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DOE OSTI2025

Process Feasibility Analysis of Waste Biomass Valorization to Biochar and Bio-Oil via Slow and Fast Pyrolysis

The United States has abundant biomass and waste feedstock to support the nation's energy addition and affordability targets. Pyrolysis, a thermochemical conversion process, decomposes lignocellulosic feedstocks into liquid, solid, and gaseous fuels that can contribute to the domestic production of biofuels, biopower, and bioproducts. Growing private sector interest in this technology is a key motivation for this comprehensive techno-economic process modeling analysis of a respective biorefinery that includes feedstock preprocessing, slow and fast pyrolysis, and product separation to bio-oil, biochar, and syngas hydrocarbons. Results show that biochar from slow pyrolysis could achieve minimum selling prices (MSPs) of $\$$188-$\$$260/t, competitive with reported market values, while bio-oil from fast pyrolysis is estimated to yield MSPs of $\$$6.49-$\$$9.68/GGE, approximately twice conventional fuel benchmarks. Sensitivity analysis identifies feedstock cost, product yield, and scale as primary cost drivers, while scenarios involving biochar carbon credits and high value applications may substantially improve economics. Overall, these results suggest that continued innovation in feedstock logistics, process integration, and market development will be critical to achieving economically viable and scalable bioproducts.

09 BIOMASS FUELS↗

DOE OSTI2024

Hierarchically Structured Catalysts Toward Sustainable Hydrogen Economy: Electro‐ and Thermo‐Chemical Pathways

Abstract Hydrogen, as an important clean energy source, plays a more and more crucial role in decarbonizing the planet and meeting the global climate challenge due to its high energy density and zero‐emission. The demand for sustainable hydrogen is increasing drastically worldwide as driven by the global shift towards low‐carbon energy solutions. Thermochemical catalysis process dominates hydrogen production at scale given its relatively mature technology and commercialization status, as well as the established manufacturing infrastructure. While due to its environmentally friendly nature and growing abundant sources of renewable electricity, the electrochemical path for hydrogen production is rising as a major alternative to the thermochemical means. Nevertheless, hierarchically structured catalysts and devices have gradually taken the center stage toward replacing the traditional counterparts, especially with the rapid advancement of the design and manufacture of such ordered nanostructure assemblies toward high activity, efficient mass transport, and superb stability. In this review, the latest progress of the hierarchically structured catalysts for hydrogen production have been surveyed on electro‐ and thermo‐ chemical pathways comparatively. It covers the structure designs of atomic dispersion, nanoscale surfaces and interfaces for achieving highly active and durable catalysts, components, and devices. Both electrochemical and thermochemical approaches are reviewed in terms of the vast design details, engineered benefits, and understandings of various Pt‐group metal (PGM) and non‐PGM based transition metal catalysts for hydrogen production. As the growing trend, brief discussions are also presented toward the high‐level assembly and manufacture of complexly structured components and devices at scale in the electrochemical and thermochemical energy systems.

Deng, Chenxin↗

NASA NTRS1996

Computer-Aided Process Model For Carbon/Phenolic Materials

Computer program implements thermochemical model of processing of carbon-fiber/phenolic-matrix composite materials into molded parts of various sizes and shapes. Directed toward improving fabrication of rocket-engine-nozzle parts, also used to optimize fabrication of other structural components, and material-property parameters changed to apply to other materials. Reduces costs by reducing amount of laboratory trial and error needed to optimize curing processes and to predict properties of cured parts.

Letson, Mischell A.↗

NASA NTRS1989

Computational aerothermodynamics

Computational aerothermodynamics concerns the coupling of real gas effects with equations of motion to include thermochemical rate processes for chemical and energy exchange phenomena. These processes concern the creation and destruction of gas species by chemical reactions and the transfer of energy between the various species and between the various energy modes (e.g., translation, rotation, vibration, ionization, dissociation/recombination, etc.) of the species. To gain some insight into when such phenomena occur for current and future aerospace flight vehicles the author shows the flight regimes of some typical vehicles (e.g., Concord, aerospace plane, Space Shuttle, associated space transfer vehicles, Apollo entry vehicle, etc.) in terms of flight altitude and flight speed. Also indicated are regimes where chemical reactions such as dissociation and ionization are important and where nonequilibrium thermochemical phenomena are important.

Deiwert, George S.↗

DOE OSTI2024

Hydrogen and its Vital Role in a Clean Energy Future

Large-scale, low -cost hydrogen production can enable an economically competitive, secure, and environmentally beneficial future energy system across multiple sectors. Furthermore, clean hydrogen can address specific sectors that are hard to decarbonize (e.g., heavy-duty trucking, load-following electricity, iron, steel, and cement) and can help the U.S. meet the net zero carbon goal by 2050. To achieve this goal, tens of millions of metric tons of clean, reliable, and affordable hydrogen will be needed annually1. In 2021, the Hydrogen Energy Earthshot was launched, and its goal is to reduce the cost of clean hydrogen to $1 per $1 kilogram in 1 decade (1 1 1) 2. One very promising pathway for large-scale hydrogen production is water splitting. Water splitting technologies range from commercial technologies such as electrolyzers to approaches that are at a much earlier stage of development, such as photoelectrochemical (PEC) and thermochemical (TCH) processes. All these water splitting pathways offer diverse benefits in energy storage, grid services, and cross-sector emissions reductions while taking advantage of the diverse domestic resources. However, critical materials-, component- and system-level challenges must be addressed to improve efficiency and durability and reduce cost. To address these barriers and move these promising and high impact technologies forward, the HydroGEN Advanced Water Splitting Materials (AWSM) and the H2 from the Next-generation of Electrolyzers of Water (H2NEW) consortia were formed and supported by the Department of Energy (DOE) EERE Hydrogen and Fuel Cell Technologies Office (HFTO). HydroGEN (https://www.energy.gov/eere/h2awsm/) consortium, established in 2016, is an Energy Materials Network (EMN) that aims to accelerate the materials R&D of low technology readiness level (TRL) advanced water splitting (AWS) technologies. The consortium comprises five core national laboratories and focuses on four early-stage AWS pathways: alkaline exchange membrane (AEM) electrolysis, proton conducting solid oxide electrolysis (p-SOEC), photoelectrochemical, and thermochemical water splitting. Liquid alkaline and PEM electrolyzers are already commercial and significant advancements in oxygen conducting solid oxide electrolysis cells (o-SOECs) have been realized. Yet, these systems are still too expensive and not sufficiently durable for wide-scale commercialization. To enable high-volume manufacturing of affordable, durable, efficient electrolyzers, H2NEW (https://h2new.energy.gov/), another multi-lab consortium, was established in 2020. This comprehensive, concerted effort is focused on overcoming barriers related to components and materials integration and scale-up to achieve performance, durability, with an initial focus to achieve $2/kg H2 by 2026.

AEM↗

DOE OSTI2025

Quantifying Impacts of Biomass Pelletization on Fast Pyrolysis Using a Single-Particle Reactor, X-ray Computed Tomography, and Computational Modeling

The pore structure and density of lignocellulosic feedstocks dictate intraparticle transport phenomena and thereby play an important role in thermochemical conversion processes such as fast pyrolysis for biofuel and biochemical production. Variations in microstructure are inherent from different biomass species and can be introduced by preprocessing techniques such as cutting and pelletization. Morphological changes also occur during conversion and lead to vastly different pore structures and behavior during pyrolysis, which impact required conversion times and product distributions. The current work presents a comprehensive comparison of fast pyrolysis of neat and pelletized pine feedstocks, which includes single-particle experiments, modeling, and 3D imaging by X-ray computed tomography (XCT). The particle-scale model included anisotropic heat and mass transport in a shrinking particle with pyrolysis reactions based on the CRECK mechanism with boundary conditions informed by reactor-scale simulations of the single-particle reactor. The models were validated by measurements of the temperature and mass loss from single-particle pyrolysis experiments of neat and pelletized pine. Quantitative analysis of XCT geometries revealed that pyrolytic conversion yielded chars with increased porosity and permeability compared to the unpyrolyzed materials, along with decreased tortuosity and anisotropy. Pelletization of the pine feedstock resulted in a much denser, less permeable material, which converted slower and produced more residual char after pyrolysis compared to neat pine. The results from particle modeling revealed that accounting for the dynamic and anisotropic heat and mass transport caused by differences in pore structure is critical to achieving agreement with experimental results. Overall, this study highlights the dramatic differences in conversion behavior imparted by pelletization and the importance of capturing microstructural attributes in computational models to guide the design and optimization of pyrolysis processes for specific biomass feedstocks.

09 BIOMASS FUELS↗

DOE OSTI2024

From Plastic Waste to Fuel: Pyrolysis and Gasification of Polyethylene for Hydrogen Production

Thermochemical conversion processes offer promising solutions to address the plastic pollution crisis by transforming plastic waste into valuable products, notably hydrogen. In this study, thermal pyrolysis and steam gasification of polyethylene (PE), the most abundantly produced plastic waste, are investigated in a drop tube reactor system. Various process parameters, namely temperature, residence time, and feedstock composition, are evaluated to establish their correlations with reaction performance. Coal refuse, obtained from discarded thickener underflow in coal processing, is introduced as a co-feedstock for gasification to enhance PE handling and examine synergistic effects on product distribution, particularly H2 yield and syngas quality. Furthermore, the potential of low-cost, environmentally friendly catalysts (i.e., iron oxides, coal ash) for tar reforming is explored.

Natesakhawat, Sittichai↗

NASA NTRS1986

Commentary on the 1985 NASA/Vanderbilt Symposium on Future Hypervelocity Flight Requirements

The discussion, started in Semiannual Status Report Number 1, on aerothermal problems of hypervelocity flight and experiments that may lead to significant improvements in analytical/computational predictive methods, continues. The commentary is based on presentations made by speakers at a symposium on this subject held in December 1985. Symposium participants focused on the serious deficiencies that exist in knowledge of real-gas, nonequilibrium thermochemical-kinetic processes, catalytic processes, surface and shock slip, gas/surface interaction, boundary layer transition, and vortical leeside flows under hypervelocity conditions. Programs of laboratory research and computations leading toward in-flight experiments were recommended. Feasibility of appropriate measurement techniques for the flight environment was assessed and problems for study in that area identified. A synopsis of the oral presentations is given.

Potter, J. L.↗

NASA NTRS1990

Computation of thermochemical nonequilibrium flows around a simple and a double ellipse

The nonequilibrium viscous reactive flows over a simple and a double ellipse at a 30 degree angle of attack were computed. The geometry and the free stream conditions are given by INRIA/GAMNI/SMAI workshop test cases 6.2-2 and 6.2-4. The governing Navier-Stokes equations coupled with thermochemical nonequilibrium processes are solved numerically using a fully coupled, implicit, finite volume technique with a dynamically adaptive grid. The nonequilibrium gas model and the numerical method used in the calculations are briefly described.

Gokcen, Tahir↗

NASA NTRS1991

Computation of thermochemical nonequilibrium flows around a simple and a double ellipse

Gokcen, Tahir↗

NASA NTRS1998

Computational Analysis of Shock Layer Emission Measurements in an Arc-Jet Facility

This paper reports computational analysis of radiation emission experiments in a high enthalpy arc-jet wind tunnel at NASA Ames Research Center. Recently, as part of ongoing arc-jet characterization work, spectroscopic radiation emission experiments have been conducted at the 20 MW NASA Ames arc-jet facility. The emission measurements were obtained from the arc-jet freestream and from a shock layer formed in front of flatfaced models. Analysis of these data is expected to provide valuable information about the thermodynamic state of the gas in the arc-jet freestream and in the shock layer as well as thermochemical equilibration processes behind the shock in arc-jet flows. Knowledge of the thermodynamic state of the gas in arc-jet test flows and especially within the shock layer is essential to interpret the heat transfer measurements such as in surface catalysis experiments. The present work is a continuation of previous work and focuses on analysis of the emission data obtained at relatively low-pressure conditions for which the arc-jet shock layer is expected to be in thermal and chemical nonequilibrium. Building blocks of the present computational analysis are: (1) simulation of nonequilibrium expanding flow in the converging-diverging conical nozzle and supersonic jet; (2) simulation of nonequilibrium shock layer formed in front of the flat-faced cylinder model; and (3) prediction of line-of-sight radiation from the computed flowfield. For computations of the nonequilibrium flow in the conical nozzle and shock layer, multi-temperature nonequilibrium codes with the axisymmetric formulation are used. For computations of line-of-sight radiation. a nonequilibrium radiation code (NEQAIR) is used to predict emission spectra from the computed flowfield. Computed line-of-sight averaged flow properties such as vibrational and rotational temperatures, species number densities within the shock layer will be compared with those deduced from the experimental spectra. Detailed comparisons of computational and experimental spectra will also be presented.

Gokcen, Tahir↗

DOE OSTI2024

Preparation and Characterization of YBa 2 Cu 4 O 8 Superconductor

Solid-state reaction of appropriate amounts of Y 2 O 3 , BaCOs, and CuO for 2 h at 800°C in flowing oxygen with a total pressure of 2.7 x 10 2 Pa (2 mm Hg), followed by cooling and annealing at 750°C for 10 h in oxygen at ambient pressure, has produced orthorhombic YBa 2 Cu 4 O 8 (124) as the main phase with YBa 2 Cu 3 O x (123) as an impurity phase. After the as-calcined powder was annealed in oxygen at 800°C for 24 h under ambient pressure, the phase purity improved considerably. Calcined 124 powder was pressed into pellets and rapidly annealed at temperatures from 870°C to 935°C. At these temperatures, the 124 decomposed into 123. The superconducting transition temperature, T c , of the annealed samples depended upon the annealing temperature and atmosphere. The decomposed samples have been characterized by low field RF SQUID magnetometer and high resolution transmission electron microscopy.

36 MATERIALS SCIENCE↗

NASA NTRS1984

Study of the sulphur-containing molecules in the EUV region. IV - The dissociation processes of SO2 in the 760 A region

The fluoresence throughout the VUV and violet regions has been observed from photoexcitation of SO2, and the absolute fluorescence cross sections of the VUV emissions have been measured at selected atomic emission lines and in the synchrotron radiation continuum from 550 to 760 A. Emissions from the O I 1304 A and several S I lines account for the fluorescence observed in the VUV region, while the fluorescence observed in the UV and violet regions is due to excited SO and, also, possibly to excited SO2(+) and SO(+). Structure in the VUV fluorescence excitation function is attributed to predissociation of Rydberg states. The VUV fluorescence resulting from an O2 elimination process, SO2 + h times nu yielding metastable S + O2, has been observed in the present work although the threshold for this process has not been determined. The threshold corresponding to the total dissociation process, SO2 + h times nu yielding metastable S + 2O, has been measured and found to agree reasonably with the expected value calculated from thermochemical data. The processes for the formation of S(+) are also discussed.

Wu, C. Y. R.↗

DOE OSTI2024

1D modeling of plasma streamers at ammonia-air flame conditions

Abstract Self-consistent 1D modeling of streamers in ammonia-oxygen-nitrogen-water mixtures has been performed in this work. A fluid model that includes species transport, electrostatic potential, and detailed chemistry was developed and verified. This model is then used to simulate the avalanche, streamer formation and propagation phases, driven by a nanosecond voltage pulse, at different thermochemical conditions derived from a 1D laminar premixed ammonia-air flame. The applicability of the Meek’s criterion in predicting the streamer inception location was successfully confirmed. Streamer formation and propagation duration were found to vary significantly with different thermochemical conditions, due to the difference in ionization rates. The thermochemical state also affected the breakdown characteristics which was tested by maintaining the background reduced electric field constant. Detailed kinetic analyses revealed the importance of O ( 1 D ) in the production of key radicals, such as O, OH, and NH 2 . Furthermore, the contributions of the dissociative electronic excitation of NH 3 towards the production of H and NH 2 radicals have also been reported. Spatial and temporal evolution of the electron energy loss fractions for various inelastic collision processes at different thermochemical states uncovered the input plasma energy spent of fuel dissociation and the large variability in the dominant processes during the avalanche and streamer propagation phases. The methodology and analyses reported in this work are key towards developing effective strategies for controlled nanosecond-pulsed non-equilibrium plasma sources used for ammonia ignition and flame stabilization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1975

Survey of hydrogen production and utilization methods. Volume 1: Executive summary

The use of hydrogen as a synthetic fuel is considered. Processes for the production of hydrogen are described along with the present and future industrial uses of hydrogen as a fuel and as a chemical feedstock. Novel and unconventional hydrogen-production techniques are evaluated, with emphasis placed on thermochemical and electrolytic processes. Potential uses for hydrogen as a fuel in industrial and residential applications are identified and reviewed in the context of anticipated U.S. energy supplies and demands. A detailed plan for the period from 1975 to 1980 prepared for research on and development of hydrogen as an energy carrier is included.

Gregory, D. P.↗

NASA NTRS1976

Nuclear driven water decomposition plant for hydrogen production

The conceptual design of a hydrogen production plant using a very-high-temperature nuclear reactor (VHTR) to energize a hybrid electrolytic-thermochemical system for water decomposition has been prepared. A graphite-moderated helium-cooled VHTR is used to produce 1850 F gas for electric power generation and 1600 F process heat for the water-decomposition process which uses sulfur compounds and promises performance superior to normal water electrolysis or other published thermochemical processes. The combined cycle operates at an overall thermal efficiency in excess of 45%, and the overall economics of hydrogen production by this plant have been evaluated predicated on a consistent set of economic ground rules. The conceptual design and evaluation efforts have indicated that development of this type of nuclear-driven water-decomposition plant will permit large-scale economic generation of hydrogen in the 1990s.

Parker, G. H.↗

NASA NTRSDate not supplied

Thermochemical Instabilities at High Temperature Ceramic Surfaces

The surface of silicon-based high temperature ceramics exhibits thermochemical instabilities when exposed to oxygen-rich high enthalpy flows. These instabilities manifest as sudden temperature jumps of several hundred degrees and rapid material failure, when temperatures exceed 2000 K. Understanding and predicting these phenomena is critical to the design of thermal protection systems for sustained high speed flight vehicles. In this talk we review a series of test cases where surface temperature jumps were observed during plasmatron wind tunnel testing of ceramic materials, including ZrB2-SiC ultra-high temperature ceramics, C/SiC ceramic matrix composites, and silicone-based coatings for low-density carbon phenolic ablators. The underlying physical processes occurring when Si-containing ceramics are exposed to high enthalpy air flow include formation of passivating scales at low temperatures, passive to active oxidation transition, melting of oxide scales, changes in surface radiative properties, formation of porosity and changes in effective conductivity, surface catalytic recombination and transitions in catalytic properties, as well as high-temperature phase changes. The role of these processes in promoting thermochemical instabilities for the different material systems is discussed.

Ultra High Temperature Ceramics, UHTC↗

NASA NTRS1983

Photodissociation of NH3 at 106-200 nm

The absorption and fluorescence cross sections for NH3 are measured in the 106-200 nm region using synchrotron radiation as the light source. The threshold wavelengths for the production of the NH (b to X) and NH (c to a) emissions from NH3 dissociation are measured and compared with previous measurements. The heat of formation of NH determined from these thresholds agrees well with the value determined from thermochemical data. The process of dissociation of NH3 into NH2(2AL) and H2(S) has a significant quantum yield whose maximum at 134 nm is about twice the NH(c) production yield. All the vibronic levels of the B and C states produce the NH2(2A1) emission, contrary to previous theoretical interpretations.

Suto, M.↗