algae biomass demonstrated that a hexane solvent based extraction protocol was most effective at recovering oil (biocrude) from algae and four strains were processed to produce oil and lipid extracted algae (residuals) for downstream testing. Membrane-based oil separation was less successful, but may still be applicable to other commercial applications in the future. Product testing demonstrated that algae biocrude is of high quality and hydrotreating generated numerous fractions of high quality composition for fuel and lubricate based applications. Aquafeed studies performed at a variety of scales showed that both whole and defatted (lipid extracted algae) microalgae were suitable as a feed ingredient, but that the specifics of the fed animal and biochemical composition of the algae are critical factors when determining formulation. Similarly, poultry studies on whole and defatted microalgae generally showed positive outcomes on animal growth and health, with some microalgae providing enhanced nutritional composition of the animal product. Economic and life cycle assessments covered a wide range of possible commercialization and sustainability scenarios. Replacement value, improved product value added, consumer values marketing added valuation and improved animal health were considered as alternatives for microalgae valuation. Using the open pond system, algae productivity was identified as the key driver of commercialization economics, but combination of co-products (e.g. animal feed) with biofuel production substantially increased the total selling price of algae. Modeled microalgae selling price exceeded $\$$1500/tonne and could generate competitive biofuel selling prices below $\$$5 gallon gas equivalents using realistic algal productivities. Short (process scale) and longer (decadal trends) sustainability assessments show that marine microalgae can enhance the sustainability of energy production and lead to other realized benefits in water, fertilizer and land use for other sectors (e.g. agriculture). This project successfully demonstrated all of the components of an end-to-end process from mass microalgae cultivation and dewatering, to recovery and conversion of algae biomass components, to final product demonstration and process valuation; the combined results provide a framework for future commercialization of algae based biofuels.

09 BIOMASS FUELS↗
DOE OSTI2020

GaAsP/Si Tandem Solar Cells: Pathway to Low-Cost, High-Efficiency Photovoltaics

Si is the dominant PV technology, now and for the foreseeable future, due to its extensive manufacturing infrastructure, supply chain, feedstock availability, and highly optimized degree of fabrication processes, which altogether has produced an economic scenario where PV electricity generation is often cheaper than conventional fossil based generation. In many places, the overarching goal of grid parity has been achieved, but further improvement in performance-cost metrics are still needed to sustain the continued LCOE reductions needed to not only compete with conventional generation, but displace it on a global scale; a matter of critical importance if we stand any hope of slowing climate change. Nevertheless, single-junction Si PV is already nearing its physical limit, both in performance and cost, and is thus cannot meet these long-term goals alone. To this end, we are working on the development of monolithic III-V/Si tandem solar cells, which improve upon the performance of pure Si by providing enhanced utilization (reduced thermalization) of high-energy photons. This architecture nominally combines the substantial existing knowledge base, manufacturing infrastructure, and low cost of Si PV with the high efficiencies afforded by the well-established multijunction approach — the only proven way to break the single-junction limit. Although the metal-halide perovskite/Si tandem architecture has garnered substantial attention in recent years, serious questions regarding reliability and service lifetime remain, whereas III-V PV has a proven track record, including in the harsh concentrator and space environments. Additionally, there are multiple fabrication approaches to producing III-V/Si tandem cells, but we are focused on monolithic epitaxial integration as it is the most likely to yield the lowest ultimate LCOE in a fully mature, scaled technology. In this work we have produced multiple generations of GaAsP/Si tandem solar cells, demonstrating a more than 10% absolute AM1.5G efficiency improvement within the time frame of the project, including two verified world records. We have done this using industry-standard fabrication methods, showing that this platform can ultimately be manufactured at scale using existing or only slightly upgraded Si and III-V tooling. Our scientific and engineering advances across a range of fundamental and applied areas – III-V/Si heteroepitaxial integration, defect control in metamorphic III-V epitaxy, fundamental materials-oriented solar cell design and modeling methodology, and more – have created clear pathways for continued advances toward the goal of >30% AM1.5G cell efficiency (and >25% module) and will serve to inform the broader research community for well beyond this immediate application. Techno-economic modeling indicates that our approach can indeed meet SunShot/SETO LCOE targets, but as with any “post-Si” technology there are difficult, but not insurmountable barriers, requiring continued focused research and development efforts.

14 SOLAR ENERGY↗
NASA NTRS2013

Space Launch System (SLS) Safety, Mission Assurance, and Risk Mitigation

SLS Driving Objectives: I. Safe: a) Human-rated to provide safe and reliable systems for human missions. b) Protecting the public, NASA workforce, high-value equipment and property, and the environment from potential harm. II. Affordable: a) Maximum use of common elements and existing assets, infrastructure, and workforce. b) Constrained budget environment. c) Competitive opportunities for affordability on-ramps. III. Sustainable: a) Initial capability: 70 metric tons (t), 2017-2021. 1) Serves as primary transportation for Orion and exploration missions. 2) Provides back-up capability for crew/cargo to ISS. b) Evolved capability: 105 t and 130 t, post-2021. 1) Offers large volume for science missions and payloads. 2) Modular and flexible, right-sized for mission requirements.

May, Todd↗
DOE OSTI2023

RAPID Manufacturing Institute Final Report

The Rapid Advancement of Process Intensification Deployment (RAPID) Manufacturing Institute, founded in 2017, is a public/private partnership between the U.S. Department of Energy and the American Institute of Chemical Engineers (AIChE). RAPID promotes the development, deployment and commercialization of Process Intensification (PI) and Modular Chemical Process Intensification (MCPI) technologies, enabling U.S. manufacturing to reduce energy consumption, improve process efficiencies and lower investment and operating costs. This mission was carried out through parallel work breakdown structure elements including the establishment of committees to guide the operations and technical direction of RAPID, the establishment of management practices and institute processes, education and workforce development (EWD), and six technical focus areas for the development of technologies to advance PI and MCPI. Throughout the initial six-year cooperative agreement, RAPID worked to meet performance metrics which focused on the operation and sustainment of the institute, education and workforce development and the development of PI and MCPI for the advancement of U.S. manufacturing. All these metrics were successfully met through a total of 43 projects which leveraged $\$$70M Federal with $\$$90M cost share. As a result of these efforts, 84 private and public organizations were brought together by RAPID as members to co-invest in R&D, commercialization and deployment of innovative technologies. In the research portfolio, 82% of the 38 projects achieved > 20% energy efficiency improvement. A RAPID Test Network was developed with 51 testbed facilities to enable access to resources, facilities, tools, and expertise. Eight EWD programs were also developed with over 13,000 impressions. RAPID’s efforts to research, develop, demonstrate, and deploy high-impact PI and modular process technology solutions have enabled reduced energy use, increased sustainability, and improved profitability for U.S. manufacturing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗