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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Subtask 2.6 – Optimization of Aerosol Mitigation Technology for Postcombustion CO 2 Capture

Growing concerns over the impact of CO 2 emissions from combustion sources on global climate change have prompted numerous research and development projects aimed at developing cost-effective technologies for CO 2 capture. One family of technologies being demonstrated at pilot and full scale globally is postcombustion CO 2 capture (PCCC) systems that employ amine-based solvents. The captured CO 2 can be compressed and permanently stored underground or used for enhanced oil recovery (EOR). The proximity of North Dakota’s lignite-fired fleet of power plants to potential CO 2 storage options creates a unique atmosphere for PCCC within the state. However, the aerosols present in lignite flue gas present a challenge for large-scale PCCC at North Dakota power plants. Aerosols can negatively impact the long-term performance of amine-based solvents for CO 2 capture. Amine-based solvents are volatile, and aerosols provide nucleation sites where amine vapors can condense. Because aerosols cannot be easily captured at the column outlet using conventional technologies, the amine-laden aerosols escape the system and lead to accelerated solvent losses. Moreover, aerosol components can chemically react with amines to form degradation products that can permanently deactivate the amine, cause fouling, and lead to hazardous emissions. Many of the elements that have been shown to catalyze solvent degradation are present in lignite coals and can exacerbate solvent replacement economics. Understanding this issue is critical to the implementation of solvent-based CO 2 capture systems as applied to lignite-fired generation systems. The Energy & Environmental Research Center (EERC) designed and carried out this project to optimize aerosol mitigation technology for PCCC at a lignite-fired power plant. To meet the goal of this project, the following objectives were identified: Determine the effectiveness of a wet electrostatic precipitator (WESP) on collection of aerosols at a low-rank coal-fired power station. Determine the impact of aerosols on the efficiency and degradation products of amine-based carbon capture systems fired with low-rank fuels. Work was conducted at Minnkota Power Cooperative’s (MPC’s) Milton R. Young (MRY) Station Unit 2 using a slipstream of flue gas from the outlet of the plant’s flue gas desulfurization (FGD) unit. To gather initial data for sizing and specifying a WESP for this system, a temporary pilot-scale WESP was rented and installed on-site. Several different conditions were tested to examine the impact of flow rate, voltage, and current on WESP performance. The WESP was effective at removing large particulate (>200 nm) but caused an increase in fine particulate (<75 nm). Fine particulate material at the inlet and outlet of the WESP was collected, analyzed, and showed that crystalline sulfates carried over from the plant’s FGD unit were being converted to fine aerosols and SO 2 was being converted to SO 3 through the WESP. Additionally, the high moisture content of the flue gas stream at this sample location also contributed to an overall increase in aerosol mass under some of the test conditions. Using the results from the rented WESP, the project team installed a smaller-scale WESP upstream of the EERC’s slipstream CO 2 capture system. Flue gas was routed through a pilot-scale FGD unit to remove SO 2 to very low levels (~1 ppm) and then through a direct contact cooler (DCC) to further cool the gas and to remove moisture. The gas exiting the DCC was then routed through the new WESP before passing to the CO 2 absorber columns. Fluor’s amine-based solvent was used to scrub CO 2 from the slipstream through a set of two absorber columns. The rich solvent was regenerated in a stripper column by heating to drive off captured CO 2 . The system operated using a catch-and-release method where the CO 2 was separated to provide data on the process, but the captured CO 2 was released back into the host site stack. Aerosols and sulfur species were measured at multiple locations throughout the pilot-scale system. The inlet FGD and DCC removed much of the particulate matter and gaseous sulfur upstream of the WESP. With this configuration, the WESP achieved >95% particulate capture. The new WESP did not show any of the increases in SO 3 or other aerosol species that had been consistently observed with the larger-scale WESP installed immediately downstream of the plant’s full-scale FGD unit. Particulate samples captured and analyzed from the WESP inlet did not show any presence of crystalline sulfate materials, indicating that the pilot-scale FGD and DCC were efficient at reducing carryover from the plant’s full-scale FGD unit. A set of parametric tests were conducted on the new WESP to assess the impacts of flow rate, voltage, number of online WESP fields, and gas-phase sulfur content on aerosol and sulfur transformations. The results showed that the WESP performed similarly well at all sets of conditions. Sulfur and particulate matter exiting the WESP were further reduced through the absorber column as the amine-based solvent captured some of the residual contaminants. Solvent analysis showed that these species were slowly concentrating in the solvent over the duration of the test. When the WESP was taken offline and the sulfur slip through the FGD allowed to rise, the sulfate content in the solvent rose sharply, showing that the extra FGD and WESP were effective at reducing sulfate and cation uptake. This would be expected to extend amine-based solvent life by slowing the formation of heat-stable salts and other degradation products. This subtask was cofunded through the EERC–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission and MPC.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Explore the Potential to Formulate Feedstock Blends from Diverse Biomass inputs for Improved Processing Performance at Lower Costs

This work aims to understand the pelleting characteristics of 2-inch top-pine residue blended with switchgrass at high moisture content. The process variables tested are blend moisture content, length-to-diameter (L/D) ratio in the pellet die, and the blend ratio. A flat-die pellet mill was also used in this study. The pine and switchgrass blend ratios that were tested include (1) 25% 2-inch top pine residue with 75% switchgrass; (2) 50% 2-inch top pine residue with 50% switchgrass; and (3) 75% 2-inch top pine residue with 25% switchgrass. The pelleting process conditions tested included the L/D ratio in the pellet die (i.e., 1.5 to 2.6) and the blend moisture content (20 to 30%, w.b.). Analysis of experimental data indicated that blending 25% switchgrass with 75% 2-inch top pine residue and 50% switchgrass with 50% 2-inch top pine residue resulted in pellets with a bulk density of >550 kg/m3 and durability of >95. Optimization of the response surface models developed for process conditions in terms of product properties indicated that a higher L/D ratio of 2.6 and a lower blend-moisture content of 20% (w.b.) maximized bulk density and durability. Higher pine in the blends improved the pellet durability and reduced energy consumption. Tests were also conducted on blends of pine and switchgrass using a pilot scale pellet mill by varying the blend moisture content and compression ratio of the pellet die. Pelleting tests on pure pine and switchgrass and their blends in a pilot scale ring die pellet mill with a throughput of 1 ton/h has indicated pellets with durability >500 kg/m3 and durability in the range of >90 and >95 %. The demonstration of high moisture pelleting of blends of 2- and 6-inch top pine residues and switchgrass blends indicated that good quality pellets with durability >90 % and bulk density of >500 kg/m3 can be produced.

09 BIOMASS FUELS↗
DOE OSTI2021

Pretreatment of Biomass by Selected Type-III Deep Eutectic Solvents and Evaluation of the Pretreatment Effects on Hydrothermal Carbonization

Hydrothermal carbonization (HTC) is a novel thermochemical conversion that converts wet biomass into energy dense solid fuel. Residual moisture under subcritical conditions reacts with a lignin-cellulose-hemicellulose matrix with the major reactions being identified as dehydration and decarboxylation. Among other reaction parameters (e.g., temperature, time, pressure), biomass morphology often plays a key role in HTC. The hypothesis of this study was enhancing the porous structure of biomass without significantly affecting biopolymer composition would augment hydrothermal carbonization (HTC). To prove the hypothesis, two type-III deep eutectic solvents (DESs), namely choline chloride:urea (ChCl:Urea, 1:2 mol/mol) and methyltriphenylphosphonium bromide:ethylene glycol (MTPB:EG, 1:4 mol/mol), were studied to pretreat loblolly pine at room temperature and ambient pressure for 1 h. DES pretreatment shows swelling of the biomass, increasing the surface fiber-to-fiber gap length by 52% and 185% for ChCl:Urea and MPTB:EG pretreatments, respectively. The total pore volume remained intact (2.6 × 10 –3 cm 3 /g), although new small pores evolved, and existing pores were abated with DES pretreatment. Hydrochars prepared from DES pretreated loblolly pine showed a high O/C and H/C ratio resulting in a significant increase of energy content (up to 42%) and a decrease of mass yield (up to 50 wt %), indicating an enhancement of HTC severity due to the alteration of surface morphology by DES. Finally, a preliminary process economics revealed that integrated DES pretreatment-HTC would increase fixed capital investment but decrease the cost of operation and manufacturing than the standalone HTC process.

09 BIOMASS FUELS↗
DOE OSTI2025

Unveiling Feedstock Variability: Insights into Corn Stover Conversion - Part I: Physicochemical Properties and Self-Degradation

Transforming agricultural waste into biofuels and bioproducts is crucial to advancing a low-carbon bioeconomy. However, the inherent variability in the composition and quality introduces uncertainties in the conversion efficiency and poses challenges in process development. Through integrating a high-throughput conversion system, material characterization techniques, and advanced data analysis tools, this study investigates the variability of corn stover and its subsequent impacts on carbohydrate conversion. The findings reveal that indoor storage substantially reduces the moisture and ash content and soil contamination, while other properties remain largely unchanged. Self-degradation due to microbial activity during storage decreases the carbohydrate content of corn stover but enhances glucose and xylose yields. A negative correlation is observed between sugar yields and lignin content across samples with varying ash and moisture content. The inhibitory effect of lignin diminishes in self-degraded samples likely due to the disrupted cell wall structure. Although self-degradation slightly increases cellulose crystallinity, no strong correlation was observed between the crystallinity and sugar yield. Hot water pretreatment under mild conditions effectively mitigates inherent variability, consistently improving the sugar yield from corn stover by up to 50%. By elucidating the feedstock variability and its impact on convertibility, these findings offer valuable insights into appropriate feedstock handling and management, highlighting potential strategies to address variability challenges.

09 BIOMASS FUELS↗
DOE OSTI2024

Precision Plant Biomass Characterization in Agriculture: Harnessing Machine Learning and Hyperspectral Imaging [Slides]

Efficient Biomass Separation Object detection of anatomical parts (Cob, Stalk, Husk) in IR images enables precise separation, improving preprocessing (e.g., drying, grinding) for biofuel production. Detailed Biomass Characterization with Hyperspectral Data Hyperspectral imaging captures spectral signatures of biomass, allowing for the identification of specific traits like moisture content, lignin levels, and nutrient composition, leading to optimized treatments for each biomass part. Enhanced Feedstock Quality By leveraging hyperspectral data, feedstock can be processed based on its chemical composition, improving conversion efficiency and biofuel yield. Automation for Large-Scale Operations Automated object detection and hyperspectral data analysis reduce manual labor, ensuring accurate sorting and faster processing, making large-scale biofuel production more efficient. Maximized Biomass Utilization Accurate identification of biomass properties minimizes waste and ensures that each part is processed according to its highest biofuel potential.

09 BIOMASS FUELS↗
DOE OSTI2020

The effect of moisture on hydrocarbon-based solvent liquefaction of pine, cellulose and lignin

In this report we examined the effect of moisture on the solvent liquefaction of loblolly pine, cellulose, and lignin in tetralin at 280 °C and pressures ranging from 15 to 70 bar. Solvent liquefaction experiments were conducted in a quasi-batch reactor capable of continuous pressure control and external vapor condensation. Moisture was varied by the controlled addition of de-ionized water. Control over the system pressure subsequently impacted the removal of water vapor from the reactor. Liquid yield decreased by 25, 21, and 35 wt%, for pine, cellulose, and lignin, respectively, when moisture content was increased from 1 to 50 wt% at 42 bar. Humins were observed in the solid residue from liquefaction of wet cellulose. Wet lignin yielded a substantial amount of solid residue compared to dry lignin with a corresponding decrease in total phenolic monomer production. It was concluded that the ionic dissociation of water was an important factor in loss of liquid yield in the presence of water. Although water was less than 20 wt% of the solvent loading in these experiments, it strongly influenced the liquefaction of biomass and biomass components.

09 BIOMASS FUELS↗
DOE OSTI2023

Co-Harvest and Anaerobic Co-Storage of Corn Grain and Stover as Biomass Feedstocks

This research investigated the utility of co-harvesting and anaerobic co-storage of corn grain and stover to positively influence their physical and chemical characteristics as a biomass feedstock. Corn grain and stover were harvested in 2019 and 2020 with a self-propelled forage harvester. Stover yield, moisture content, and composition were altered by the harvest date, stubble height, and header configuration. Harvest date had the utility of varying the stover moisture content (p < 0.001) from 42.3% to 53.5% (w.b.) and 43.1% to 53.9% (w.b.) for the 2019 and 2020 harvest years, respectively. Stubble height was also utilized to vary stover moisture content. A negative linear relationship was established between stubble height and stover moisture content for the early (R2 = 0.76) and late harvest (R2 = 0.91) dates for both years. Stover yield also showed a negative linear relationship (R2 = 0.76) with stubble height over both years. Regardless of the stubble height, the row-crop header collected more stover (p < 0.001) than the ear-snapper header. In 2020, harvested stover ranged from 5.0 to 10.5 Mg ha-1, with ha-1 representing 41% to 85% of the total available stover. In both years, stover ash content was less than 64 g kg-1. Material stored in pilot-scale silos (19 L) was well conserved during anaerobic storage, with average DM losses of 4.8% and 3.4% in 2019 and 2020, respectively. Grain moisture content averaged 23.6% (w.b.) at harvest, and 31.0% (w.b.) after storage as moisture migrated from the moist stover to the drier grain. Harvesting whole-plant corn with a forage harvester had the unwanted effect of reducing the particle size of the grain fraction, which would complicate downstream utilization. However, reducing the harvester cutterhead speed increased the fraction of intact kernels from 47% to 85% by mass. The studied system was a viable alternative to conventional corn grain and stover systems for producing feedstocks for biochemical conversion.

09 BIOMASS FUELS↗
DOE OSTI2021

Optimization models for integrated biorefinery operations

Variations of physical and chemical characteristics of biomass lead to an uneven flow of biomass in a biorefinery, which reduces equipment utilization and increases operational costs. Uncertainty of biomass supply and high processing costs increase the risk of investing in the US’s cellulosic biofuel industry. We propose a stochastic programming model to streamline processes within a biorefinery. A chance constraint models system’s reliability requirement that the reactor is operating at a high utilization rate given uncertain biomass moisture content, particle size distribution, and equipment failure. The model identifies operating conditions of equipment and inventory level to maintain a continuous flow of biomass to the reactor. Furthermore, the sample average approximation method approximates the chance constraint and a bisection search-based heuristic solves this approximation. A case study is developed using real-life data collected at Idaho National Laboratory’s biomass processing facility. An extensive computational analysis indicates that sequencing of biomass bales based on moisture level, increasing storage capacity, and managing particle size distribution, increases utilization of the reactor and reduces operational costs.

09 BIOMASS FUELS↗
DOE OSTI2025

Go with the Flow: Additives to Improve the Flowability of Crumbled Corn Stover

For this work, magnesium stearate (MgSt), a common flow additive and anticaking agent, was applied to corn stover feedstocks with three particle sizes. The material handling properties of dry, 15%, and 30% moisture content corn stover were measured with a Freeman FT-4 powder rheometer and mass flow hopper calculations. While hydrated biomass typically exhibits poor flowability, introducing MgSt led to a significant increase in flowability for dry and 15% moisture content feedstocks, with less impact at 30% moisture content. Inverse gas chromatography showed a decrease, up to 40%, in the surface energy of MgSt-coated corn stover. While MgSt may not be ideal for biofuel or chemical production, this study highlights the potential of flow additives to reduce adhesive and cohesive forces, improving biomass feedstock handling.

09 BIOMASS FUELS↗
DOE OSTI2020

Characterizing Variability in Lignocellulosic Biomass: A Review

Feedstock variability is a significant barrier to the scale-up and commercialization of lignocellulosic biofuel technologies. Variability in feedstock characteristics and behavior creates numerous challenges to the biorefining industry by affecting continuous operation and biofuels yields. Recently, feedstock variability is understood and explained largely on the basis of chemical composition. Physical and mechanical properties and behavior of lignocellulosic feedstock in various unit operations, studied through advanced analytical methods, can further explain variability. Such studies will enable us in developing processes and designing equipment to improve operation and conversion performance. In this perspective, we review several advanced analytical methods that measure density, moisture content, thermal properties, flowability, grindability, rheology properties, and micromorphological characteristics. We also discuss the correlations and interactions among these properties that reflect the complexity of lignocellulosic biomass as a feedstock and the associated quality metrics and logistics of supplying consistent quality feedstock to a biorefinery. We further examine methods that have not traditionally been used to characterize lignocellulosic feedstocks but have the potential to bridge the gap in our explanation of feedstock variability.

09 BIOMASS FUELS↗
DOE OSTI2025

Effect of particle size and moisture on flow performance of loblolly pine anatomical fractions: Experimental findings and model predictions

The rising energy demand has highlighted biomass as a promising next-generation energy source. However, commercializing biomass-derived energy faces challenges, particularly in handling biomass feedstock. Factors like particle size, shape, moisture content, and surface roughness significantly impact biomass flowability. This study addresses a crucial knowledge gap by examining the effects of particle size and moisture content on the flow behavior and shear properties of different anatomical fractions of loblolly pine (Pinus taeda). The bulk shear behavior was examined using a Schulze ring shear tester, while flow performance was tested through gravity-driven flow experiments in a variable wedge-shape hopper. Results were incorporated into empirical and machine learning-based flow prediction models to evaluate their accuracy and limitations. The study found that samples with higher moisture content show higher unconfined yield strength. The critical arching distance increased with particle size, e.g., from approximately 13 and 33 mm for 2- and 6-mm whole chips, respectively at a 32-degree inclination angle. Conversely, the flow rate decreased for a given hopper opening as particle size increased. For instance, at a 60-mm hopper opening and a 32-degree inclination angle, the mass flow rates for 2- and 6-mm whole chips were 7.83 and 6.42 tonne/h, respectively. The empirical model consistently overpredicted the mass flow rate for all anatomical fractions, while the machine learning model more accurately predicted the central tendency of flow rate but was insensitive to varying tissue proportions. These novel findings provide comprehensive characterization of anatomical fractions, reveal significant combined effects of particle size and moisture content on biomass flow behavior, and demonstrate a better predictive accuracy of a machine learning model, all of which are useful for optimizing material handling strategies and biomass utilization technologies in the industry.

09 - BIOMASS FUELS↗
DOE OSTI2022

Plant organic matter inputs exert a strong control on soil organic matter decomposition in a thawing permafrost peatland

Peatlands are climate critical carbon (C) reservoirs that could become a C source under continued warming. A strong relationship between plant tissue chemistry and the soil organic matter (SOM) that fuels C gas emissions is inferred, but rarely examined at the molecular level. Here we compared Fourier transform infrared (FT-IR) spectroscopy measurements of solid phase functionalities in plants and SOM to ultra-high-resolution mass spectrometric analyses of plant and SOM water extracts across a palsa-bog-fen thaw and moisture gradient in an Arctic peatland. From these analyses we calculated the C oxidation state (NOSC), a measure which can be used to assess organic matter quality. Palsa plant extracts had the highest NOSC, indicating high quality, whereas extracts of Sphagnum, which dominated the bog, had the lowest NOSC. The percentage of plant compounds that are less bioavailable and accumulate in the peat, increases from palsa (25%) to fen (41%) to bog (47%), reflecting the pattern of percent Sphagnum cover. The pattern of NOSC in the plant extracts was consistent with the high number of consumed compounds in the palsa and low number of consumed compounds in the bog. However, in the FT-IR analysis of the solid phase bog peat, carbohydrate content was high implying high quality SOM. Here, we explain this discrepancy as the result of low solubilization of bog SOM facilitated by the low pH in the bog which makes the solid phase carbohydrates less available to microbial decomposition. Plant-associated condensed aromatics, tannins, and lignin-like compounds declined in the unsaturated palsa peat indicating decomposition, but lignin-like compounds accumulated in the bog and fen peat where decomposition was presumably inhibited by the anaerobic conditions. A molecular-level comparison of the aboveground C sources and peat SOM demonstrates that climate-associated vegetation shifts in peatlands are important controls on the mechanisms underlying changing C gas emissions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Let’s Stick Together: Interplay of Moisture, Particle Size, and Anatomical Fraction in the Flowability of Corn Stover Crumbles

Handling of agricultural waste biomass feedstocks (such as corn stover) is a persistent challenge in the production of biofuels and chemicals at integrated biorefineries. Inconsistent flowability and high feedstock variability creates equipment downtime and processing challenges. This work investigates the influence of anatomical fractionation and moisture content on the bulk solids handling behavior of corn stover crumbles. A combination of rotational shear testing, tribological measurements, and surface and sorption characterization techniques (inverse gas chromatography (IGC), dynamic vapor sorption (DVS), and electron microscopy) were used to evaluate the contributions of particle composition, size, and surface properties to flow behavior. Shear and frictional testing revealed that moisture content has the greatest effect on flowability, significantly increasing unconfined yield strength (ƒ c ) and reducing the flow function coefficient (F F C), regardless of anatomical fraction. While differences in surface energy were observed between fractions, particularly in polar contributions (γ AB ), these did not correspond to meaningful differences in flow behavior. Coarser 6 mm particles exhibited poorer flow performance than 4 mm crumbles, likely due to broader particle size distributions and increased particle interlocking. Taken together, these results suggest that anatomical fractionation provides minimal benefit from a bulk handling perspective. Moisture content and particle size heterogeneity dominate handling behavior, reinforcing the utility of unfractionated corn stover in processing environments. These insights can inform the design of more efficient and reliable feedstock processing systems for agricultural biomass in integrated biorefineries.

09 BIOMASS FUELS↗
DOE OSTI2022

Chloride Salt Purification by Reaction With Thionyl Chloride Vapors to Remove Oxygen, Oxygenated Compounds, and Hydroxides

Molten chloride salts (including MgCl 2 , KCl, NaCl, and ZnCl 2 ) are being considered for heat transfer media for renewable (solar) and nuclear power generators, as fuel carrier for nuclear reactors, and as thermal energy storage media. Impurities such as oxygen, hydroxides, moisture, and sulfur are known to negatively influence the corrosion of materials in contact with the salt (e.g., structural metals). Commercially available chloride salts come with a range of impurities. Before using the chloride salts at high temperature, it is desirable to remove the impurities to increase the performance of the salt and reduce corrosion. In this study, we tested the use of thionyl chloride vaporized into a stream of argon to react with oxygenated impurities in a mixture of MgCl 2 -KCl-NaCl, removing them as HCl and SO 2 . The reagent was bubbled through the salt when both above and below the melting point. The reaction was followed using thermocouple data from the salt and by Fourier transform infrared (FTIR) spectroscopy on the exhaust of the reactor. The reaction kinetics were followed by comparing the peaks from SO 2 product to SOCl 2 reagent in the FTIR spectra. The purity of the salt was assessed at the end of the purification process by x-ray diffraction and inductively coupled plasma analysis. Although the process was effective in removing the oxygen content of the mixture, ternary compounds were formed in the process, including KNiCl 3 and KMgCl 3 . The nickel in KNiCl 3 came from the reaction between the salt and the nickel vessel. Thus, these experiments suggest that improvements to the process must be made before using SOCl 2 vapors for the purification of chloride salts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Physical Properties of Moist, Fermented Corn Kernels

A novel approach to producing corn stover biomass feedstock has been investigated. In this approach, corn grain and stover are co-harvested at moisture contents much less than typical corn silage. The grain and stover are conserved together by anaerobic storage and fermentation and then separated before end use. When separated from the stover, the moist, fermented grain had physical characteristics that differ from typical low-moisture, unfermented grain. A comprehensive study was conducted to quantify the physical properties of this moist, fermented grain. Six corn kernel treatments, either fermented or unfermented, having different moisture contents, were used. Moist, fermented kernels (26 and 36% w.b. moisture content) increased in size during storage. The fermented kernels’ widths and thicknesses were 10% and 15% greater, respectively, and their volume was 28% greater than the dry kernels (15% w.b.). Dry basis particle density was 9% less for moist, fermented kernels. Additionally, the dry basis bulk density was 29% less, and the dry basis hopper-discharged mass flow rate was 36% less. Moist, fermented grain had significantly greater kernel-to-kernel coefficients of friction and angles of repose compared to relatively dry grain. The friction coefficient on four different surfaces was also significantly greater for fermented kernels. Fermented corn kernels had lower individual kernel rupture strengths than unfermented kernels. These physical differences must be considered when designing material handling and processing systems for moist, fermented corn grain.

09 BIOMASS FUELS↗
DOE OSTI2023

Evaluation of Desiccation Behavior in Basalt Microfiber–Reinforced Bentonite Clay for Geological Repositories of Nuclear Spent Fuel Using Digital Image Correlation

ABSTRACT Secure storage of nuclear spent fuel (NSF) is of great concern for protecting public health and safety. The preferred long-term solution is underground containment in geological repositories, where one or more engineered barrier materials (EBM) encapsulate the NSF and separate it from the natural rock. Bentonite clay is commonly used as an EBM due to its many advantageous properties including low hydraulic conductivity, which ensures limitation of water infiltration to the system and the subsequent risk of corrosion in NSF canisters. However, bentonite clay subjected to heating from nuclear decay may form desiccation cracking. This study conducted disk-shaped free shrinkage tests and ring-shaped restrained shrinkage tests of bentonite clay samples reinforced with basalt microfibers. Digital image correlation was used as a noncontact full-field displacement measurement to track the time-evolving shrinkage and desiccation cracking phenomena and make quantified comparisons between plain bentonite and bentonite with varying contents of basalt microfibers (i.e., 0.0, 0.5, 1.0, and 1.5 % wt.). Results indicate that plain bentonite and basalt microfiber-reinforced samples showed similar free shrinkage behavior, while desiccation cracking behavior was significantly altered by adding basalt microfibers. Microfiber reinforcement effectively reduced major cracks through a “crack-bridging” effect while causing minor cracks to initiate earlier and at higher moisture contents than plain bentonite. Results infer that reinforcing plain bentonite with inorganic microfibers can potentially control desiccation cracking, leading to safer and improved nuclear waste management.

Materials Science↗
DOE OSTI2025

Predicting the evolution of biomass bulk density through feedstock preprocessing: Discrete element modeling, regression analysis, and pilot-scale validation

Bulk density is an important material property of biomass feedstocks, influencing handling, storage, transport costs, and conversion efficiency. In this study, predictive regression models for loose and tapped bulk densities of Alamo and Cave-in-Rock switchgrass are developed using a comprehensive dataset generated via calibrated bonded-sphere discrete element method (DEM) simulations. Here, a key contribution of this study is the use of a DEM-based approach, which correlates density with moisture content and particle size distribution parameters and enables analysis across a continuous particle size range, overcoming limitations of purely experimental data. For comparison, regression models are also developed using only experimental data from pilot-scale runs at the Biomass Feedstock National User Facility at Idaho National Laboratory. Validation against pilot-scale data showed reasonable prediction accuracy for both model types, particularly for smaller particle sizes (post-secondary grinding). While the experimental model showed slightly better performance matching the validation data in some cases, the DEM-based model benefits from a much larger dataset, reduced predictor multicollinearity, and continuous parameter coverage, highlighting the utility of validated simulation models for developing robust predictive tools for biomass preprocessing applications.

09 - BIOMASS FUELS↗
DOE OSTI2021

Cryogenic Carbon Capture™ (CCC) Status Report

The Cryogenic Carbon Capture™ (CCC) process separates CO2 from light gases in essentially any continuous process. CCC cools the gases to the frost or desublimation point of CO2 (-100 to -135 °C), separates and pressurizes the solids, and warms all streams to produce a CO2-depleted stream at ambient pressure and a pure (99+%) pressurized liquid CO2 stream typically to about 150 bar, both at ambient temperature. The process also recovers all gas moisture and most gas impurities less volatile than CO2 (NOx, SOx, Hg, PM, UHC, CCC, etc.) in separable streams. CCC nearly eliminates refrigeration energy for sensible temperature changes through heat integration. CCC does require energy to change the CO2 phase from a mixed vapor to a pressurized fluid, which represents the minimum energy required of any process for this separation. CCC uses additional energy for turbomachinery inefficiencies, heat losses, moisture removal and overall process pressure drop. Aside from these real-world energy demands, CCC operates near the minimum energy required to perform this gas separation by minimizing stream recycling. CCC compresses CO2 as a liquid, which is one of several reasons it costs about about half as much and consumes about half as much energy as an amine process when using flue gases with about 15% CO2. The process also has several major additional advantages, including (a) it is a bolt-on retrofit technology that does not need steam or any modification of existing equipment, (b) it recovers water and nearly all pollutants in addition to CO2 from the flue gas, (c) it enables highly efficient and cost effective energy storage at grid scale and on time scales of minutes, (d) it enables NG storage if the energy storage option is used, and (d) it has a small footprint and is minimally disruptive to existing plants, requiring only electrical power and a gas source to operate. Sustainable Energy Solutions (SES) has scaled this technology through several levels, the largest of which captures nominally 1 tonne of CO2/day and is called the skid system. Skid system field tests include utility-scale power plants, cement plants, heating plants, and other utility or industrial sites that burn natural gas, biomass, coal, shredded tires, municipal waste, and combinations of these fuels. These field tests produced 95-99% CO2 capture with CO2 purities of 99+% and initial CO2 contents that range from 4 to 28%. SES currently seeks to scale the system to merchant scale (10-80 tonnes of CO2 per day). In the process of doing so, SES has demonstrated the potential for CCC to contribute to energy storage and direct air capture in innovative and cost-effective ways. This presentation discusses the overall process and highlights results from field and in-house tests. These include (a) measured CO2 capture rates and operating conditions from in-house and field tests, and (b) predicted utility-scale costs and energy demands. This discussion also includes the application of the CCC technology to energy storage and direct air capture.

20 FOSSIL-FUELED POWER PLANTS↗