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DOE OSTI2020

Metal oxide supported Ni-impregnated bifunctional catalysts for controlling char formation and maximizing energy recovery during catalytic hydrothermal liquefaction of food waste

Nickel (Ni)-impregnated metal oxide catalysts, Ni/CeZrO x , Ni/ZrO 2 , and Ni/CeO 2 , were investigated to maximize energy recovery and reduce char yield during catalytic hydrothermal liquefaction (CHTL) of food waste. Yields of char, biocrude, water soluble products, and gas were measured at 300 °C and 1 hour for both the parent oxides (CeZrO x , ZrO 2 , and CeO 2 ) and the Ni-impregnated versions. Using Ni-based catalysts reduced the carbon-weighted char yield from 16–24% to <10% and decreased the energy recovery of char from 39–47% to <21%, as compared with control tests. In particular, using Ni/ZrO 2 resulted in the greatest biocrude yield, greatest reduction of char yield, and greatest energy recovered as biocrude (39.2%). After factoring in all forms of usable energy produced from food waste, the total energy recovery obtained for the catalysts studied here was >60%. Ni/ZrO 2 and Ni/CeO 2 show the greatest potential for controlling char growth and maximizing energy recovered from food waste. The crystalline structures of all three oxides were hydrothermally stable. Catalyst reuse tests indicate that the biocrude and char yields remained the same for the first and second use (within uncertainty) and that the catalyst retains its initial crystallinity and 93% of its initial Ni content. Molecular composition of biocrudes analyzed by the state-of-the-art analytical platforms (including GC-MS, GC × GC, FT-ICR MS, and 1H NMR) revealed minor differences in the chemical constituents of biocrudes obtained using different catalysts and provided some insight regarding reaction mechanism.

09 BIOMASS FUELS↗

DOE OSTI2026

PERFORMANCE ANALYSIS OF AN ENGINEERING SCALE HYDROTHERMAL LIQUEFACTION SYSTEM

This work evaluates the Modular Hydrothermal Liquefaction System (MHTLS), an engineering-scale, integrated continuous HTL plant operated at the Pacific Northwest National Laboratory (PNNL), for converting realistic wet wastes into energy-dense biocrudes. The production campaigns discussed here processed algae, sewage sludges, lignocellulosic blends, Industrial food waste, and engineered food-waste slurries at 350?°C and around 200?bar, with nominal feed rates of ~12?L?h?¹. We report biocrude yields and composition, establish mass and elemental (C, N) balances, and quantify energy performance via heater duties, heat-exchanger behavior, and system-level efficiencies. Biocrudes contained 76–80?wt?% C (dry, ash-free) with HHVs of 38-41?MJ?kg?¹, substantially higher than feed materials HHVs of 16.6–26.1?MJ?kg?¹ and approaching petroleum fuels. Dry, ash-free biocrude yields of 32–53?wt?% corresponded to 43–71?wt?% carbon yields, with 18–40?wt?% of feed carbon routed to the aqueous phase. Thermal efficiencies were 50-65%, and total energy efficiencies, including reactor heat input, were 35-55%. A counter-current tube-in-tube heat exchanger delivered U values of 200–450?W?m?²?K?¹, with fouling-induced declines impacting heat recovery and heater duty. The analysis highlights three priorities for the process intensification of HTL: robust, fouling-resistant heat recovery, hydrodynamically suitable reactor and heat-exchanger designs, simplified and predictable solids management, and biocrude-water separation.

Biocrude production↗

DOE OSTI2017

Conceptual Biorefinery Design and Research Targeted for 2022: Hydrothermal Liquefacation Processing of Wet Waste to Fuels

The Department of Energy Bioenergy Technologies Office (BETO) invests in research and development of new pathways for commercially viable conversion of biomass into drop-in ready transportation fuels, fuel blendstocks and products. The primary emphasis has been on terrestrial and algae feedstocks, but more recently BETO has begun to explore the potential of wet wastes for biofuel production, with focus on wastewater residuals, manure, food waste, and fats, oils and grease. A recent resource analysis estimates that 77 million dry tons per year of these wastes are generated annually, 65% of which are underutilized for any beneficial purpose. Approximately 14 million dry tons of the total resource is wastewater residuals (sludge and biosolids) generated at the nation’s wastewater treatment plants (WWTPs). Conversion of this resource into transportation fuels could significantly contribute to the creation of a new domestic bioenergy and bioproduct industry, while providing an economically and environmentally sustainable alternative for current waste disposal practices. Hydrothermal liquefaction (HTL) is a process that uses hot, pressurized water in the condensed phase to convert biomass to a thermally stable oil product, also known as “biocrude”, which can then be thermo-catalytically upgraded to hydrocarbon fuel blendstocks. HTL is conceptually simple, has a high carbon efficiency, and can be applied to a wide range of wet feedstocks at similar processing conditions. The purpose of this report is to document the conceptual design, economics and supporting data for a sludge-to-fuel pathway via HTL and biocrude upgrading. The configuration includes a HTL plant that is co-located with a WWTP and a larger scale biocrude upgrading plant for production of hydrocarbon fuel blendstocks. Experimental data from bench scale testing of a 1:1 mixture of primary:secondary sludges are used to establish the economic and technical assumptions for the analysis. The design represents a goal case for the pathway, targeting performance that is anticipated to be achievable by 2022 with further research and development. The year 2022 is BETO’s target year for verification of hydrocarbon biofuel pathways. As this analysis represents a goal case, assumed values of several design parameters represent improvements in the technology relative to what has currently been demonstrated in the laboratory. While HTL is fairly well developed and may therefore be ready for commercialization prior to 2022, there are specific advancements addressed in this analysis that are necessary to enhance performance compared to what has been demonstrated to date. In addition, an important aspect to the pathway is the upgrading of biocrude to fuel blendstock, an area that has received much less attention and requires significant research to validate the goal case performance parameters. The estimated plant gate minimum fuel selling price for fuel blendstock from sludge HTL and upgrading is $3.46/gasoline gallon equivalent (gge). This price is within the tolerance (+$0.49/gge) of BETO’s $3/gge programmatic cost target and illustrates that fuel blendstocks generated from HTL of sludge and centralized biocrude upgrading have the potential to be competitive with fossil fuels. This analysis illustrates the feasibility of HTL for point-of-generation conversion of waste feedstock at a scale 1/20th that of the standard lignocellulosic biorefinery scale typically used in BETO design cases. The relevance of this work reaches beyond wastewater treatment sludge to lay the groundwork for application to other distributed wet wastes and blends that together represent a significant resource of underutilized biomass.

09 BIOMASS FUELS↗

DOE OSTI2017

Bench-Scale Evaluation of the Genifuel Hydrothermal Processing Technology for Wastewater Solids

Hydrothermal Liquefaction (HTL) and Catalytic Hydrothermal Gasification (CHG) proof-of-concept bench-scale tests were performed to assess the potential of the Genifuel hydrothermal process technology for handling municipal wastewater sludge. HTL tests were conducted at 300-350°C and 20 MPa on three different feeds: primary sludge (11.9 wt% solids), secondary sludge (9.7 wt% solids), and post-digester sludge (also referred to as digested solids) (16.0 wt% solids). Corresponding CHG tests were conducted at 350°C and 20 MPa on the HTL aqueous phase output using a ruthenium based catalyst. A comprehensive analysis of all feed and effluent phases was also performed. Total mass and carbon balances closed to within ± 15% in all but one case. Biocrude yields from HTL tests were 37%, 25%, and 34% for primary sludge, secondary sludge, and digested solids feeds, respectively. The biocrude yields accounted for 59%, 39%, and 49% of the carbon in the feed for primary sludge, secondary sludge, and digested solids feeds, respectively. Biocrude composition and quality were comparable to that seen with biocrudes generated from algae feeds. Subsequent hydrotreating (i.e., upgrading) of the biocrude produced from primary sludge and digested solids resulted in a product with comparable physical and chemical properties to petroleum crude oil. CHG product gas consisted primarily of methane, with methane yields (relative to CHG input) on a carbon basis of 47%, 61%, and 64% for aqueous feeds that were the output of HTL tests with primary sludge, secondary sludge, and digested solids, respectively. Siloxane concentrations in the CHG product gas were below the detection limit and well below fuel input composition limits set by several engine manufacturers. Relative to that of the sludge feeds, the HTL-CHG process resulted in a reduction in chemical oxygen demand (COD) of greater than 99.9% and a reduction in residual solids for disposal of 94-99%. The test results, as a whole, support further long term testing in a larger scale integrated system that is representative of what would be installed at a water resource recovery facility (WRRF) in order to fully assess the technical and economic viability of this technology for wastewater sludge treatment.

biocrude↗

DOE OSTI2016

Hydrothermal Liquefaction of Wastewater Treatment Plant Solids

Feedstock cost is the greatest barrier to the commercial production of biofuels. The merits of any thermochemical or biological conversion process are constrained by their applicability to the lowest cost feedstocks. At PNNL, a recent resource assessment of wet waste feedstocks led to the identification of waste water treatment plant (WWTP) solids as a cost-negative source of biomass. WWTP solids disposal is a growing environmental concern [1, 2] and can account for up to half of WWTP operating costs. The high moisture content is well-suited for hydrothermal liquefaction (HTL), avoiding the costs and parasitic energy losses associated with drying the feedstock for incineration. The yield and quality of biocrude and upgraded biocrude from WWTP solids is comparable to that obtained from algae feedstocks but the feedstock cost is $500-1200 less per dry ton. A collaborative project was initiated and directed by the Water Environment & Reuse Foundation (WERF) and included feedstock identification, dewatering, shipping to PNNL, conversion to biocrude by HTL, and catalytic hydrothermal gasification of the aqueous byproduct. Additional testing at PNNL included biocrude upgrading by catalytic hydrotreatment, characterization of the hydrotreated product, and a preliminary techno-economic analysis (TEA) based on empirical results. This short article will cover HTL conversion and biocrude upgrading. The WERF project report with complete HTL results is now available through the WERF website [3]. The preliminary TEA is available as a PNNL report [4].

biocrude upgrading↗

DOE OSTI2017

Co-liquefaction of mixed culture microalgal strains under sub-critical water conditions

In this work, we report the co-liquefaction performance of unicellular, red alga Cyanidioschyzon merolae and Galdieria sulphuraria under sub-critical water conditions within a stainless-steel batch reactor under different temperatures (150–300 °C), residence time (15–60 min), and Cyanidioschyzon merolae to Galdieria sulphuraria mass loading (0–100%). Individual liquefaction of C. merolae and G. sulphuraria at 300 °C achieved maximum biocrude oil yield of 18.9 and 14.0%, respectively. The yield of biocrude oil increased to 25.5%, suggesting a positive synergistic effect during the co-liquefaction of 80–20 mass loading of C. merolae to G. sulphuraria . The biocrude oils were analyzed by FT-ICR MS which showed that co-liquefaction did not significantly affect the distribution of product compounds compared to individual oils. The co-liquefied biocrude and biochar have a higher-heating-value of 35.28 and 7.96 MJ/kg. Ultimate and proximate analysis were performed on algae biomass, biocrude and biochar.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Uncertainty analysis for techno-economic and life-cycle assessment of wet waste hydrothermal liquefaction with centralized upgrading to produce fuel blendstocks

Wet waste hydrothermal liquefaction is a promising technology for producing transportation fuels with much lower greenhouse gases emissions than petroleum-based fuels. However, its techno-economic and life cycle assessment are primarily based on laboratory scale testing data, subject to considerable uncertainties, and even bias, due to knowledge gaps. Here, a preliminary uncertainty analysis of key economic measures was conducted based on the 2019 state-of-technology model for biocrude production. Building on the preliminary analysis, this work presents a comprehensive uncertainty analysis in both economic and environmental measures of the entire supply chain of wet waste hydrothermal liquefaction to fuel blendstocks including biocrude upgrading based on the 2021 state-of-technology model. The analysis includes the most recent developments in hydrothermal liquefaction and biocrude upgrading technologies and Monte Carlo simulation based on an integrated model system including an improved reactor yield model, reduced-order process model, discounted cash flow economic model and simplified life-cycle assessment model. The estimated biocrude yield ranges from 42.2% to 52.4% with a median of 47.3%. The estimated fuel yield ranges from 34.7% to 42.7% with a median of 38.7%. The estimated minimum fuel selling price ranges from $\$ $2.28/gge to $\$ $3.45/gge with a median of $\$ $2.80/gge. Relative to petroleum-derived diesel, the estimated reduction in supply chain greenhouse gas emissions ranges from 73.4% to 81.8% with a median of 77.7%. Compared to the 2019 state-of-technology analysis, a significant improvement in biocrude selectivity and economic measures and reduction in uncertainties were achieved due to the incorporation of additional continuous experimental data sets, technology development and de-risking, and improvement in model accuracy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Computational and Experimental Study for the Denitrification of Biomass-Derived Hydrothermal Liquefaction Oil

Hydrothermal liquefaction (HTL) is a promising method for processing wet biomass and waste feedstock to produce biofuels. During the HTL process, proteins and other biomolecules in certain feedstock get converted into nitrogenous compounds in produced biocrude, which represents a major challenge to further upgrading them into fuels. One promising approach is to separate nitrogenous compounds from the biocrude using polymeric resins. In this study, experiments were conducted to down-select sorbent and resin systems using a nitrogen-compound-containing surrogate biocrude. We model the binding interactions between an Amberlyst polymeric resin with various compounds present in the biocrude mixture such as nitrogenous compounds like pyrrole, pyridine, hexanamide, and representative co-existing compounds like phenol and dodecanoic acid. To ascertain the efficiency of various resins in the denitrogenation process, we have developed a quantitative structure–function model for the interacting components in the mixture. Our results suggest that the Amberlyst resin is a viable candidate for efficient removal of target nitrogen-containing compounds (such as pyridine) from the biocrude as a result of favorable interactions. The computational studies provide some insight into how and why the identified resin (Amberlyst) works in selective extraction of nitrogenous compound(s).

09 BIOMASS FUELS↗

DOE OSTI2022

Experimental-based mechanistic study and optimization of hydrothermal liquefaction of anaerobic digestates

Valorization of agricultural and food waste digestates is crucial for sustainable waste management to reduce environmental impacts and improve the economics of commercial farms. Hydrothermal liquefaction (HTL) of anaerobic digestates was evaluated to recover resources by converting them into carbon-dense biocrude oil and a nutrient-rich HTL aqueous phase (HTL-AP) coproduct. The effects of HTL temperature (280–360 °C), reaction time (10–50 min), feedstock pH (2.5–8.5), digestate salt content (1–5 wt%), and digestate cellulose-to-lignin ratio (0.2–1.8) on energy and nutrient recovery were systematically investigated in a set of well-designed experiments following a half-fractional central composite protocol. Response surface analysis combined with HTL product characterization and comparative literature study produced a comprehensive reaction pathway for HTL of anaerobic digestates. Moreover, this analysis revealed the importance of acidic feedstocks (pH 3.00–5.53), high reaction temperatures (337–360 °C), and reaction times <45 or 45–50 min for digestates with Cel/Lig >1 or <1, for maximizing the energy recovered in biocrude (high carbon yield and low heteroatom content) and the amounts of P, NH 3 –N, and Mg distributed in the HTL-AP. Acidic conditions catalyzed biocrude production, inhibited the Maillard reaction (lowering the nitrogen content in biocrude), and partitioned nutrients into the HTL-AP. Higher reaction temperatures coupled with longer reaction times activated hydro-denitrogenation and deoxygenation reactions to improve biocrude quality. Finally, this work provides not only validated methods to achieve targeted resource recovery for specific feedstock compositions using HTL, but also a comprehensive mechanistic understanding of the HTL of biomass waste for controlling target product characteristics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Tailored Bioblendstocks with Low Environmental Impact to Optimize MCCI Engines

The overall objective of the project is to develop and demonstrate a microalgae bio-blendstock with greater than 60% greenhouse gas reduction potential relative to petroleum diesel, that can reduce sooting propensity, increase cetane number and improve engine thermal efficiency relative to a baseline diesel engine operating on conventional fuel. Specific objectives include: (1) development of a new framework for both LCA and TEA that explicitly considers temporal variation in productivity and the frequency of crop loss; (2) determination of how fuel compounds that can be produced from the algal biomass can be ‘bio-tailored’ based on the species composition and biological production process, and subsequent processing via HTL to biocrude, and upgrading of the biocrude; (3) execution of a feedback loop (algae production  biocrude refining  combustion optimization  feedback to refining stage), for optimization of fuels for MCCI combustion; (4) optimization of MCCI combustion and emissions performance, accounting first for the biological processes that dictate the chemical composition of biocrude oil, and second for the subsequent chemical processes that comprise mixing controlled compression ignition combustion; (6) simulation of MCCI engine combustion processes to demonstrate the incorporation of relevant fuel chemistry that captures the specific impacts of optimized algal fuels.

09 BIOMASS FUELS↗

DOE OSTI2018

Bench-Scale Evaluation of Hydrothermal Processing Technology for Conversion of Wastewater Solids to Fuels

Hydrothermal Liquefaction (HTL) and Catalytic Hydrothermal Gasification (CHG) proof-of-concept bench-scale tests were performed to assess the potential of hydrothermal treatment for handling municipal wastewater sludge. HTL tests were conducted at 300-350°C and 20 MPa on three different feeds: primary sludge, secondary sludge, and digested solids. Corresponding CHG tests were conducted at 350°C and 20 MPa on the HTL aqueous phase output using a ruthenium based catalyst. Biocrude yields ranged from 25-37%. Biocrude composition and quality were comparable to biocrudes generated from algae feeds. Subsequent hydrotreating of biocrude resulted in a product with comparable physical and chemical properties to crude oil. CHG product gas methane yields on a carbon basis ranged from 47-64%. Siloxane concentrations in the CHG product gas were below engine limits. The HTL-CHG process resulted in a chemical oxygen demand (COD) reduction of > 99.9% and a reduction in residual solids for disposal of 94-99%.

biocrude↗

DOE OSTI2018

Evaluation of lipid extractability after flash hydrolysis of algae

Microalgae is identified as a promising feedstock for producing renewable liquid transportation fuels; however, lipids extraction from microalgae for downstream processing to biofuels is one of the important challenges for algal based biorefineries. This work aims at evaluating the potential of applying flash hydrolysis (FH) as a chemical-free technique to increase the lipids extractability of algal biomass as well as its integration with the hydrothermal liquefaction (HTL) of microalgae to enhance the biocrude yields and characteristics for fuel production. To this aim, the FH process was performed on three different algal species (Scenedesmus sp., Nannochloropsis sp., and Chlorella vulgaris) at 280 degrees C and 10 s of residence time. Following FH, in addition to the nutrients rich hydrolysate, approximately, 40 wt% of solids containing almost all (>90 wt%) the lipids termed as biofuels intermediates (BI), were recovered. Kinetics study on lipids extractability from the BI and their lipid profile analyses were conducted for each algal species. The results showed that the FH process had significantly enhanced the lipids extractability. For all three algae species, lipid yields from BI were higher than that of the raw algae. Lipid yields of Chlorella vulgaris in the first 15 min were more than five times higher (52.3 +/- 0.8 vs. 10.7 +/- 0.9 wt%) than that of raw algae during n-hexane based solvent extraction. The kinetics of lipids extractability followed a zero-order reaction rate for all wet raw microalgae and the BI of Scenedesmus sp., while the BI recovered from the other two algal species were determined as a second-order reaction. Comparison of fatty acids profiles indicated the contribution of the FH process in saturating fatty acids. Subsequent to lipids extraction, a conventional hydrothermal liquefaction was performed at 350 degrees C and 1 h to compare the biocrude yields from raw versus BI of Chlorella vulgaris microalgae. The results showed that the biocrude yields from the BI and its quality was significantly enhanced post FH than that of raw algae. The FH process was proven to be a viable option for lipid extraction by increasing the extent of recovery and decreasing the extraction time. Its integration with HTL notably impact the biocrude yields and characteristics for fuel production.

09 BIOMASS FUELS↗

DOE OSTI2016

Target Cultivation and Financing Parameters for Sustainable Production of Fuel and Feed from Microalgae

Production of economically competitive and environmentally sustainable algal biofuel faces technical challenges that are subject to high uncertainties. Here we identify target values for algal productivity and financing conditions required to achieve a biocrude selling price of $\$5$ per gallon and beneficial environmental impacts. A modeling framework—combining process design, techno-economic analysis, life cycle assessment, and uncertainty analysis—was applied to two conversion pathways: (1) “fuel only (HTL)”, using hydrothermal liquefaction to produce biocrude, heat and power, and (2) “fuel and feed”, using wet extraction to produce biocrude and lipid-extracted algae, which can substitute components of animal and aqua feeds. Our results suggest that with supporting policy incentives, the “fuel and feed” scenario will likely achieve a biocrude selling price of less than $\$5$ per gallon at a productivity of 39 g/m 2 /day, versus 47 g/m 2 /day for the “fuel only (HTL)” scenario. Furthermore, if lipid-extracted algae are used to substitute fishmeal, the process has a 50 percent probability of reaching $\$5$ per gallon with a base case productivity of 23 g/m 2 /day. As a result, scenarios with improved economics were associated with beneficial environmental impacts for climate change, ecosystem quality, and resource depletion, but not for human health.

09 BIOMASS FUELS↗

DOE OSTI2022

Elucidating the role of reactive nitrogen intermediates in hetero-cyclization during hydrothermal liquefaction of food waste

Hydrothermal liquefaction (HTL) has emerged as a promising strategy for converting abundant, water-rich organic streams into an energy-dense, sustainable, biocrude. Despite major strides in improving oil yields and process intensification, a key underlying challenge persists in relating the composition of the feedstock to the ultimate fate of nitrogen, which is especially important for biocrude quality. To elucidate how nitrogen partitions into the respective gas, aqueous, oil and solid hydrothermal products, food waste was treated under HTL conditions (15 wt% solids, 575 K reaction temperature, and 1 hour reaction time) and elemental, chromatographic and mass spectroscopy analyses were performed on the products to establish dominant product classes and to close mass, carbon, and nitrogen balances. Liquid products (aqueous and biocrude) were found to contain nearly 60% of the nitrogen, with a majority of the biocrude-phase nitrogen in the form of amides. Ab initio thermodynamic and kinetic simulations on model reactants were used to evaluate potential reaction pathways involving reactive nitrogen intermediates. A subsequent kinetic model was evaluated at reaction temperatures ranging 300–1000 K and for a range of feedstock compositions to identify primary reaction pathways. The Maillard reaction is revealed to be the dominant pathway for converting reactive nitrogen intermediates into observed products, especially those in which nitrogen is present as a heterocyclic aromatic. Subsequent product analysis by Fourier Transform Ion Cyclotron Resonance Mass Spectrometry (FT-ICR MS) confirms strong agreement among the experimental data, kinetic model and proposed Maillard pathways.

09 BIOMASS FUELS↗

DOE OSTI2023

Near-Critical CO 2 -Assisted Liquefaction-Extraction of Biomass and Wastes to Fuels and Value-Added Products

With the growing need for sustainable carbon-neutral liquid fuels, low-grade feedstocks, such as lignocellulosic biomass, and municipal solid wastes offer sufficient potential via thermochemical conversion. But the existing thermochemical means are limited in feed flexibility and scalability and require significant processing (energy and costs) of the intermediates. Bio-oil/biocrude intermediate from fast pyrolysis and hydrothermal techniques is impeded by issues of stability and oxygen content, along with hydrotreating viability. To address these issues, we investigated a novel pathway of near-critical CO 2 -assisted integrated liquefaction-extraction (NILE) technology in conceptual aspects for conversion of various biomass and municipal solid wastes into high-quality biocrude with high compatibility for co-hydrotreating with traditional fossil crude for liquid fuel needs in power and transportation sectors. Using supercritical CO 2 for dewatering wet feedstocks, for liquefaction, and extraction for lighter biocrude has produced biocrude with lower oxygen content by 50%, lowered metal content by 90%, stable viscosity, low acidity, and good aging stability compared to that produced from hydrothermal liquefaction along with higher hydrotreating and co-hydrotreating compatibility. Hydrotreating of the biocrude extract from supercritical CO 2 extraction also was feasible with no detected coke deposition, an oxygen content of 1%, and catalyst deactivation. Here, the validation and capabilities of the NILE concept urge for its further development to obtain sustainable liquid fuels with lower greenhouse gas emissions and costs.

09 BIOMASS FUELS↗

DOE OSTI2020

TAILORED BIOBLENDSTOCKS WITH LOW ENVIRONMENTAL IMPACT TO OPTIMIZE MCCI ENGINES

09 BIOMASS FUELS↗

DOE OSTI2025

Harvesting Energy from Wastewater by Converting Sewage

This project aims were to develop and demonstrate a scalable, integrated process to convert sewage sludge into renewable natural gas (RNG), enabling wastewater treatment plants (WWTPs) to become net energy producers. The system proposal integrates autothermal hydrothermal liquefaction (AT-HTL), supercritical salt precipitation (SCSP), and hydrothermal gasification (HTG), collectively forming the Supercritical Sludge-to-Gas (SC-S2G) platform. Initially, batch hydrothermal liquefaction reactions were used to screen sewage sludge using AT-HTL (later termed RI-HTL) conversion to biocrude, aqueous and char phases compared to hydrothermal liquefaction (HTL). Significant improvement in biocrude yield using peroxide addition at O:C ratio of 0.05 and under conditions of 300°C for 10 minutes gave 57% biocrude yield and 85% fluid carbon yield (biocrude plus aqueous), while minimizing the loss of carbon to char solids (~7%). Hence, RI-HTL was shown to be effective for conversion of real sewage sludge. The corrosion of the alloy reactor tubes or vessels is an important factor when developing a process that includes an oxidant and a chemically complex feed like sewage sludge. We investigated the corrosion rates on metal alloys at 350°C for 240 hours. Corrosion rates of 0.21 and 0.26 mpy for 304L and 316L stainless steel were measured respectively. The corrosion information obtained in this investigation was utilized by PNNL for design, materials sourcing and construction of the pilot scale continuous flow system.

09 BIOMASS FUELS↗

DOE OSTI2019

Potential synergies of drop-in biofuel production with further co-processing at oil refineries

Drop-in biofuels have been defined as functionally equivalent to petroleum-based transportation fuels and are fully compatible with the existing petroleum infrastructure. They will be essential in sectors such as aviation if we are to achieve emission reduction and climate mitigation goals. Currently, 'conventional' drop-in biofuels, which are primarily based on upgrading of lipids / oleochemicals, are the only significant source of commercial volumes of drop-in biofuels. However, the necessary increased, future volumes will likely come from 'advanced' drop-in biofuels based on biomass feedstocks such as forest and agriculture residues. Biocrudes / bio-oils produced from lignocellulosic feedstocks using thermochemical technologies such as gasification, pyrolysis, and hydrothermal liquefaction need to be further upgraded to drop-in biofuels. However, advanced drop-in biofuels have been slow to reach commercial maturity due to significant technical challenges, high capital costs, and the challenge of generally lower oil prices. It is likely that the co-processing of drop-in biofuels with conventional petroleum refining could considerably reduce capital costs. Initially, co-processing is likely to be established through the upgrading of conventional / oleochemical feedstocks (lipids). Lipids are readily available in large volumes (global production in 2017 was ~185 million metric tonnes) and can be more easily integrated into oil-refinery processes. In contrast, lignocellulose-derived biocrudes / bio-oils are not yet available in significant volumes and are more complex to co-process in a refinery. The likely strategies for co-processing of oleochemicals (lipids) and bio-oil and biocrude feedstocks based on different insertion points within the refinery infrastructure are discussed.

09 BIOMASS FUELS↗