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DOE OSTI2026

Evaluating CO 2 mitigation strategies in SAF biorefineries: Techno-economic and life cycle analysis

The aviation sector requires scalable decarbonization strategies, and lignocellulosic sustainable aviation fuel (SAF) represents a promising pathway. This study comparatively evaluates the techno-economic analysis and life cycle assessment (LCA) of three CO 2 management strategies integrated within a U.S.-based gasification–Fischer–Tropsch SAF biorefinery: (i) catalytic hydrogenation of captured CO 2 to methanol, (ii) geological CO 2 sequestration, and (iii) mineralization to sodium bicarbonate (NaHCO 3 ). Techno-economic analysis indicates that methanol synthesis requires approximately 26% higher capital investment and 33% higher operating costs than mineralization. Although methanol co-production generates the highest gross revenue, NaHCO 3 production reduces the SAF minimum selling price by approximately 38% relative to both methanol synthesis and geological sequestration pathways, reflecting a more balanced cost allocation through mineral co-product valorization. Geological sequestration lowers operating costs by nearly 50% compared with methanol synthesis but remains highly dependent on carbon credit mechanisms. LCA reveals substantial divergence in climate performance. Relative to methanol synthesis, sequestration improves net greenhouse gas performance by approximately 163%, transitioning the system from net-positive to net-negative emissions. Mineralization further enhances carbon mitigation, achieving roughly 85% greater carbon reduction than sequestration and over sixfold improvement relative to methanol synthesis within the defined system boundary. Sensitivity analysis identified hydrogen price, co-product market value, and process emissions as dominant drivers. Under baseline assumptions, CO 2 mineralization is found to offer the most balanced pathway.

Carbon capture and storage↗

DOE OSTI2020

Life cycle greenhouse gas emissions of different CO 2 supply options for an algal biorefinery

This paper characterizes the greenhouse gas (GHG) emissions from the provision of CO 2 for twelve hours of the day from a range of sources operating on a twenty-four-hour basis. Twelve CO 2 supply cases spanning from fossil fuel power plant stack gases to direct air capture (DAC) systems are modeled. The results are compared in a life cycle assessment (LCA) framework. The CO 2 supply from the combustion or gasification of biomass has GHG emissions of –1.62 gCO 2 eq./g CO 2 delivered and is the case with the lowest carbon footprint for supplied CO2. The emissions for all the CO 2 supply cases were found to be negative, either because of capturing more CO 2 from the atmosphere than is released from the CO 2 production process, or because of production of excess electricity that is exported to the grid (replacing emissions from grid electricity). A purpose-built Natural Gas Combined Cycle (NGCC) power plant CO 2 source has the highest GHG emissions of -0.40 gCO 2 eq./gCO 2 delivered of the cases considered because of nighttime emissions and natural gas supply chain losses. The impact of a diurnal cycle can be mitigated by using capture and refrigeration systems as part of the CO 2 management system. The results are sensitive to the GHG emissions of the grid electricity, which is imported or exported in different cases. The results provide a benchmark for the comparison of different CO 2 supply options for the establishment of a sustainable algal biorefinery.

42 ENGINEERING↗

DOE OSTI2024

Pyrolysis of high-density polyethylene: Degradation behaviors, kinetics, and product characteristics

Pyrolysis is a promising technology for converting plastic waste into valuable raw materials while offering a potential solution to the global plastic pollution crisis. In this study, the thermal pyrolysis of high-density polyethylene (HDPE) is investigated in a drop tube reactor under nearly isothermal conditions. The impact of reaction temperature and gas/volatile residence time on carbon conversion and product distribution is examined across a range of 500–900°C and 3.6–32.2s, respectively. Non-condensable gas products detected by online mass spectrometry are H 2 , CH 4 , C 2 H 4 , C 2 H 6 , C 3 H 6 , and C 3 H 8 . At elevated temperatures and prolonged residence time, H 2 yield reaches as high as 8.6 wt% of the initial HDPE mass due to intensified cracking reactions of C 2 –C 3 hydrocarbons and long-chain aliphatic compounds. Consequently, pyrolysis tars consist mainly of polycyclic aromatic hydrocarbons (PAHs) with 5–7 rings, accompanied by visible coke deposition within the reactor. HDPE decomposition to volatiles is an endothermic process and it is complete at a temperature between 492°C and 525°C, depending on the heating rate employed, from non-isothermal thermogravimetric analysis and differential scanning calorimetry (TGA-DSC) measurements. The thermal degradation of HDPE pellets follows the two-dimensional nucleation growth model for conversion levels up to 0.8 with an apparent activation energy of 259–270 kJ/mol and a pre-exponential factor of 4.83 × 10 17 –1.37 × 10 19 min -1 , determined from various isoconversional methods such as Flynn-Wall-Ozawa (FWO), Kissinger-Akahira-Sunose (KAS), and Starink, along with Criado's master plots. Further, these findings provide valuable insights into optimizing process parameters and refining reactor design for pyrolysis, which can be integrated with gasification and reforming processes to enhance hydrogen production on a larger scale.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Microwave-induced selective decomposition of cellulose: Computational and experimental mechanistic study

Understanding microwave-material interactions will help facilitate the utilization of microwave technology in gasification and renewable energy production. In this study, cellulose was used as a model compound to simulate the organic matter in biomass, and its catalytic decomposition under a microwave (MW) field was studied to identify structural changes from the reaction. The study was conducted using a MW source coupled to a fixed-bed gas-flow reactor, mass spectroscopic, and Fourier transform infrared spectroscopy post-reaction analysis. Zeolite 13X was chosen as a microwave absorber to study the catalytic enhancement of the decomposition of cellulose. Density functional theory (DFT) was used to gain insights into the molecular transformations occurring in the presence of a static electric field, which was used to simulate the electric field component of the microwave electromagnetic radiation. Theoretical calculations demonstrated that both the positive and negative portion of the electric field interact with the permanent dipoles of the cellulose effecting the decomposition through the glycosidic bond breaking mechanism. The theoretical result was verified using infrared spectroscopic analysis of the pure cellulose during microwave heating. The theoretical calculations suggest only the positive electric field component may be active for the cellulose decomposition in the presence of Zeolite 13X. Physically mixing Zeolite 13X with the cellulose led to a significant enhancement in the decomposition rate of the glycosidic bond. Zeolite 13X enhanced the glycosidic O-C decomposition at lower MW power (lower temperatures), whereas the O-H functional group required higher MW power (higher temperature) for its decomposition. The DFT study coupled with the reaction studies revealed that the electric field polarizability is dependent upon both the direction and the orientation of the cellulose. Gas products revealed that applying 250 W of MW power led to the production of CO, H 2 , along with some CO 2 , CH 4 , and benzene at 305 °C. Finally, reaction under 500, 750, and 1000 W of power at constant temperature (305 °C) revealed that higher power led to the complete decomposition of cellulose to mostly CO, H 2 , and CO 2 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Microporous pentiptycene-based polybenzimidazole membranes for high temperature H 2 /CO 2 separation

Separating H 2 from syngas at elevated temperatures (100–250 °C) have attracted significant attention in recent years as a means to reduce energy consumption and capital costs in precombustion carbon capture processes, such as those following steam reforming of natural gas or coal gasification. Polybenzimidazole (PBI), particularly m-PBI, has been reported as a leading membrane material for high-temperature H 2 /CO 2 separation. However, m-PBI exhibits extremely low H 2 permeability, even at high temperatures, which limits its productivity in H 2 /CO 2 separation applications. Here, to address this limitation, this work introduces a new pentiptycene-based polybenzimidazole (PPBI) featuring significantly enhanced H 2 permeability and attractive high-temperature H 2 /CO 2 separation performance, which stems from the unique configurational free volume elements introduced by pentiptycene moieties. Further tuning of the free volume architecture of PPBI films is achieved via acid doping with phosphoric acid (PA) or trans-aconitic acid (TaA), which introduces crosslinking among PPBI chains. Under mixed-gas environment (50/50 mol% H 2 /CO 2 ) at 180 °C, the acid-doped PPBI films exhibit a ∼230 % increase in H 2 /CO 2 selectivity compared to pristine PPBI film while maintaining high H 2 permeability that is nearly 500 % of m-PBI. These properties approach the predicted upper bound for membrane operating at 180 °C, highlighting its great potential for high-temperature H 2 /CO 2 separation.

Liu, Mengdi [University of Notre Dame, IN (United ↗

DOE OSTI2022

Scaling CFB risers: Maintaining microstructure dynamics

Over the years there have been numerous approaches to develop a scaleup methodology for circulating fluidized beds. Many of these past approaches have relied on macroscopic definitions of similitude to define dimensionless groups such as Reynolds number, Froude number, density ratios, and dimensional ratios involving different length scales. These approaches have demonstrated various levels of success, but often fail when used outside the bounds of experimental datasets. The issue with these methods is that they rely on macroscopic similitude with the hopes that those conditions would provide microscopic similitude as it does in single phase systems where the Buckingham Pi techniques have given reasonable success. Two of the main reasons for failure are 1) changing fluidization regimes and 2) changing material properties that result in the material falling into a different Geldart group. Both are certain to change the microstructure (local instantaneous volume solids fraction) and changes to the microstructure affect the interphase transport properties of the reactor system, namely the mass transfer and heat transfer. Here, this work presents a new approach towards scaling based upon maintaining similitude at the microscale. It reviews a novel dimensionless flow regime map developed from analysis of the deterministic chaos parameters and higher order moments to ensure microstructure similitude. The work then examines four cases from the literature to assess the scaling approach used: (1) same particle-different scale risers for Geldart Group B particles, (2) Glicksman scaling of atmospheric circulating fluidized bed combustor, (3) same particle-different scale risers for Geldart Group A particles and (4) Glicksman scaling for pressurized gasification. General findings are that none of the scaling approaches produced directly applicable microstructure similar behavior based upon the chaotic and higher moment analysis. The positive take away is that the approach can define scale conditions that will provide similar microstructure that can be us to predict transport behavior.

42 ENGINEERING↗

DOE OSTI2016

The effect of model fidelity on prediction of char burnout for single-particle coal combustion

In this study, practical simulation of industrial-scale coal combustion relies on the ability to accurately capture the dynamics of coal subprocesses while also ensuring the computational cost remains reasonable. The majority of the residence time occurs post-devolatilization, so it is of great importance that a balance between the computational efficiency and accuracy of char combustion models is carefully considered. In this work, we consider the importance of model fidelity during char combustion by comparing combinations of simple and complex gas and particle-phase chemistry models. Detailed kinetics based on the GRI 3.0 mechanism and infinitely-fast chemistry are considered in the gas-phase. The Char Conversion Kinetics model and nth-Order Langmuir–Hinshelwood model are considered for char consumption. For devolatilization, the Chemical Percolation and Devolatilization and Kobayashi-Sarofim models are employed. The relative importance of gasification versus oxidation reactions in air and oxyfuel environments is also examined for various coal types. Results are compared to previously published experimental data collected under laminar, single-particle conditions. Calculated particle temperature histories are strongly dependent on the choice of gas phase and char chemistry models, but only weakly dependent on the chosen devolatilization model. Particle mass calculations were found to be very sensitive to the choice of devolatilization model, but only somewhat sensitive to the choice of gas chemistry and char chemistry models. High-fidelity models for devolatilization generally resulted in particle temperature and mass calculations that were closer to experimentally observed values.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Detailed modeling of hydrogen release and particle shrinkage during pyrolysis of inhomogeneous wood

Hydrogen release during pyrolysis of woody biomass is studied considering anisotropicity and inhomogeneity of wood structure. A new anisotropic shrinkage model is proposed based on the decomposition of main wood constituents, i.e., cellulose, hemicellulose, and lignin. The new shrinkage model can predict the temporal evolution of the wood structure, and the differences between axial and radial shrinkage during pyrolysis. The model agrees very well with several experimental data from the literature. Based on particle temperature during conversion, the pyrolysis is partitioned into four stages, and the hydrogen release and H 2 formation from each stage are investigated. Stage (IV) of pyrolysis, from 1000 to 1273 K, is found to be efficient for H 2 production owing to the production of considerable mass of H with a minimal amount of tar species. Furthermore, the char quality is found to be different at the end of stages (II), (III), and (IV), where around 67.7, 80.5, and 93.4% wt. of solid residue is made of carbon, respectively. The model is also used to explain how the heating rate affects the temperature distribution inside the particle and how it shifts the peak of hydrogen release. Finally, the pyrolysis of two inhomogeneous wood samples — a beech twig with bark and a beech dowel with growth rings — are investigated. The bark can affect the pyrolysis rate, products, and flow pattern inside the particle. The growth rings do not have a considerable effect on the pyrolysis rate and products, but they have a significant impact on the flow pattern. This has an important implication for char conversion studies where the internal surface area and porosity field distribution have a significant effect on the gasification and oxidation rates.

09 BIOMASS FUELS↗

DOE OSTI2025

Process and environmental safety of thermochemical conversion of biomass

Biomass presents a promising opportunity for converting waste into valuable energy, fuels, and chemicals through various thermochemical processes, including hydrothermal carbonization, hydrothermal liquefaction, pyrolysis, gasification, and combustion. However, these processes operate under extreme conditions, introducing significant safety hazards that necessitate meticulous management to prevent accidents. This review discusses potential hazards, risk mitigation strategies, and safety management practices, emphasizing the importance of integrated safety measures into the design and operation of these processes. It also highlights the critical need for robust safety engineering and environmental management strategies tailored to each thermo-chemical process. As these processes transition from laboratory to industrial scale, there is an imperative to develop a clear and concise pathway for emerging industries to achieve regulatory compliance, achieve safety certification, and enable effective stewardship of potential fugitive emissions. By addressing safety and environmental concerns, stakeholders can optimize economic benefits, rural development, and achieve sustained domestic energy generation benefits offered by biomass conversion technologies. Further research on plant design optimization, operational safety, environmental evaluation standardization, and innovative waste management solutions will support the safe and effective scaling of these technologies, ultimately contributing to sustainable management and resource recovery.

09 - BIOMASS FUELS↗

DOE OSTI2018

Nowcasting, predictive control, and feedback control for temperature regulation in a novel hybrid solar-electric reactor for continuous solar-thermal chemical processing

A novel 15 kW reactor for the hybridization of concentrated solar and conventional electric heat was fabricated for renewable and continuous chemical processing at temperatures up to 1700 °C. Solar-electric controllers based on feedback or predictive linear models were used to regulate the device at 925 °C for the production of syngas via the gasification of carbon. The system was challenged with cloud transients programmed on a 45 kW high-flux solar simulator that approximated weather observed in the San Luis Valley (Colorado, USA). In experiment it was found that model predictive control with a 1 min ahead nowcast of incipient clouding best regulated solar-electric reactor temperatures, potentially averting thermal fatigue. Upon clouding, model predictive control with a nowcast yielded temperature disturbances of ±10 °C, whereas feedback control alone featured ±25 °C excursions. Overall, the performance of model predictive control with a nowcast was 75% better than feedback as indicated by the integral squared error of temperature excursion residuals. The importance of nowcast accuracy was explored, and although the model-based controller was robust to forecast amplitude inaccuracy, temporal forecast inaccuracy wholly negated the benefits of predictive control.

14 SOLAR ENERGY↗

DOE OSTI2021

Effect of Biochar and Biochar Particle Size on Plant-Available Water of Sand, Silt Loam, and Clay Soil

Biochar is being used as a soil amendment to improve soil hydraulic properties. It has been reported that biochar increases plant-available water, particularly in coarse-textured soils; however, effects on fine-textured soils are less pronounced. Here, we quantified the effects of biochar particle size on plant-available water in sand, silt loam, and clay soils. We amended these soils with a hydrophilic biochar, and packed soil-biochar mixtures into columns of 5.35-cm diameter and 3.0-cm height. Biochar was produced by gasification of woody forest residues. We applied the biochar at two different rates (0.5\% and 2\% by weight of C) and with four different biochar particle-size fractions ($<$4.75, $<$2.0, $<$1.0 and $<$0.5 mm). Our results show that biochar amendments increased the plant-available water (when expressed gravimetrically) of all three soils, particularly at the highest biochar application rate. Although the absolute increase in plant-available water was largest for the silt loam soil, the relative increase of plant-available water was greater for the sand than for the silt loam and clay. When expressed in volumetric terms, however, the effects on water retention were less pronounced: the sand showed a small increase in plant-available water with biochar amendment, and no change was observed with the silt loam and clay. Particle size of biochar had little effect on plant-available water (when expressed in gravimetric terms) in the three soils, but silt loam and clay showed increased plant-available water (when expressed in volumetric terms) with decreasing biochar particle size, while no effect was observed for the sand. While our findings corroborate many of the previously reported effects of biochar on soil-water retention, we show that the effects and their magnitude depend on whether the results are reported in terms of gravimetric or volumetric water contents. Because bulk density tends to decrease with increasing biochar application, so will the volumetric water content, and thus the magnitude of the effect on plant-available water will be smaller when expressed in volumetric water content.

hydraulic properties, water holding capacity, soil↗

DOE OSTI2017

Environmental performances of different configurations of a material recovery facility in a life cycle perspective

Highlights: • An attributional LCA assessed the environmental performances of an integrated MRF. • Different configurations of the MRF technological evolution have been analysed. • Reliable data provide a large LCI table for all the configurations and each sub-units. • A biological treatment in-situ improves the potentials of land occupation and global warming. • The inclusion of a small-scale gasifier could improve almost all the environmental potentials. - Abstract: The study evaluated the environmental performances of an integrated material recovery facility (MRF) able to treat 32 kt/y of unsorted mixed waste, made of residuals from household source separation and separate collection. The facility includes a mechanical sorting platform for the production of a solid recovered fuel (SRF) utilized in an external waste-to-energy plant, bio-cells for tunnel composting of organic fraction, and a sanitary landfill for the safe disposal of ultimate waste. All the MRF sub-units have been analysed in depth in order to acquire reliable data for a life cycle assessment study, focused on the environmental performances of different configurations of the facility. The study investigated a “past” configuration, including just mechanical sorting, landfilling and biogas combustion in a gas engine, and the “present” one, which includes also a composting unit. Two possible “future” configurations, having a gasifier inside the MRF battery limits, have been also analysed, assessing the performances of two fluidized bed reactors of different size, able to gasify only the residues generated by the sorting platform or the whole amount of produced SRF, respectively. The analysis evaluated the contributions of each unit in the different configurations and allowed a reliable assessment of the technological evolution of the facility. The results quantified the positive effect of the inclusion of an aerobic treatment of the waste organic fraction. The SRF gasification in situ appears to improve the MRF environmental performances in all the impact categories, with the exclusion of that of global warming.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Mechanical and chemical recycling of solid plastic waste

Highlights: • This paper reviews the current pathways for recycling of solid plastic waste, via both mechanical and chemical recycling. • The predominant industrial technologies, design strategies and recycling examples of specific waste streams are reviewed. • The main challenges and some potential remedies are discussed. - Abstract: This review presents a comprehensive description of the current pathways for recycling of polymers, via both mechanical and chemical recycling. The principles of these recycling pathways are framed against current-day industrial reality, by discussing predominant industrial technologies, design strategies and recycling examples of specific waste streams. Starting with an overview on types of solid plastic waste (SPW) and their origins, the manuscript continues with a discussion on the different valorisation options for SPW. The section on mechanical recycling contains an overview of current sorting technologies, specific challenges for mechanical recycling such as thermo-mechanical or lifetime degradation and the immiscibility of polymer blends. It also includes some industrial examples such as polyethylene terephthalate (PET) recycling, and SPW from post-consumer packaging, end-of-life vehicles or electr(on)ic devices. A separate section is dedicated to the relationship between design and recycling, emphasizing the role of concepts such as Design from Recycling. The section on chemical recycling collects a state-of-the-art on techniques such as chemolysis, pyrolysis, fluid catalytic cracking, hydrogen techniques and gasification. Additionally, this review discusses the main challenges (and some potential remedies) to these recycling strategies and ground them in the relevant polymer science, thus providing an academic angle as well as an applied one.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

A review on technological options of waste to energy for effective management of municipal solid waste

Highlights: • The current status, options and challenges of WTE techniques were analysed. • Incineration is the most widely used WTE technology in the developed countries. • Landfilling is the most common practice of MSWM in developing countries. • Approximately 50 million tonnes of methane is emitted annually from landfills. • WTE will ensure both the energy security and environmental protection. - Abstract: Approximately one-fourth population across the world rely on traditional fuels (kerosene, natural gas, biomass residue, firewood, coal, animal dung, etc.) for domestic use despite significant socioeconomic and technological development. Fossil fuel reserves are being exploited at a very fast rate to meet the increasing energy demands, so there is a need to find alternative sources of energy before all the fossil fuel reserves are depleted. Waste to energy (WTE) can be considered as a potential alternative source of energy, which is economically viable and environmentally sustainable. The present study reviewed the current global scenario of WTE technological options (incineration, pyrolysis, gasification, anaerobic digestion, and landfilling with gas recovery) for effective energy recovery and the challenges faced by developed and developing countries. This review will provide a framework for evaluating WTE technological options based on case studies of developed and developing countries. Unsanitary landfilling is the most commonly practiced waste disposal option in the developing countries. However, developed countries have realised the potential of WTE technologies for effective municipal solid waste management (MSWM). This review will help the policy makers and the implementing authorities involved in MSWM to understand the current status, challenges and barriers for effective management of municipal solid waste. This review concluded WTE as a potential renewable source of energy, which will partly meet the energy demand and ensure effective MSWM.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Biomass Demineralization: A Critical Need for Future Biorefineries

Biomass contains up to 14 essential elements that serve as nutrients for plant growth and development, including photosynthesis and enzyme functionalities. These elements in different chemical forms (e.g., minerals) constitute the inorganic fraction of biomass and can cause operational issues in thermal and biochemical biomass conversion technologies. In biomass gasification and pyrolysis processes, for instance, inorganics can cause fouling, tar formation, and corrosion. In catalytic and biochemical processes, inorganics can poison catalysts, alter biochemical pathways, and modify product yields and selectivity. This review provides an overview of the inorganic content in biomass feedstocks, the critical role inorganics play in plant biochemistry, the effect that inorganics have in various thermochemical and biochemical biomass conversion technologies, and different approaches to remove them from biomass. We provide recommendations for future research, focusing on developing technologies to effectively remove inorganics from biomass, using the inorganics to improve soil quality and for alternative applications, and designing biorefineries to convert demineralized biomass obtained from diverse sources.

09 - BIOMASS FUELS↗

DOE OSTI2017

Warm Cleanup of Coal-Derived Syngas: Multicontaminant Removal Process Demonstration

Warm cleanup of coal- or biomass-derived syngas requires sorbent and catalytic beds to protect downstream processes and catalysts from fouling. Sulfur is particularly harmful because even parts-per-million amounts are sufficient to poison downstream synthesis catalysts. Zinc oxide (ZnO) is a conventional sorbent for sulfur removal; however, its operational performance using real gasifier-derived syngas and in an integrated warm cleanup process is not well reported. In this paper, we report the optimal temperature for bulk desulfurization to be 450oC, while removal of sulfur to parts-per-billion levels requires a lower temperature of approximately 350oC. Under these conditions, we found that sulfur in the form of both hydrogen sulfide and carbonyl sulfide could be absorbed equally well using ZnO. For long-term operation, sorbent regeneration is desirable to minimize process costs. Over the course of five sulfidation and regeneration cycles, a ZnO bed lost about a third of its initial sulfur capacity, however sorbent capacity stabilized. Here, we also demonstrate, at the bench-scale, a process and materials used for warm cleanup of coal-derived syngas using five operations: 1) Na2CO3 for HCl removal, 2) regenerable ZnO beds for bulk sulfur removal, 3) a second ZnO bed for trace sulfur removal, 4) a Ni-Cu/C sorbent for multi-contaminant inorganic removal, and 5) a Ir-Ni/MgAl2O4 catalyst employed for ammonia decomposition and tar and light hydrocarbon steam reforming. Syngas cleanup was demonstrated through successful long-term performance of a poison-sensitive, Cu-based, water-gas-shift catalyst placed downstream of the cleanup process train. The tar reformer is an important and necessary operation with this particular gasification system; its inclusion was the difference between deactivating the water-gas catalyst with carbon deposition and successful 100-hour testing using 1 LPM of coal-derived syngas.

Spies, Kurt A.↗

DOE OSTI2025

Carbon Capture and Storage for Small-to-Medium Biorefineries: Promising Carbon Removal Solution with Economic Challenges

Carbon capture and storage (CCS) integrated with biomass-based fuel production can provide cost-effective biomass carbon removal and storage (BiCRS) and produce high-value bioproducts, such as sustainable aviation fuels. To accelerate BiCRS deployment, it is crucial to quantify the costs of CCS integration, particularly for small- and medium-scale biorefineries that are representative of early-stage deployment. Existing studies tend to focus on plant sizes that are orders-of-magnitude larger than early-stage installations, possibly underestimating CCS costs for small-to-medium biorefineries. We show that the capture, transport, and storage costs to maximize CO 2 removal from a 526 dry tonne per day (tpd) biomass gasification plant (largest existing size) could be 13–47% higher than costs for a typical modeled plant size (2000 dry tpd). The higher cost estimates are driven by less favorable economies of scale and realistic assumptions about the availability of affordable CO 2 transport infrastructure with both drivers broadly applicable to other BiCRS technologies. Compliance and voluntary carbon markets could incentivize biorefinery CCS, but both carry a high degree of uncertainty. In conclusion, these findings highlight that sufficient and reliable financial mechanisms would be essential to unlocking the full CO 2 removal potential of biorefineries and facilitating BiCRS scale-up.

Biological transport↗

DOE OSTI2017

Nonlinear Dynamic Model-Based Multiobjective Sensor Network Design Algorithm for a Plant with an Estimator-Based Control System

Here, a novel sensor network design (SND) algorithm is developed for maximizing process efficiency while minimizing sensor network cost for a nonlinear dynamic process with an estimator-based control system. The multiobjective optimization problem is solved following a lexicographic approach where the process efficiency is maximized first followed by minimization of the sensor network cost. The partial net present value, which combines the capital cost due to the sensor network and the operating cost due to deviation from the optimal efficiency, is proposed as an alternative objective. The unscented Kalman filter is considered as the nonlinear estimator. The large-scale combinatorial optimization problem is solved using a genetic algorithm. The developed SND algorithm is applied to an acid gas removal (AGR) unit as part of an integrated gasification combined cycle (IGCC) power plant with CO 2 capture. Due to the computational expense, a reduced order nonlinear model of the AGR process is identified and parallel computation is performed during implementation.

Lexicographic optimization↗