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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Feedstock and Catalyst Impact on Bio-Oil Production and FCC Co-Processing to Fuels

NREL’s thermochemical biomass conversion research is focused on ex-situ upgrading of biomass fast-pyrolysis (FP) vapors as an efficient and economical route to completely biogenic pyrolysis-based fuel precursors, potential fuels, and value-added chemicals depending on catalyst choice and process conditions. In this approach, biomass vapors are generated via fast pyrolysis with destabilizing vapor components (char, inorganics, tar aerosols) removed by hot gas filtration to produce conditioned vapors more responsive to catalytic upgrading. A Davison Circulating Riser (DCR), a petroleum industry standard for fluidized catalytic cracking (FCC) catalyst evaluation, was coupled with a custom pyrolyzer system designed to produce consistent composition pyrolysis vapors as feed to the DCR. The coupled system is shown below (Figure 1). Pyrolysis vapors, derived from pure hardwood and softwood, were upgraded using commercially available and laboratory modified zeolite-based catalysts. Upgraded oils were analyzed via 31P and 13C NMR spectroscopy, GCxGC-TOF/MS, carbonyl and ultimate analysis (CHNO), and micro distillation to assess both oil chemistry and distillation behavior as they relate to catalyst and feedstock type for producing fungible hydrocarbon product liquids. Measured process parameters identified from technoeconomic process analysis included achieving oil oxygenate contents of 20% or less, carbon-conversion efficiencies of 30% or more, and catalyst coking rates of 10% or less. A proprietary modified zeolite catalyst from Johnson Matthey produced oils that met these requirements. Using the DCR equipped with a proprietary nozzle system, a second approach focused on reducing the carbon intensity of petroleum-derived hydrocarbon fuels by FCC co-processing these CFP oils with petroleum vacuum gas oil (VGO) to produce biogenic carbon containing fuels. The vapor-phase upgrading results demonstrated for the first time the feasibility of producing refinery-compatible hydrocarbon fuel intermediates entirely from biomass-derived fast-pyrolysis vapors using an industry-accepted DCR system for catalytic upgrading. The co-processing results demonstrated the feasibility of using CFP oils with VGO feeds in FCC refinery operations to produce biogenic carbon containing fuels.

bio-oil↗
DOE OSTI2024

Towards Net-Zero: Nuclear-Assisted Waste Biomass to Liquid Fuel in Eastern Idaho

A nuclear assisted carbon negative hybrid energy process that enables production of synthetic bio-crude oil and biochar from Eastern Idaho waste biomass is proposed. The process integrates nuclear powered electricity with high temperature steam electrolysis and biomass hydropyrolysis. The bio-crude oil is of sufficient composition and blended with traditional crude oil at a refinery. Hydrogen from the electrolyzer is pressurized and inserted into the pyrolyzer. Non condensable gases generated in the hydropyrolysis process are burned with oxygen from the electrolyzer to produce heat for the electrolyzer, biomass dryer, and pyrolyzer. The biochar is returned to the soil via fertilizer application and remains there for thousands of years. Since the total process uses nuclear generated electricity, the carbon in the biochar is ultimately sequestered from the atmosphere, thus making the process carbon negative. Using Eastern Idaho wheat or barley straw, this hybrid energy process has the potential to provide an alternative petroleum source. Two options exist for the system design: 1) send electricity from the nuclear plant and straw to a chemical processing plant to produce the bio-crude and biochar, 2) construct the biomass processing facility near the nuclear plant to allow use of nuclear-generated process heat to drive the chemical. Process model description and results are discussed. The process is sized to produce gasoline and diesel at the rate that the INL uses every day for fleet usage.

09 BIOMASS FUELS↗
DOE OSTI2020

Microalgae Biomass Production for Utilization of CO2 and Mitigation of Greenhouse Gas Emissions

Microalgal cultivation processes for production of foods, feeds, fuels, fertilizers and other bioproducts and wastewater treatment are being considered for reducing CO2 and other greenhouse gas emissions. Major differences between microalgae and higher plant biomass cultivation are include their potential for much higher productivities, their higher content of major (N-P-K) and minor nutrients, and the challenge of harvesting such microscopic plants. Most critical, microalgal mass cultures, unlike higher plants, currently require fertilization with concentrated sources of CO2. As practically all of the C fixed into algal biomass will be re-emitted into the atmosphere in short order, algae processes do not sequester carbon. Their potential for CO2 emissions reductions must thus be based on comparisons with current technologies for the production of competing products, such as biofuels or animal feeds, or in wastewater treatment. Further, due to economic limitations to flue gas transport (3 to 12 % CO2), as well as highly variable diurnal and seasonal CO2 utilization and limited land and water availability near most CO2 sources, only a small fraction of waste CO2 emissions will be directly utilizeable for microalgae biomass production. However, for long-distance transport, flue gas CO2 capture by chemical processes would greatly increase the costs of flue gas utilization. More concentrated, sources of CO2 from refineries, fertilizer, chemical plants, and fermentations are available, but are also very limited relative to the quantities required for commodity production. Microalgae can also be cultivated on organic wastes, which provide both nutrients (N, P, K, etc.) and organic and inorganic carbon for algal growth, reducing greenhouse gas emissions compared to conventional treatment processes. To maximize the potential for algae biomass production and CO2 utilization, direct capture of CO2 from air will be required. This could be accomplished with the algal cultivation process itself in large open-raceway ponds, through chemical and biological enhancements of CO2 transfer into algal cutures. The relative productivities, economics, greenhouse gas balances, and resource potentials of these alternative CO2 sources for large-scale production of microalgae will be reviewed.

09 BIOMASS FUELS↗
DOE OSTI2020

Remediation of Temporary Storage Sites in Support of the Port Hope Area Initiative - 20295

The Port Hope Area Initiative is a community-based solution for the long-term management of historic low level radioactive waste (LLRW) resulting from 60 years of uranium and radium processing operations in the Town of Port Hope which is located in Ontario, Canada. The Eldorado refinery, on the north shore of Lake Ontario, began refining radium-226 from pitchblende ore, later transitioning to the refining of uranium. Through the history of the operation, LLRW was deposited throughout the town of Port Hope as a result of fugitive emissions from the plant and/or through the re-use of process residues as building material and backfill. Historical clean-up activities conducted in the late 1970's involved the remediation of approximately 400 properties and the relocation of 100,000 cubic metres of contaminated soil to a disposal facility in Chalk River operated by Atomic Energy of Canada Limited (AECL). Owing to space limitations at that disposal facility, any LLRW identified through construction monitoring since that time has been stored in the community at three temporary storage sites located throughout the town. These include: the Centre Pier mound that contained approximately of 19,800 m{sup 3} of LLRW-impacted soil that originated from the construction of a new water treatment plant; two mounds located at a licensed storage facility containing LLRW obtained from residential clean-up activities (11,000 m{sup 3}); and a small pad adjacent to the municipal sewage treatment plant containing 2200 m{sup 3} of LLRW-containing sludge. With the construction of a new long-term waste management facility (LTWMF) that has been designed to house all of the LLRW identified within Port Hope, the three sites were early candidates for remediation. The clean-up of the three temporary storage sites was a significant milestone for the Port Hope Area Initiative. After a decade of planning and consultation, this work represents the first sites in the municipality to be remediated with the waste being safety removed and transferred to the newly constructed LTWMF. This paper discusses the challenges associated with the clean-up activities for these three sites and the strategies employed to address those challenges. These included weather-related challenges, owing to the seasons over which the work was conducted as well as those associated with working within a closely-knit community. Canadian Nuclear Laboratories (CNL), working on behalf of the federal government, has worked diligently to develop a positive and trusting relationship with the community. Consequently, the successful execution of this project needed to be sensitive to, and respectful of the needs of the community. In addition to the usual Health, Safety and Environment training, project staff received community awareness training that spoke to the history of this community-based initiative and the expected behavior when working within the community. Transportation routes were defined based on safety and the need to minimize disruption to local traffic while haul-times where scheduled around school bus hours to enhance public safety. The successful completion of this first of many remediation projects to be completed under the Port Hope Area Initiative reflected years of careful planning. Nevertheless, there were a number of 'lessons learned' that have been applied on other ongoing projects be completed under the Port Hope Area Initiative. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Recent Advances in the Use of Ionic Liquids and Deep Eutectic Solvents for Lignocellulosic Biorefineries and Biobased Chemical and Material Production

Biorefineries, which process biomass feedstocks into valuable (bio)products, aim to replace fossil fuel-based refineries to produce energy and chemicals, reducing environmental and health hazards, including climate change, and supporting a sustainable economy. In particular, lignocellulose-based biorefineries, utilizing the most abundant renewable feedstock on Earth, have significant potential to supply sustainable energy, chemicals and materials. Ionic liquids (ILs, organic salts with low melting temperatures) and deep eutectic solvents (DESs, mixtures with eutectic points lower than the ideal mixture) are capable of dissolving some of the key lignocellulose polymers, and even the whole biomass. Furthermore, they have intrinsic advantages over molecular solvents, including safer usage profiles and high tunability, which allow tailored physicochemical properties. Such properties provide unique opportunities for the development of new processes that could unlock the full potential of future biorefineries. Here, we review the current state of lignocellulosic biomass processing with ILs and DESs, with a specific focus on the pretreatment chemistry, process flow and products from each component; followed by discussions on sustainability assessments and technological challenges. We aim to inform the research community about the opportunities, challenges and perspectives in developing truly sustainable lignocellulose-based biorefineries.

09 BIOMASS FUELS↗
NASA NTRS1980

Aviation fuels outlook

Options for satisfying the future demand for commercial jet fuels are analyzed. It is concluded that the most effective means to this end are to attract more refiners to the jet fuel market and encourage development of processes to convert oil shale and coal to transportation fuels. Furthermore, changing the U.S. refineries fuel specification would not significantly alter jet fuel availability.

Momenthy, A. M.↗
NASA NTRS1982

Hydrogen uses and demands through the year 2025

The magnitude and markets for applications of hydrogen produced by water-splitting through thermal or electrolytic means are projected up to the year 2025. Uses are divided into energy and nonenergy categories, with U.S. synfuels programs accounting for 65% of the increased demand for hydrogen. Applications for transportation fuel, as a natural gas supplement, in fuel cells, in refinery and synfuels industries, for synthesizing chemicals, and for manufacturing semiconductors are summarized. Electrolytic processes are noted to be more suitable for smaller scale production, where use is on-site or local. An annual growth of 8.4-9.2% is foreseen in the energy sector and 3-3.6% in the nonenergy sector, with a total contribution to the primary energy uses of 12-13% by the year 2025. Hydrogen's negligible environmental impact and the ability to interface hydrogen systems with existing equipment are seen as factors encouraging hydrogen-use growth.

Kelley, J. H.↗
DOE OSTI2026

Cost and Carbon Intensity Implications of Coprocessing Sustainable Aviation Fuel at Petroleum Refineries

Sustainable aviation fuel (SAF) will play a critical role in decarbonizing the aviation industry. Among SAF production pathways, alcohol-to-jet (ATJ) stands out for its scalability, supported by abundant feedstock availability and a well-established bioethanol industry. However, significant reductions in SAF carbon intensity (CI) require the use of future feedstocks (e.g., cellulosic) whose adoption is hindered by high capital costs for feedstock processing and ethanol upgrading. Here, we evaluate the financial viability and environmental implications of integrating an ATJ SAF biorefinery within a petroleum refinery, utilizing miscanthus and switchgrass as example feedstocks. Three scenarios are evaluated: standalone (benchmark), colocated, and repurposing (coprocessing SAF within the petroleum refinery). Results show repurposing reduces baseline capital costs by 36% and SAF minimum selling price (MSP) by 12% to 8.14 USD·gal −1 ; the superior performance of repurposing is consistent across both feedstocks. Integration has a limited effect on SAF CI, which remains stable across scenarios, whereas using cellulosic feedstocks reduces CI by over 70% relative to corn, with baseline values of 17.01 g CO 2 e· MJ −1 for miscanthus and 12.23 g CO 2 e·MJ −1 for switchgrass. Global sensitivity analysis reveals MSP declines with greater coprocessing levels.

09 BIOMASS FUELS↗
DOE OSTI2026

Hydrogenolysis Versus Hydrocracking for Polyolefin Upcycling

Global plastic production has reached 413.8 million metric tons in 2024 and is forecasted to surpass 1.2 billion metric tons by 2050. Polyolefins, mainly polyethylene (PE) and polypropylene (PP), dominate single-use packaging and account for approximately 55% of global plastic waste. The chemical inertness that makes these materials desirable for commercial applications also renders them persistent in the environment. Current recycling technologies have proven to be insufficient to divert plastic waste from landfills or environmental loss due to technical limitations and poor economic incentives. Conventional mechanical recycling is a form of downcycling, in which the polymer remelting process results in products with inferior material properties and reduced market value. Pyrolysis, a thermochemical route used for the chemical recycling of plastic wastes into refinery feedstock, requires severe conditions, typically 400–600 °C in an oxygen-free environment. The high temperature drives up energy costs and produces a wide range of poorly defined products, including undesirable light gases and heavy tars that pose challenges for downstream processing. As an alternative, catalytic chemical recycling offers a promising route for converting waste polyolefins back into value-added hydrocarbons—such as fuels, lubricant base oils, and other chemical feedstocks—at temperatures typically below 300 °C. This opinion article focuses on two dominant pathways in heterogeneous catalysis that are used to cleave the C–C bonds of polyolefins: hydrogenolysis and hydrocracking. Both catalytic pathways have the potential to selectively convert polyolefin waste into valuable fuels and chemical feedstocks under mild conditions. Notably, while hydrocracking primarily yields branched hydrocarbon products, hydrogenolysis predominantly produces linear hydrocarbons. Here, we compare the mechanisms and catalyst designs for hydrocracking and hydrogenolysis, analyze critical technical challenges from catalyst stability to process engineering, and provide an outlook on how these complementary pathways can be used to repurpose plastic waste into valuable products.

Zhang, Ruoxi [Iowa State Univ., Ames, IA (United S↗
NASA NTRS1995

Valve For Extracting Samples From A Process Stream

Valve for extracting samples from process stream includes cylindrical body bolted to pipe that contains stream. Opening in valve body matched and sealed against opening in pipe. Used to sample process streams in variety of facilities, including cement plants, plants that manufacture and reprocess plastics, oil refineries, and pipelines.

Callahan, Dave↗
DOE OSTI2024

Review of Hazards and Accidentology of an Integrated Energy Systems to Nuclear Power Plant Safety

With the interconnectivity of industrial processes in a nuclear integrated energy system (IES) the primary issue becomes the safety of the nuclear power plant (NPP). The industrial processes being supported are assumed to have been in colocation prior to the addition of an NPP. Do the hazards from each process reach beyond the perimeter of the plant to affect the NPP? This paper reviews hazards and accident statistics from processes in an IES as a first step to answer this question. Hazards and accidentology discussed cover hydrogen, ammonia, syngas, methanol, synthetic fuels, and oil refineries. They include mainly fire, explosion, and toxicity in varying degrees. Historical accident statistics are given whenever available, and accident causes are evaluated and ranked based on their frequencies. Lessons learned from previous accidents are presented. Future work will focus on utilizing the data collected for accidentology of the industrial processes to perform Failure Modes and Effects Analysis and analyze the impacts of additional hazards on the colocated existing nuclear power plant or newly built advanced nuclear reactor. The analysis will provide the frequency and consequence of external events that can affect the NPP.

08 - HYDROGEN↗
DOE OSTI2023

Perspectives on biorefineries in microbial production of fuels and chemicals

Microbes drive our complex biosphere by regulating the global ecosystem through cycling elements and energy. Humankind has barely begun leveraging this biotransformation capacity to impact global economies and ecologies. Advances in genetic engineering, molecular analysis, metabolic flux modeling, microbial consortia/biome mapping and engineering, cell-free bioproduction, artificial intelligence/machine learning and the ever expanding -omics frontiers have set the stage for paradigm changes to how humankind produces, uses, transforms, and recycles carbon and energy through microbes. Harnessing this enormous potential could drive a global bioeconomy and manage carbon at a planetary level but requires understanding and application at a grand scale across a broad range of science and engineering disciplines. The penultimate manifestation of these advances is the “bio-refinery”, which is often referenced, but is a long way from being fully developed as a global carbon management platform. Broadening the feed stocks, processing operations, and product portfolio to a sequential cascade optimizing the conversion as a whole instead of limited outputs could greatly advance deployment and stability of a bioeconomy.

09 BIOMASS FUELS↗
DOE OSTI2024

Energy-based break-even transportation distance of biomass feedstocks

The distance a solid biomass feedstock could be used to transport the feedstock when used as biobased fuel is critical information for transportation analysis. However, this information is not available. The break-even transportation distance (BTD) of various fuels from biomass feedstocks and fossil sources was analyzed for truck, rail, and ship transport modes based on bulk density, moisture content, and specific energy. Fourteen different biomass feedstocks, such as crop residues (e.g., corn stover), woody biomass (e.g., wood chips), including thermally pretreated (torrefied) and densified forms (pellets), cattle feedlot compost, and three standard fossil fuels, namely, coal, lignite, and diesel, were considered for BTD analysis and comparison. The BTD values were derived by comparing the energy content of biomass feedstocks with the energy expended in transporting the fuels through selected transportation modes. For ready reference, an alternative derivation of BTD equations and example calculations were also presented. Among the biomass feedstocks, torrefied pellets had the highest BTD (4.16 × 10 4 , 12.47 × 10 4 , and 54.14 × 10 4 km), and cattle feedlot compost had the lowest BTD (1.29 × 10 4 , 3.88 × 10 4 , and 9.23 × 10 4 km), respectively, for truck, rail, and ship. Higher bulk density and higher specific energy of the biomass feedstocks increased the BTD for all modes of transport. Transport is most efficient when mass-limited. Biomass feedstock bulk densities where transportation becomes mass-limited are 223, 1,480, and 656 kg/m 3 for truck, rail, and ship, respectively. Truck transport is typically mass-limited (payload limit restriction; increased BTD), whereas rail transport is entirely volume-limited (cargo space restriction; decreased BTD), and ship transport is mostly volume-limited for biomass feedstocks and mass-limited for densified biomass feedstocks. Ship transport is the most efficient, followed by rail and truck; on average for the materials (17) studied, rail is 3.1 times and ship is 9.2 times the truck's BTD. Based on the bulk density and higher specific energy of the biomass feedstocks, regardless of the refinery location, interstate truck transport of these feedstocks is not a limiting factor in the bio-refining process., with the studied biomass feedstock BTD per truckload representing between 0.89 and 2.88 times the US perimeter.

09 BIOMASS FUELS↗
DOE OSTI2022

Screening and evaluation of biomass upgrading strategies for sustainable transportation fuel production with biomass-derived volatile fatty acids

Biomass conversion to fuels and chemicals is crucial to decarbonization, but choosing an advantageous upgrading pathway out of many options is challenging. Rigorously evaluating all candidate pathways (process simulation, product property testing) requires a prohibitive amount of research effort; even simple upgrading schemes have hundreds of possible permutations. We present a method enabling high-throughput screening by approximating upgrading unit operations and drop-in compatibility of products (e.g., fuel properties) and apply it to volatile fatty acid (VFA) conversion to liquid transportation fuels via a MATLAB script, VFA Upgrading to Liquid Transportation fUels Refinery Estimation (VULTURE). VULTURE selects upgrading configurations that maximize fuel blend bio-derived content. We validate VULTURE's approximations through surrogate fuel property testing and process simulation. Techno-economic and life cycle analyses suggest that VFA upgrading processes down-selected by VULTURE are profitable and have low carbon intensities, demonstrating the potential for the strategy to accelerate process development timelines at decreased costs.

09 BIOMASS FUELS↗
DOE OSTI2022

Research and development of hydrogen carrier based solutions for hydrogen compression and storage

Industrial and public interest in hydrogen technologies has risen strongly recently, as hydrogen is the ideal means for medium to long term energy storage, transport and usage in combination with renewable and green energy supply. In a future energy system, the production, storage and usage of green hydrogen is a key technology. Hydrogen is and will in future be even more used for industrial production processes as a reduction agent or for the production of synthetic hydrocarbons, especially in the chemical industry and in refineries. Under certain conditions material based systems for hydrogen storage and compression offer advantages over the classical systems based on gaseous or liquid hydrogen. This includes in particular lower maintenance costs, higher reliability and safety. Hydrogen storage is possible at pressures and temperatures much closer to ambient conditions. Hydrogen compression is possible without any moving parts and only by using waste heat. In this paper, we summarize the newest developments of hydrogen carriers for storage and compression and in addition, give an overview of the different research activities in this field.

08 HYDROGEN↗
DOE OSTI2021

The intrinsic value of bioblendstocks: Prenol as a case study

Decarbonizing the transportation sector is likely to require both electrification and increased incorporation of biofuels and/or bioblendstocks. While the social and environmental benefits of bioblendstocks are well understood, their real value for the fuel producers has not been established. As such, this work considers prenol as a bioblendstock case study to identify sources of intrinsic value to fuel blenders by studying the properties of binary mixtures with gasoline components. The considered refinery blendstocks were samples of full range naphthas from the distillation, fluidized catalytic cracking, isomerization, alkylation, and reforming units. Octane numbers, Reid vapor pressure, distillation curves, and sulfur content were evaluated. Our results indicate the need for adjusting the formulation of the base fuel, depending on the interplay among the properties of the bioblendstock and those of the base fuel. Prenol increased research octane number (RON) and octane sensitivity (OS) of the base fuel, by up to 25 and 10 octane numbers, respectively. Additionally, 10 vol% prenol reduced RVP up to 2.2 psi, for the more volatile blendstock. Thus, considering prenol as a low volatility, RON/OS boosting bioblendstock, the composition of the preferred base fuel was proposed as containing reduced olefins and aromatics, and increase light fractions. The potential impact of this new gasoline formulation on refining processes and products gives rise to direct sources of value to the refiners, such as exporting products to the chemicals market, increasing the value of intermediate refinery streams, decreasing operating severity of certain refinery units, and broadening of the product suite.

09 BIOMASS FUELS↗
DOE OSTI2023

Nuclear-Driven Chemical Conversion Pathways

The purpose of this work is to explore the possibilities of using coal as a carbon resource by converting it to fuels and chemicals with heat from a nuclear power plant. While many previous studies have focused on coal gasification, this process requires combusting a portion of the coal and producing heat. By employing pyrolysis over gasification, the energy content in the coal can be preserved. Pyrolysis of coal also results in a large portion of solid char, which can be converted to activated carbon and sold to various markets. This model uses hydrogen produced by nuclear-supplied heat and electricity to convert the syngas stream to methanol, which has many pathways for further processing into fuels, chemicals, and plastics. Specifically, this project focuses on non-fuel products for methanol pathways. The CO2 captured within the refinery model can also be combined with hydrogen to produce more chemical products and reduce CO2 emissions.

01 COAL, LIGNITE, AND PEAT↗