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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Stochastic Techno Economic Model

The Stochastic Techno-Economic Model or STEM is an analytical tool that estimates the logistics cost of different biomass feedstocks by incorporating uncertainty into the modeling framework. The scope of the model covers multiple stages of the biomass life cycle spanning feedstock harvest, collection, transportation and handling, preprocessing, and storage. The model determines the total logistics cost per dry metric ton ($/DM ton) for biomass and breaks down the costs for important cost categories including ownership related costs such as interest and depreciation, insurance, housing, and taxes as well as operating costs like repairs and maintenance, labor costs, and fuel and lube costs.

Burli, PralhadH↗
DOE OSTI2022

Image Analysis for Rapid Assessment and Quality-Based Sorting of Corn Stover

Imaging in the visible spectrum is a low-cost tool that can be readily deployed for in-field or over-belt monitoring of biomass quality for bio-refining operations. Rapid image analysis coupled with innovative preprocessing may reduce the impacts of feedstock variability through identification of contaminants or other material attributes to guide selective sorting and quality management. Image analysis was employed to evaluate the quality of corn stover in red-green-blue (RGB) chromatic space. This study used controlled, bench-scale imaging as a proof-of-concept for rapid quality assessment of corn stover based on variations in material attributes, including chemical and physical attributes, that relate to biological degradation and soil contamination. Additionally, logistic regression-based classification algorithms were used to develop a method for biomass screening as a function of biological degradation or soil contamination. This study demonstrated the use of image analysis to extract features from RGB color space to investigate variations in critical material attributes from chemical composition of corn stover. Fourier transform infrared (FT-IR) suggested a correlation between red band intensity and biological degradation, while detailed surface texture analysis was found to distinguish among variations in ash. These insights offer promise for development of a rapid screening tool that could be deployed by farmers for in-field assessment of biomass quality or biorefinery operators for in-line sorting and process optimization.

09 BIOMASS FUELS↗
DOE OSTI2014

Bioenergy

Scientists and engineers at Idaho National Laboratory are working with partners throughout the bioenergy industry in preprocessing and characterization to ensure optimum feedstock quality. This elite team understands that addressing feedstock variability is a critical component in the biofuel production process.

09 BIOMASS FUELS↗
DOE OSTI2025

Novel Preprocessing Techniques for Enhancing Flowability of Miscanthus

Purpose-grown energy crops possess significant potential as promising feedstocks for biofuel and biochemical production. However, similar to other biomass feedstocks, their utilization has been hindered by handling and feeding challenges such as clogging and segregation, which prevent biorefineries from operating at full capacity. These challenges arise primarily due to particle attributes including irregular shape, high flexibility, and high compressibility, leading to interlocking, high compaction, and significant friction under stress consolidation. To enhance operational reliability, it is crucial to focus on preprocessing techniques to address these issues, alongside accurately characterizing the mechanical and physical properties and flow performance of these feedstocks. This study investigates novel preprocessing techniques, including pelletization and torrefaction, to fundamentally alter these particle attributes and improve flowability. Miscanthus, an herbaceous energy crop, was the primary focus of this study. Samples were processed using a Forest Concepts Crumbler rotary shear system and an oscillating multi-stack screen bed to achieve two nominal (baseline) particle sizes: 6mm and 2mm. The study evaluated the efficiency and energy consumption of size reduction, revealing that while 2mm particles required more energy, they exhibited better flowability and higher yield strength compared to 6mm particles. Shear and compression tests assessed the material's shear strength, internal friction, and elastic modulus, while wedge-shaped hopper tests measured the critical arching distance and mass flow rate. The results provide valuable insights into the mechanical properties and processing efficiency of Miscanthus, contributing to the development of a preprocessing framework that enhances energy efficiency and material flowability in bioenergy production. However, further preprocessing and development are required to optimize this framework fully.

09 - BIOMASS FUELS↗
DOE OSTI2013

MODEL BASED BIOMASS SYSTEM DESIGN OF FEEDSTOCK SUPPLY SYSTEMS FOR BIOENERGY PRODUCTION

Engineering feedstock supply systems that deliver affordable, high-quality biomass remains a challenge for the emerging bioenergy industry. Cellulosic biomass is geographically distributed and has diverse physical and chemical properties. Because of this feedstock supply systems that deliver cellulosic biomass resources to biorefineries require integration of a broad set of engineered unit operations. These unit operations include harvest and collection, storage, preprocessing, and transportation processes. Design decisions for each feedstock supply system unit operation impact the engineering design and performance of the other system elements. These interdependencies are further complicated by spatial and temporal variances such as climate conditions and biomass characteristics. This paper develops an integrated model that couples a SQL-based data management engine and systems dynamics models to design and evaluate biomass feedstock supply systems. The integrated model, called the Biomass Logistics Model (BLM), includes a suite of databases that provide 1) engineering performance data for hundreds of equipment systems, 2) spatially explicit labor cost datasets, and 3) local tax and regulation data. The BLM analytic engine is built in the systems dynamics software package PowersimTM. The BLM is designed to work with thermochemical and biochemical based biofuel conversion platforms and accommodates a range of cellulosic biomass types (i.e., herbaceous residues, short- rotation woody and herbaceous energy crops, woody residues, algae, etc.). The BLM simulates the flow of biomass through the entire supply chain, tracking changes in feedstock characteristics (i.e., moisture content, dry matter, ash content, and dry bulk density) as influenced by the various operations in the supply chain. By accounting for all of the equipment that comes into contact with biomass from the point of harvest to the throat of the conversion facility and the change in characteristics, the BLM evaluates economic performance of the engineered system, as well as determining energy consumption and green house gas performance of the design. This paper presents a BLM case study delivering corn stover to produce cellulosic ethanol. The case study utilizes the BLM to model the performance of several feedstock supply system designs. The case study also explores the impact of temporal variations in climate conditions to test the sensitivity of the engineering designs. Results from the case study show that under certain conditions corn stover can be delivered to the cellulosic ethanol biorefinery for $35/dry ton.

09 BIOMASS FUELS↗
DOE OSTI2024

The Effect of Air Separations on Fast Pyrolysis Products for Forest Residue Feedstocks

This study investigates the intricate relationship between biomass preprocessing and pyrolysis product yields, employing the air classification technique for the treatment of loblolly pine residues with varying moisture content. A comprehensive exploration of the physicochemical properties of air-classified loblolly pine informs a sophisticated pyrolysis simulation model. Given the complex and multifaceted nature of biomass pyrolysis, operating across diverse temporal and spatial scales, a pyrolysis kinetics-based CFD–DEM simulation method is employed to predict product yields. Results showed that the elevated moisture content amplifies particle adhesiveness, necessitating augmented air velocities for effective separation, thereby influencing the efficiency of the separation process. While carbon and hydrogen contents exhibit relative stability across diverse moisture contents and blower frequencies, the oxygen content undergoes noticeable changes. For example, the oxygen contents were measured as 29.2 and 38.6 wt% in the light fraction of 30% moisture content sample at blower frequencies of 10 and 20 Hz, respectively. An intriguing finding emerges from pyrolysis simulation, indicating that a lower blower frequency in air classification moderately enhances bio-oil yield and significantly improves its quality, particularly in terms of water content. For instance, the water content in the bio-oil was about 1.5% and 10% in the heavy and light fractions, respectively from 10% moisture sample under 15 Hz blower frequency. In summary, a detailed understanding and strategic manipulation of critical material attributes in biomass through efficient fractionation techniques are imperative for advancing fast pyrolysis as a sustainable avenue for renewable energy and chemical production.

09 BIOMASS FUELS↗
DOE OSTI2017

Cornerstone Resources Feedstock Characterization and Conversion Assessment of Treated MSW Materials (CRADA Closeout Final Report)

Cornerstone Resources has developed a proprietary advanced preprocessing technology, the BurCell® System, for production of a high quality organic biomass feedstock from numerous waste resources. While suitable for a variety of feedstock, the focus of development for the BurCell® System has been thus far municipal solid waste (MSW). In MSW, the system technology is able to capture non-recyclable waste paper, cardboard, and organic materials, homogenize these materials and allow for separation of the non-organic fraction. The resulting homogenized organic material typically represents in excess of 50% of the raw MSW feed. The recently released Billion Ton Study now includes MSW as a feedstock resource showing it to be one of the lowest cost and most widely distributed biomass resources available; however, acknowledging the concerns with the potential physical and chemical variability of an MSW based feedstock stream. The focus on MSW has also been driven by MSW being a resource with a clear, well understood and mature supply-chain. Treating MSW in the BurCell® System will make that source of biomass substantially more accessible. To further promote the use of this MSW derived biomass and beneficially exploit the use of the BurCell® System for processing of biomass for Bioenergy production facilities, more detailed lab data is now required.

09 BIOMASS FUELS↗
DOE OSTI2020

Pilot Plant Reliability Metrics for Grinding and Fast Pyrolysis of Woody Residues

The reliability of biomass size reduction, feeding, and conversion processes remains a critical technical hurdle and important cost driver for biomass conversion systems. While Biorefinery projects have typically focused on scaling up conversion technologies that maximize yield of desired products, e.g. fuels and chemicals, solids handling and reactor feeding systems are often considered secondarily. These are frequently scaled down or adapted from other industries, without a full appreciation of how biomass heterogeneity and variability impact process reliability. Here we present the effects of feedstock variability on relative throughput, mass loss, plant uptime, operator intervention, product yield, and product quality for grinding and fast pyrolysis operations at the pilot scale. Loblolly pine residues were sourced and collected using commercial harvesting techniques. Grinding and pyrolysis experiments were performed at INL's Biomass Feedstock National User Facility and NREL's Thermal and Catalytic Process Development Unit, respectively. Preprocessing throughput using a hammer mill varied between 31-48% of nameplate capacity (5 tons/hr), and fast pyrolysis throughput varied between 57-72% of nameplate capacity (20 kg/hr) for an overall system throughput of 18-35% of nameplate capacity across biomass preprocessing and conversion to pyrolysis oil. Pyrolysis oil yields varied between 46-53% (feedstock carbon to oil, dry basis). Grinder overloads in the size reduction step were more prevalent for lower ash and higher moisture materials. During fast pyrolysis operations, downtime was caused by bridging in the feed and char removal systems and plugging in the condensation system, and significant variation in the type and frequency of operator intervention was observed between feedstocks. Cohesion of solids (feedstock and char) leading to system plugging appeared less problematic for higher ash feedstocks, and differences in condenser plugging behavior between high and low ash feedstocks indicates the composition and physical nature of the deposited material is important for process reliability and is feedstock dependent.

09 BIOMASS FUELS↗
DOE OSTI2019

Signatures of Biologically Driven Hemicellulose Modification Quantified by Analytical Pyrolysis Coupled with Multidimensional Gas Chromatography Mass Spectrometry

Biomass storage operation is one major source of feedstock quality variability that impacts on downstream preprocessing, feeding, handling and conversion into biofuels, chemicals and products. In field Ccorn stover biomass bales undergoes degradation and cell wall components modification resulting from microbial biological heating occurring during storage. A molecular characterization of the modification was achieved to unveil and understand the changes of structural cell wall modification in corn stover samples by conducting low temperature (400°C) pyrolysis, comparing samples that were mildly biologicallyun heated to those that had been subjected to microbial severe biological heating (~60°C). Pyrolysis of the samples originating from biomass that had been heated during storage generated small oxygenates such as furfural, 5-methylfurfural and 2-(5H)-furanone with efficiencies that were as much as ten times greater than those measured for the mildly unheated samples. Most of the compounds having enhanced efficiencies were C5 oxygenates, suggesting that the pyrolysis products may be formed from hemicellulosic precursor polymers in the corn stover. The findings suggest that microbial heating may be disrupting the cell wall structure, fragmenting the hemicellulose or cellulose chains, generating more polymer termini that have higher efficiency for generating the oxygenates at lower temperatures. Pyrolysis variability with temperature may be a beneficial strategy for improved biomass cell wall characterization, and for guiding control strategies for enhanced control over product distributions , providing insights to understand and manage the feedstock variability as well as to inform harvest and storage best management practices.

09 BIOMASS FUELS↗
DOE OSTI2013

Feedstock Pathways for Bio-oil and Syngas Conversion Pathways

The goal of this technical memorandum is to support the DOE strategic goal of demonstrating $\$$3/gge drop-in hydrocarbon biofuel production in 2017. A critical component of achieving that goal is developing supply chains that can deliver high quality, low cost biomass to the biofuel conversion reactor throat. This report develops a biomass supply chains that utilize advanced preprocessing strategies to achieve the $\$$80/DMT reactor throat feedstock cost target while consistently achieving the targeted feedstock specifications for the both the bio-oil and syngas conversion technology pathways.

09 BIOMASS FUELS↗
DOE OSTI2024

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

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

09 - BIOMASS FUELS↗
DOE OSTI2017

Biomass Blending and Densification: Impacts on Feedstock Supply and Biochemical Conversion Performance

The success of lignocellulosic biofuels and biochemical industries depends on an economic and reliable supply of high-quality biomass. Many research and development efforts, however, have been historically focused on the utilization of agriculturally derived cellulosic feedstocks, without considerations of their low energy density, high variations in compositions and potential supply risks in terms of availability and affordability. This book chapter demonstrated a strategy of feedstock blending and densification to address the supply chain challenges. Blending takes advantage of low cost feedstock to avoid the prohibitive costs incurred through reliance on a single feedstock resource while densification produces feedstocks with increased bulk density and desirable feed handling properties as well as reduced transportation cost. We also review recent research on the blending and densification dealing with various types of feedstocks with a focus on the impacts of these preprocessing steps on biochemical conversion, i.e., various thermochemical pretreatment chemistries and enzymatic hydrolysis, into fermentable sugars for biofuel production.

09 BIOMASS FUELS↗
DOE OSTI2021

Herbaceous Feedstock 2021 State of Technology Report

The U.S. Department of Energy (DOE) promotes the production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the State of Technology (SOT). As part of its involvement with this mission, Idaho National Laboratory (INL) completes an annual SOT report for biomass feedstock logistics. This report summarizes supply system impacts of Bioenergy Technologies Office (BETO)-funded research and development efforts at INL and INL collaboration with external partners (e.g. Forest Concepts, Purdue University ) that lead to improvements in feedstock supply systems. These include improvements to and observed performance of innovative harvest and collection methods, storage technologies, transportation and handling approaches, and advanced preprocessing technologies. Biomass quality and variability, and the interface between feedstock quality and conversion performance are key drivers in addition to delivered feedstock cost. In this report, we estimate the benefits of R&D technology improvements to individual supply system unit operations and present the status of feedstock logistics technology development for converting herbaceous biomass into biofuels. These analyses are supported by experimental data where possible and help to align the SOT relative to the cost goals defined in the Multi-Year Plan.

09 BIOMASS FUELS↗
DOE OSTI2023

Comparative Techno-Economic Analysis of Available Feedstocks for High-Temperature Conversion: Whole Tree Thinnings and Mature Pine Residues

The TEA and LCA impacts of utilizing low-cost feedstocks in a high-temperature conversion process are of great interest. Here, we investigate the conversion cost impacts of two underutilized feedstocks from the commercial pine industry; 13-year-old whole trees, representing trees removed for the purpose of pre-commercial thinning, and 23-year-old pine residues, representing a waste stream produced from the deconstruction of mature trees for other purposes. Experimental fast pyrolysis data for each feedstock was used in tandem with results from supply and preprocessing analyses in order to evaluate the field-to-fuel economics. A low difference in MFSP was found between the conversion costs for the two feedstocks, with residues demonstrating a net benefit of $0.27/GGE compared to the whole tree thinnings, driven primarily by feedstock supply costs. This suggests that both whole tree thinnings and pine residues may be viable feedstock options for CFP conversion. Life cycle inventories were also generated for each case, enabling a field-to-fuel quantification of the cost and carbon cycle associated with each feedstock.

09 BIOMASS FUELS↗
DOE OSTI2016

Techno-economic analysis comparison of comminution of wood chips using a hammer mill and a rotary shear

Preprocessing is a crucial step in the utilization of biomass feedstocks for the production of fuel and biomaterials [1]. Size reduction and drying of the material, where used, are two of the most costly and energy intensive operations that are undertaken during preprocessing, reduction of the energy usage during these two phases will reduce cost of processing and ultimately reduce the overall cost to the final user. Traditionally, a hammer mill has been the primary method used for secondary size reduction. For wet material, a hammer mill requires high amounts of energy, while for dry material the hammer mill produces a large quantity of small particles [2]. In both cases, the costs increase either from additionally needed fuel cost or from the cost of lost material. In effort to lower the cost for size reduction, a rotary shear has been developed for the comminution of biomass feedstocks. The rotary shear utilizes interlocking, rotating disk that shear the material rather than using impact to reduce the particle size of the materials. Because the material is size reduced using a cutting motion, rather than impact, the distribution of particle sizes is much narrower than produced by hammer mills.

09 BIOMASS FUELS↗
DOE OSTI2021

FCIC DFO--Moisture Management and Optimization in Municipal Solid Waste Feedstock through Mechanical Processing

The project goal is to produce densified product, focusing on characteristics of bulk density, durability, and moisture content, to reduce the cost of preprocessing. The objective of the project is to efficiently manage and handle the properties of MSW feedstock through INL-developed fractional milling, high moisture pelleting, and low temperature drying preprocessing technologies .

09 BIOMASS FUELS↗
DOE OSTI2023

Improving knife milling performance for biomass preprocessing by using advanced blade materials

Mechanical preprocessing of biomass, including size reduction, is a crucial step in converting biomass into biofuel. However, feedstock inevitably contains abrasive intrinsic and extrinsic inorganics that may cause excessive tool wear in preprocessing. Here, this work demonstrates that performance of a knife mill can be significantly improved by applying a more wear-resistant blade material. A series of full-scale knife mill tests were performed for size reduction of forest residue using blades of tungsten carbide (WC–Co), iron-borided tool steel, and diamond-like carbon (DLC) coated tool steel. Blade material loss was quantified in correlation to the amount of feedstock processed and wear mechanisms were investigated via worn surface characterization. While the thin DLC coating was removed quickly, the WC-Co and iron-borided blades improved the tool life by 8X and 3X compared with the M2 tool steel blades (baseline), respectively. The in-situ throughput and power consumption measurements provided additional insights. The WC-Co and iron-borided blades had ~3X higher throughput than the baseline blades by the end of the test with lower normalized power consumption. The experimental results were then used as input for a techno-economic analysis, which suggested that the more wear resistant blades could cut the knife milling cost by $2–3 per ton of biomass processed with downtime reduced by 65–85%.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Life-Cycle Greenhouse Gas Emission Impacts of Forest Residue Pre-processing with Wet Milling

The goal of this analysis was to evaluate the environmental impact of a Case Study that uses wet milling to preprocess logging residues before feeding to a catalytic fast pyrolysis conversion step. The results of the Case Study were compared to those of the status quo Base Case system where dry milling is used. The results reveal that wet milling achieved 65% lower GHG emissions per dry ton of conversion-ready feedstock than the conventional dry milling technology. This is mainly because wet milling greatly reduced the energy consumption for drying. In addition, wet milling also generates fewer fines, thus improving the throughput of conversion-ready feedstock

biomass preprocessing↗