Results for “corn” — Page 49

DOE OSTI2023

Biomass Gasification for Chemicals Production Using Chemical Looping Techniques (Final Report)

The Ohio State University (OSU) is investigating the Biomass to Syngas (BTS) chemical looping technology to produce syngas for chemical production applications from biomass under US Department of Energy (DOE) Award #DE-EE0007530. The BTS process aligns with the programmatic area of interest of “Conversion, via biological, thermal, catalytic or chemical means, of acceptable feedstocks into advanced biofuels and/or biobased products including intermediate and end-use products”. Compared to conventional biomass gasification processes, the BTS process eliminates the need for air separation units and tar reforming reactors, which leads to energy efficiency improvement and capital cost reduction. The overall objective is to ascertain the potential of biomass gasification based on the chemical looping technique through mitigation of the possible techno-economic challenges in the steps of scale up for commercialization. The scope of work consists of 1) designing, constructing and operating a 10 kWth commercially scalable sub-pilot BTS system and; 2) completing a comprehensive techno-economic analysis (TEA) of the BTS process using methanol production as an example. Over the course of the project, the project team completed the design, fabrication, and operation of a 10 kWth sub-pilot scale test unit for the BTS process. Corn cob and wood pellets were successfully tested in the unit for high purity syngas generation in extended test campaigns that totals over 200 hours. Syngas purity (H2 and CO) of >70% was achieved with a CH 4 concentration of <6%. The H 2 /CO ratio was greater than 1.8. A comprehensive techno-economic analysis was performed to compare the BTS process and a reference indirectly heated gasification process for methanol synthesis. The result, updated with experimental results for BTS process performance, shows a methanol required selling price (MSP) of $\$ $1.15/gal, compared to $1.28/gal for the reference case.

08 HYDROGEN↗

DOE OSTI2022

Evaluation of Hopper Flow Prediction based on Cubical Triaxial Tester Data and FEM

A cubical triaxial tester (CTT) laboratory device was used to collect key bulk flow characteristics of Crumbles® 6mm rotary sheared woody biomass and Crumbles® 2mm rotary sheard corn stover. The flow properties and a CAD model of a hopper and conveyor system to predict the consistency of flow of material from the hopper. Prediction included the likeliness of jamming, bridging, or ratholing. Each material was then loaded into the hopper and the actual bulk flow was measured. Measured flow closely matched the predicted flow.

09 BIOMASS FUELS↗

DOE OSTI2023

Modeling of High Solids Biomass Liquefaction, Techno-economic Assessment and Life Cycle Assessment for Industrial Scale UP

Biomass liquefaction improves corn-stover slurry transport within a biorefinery, and reduces challenges associated with solids handling. Slurries, formed with yield stresses (i.e., viscosities) that are low enough to facilitate pumping from one unit operation to the next, and that enable mixing at reasonable power inputs in large fermentation vessels, enable scaling of cellulose fermentations. Three liquefaction methods: enzyme, enzyme mimetic, and a hybrid approach were analyzed by a combination of techno-economic and life-cycle analyses, resulting in an assessment of cost-effectiveness and environmental impact. Of the three scenarios, enzyme-based processes emerged as the most efficient, both in cost and emissions reduction (gCO2-equivalent/kg slurry).

Ramirez, Jorge↗

DOE OSTI2024

Sustainable Aviation Fuels from 30,000 feet – Scoping Report

A literature review, first principles analysis, and mapping of the airline-fuel infrastructure were performed to reassess the potential for various means of realizing a sustainable aviation sector. The literature review found a plethora of technical methods to make the airline industry net-zero CO 2 but limited work on the emergent barriers to sustainable aviation implementation such as land use, repurposing of fuel refining assets, and airline cost structures. First principles analyses of the energy, land, and costs of three broad net-zero strategies were performed to determine if sustainable aviation is feasible even in the most optimistic scenarios. Those methods were biomass-derived sustainable aviation fuel (SAF), fuel produced from CO 2 captured from the air and H 2 produced from water electrolysis (air-to-fuel: ATF), and offsetting fossil-derived Jet Fuel with carbon dioxide removal from the atmosphere (direct air capture and storage: DACS). Offsetting CO 2 emissions from using fossil Jet Fuel with DACS was found to consume the least energy, require the smallest quantity of land, and be the cheapest option. Replacing Jet Fuel with SAF was found to be only slightly more expensive than DACS but require substantially more land. ATF was found to be the most expensive and energy intensive option, though it did spare land relative to SAF. We found that calls to utilize waste biomass are well-founded, but wastes alone cannot cover the needs of the global airline industry. This means additional land will need to be allocated for biomass cultivation if SAF becomes the primary pathway to sustainable aviation. While differences were found in the performance of different types of biomass, those differences were small relative to differences with ATF and DACS. An analysis of the pricing structure of the airline industry suggests that some of the cost advantage of DACS may be erased by consumer sentiment which could explain why, to-date, the airline industry is focused primarily on SAF and to a lesser extent ATF. Further work is required to estimate the transportation, capital cost, and financing cost implications of greenfield and brownfield sites for SAF, DACS, and ATF. In the final report, we will analyze the potential to retrofit corn ethanol facilities to operate the ethanol-to-jet fuel process in response to decreasing gasoline demand as the electrification of road transport progresses. We will also construct a prioritization of land use to determine whether each net-zero CO 2 aviation pathway can make claim to the land required by their technology.

09 BIOMASS FUELS↗

DOE OSTI2024

The Role of Biofuels and Biomass Feedstocks for Decarbonizing the U.S. Economy by 2050 - (DECARB) Decarbonizing Energy Through Collaborative Analysis of Routes and Benefits

Utilizing biomass resources, such as cellulosic biomass and waste, can greatly contribute to decarbonization efforts in the U.S. economy. The U.S. bioenergy sector includes corn ethanol production, biodiesel, renewable diesel production, and the utilization of biomass wastes for electricity generation being the primary applications. Within the electricity sector, biopower can play a crucial role as a stable low-carbon resource. Enhancing the electricity mix's diversity could enhance grid reliability. If the issues regarding hot gas cleanup can be resolved, flexible biopower resources like biomass gasification facilities could complement the integration of variable renewable energy sources due to their quick ramp-up and ramp-down times. The criticality of bioenergy deployment lies in its ability to decarbonize hard-to-electrify sectors, such as aviation, where alternative decarbonization options may not be viable in the short term. Moreover, bioenergy has the potential to be converted into process heating, building materials, and plastics, which are not considered in this study. A set of pathways was carefully chosen to represent viable options for converting ample herbaceous and woody cellulosic feedstocks into fuels, chemicals, and electricity in this study. In conclusion, biomass pathways provide flexibility by generating various types of bioenergy and bioproducts, including electricity, hydrogen, liquid fuels, biochemicals, and bioplastics. When paired with carbon dioxide capture and storage (CCS), specific bioenergy approaches can effectively extract carbon dioxide from the atmosphere, thus providing an effective decarbonization option for the transportation sector.

09 BIOMASS FUELS↗

DOE OSTI2020

Transfer Factors for the FRMAC Assessment Manual and Turbo FRMAC to Improve Radiological Dose Assessment

The Turbo FRMAC analysis tool is used to perform complex calculations to quickly evaluate radiological consequences and aid in decision making during an emergency response by assessing impacts to the public, workers, and the food supply. Turbo FRMAC calculations are based on methods established by the Federal Radiological Monitoring and Assessment Center (FRMAC). To be able to assess impacts, input data called transfer factors that describe radionuclide uptake by local plants and animals are required. During the code application exercises in late 2016, identifying, finding, and validating nonstandard transfer factors proved to be time consuming and diverted the teams’ activity away from other critical tasks. As a result, a task was undertaken to dramatically expand the list of available transfer factors (food and non-food) and incorporate these factors into Turbo FRMAC. This will ultimately result in improved efficiency of the assessment team to perform calculations during times when the FRMAC is activated and provide more defensible, vetted data from which to calculate results. As a result of these and subsequent exercises, transfer factors were needed for the following items: bell peppers, Christmas tree, deer, flowers, fresh cucumbers, tomatoes, grapefruit, lichens, mushrooms, oranges, snap beans, squash, strawberries, sugarcane for sugar and seed, sweet corn, tea, tobacco, tree bark, and watermelon. To expand the applicability of the information tables, generic transfer data were also provided for common categories and recommendations were made for expanding the list of chemicals based on chemical similarity. The data presented in this report were compiled from recent literature with most of the data encompassing the period from 2000 to 2018. The following radionuclides were targeted during the literature search: elements associated with reactor accidents or nuclear detonations (Sr 89/90, Cs 134/137, Ce 141/144, Ru 103/106, I 129/131/133, Pu 238/239, Am 241, Zr 95, and Nb 95) and elements associated with industrial accidents or dirty bombs (Ir 192 and Co 60). Data from other elements were evaluated if they were identified during the literature search. In addition, reports were evaluated that were recommended by the research consultants. For each plant or animal transfer factor, the goal was to determine the geometric mean, the geometric standard deviation, the minimum, the maximum, and the number of measurements used. If only one measurement was available that was presented as the mean. Concentration ratios with large geometric standard deviations (GSDs) were generally the result of a paucity of measurements or a few disparate measurements. Measurement disparity was observed for data from different soil types. The geometric mean (GM) is a good reference value for planning and responses purposes, but the location-specific concentrations are unlikely to be similar to the model results. Recommendations for further work include: segregating the data to reflect the influence of soil type, developing approaches to incorporate animal data based on aggregated transfer measurements, and including data for foliar deposition on plants.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2024

Front End Engineering Design Study on Gasification of Coal and Biomass to Generate Carbon- Free Electric Power and Hydrogen

A 2nd Phase Front End Engineering Design study of a gasification plant concept to co-produce electric power and hydrogen with net-negative CO2 emissions is being completed under the U.S. Department of Energy’s (DOE’s) 21st Century Power Plants initiative, whose goal is to advance innovative power plant concepts that are capable of flexible, net-zero carbon emission operations while producing cost-effective hydrogen to support economy-wide decarbonization goals. The proposed standalone plant would be constructed in Nebraska, USA. The specified design feedstock is a hybrid blend of Powder River Basin (PRB) subbituminous coal from Wyoming and local Nebraska biomass (corn stover), 50% each by weight (dry basis). Other potential feedstocks, including woody biomass (eastern red cedar) and waste plastic (auto shredder residue) were evaluated as alternates. The process block comprises a high-pressure, oxygen-blown fluidized bed gasifier coupled with water-gas shift, Selexol process for acid gas (H2S and CO2) removal, and pressure-swing adsorption (PSA) to yield 8,500 kg/h of high-purity hydrogen. Off-gas from the PSA unit is used in a gas turbine combined cycle plant (the power block) to supply 50 MWe net electric power to the grid. Overall thermal efficiency of the plant is 50% (HHV) with net atmospheric CO2 removal at a rate of 32 t/h. Design activities necessary to provide input to the current front-end engineering design (FEED) study, including, site selection, gasifier technology selection, investment case preparation, and the development of the Environmental Information Volume (EIV) for the host site, have been completed. These, as well as the current FEED activities, are described in this presentation.

gasification, biomass, coal, hydrogen, power gener↗

DOE OSTI2023

Extrapolation Domains for Aggregating Environmental Outcomes from Local to Regional Levels

Billions of dollars are invested every year to run field experiments to quantify the response of crops to new technologies and associated environmental outcomes. Given the diversity of environments where crop production occurs, conducting these research studies without a robust framework for research site selection and upscaling results to larger spatial scales is inefficient. In this project, researchers from the University of Nebraska-Lincoln used their unique Technology Extrapolation Domains framework (TED) as a tool to guide the selection of experimental sites and as basis for aggregating and validating environmental outcomes from local to regional levels. In the present project, we first used the TED framework to evaluate the current distribution and area coverage of the current SMARTFARM sites. The purpose was to showcase how it is possible to use the TED framework to guide site selection and extrapolate results over space. Additionally, the original TED framework was expanded to account for other factors influencing environmental outcomes by inclusion of three additional variables: soil organic matter, soil texture, and topographic wetness index. The resulting expanded framework (TED-E) was validated using nitrogen (N) losses from corn in the United States as a case study. To do so, we used N balance as a proxy to N losses and we evaluated the capacity of the framework to explain variation in N balance across fields and across countries. We found that the TED-E has substantially higher predictive power than the original TED framework to explain spatial variation in N balance. However, improvements in predictive power with the TED-E tool come at the expense of a higher number of TEDs needed to achieve a given crop area coverage compared with the original TED framework. We conclude that the new TED-E framework can help aggregate and extrapolate environmental outcomes from research sites to regional levels and improve the visualization of their spatial patterns across the United States. An online version of the framework is available at: https://www.toolted.org/

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Performance Testing of a Moving Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Gasification of Mixed Blends of Coal, Biomass, and Plastic Waste

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Direct Air Capture and Electromicrobial Production (DAC-EMP) (Final Technical Report for ARPA-E Project)

The collaborative effort of UC Berkeley and GE Vernova (formerly GE Research) aimed to develop an integrated, three-step process to directly capture and convert carbon dioxide (CO 2 ) from ambient air into butanol, a platform molecule for diesel and jet fuels. This new process is intended to address the unmet need for carbon-neutral drop-in substitutes for fossil gasoline, which would substantially reduce the carbon footprint of the transportation sector without requiring significant changes to the nation’s transportation infrastructure. The U.S. alone consumes ~120 billion gallons of gasoline per year, and the use of fossil fuels in transportation accounts for ~30% of U.S. greenhouse gas emissions, a major contribution to the ongoing climate crisis. A successful replacement fuel must therefore be produced in a process that has low carbon emissions over its life cycle while demonstrating both scalability and economic competitiveness. The proposed system is tailorable to a wide range of applications and can establish a viable approach for direct capture and conversion of CO 2 to value-added products with much lower land use compared to a biotechnological process relying on corn-derived glucose.

09 BIOMASS FUELS↗

DOE OSTI2025

BT23 Updates for Med $70

BT23 update using the 2025 baseline and starting results in 2024 for Med $70 with updated budgets. Cost updates include: 1) Increased the nitrogen application for the following crops: willow, camelina, carinata, pennycress, and willow. 2) Removed roundup during establishment for the following crops: camelina. 3) Harvest costs were updated because the combine width was adjusted. This affected the following crops: barley, camelina, carinata, corn, oat, pennycress, rice, sorghum, soybean, and wheat. 4) Harvest cost was updated with biomass sorghum because an additional tractor was added to pull the high dump forage wagon, and the wagon width was adjusted to not constrain the harvest operation with the combine. 5) Added poplar in the ag budget database for regions 1 and 13.

agricultural crop↗

DOE OSTI2026

Agricultural crop production by county - mature-market medium scenario

This dataset contains data on agricultural crop production by county from 2022 to 2041. The agricultural crop in this dataset includes barley, biomass sorghum, corn, cotton, energy cane, eucalyptus, grain sorghum, hay, miscanthus, oats, pine, poplar, rice, soybean, switchgrass, wheat, and willow. The dataset was obtained from the database of the BT23 (Davis et al., 2024) for the mature-market medium scenario with biomass market prices from $30 to $130 per dry ton.

agricultural crop↗

DOE OSTI2026

Agricultural residue production by county - mature-market medium scenario

This dataset contains data on agricultural residue production by county from 2022 to 2041. The agricultural residue includes barley straw, corn stover, oats straw, sorghum stubble, and wheat straw. The dataset was obtained from the database of the BT23 (Davis et al., 2024) for the mature-market medium scenario with biomass market prices from $50 to $130 per dry ton. For access to this dataset, please use the contact form and indicate the dataset by name.

agricultural residues↗

DOE OSTI2020

Enhancing Photosynthetic Production of Glycogen-Rich Biomass for Use as a Fermentation Feedstock

Current sources of fermentation feedstocks, i.e., corn, sugar cane, or plant biomass, fall short of demand for liquid transportation fuels and commodity chemicals in the United States. Aquatic phototrophs including cyanobacteria have the potential to supplement the supply of current fermentable feedstocks. In our strategy, cells are engineered to accumulate storage molecules including glycogen, cellulose, and/or lipid oils that can be extracted from harvested biomass and fed to heterotrophic organisms engineered to produce desired chemical products. Here in this manuscript, we examine the production of glycogen in the model cyanobacteria, Synechococcus sp. strain PCC 7002, and subsequent conversion of cyanobacterial biomass by an engineered Escherichia coli to octanoic acid as a model product. In effort to maximize glycogen production, we explored the deletion of catabolic enzymes and overexpression of GlgC, an enzyme that catalyzes the first committed step toward glycogen synthesis. We found that deletion of glgP increased final glycogen titers when cells were grown in diurnal light. Overexpression of GlgC led to a temporal increase in glycogen content but not in an overall increase in final titer or content. The best strains were grown, harvested, and used to formulate media for growth of E. coli. The cyanobacterial media was able to support the growth of an engineered E. coli and produce octanoic acid at the same titer as common laboratory media.

09 BIOMASS FUELS↗

DOE OSTI2022

Investigation of Cutter–Woodchip Contact Pressure in a New Biomass Comminution System

A Crumbler ® rotary shear system was recently developed to process fuel-grade woodchips into feedstocks having more uniform particle sizes for improved flowability and higher thermochemical output yield than a traditional hammer mill. It represents a significant innovation in the state of the art of biomass comminution equipment. However, the milling unit has experienced significant abrasive wear of the feeding teeth and cutters when processing hard and dusty feedstocks, such as logging residue and corn stover. Here, we present initial simulation results from a finite-element stress analysis of the rotary shear, which is used to investigate the dynamics of interaction between the cutters and woodchips. This is the first step for optimizing the cutter design to improve the system lifetime and processing efficiency, thus reducing downtime and improving overall productivity.

42 ENGINEERING↗

DOE OSTI2022

From Farm to Flight: CoverCress as a Low Carbon Intensity Cash Cover Crop for Sustainable Aviation Fuel Production. A Review of Progress Towards Commercialization

Thlaspi arvense L. (Field Pennycress; pennycress) is being converted into a winter-annual oilseed crop that confers cover crop benefits when grown throughout the 12 million-hectares U.S. Midwest. To ensure a fit with downstream market demand, conversion involves not only improvements in yield and maturity through traditional breeding, but also improvements in the composition of the oil and protein through gene editing tools. The conversion process is similar to the path taken to convert rapeseed into Canola. In the case of field pennycress, the converted product that is suitable as a rotational crop is called CoverCress™ as marketed by CoverCress Inc. or golden pennycress if marketed by others. Off-season integration of a CoverCress crop into existing corn and soybean hectares would extend the growing season on established croplands and avoid displacement of food crops or ecosystems while yielding up to 1 billion liters of seed oil annually by 2030, with the potential to grow to 8 billion liters from production in the U.S. Midwest alone. The aviation sector is committed to carbon-neutral growth and reducing emissions of its global market, which in 2019 approached 122 billion liters of consumption in the U.S. and 454 billion liters globally. The oil derived from a CoverCress crop is ideally suited as a new bioenergy feedstock for the production of drop-in Sustainable Aviation Fuel (SAF), renewable diesel, biodiesel and other value-added coproducts. Through a combination of breeding and genomics-enabled mutagenesis approaches, considerable progress has been made in genetically improving yield and other agronomic traits. With USDA-NIFA funding and continued public and private investments, improvements to CoverCress germplasm and agronomic practices suggest that field-scale production can surpass 1,680 kg ha -1 (1,500 lb ac -1 ) in the near term. At current commodity prices, economic modeling predicts this level of production can be profitable across the entire supply chain. Two-thirds of the grain value is in oil converted to fuels and chemicals, and the other one-third is in the meal used as an animal feed, industrial applications, and potential plant-based protein products. In addition to strengthening rural communities by providing income to producers and agribusinesses, cultivating a CoverCress crop potentially offers a myriad of ecosystem services. The most notable service is water quality protection through reduced nutrient leaching and reduced soil erosion. Biodiversity enhancement by supporting pollinators’ health is also a benefit. While the efforts described herein are focused on the U.S., cultivation of a CoverCress crop will likely have a broader application to regions around the world with similar agronomic and environmental conditions.

09 BIOMASS FUELS↗