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Bio-Restore Workshop Summary Report

This report summarizes the results of a Bioenergy Technologies Office-sponsored public workshop held at Argonne National Laboratory on September 25–26, 2019. The purpose of the Bio-Restore Workshop was to bring together experts to discuss the current state of the technology and to identify data and R&D relevant to the bio-restore concept. Specific topics included using dedicated energy crops and other biomass sources to provide environmental benefits, implementing algae technologies (e.g., wastewater treatment, direct bloom harvest, turf scrubbers, macroalgae), quantifying and valorizing ecosystem services, developing low-cost sensors and data management systems, and integrating “bio-restore biomass” with supply chain needs. For the purposes of the workshop, the term “bio-restore biomass” refers to terrestrial and algal biomass that provides environmental benefits when produced or harvested. For terrestrial biomass, this primarily includes energy crops (herbaceous and woody), other cellulosic biomass, and waste biomass. For algal biomass, this includes wastewater treatment algal biomass, algal blooms, algal turf scrubbers/attached growth systems, and macroalgae. Types of biomass not of interest to the workshop discussions include oilseed crops, crops generally grown for food or feed, and algae grown in artificial light conditions or other energy-intensive cultivation designs.

09 BIOMASS FUELS↗

Electric Vehicle Lithium-Ion Battery Life Cycle Management

There is no question that electric vehicles (EVs), which are key for addressing climate change impacts from the transportation sector, are quickly gaining popularity and availability. With limits and other challenges related to the supply of critical battery minerals, maximizing the use of EV batteries and ensuring recovery of battery minerals is imperative. Therefore, proper end-of-life-cycle management (reuse and recycling) of these batteries must be part of the EV ecosystem from the perspective of both the supply chain and environmental footprint. Second use of batteries for energy storage systems extends the initial life of these resources and provides a buffer until economical material recovery facilities are in place. Although there are multiple pathways to recycling and recovery of materials, new recovery technologies are moving toward commercially available hydrometallurgy and promising direct recycling, which analysis has shown has the lowest overall carbon footprint. Strategically locating these plants close to battery collection further reduces transportation and thus recycling and recovering costs. Proper life cycle management could alleviate future lithium-ion battery materials supply chains for EVs. Governments and other stakeholders around the world have started initiatives and proposed regulations to address the challenges associated with life cycle management of EV lithium batteries. Finally, as manufacturers are increasingly faced with the likelihood of such extensive regulatory requirements, attention should be given to new designs, sales, and service models that can reduce life cycle management costs.

25 ENERGY STORAGE↗

Minimum GHG emissions and energy consumption of U.S. PET and polyolefin packaging supply chains in a circular economy

There is a wide agreement on the urgency of transforming linear management of plastics towards a circular economy model. However, no clear pathways exist as to required recycling technologies involved and system-wide environmental impacts. This study explores such pathways in the U.S. for the most commonly used packaging plastics through a combination of mechanical and emerging advanced recycling technologies. A system optimization model aimed at minimizing environmental impacts was developed to determine optimal end-of-life (EOL) management and locations of existing and emerging U.S. recycling infrastructures. Our study includes material flows from virgin resin production through semi-manufacturing processes to existing EOL disposal and recycling processes. An optimized circular plastics packaging system achieved greenhouse gas (GHG) emission savings of up to 28% and cumulative energy demand (CED) savings of up to 46%, compared to the linear economy. Moreover, these savings of GHG emissions and CED impacts represent a reduction of 0.16% and 0.49% compared to annual U.S. GHG emissions and energy consumption in 2022, respectively. The optimal recycling rates and systems-level circularity ranged from 78–99% and 57–75%, respectively. Increased energy savings led to increased GHG emissions showing a potential trade-off between GHG emissions and energy. Analysis of 40 scenarios showed the importance of material collection distances, blend limit of mechanically recycled resins, process yields, and mandated recycling rates for achieving a sustainable circular economy of plastics.

09 - BIOMASS FUELS↗

Circular Economy Modeling Efforts at NREL: Circular Economy Lifecycle Analysis and Visualization (CELAVI) and the Circular Economy Agent-Based Model (ABM)

Circular Economy (CE) aims at decoupling human activities from economic growth and resource use. While CE economic and environmental benefits are often touted by its proponents, increased circularity and improved sustainability do not necessarily go hand-in-hand. The Circular Economy Lifecycle Assessment and Visualization (CELAVI) framework simulates the transition of renewable energy technology supply chains towards circularity and quantifies spatially explicit environmental impacts and supply chain costs. Using wind blade end-of-life (EOL) management as a case study, this presentation will highlight CELAVI's features. Furthermore, envisioned extension to the framework could improve the stakeholder decision model by accounting for logistical and other factors. The CELAVI framework could be leveraged to answer crucial questions regarding renewables EOL management.

circular economy↗

Securing the Modern Grid: Federal Investments, Digitization, and Supply Chain Strategy

Across the United States (U.S.) grid expansion and modernization is underway, paving the way for accelerated load growth and intelligent resource management. Digitization of the grid is supported by several state and federal programs, providing support for utilities installing advanced metering infrastructure (AMI), AI-powered analytics systems, battery energy storage systems (BESS), and distributed energy resource management systems (DERMS) to transform the grid from a one-way power delivery system into an intelligent, responsive network that will enable faster load growth and power expansion of data centers for advanced artificial intelligence (AI) applications. The digital transformation of America's grid presents opportunity for increased efficiency and resiliency but also introduces new digital risks that require careful management. Digital equipment often contains several vulnerabilities such as unencrypted communication protocols, and persistent remote access capabilities that could be exploited to manipulate device settings, coordinate service disruptions, or inject false data into grid operations. These digital risks become particularly important as the grid must rapidly scale to support AI-driven data centers, which the administration has identified as essential for maintaining U.S. technological leadership and economic competitiveness. These vulnerabilities are compounded by supply chain realities: Chinese manufacturers currently produce 70-90% of essential grid components including inverters, batteries, and control systems, with the U.S. lacking domestic manufacturing capacity for critical assets like extra-high voltage transformers. Recent federal legislation has established Foreign Entity of Concern (FEOC) restrictions to address these risks, requiring projects to achieve escalating thresholds of non-FEOC content to receive tax credits while utilities work to expand sourcing channels for their supply chains and strengthen security measures. These restrictions arrive precisely when utilities face unprecedented electricity demand growth driven by the rapid growth in data centers, creating a considerable challenge: rapidly expanding infrastructure while navigating complex compliance requirements while lacking viable alternatives for many critical components. Idaho National Laboratory (INL) and its partners have developed practical approaches to help utilities navigate these intersecting challenges as they leverage federal investment to strengthen and grow the grid. These solutions include Cyber-Informed Engineering (CIE) principles that build resilience directly into systems, the Cirrus tool for secure cloud migration, and enhanced procurement guidance that embeds security requirements throughout equipment lifecycles. Federal initiatives, such as the Technical Assistance for Digital Assurance (TADA) project, provide direct support to utilities implementing these approaches while facilitating knowledge sharing across the industry. While these tools and frameworks cannot eliminate all risks inherent in foreign supply chain dependencies, they offer pragmatic pathways for strengthening security posture without sacrificing the deployment momentum essential to meeting surging electricity demand. Ultimately, securing America's digital energy infrastructure demands dedicated coordination across multiple fronts: building domestic supply chains, implementing robust digital assurance practices, and maintaining the aggressive modernization timeline necessary for reliability, resilience, and energy independence.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Profitability, Scalability and Optimized Siting for Waste-to-Energy Supply Chains: A Case Study on Hydrothermal Liquefaction

Waste-to-Energy (WtE) conversion technologies have the potential to simultaneously reduce waste volumes, treatment-related emissions, and carbon intensity while producing valuable energy services. However, questions remain regarding under which conditions emerging WtE technologies are feasible to deploy. In this project, we develop an optimized siting method for WtE technologies to assess cost-effective WtE processor locations, throughput scales, and profitability. We apply the model using Hydrothermal Liquefaction (HTL) as an example WtE technology. We develop calibrated capital and operating expense cost curves based on literature data to study the techno-economic characteristics of WtE supply chains. Prior to solving the siting optimization, we analyze the model parameters to describe organic waste management system behavior under four different HTL deployment configurations: Co-Processing, where HTL plants send biocrude to existing conventional refineries via assumed pipelines; Co-Location, where biorefineries are co-located with HTL plants; and two alternative Standalone Biorefining cases, where distributed HTL plants transport biocrude intermediate via either assumed pipelines or trucking to centralized biorefineries. We also define and apply several feedstock gate fee calculations, representing different revenue distribution options, to investigate how bioproduct value could impact WtE supply chain economics in terms of waste producer and processor profit or cost reduction.

09 BIOMASS FUELS↗

Better management practices for environmentally sustainable production of microalgae and algal biofuels

The commercialization of biofuels produced from microalgae is in its infancy; therefore, many resource-management practices and production processes are still flexible. The purpose of this paper is to guide development of supply chains toward more environmentally sustainable practices. Furthermore, in this work, we review current and projected technologies and practices for autotrophic microalgae cultivation that promote environmental sustainability. We develop a framework that leverages these studies to propose better management practices (BMPs) for water quality and quantity, biodiversity, or greenhouse gas emissions in concert with productivity and profitability considerations. Some proposed BMPs are linked to numerical environmental targets, such as percent reductions in nutrient loadings to streams, whereas others seek to avoid thresholds leading to adverse health or ecological effects. Still others involve using the best available technologies, developed iteratively through life-cycle and techno-economic analyses. Proposed BMPs for microalgae cultivation focus on water quality and quantity, as well as improving greenhouse gas (GHG) emissions to obtain advanced biofuel designation. BMPs must allow producers to meet productivity and profitability targets, as well as environmental targets. These example BMPs characterize the state of science and engineering; thus, they will change over time.

09 BIOMASS FUELS↗

Overview and Commentary on Applying the Coordinated Vulnerability Disclosure Process to Photovoltaic System Devices

The rapid expansion of photovoltaic (PV) systems, particularly inverters, has introduced new cybersecurity challenges that threaten both local operations as well as the broader electrical grid’s stability. PV inverters, integrated into critical energy infrastructure are potential targets for cyber attacks due to vulnerabilities in firmware, remote access systems, and communication protocols. The Coordinated Vulnerability Disclosure (CVD) process, as defined by the Cybersecurity and Infrastructure Security Agency (CISA), provides a framework for identifying, reporting, and addressing these vulnerabilities in a transparent and collaborative manner. This report outlines the CVD process as it applies to PV systems, detailing the roles of key stakeholders, such as manufacturers, grid operators, and security researchers. The report also highlights specific challenges in managing vulnerabilities for new and legacy PV systems, which includes those introduced by insecure communications and third-party supply chain components. By adhering to the CVD process, the PV industry can mitigate cybersecurity risks, ensure regulatory compliance, and maintain consumer trust, while safeguarding the operational resilience of the energy grid. Ultimately, the effective coordination of vulnerability management is crucial for securing the future of PV systems within the critical electric grid infrastructure landscape.

14 SOLAR ENERGY↗

Enabling Sustainable Lithium-Ion Battery Manufacturing via Recycling

With millions of electric vehicles set to hit the road, challenges arise with both the access to a reliable supply of critical raw materials and management of spent Li-ion batteries that once powered those vehicles. From a circular economy perspective, it is critical to develop cost-effective and environmentally sustainable recycling technologies to manage end-of-life batteries and reintroduce the recovered materials into the supply chain to maintain a secure and healthy battery ecosystem. In this chapter, an overview of the current state of battery recycling is discussed by analyzing recycling’s benefits, key issues, and recycling strategies including pyrometallurgy, hydrometallurgy, and direct recycling. We also compare those recycling processes and highlight the direct recycling strategy by analyzing its benefits, working principles, and challenges. Direct recycling is still in the development stage and some recent advancements are discussed.

Bai, Yaocai↗

Transforming Energy Through Sustainable Mobility: Expanding Low-Carbon Transportation R&D Solutions

As the nation's premier laboratory for cutting-edge transportation decarbonization research and development solutions, the National Renewable Energy Laboratory (NREL) pioneers the creation and deployment of sustainable mobility technologies and strategies, with a focus on slashing transportation sector greenhouse gas emissions and combatting climate change. Trucks, planes, cargo ships, and other difficult-to-decarbonize vehicles are part of this essential transition for the transportation sector, which is currently the nation's largest source of the greenhouse gas emissions. NREL provides the scientific building blocks needed to spur innovation through multifaceted analysis, research, and engineering. This work acts as a catalyst to help industry bring affordable, high-performance, energy-efficient, and low-emission modes of transport and related infrastructure to market sooner. Our researchers collaborate closely with academic, government, and industry partners to design better batteries, drivetrains, and engines. They develop technologies for high-power charging, thermal management, energy storage, and power electronics. They are also reimagining fuels and combustion while creating sustainable lightweight materials. Unbiased expert guidance - backed by credible data and analysis, tools, and scientific rigor - empowers partners to make informed decisions about sustainable transportation. NREL recognizes that communities with limited mobility options face reduced access to employment opportunities, health care, and education, lowering overall quality of life. Alongside partners, NREL experts are creating transportation solutions that meet community-identified needs and increase mobility equity in historically underserved and overburdened communities. Rather than providing a one-size-fits-all solution, we take an interdisciplinary approach to mobility equity that considers the needs and challenges of diverse groups, maximizing benefits at the individual, community, and societal levels.

ADVANCED PROPULSION SYSTEMS↗

Resilience Lessons From the Southeast United States Woody Pellet Supply Chain Response to the COVID-19 Pandemic†

The Coronavirus Disease 2019 (COVID-19) instigated a pandemic that impacted economies, employment, and shipping worldwide. This paper reviews how one international supply chain performed and identifies lessons that may be helpful to improve future resilience. Economic and employment data through November 2020 are used to review the effects of COVID-19 on operations of the bioenergy supply chain in the southeastern United States (SE United States) that utilizes wood fiber to fabricate pellets. Conditions associated with the production of pellets in the SE United States changed with the outbreak of COVID-19. Federal and state government programs and classification of workers in this sector as “essential” during the pandemic helped maintain the woody pellet supply chain and other industries during a period of general shut down in 2020. The availability of personal protective equipment, long-term supply contracts, and established safety cultures are among the factors that enhance supply chain resilience while limited availability of skilled workers, inadequate stakeholder engagement, and dependence on external policies are among factors that reduce resilience. The analysis concludes with recommendations for the SE pellet supply chain, and other biomass supply chains, to improve their resilience to future disturbances. When best practices are implemented, SE United States biomass offers opportunities to contribute to post-pandemic economic recovery while incentivizing better forest resource management.

09 BIOMASS FUELS↗

Regional economic potential for recycling consumer waste electronics in the United States

Waste electronics are a growing environmental concern but also contain materials of great economic value. If properly recycled, waste electronics could enhance the sustainability of vital metal supply chains by offsetting the increasing demand for virgin mining. However, rapid changes in the size and composition of electronics complicate their end-of-life management. Here we couple material flow and geospatial analyses on over 90 critical consumer electronic products and find that over 1 billion devices, representing up to 1.5 million tonnes of mass, could be discarded annually in the United States by 2033. Emerging electronics such as connected home, health and augmented/virtual reality devices have become the fastest-growing types in the waste stream. Here we highlight policy opportunities to develop various sustainable circularity strategies around metal supply chains by showing the potential to integrate waste electronics and virgin mining pathways in western US regions, while new infrastructure designed specifically for waste electronics treatment is favourable in the central and eastern United States. Furthermore, we show the importance of building national-level refining and tear-down databases to improve electronics end-of-life management in the next decade.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Unlocking the Future of Aircraft Manufacturing: The Environmental Benefits of Laser Patterning for Surface Enhancement of Aircraft-Certified Alloys

Surface protection and functional modification of aircraft-certified aluminum alloys are essential for corrosion resistance, durability, and long-term airworthiness. At the same time, increasingly restrictive environmental regulations motivate the development of alternatives to legacy wet-chemical surface treatments. This study presents an integrated assessment of ultrafast femtosecond laser surface texturing as a surface functionalization approach for Aluminum 6061 alloys within an aerospace manufacturing and sustainability context. Ultrashort-pulse laser processing enables controlled micro- and nano-scale surface topographical modification with limited thermal impact, allowing adjustment of wettability and surface functionality while preserving bulk material integrity. As a dry and contactless process, femtosecond laser treatment eliminates the use of hazardous chemicals, reduces consumable inputs, and generates minimal secondary waste. A streamlined cradle-to-gate life cycle assessment conducted in accordance with ISO 14040/14044 indicates a lower global-warming potential per functional unit compared with conventional surface treatments, including anodization, plasma-assisted coatings, and organic coating systems. Complementary qualitative analyses addressing environmental health and safety, supply-chain risk, and ESG alignment indicate potential advantages related to occupational safety, regulatory compliance, waste management, and end-of-life recyclability. The investigation is performed on planar Aluminum 6061 reference surfaces with a treated area of 25 mm 2 , providing a controlled laboratory-scale basis for analyzing process behavior, functional surface modification, and associated environmental metrics. Within this defined scope, the results support further evaluation of femtosecond laser surface texturing as a surface engineering option for future aerospace manufacturing.

corrosion resistance↗

CyTRICS™ Assessment Report: Whole Home Battery Applications

This report examines the software supply chain security posture of mobile applications developed for consumer whole-house battery and energy-management products. While these applications are not currently integrated with critical infrastructure, their growing role in connected energy domain spaces underscores the importance of understanding the external dependencies, permission structures, and runtime behaviors that could introduce systemic risk; particularly, if adoption expands into more critical environments.

25 ENERGY STORAGE↗

Circular Economy for Photovoltaics in Service of Energy Transition

The challenge of energy transition is immediate and immense; current projections target 75 TW of photovoltaics (PV) capacity by 2050. While any transition to renewable energy technology is preferable to the current fossil-based system, it is ideal to improve the sustainability of PV to minimize negative environmental and social impacts. Circular economy (CE) has been proposed as a method to improve the sustainability of PV, especially for emerging materials like perovskites. CE is a set of actions, principles, and systems which aim to design out waste and keep products and materials in use, to reduce environmental impacts and enable sustainable development. At the most basic level, CE is "reduce, reuse, recycle", the R-actions, in ranked order. CE of a PV technology can be metricized in a variety of ways, such as the Material Circularity Indicator (Smith and Jones, Ellen MacArthur Foundation, 2019) or recycling rates. Unfortunately, standard CE metrics have several shortcomings for measuring renewable energy technologies in the context of deployment for energy transition (Figge 2018, Saidani 2019): 1) Only measure mass flows; 2) De-prioritization of the use phase in favor of mass circularity when scoring; and 3) Tight focus on a single product scale The use phase and energy flows of PV are key to energy transition, and therefore need to be quantified. Additionally, correlating product-scale to system-scale is necessary for quantifying the environmental impacts of energy transition. Life Cycle Assessment (LCA) can address some of these concerns, but also focuses on a single product scale and has trouble capturing the dynamics of system-scale energy transition, such as the interaction of module lifetime with manufacturing demands for energy transition deployment schedules. Therefore, we developed an open-source Python-based system dynamics model to quantify the mass, energy and carbon impacts of CE R-actions for PV technologies in the energy transition; PV in the CE (PV ICE) (Ovaitt & Mirletz 2021). The tool captures supply chains from material extraction through end of life, incorporating 5 circular end of life pathways. PV ICE takes in any evolving bill of materials, module properties and deployment schedule to support researchers and decision makers with data-backed insights. In this work, we quantify and compare proposed CE sustainable PV module designs and lifecycle management strategies, spanning currently commercialized technologies, government and industry technology targets, and several low Technology Readiness Level (TRL) emerging PV technologies, including perovskites. Our analyses capture the projected evolutions of lifetime, efficiency and material circularity of these PV technologies, as well as their material supply chains. Our analyses emphasize the importance of examining a suite of metrics to identify priorities and tradeoffs, and inform design or lifecycle management decisions holistically. Previous analyses have demonstrated the central importance of PV module lifetime to support energy transition while minimizing impacts. High levels of material circularity (>90%) enable minimizing lifecycle wastes, can reduce virgin material demands if paired with improving efficiency, but demonstrate tradeoffs in energy return on investment. In the fervor of new material and technology development, it is important to remember that CE is not the end goal; decarbonization and energy transition are the end goal. CE should be used in service to improve the sustainability of PV, and R-actions evaluated for their usefulness and efficacy to this end.

carbon↗

Life cycle greenhouse gas emissions of different CO 2 supply options for an algal biorefinery

This paper characterizes the greenhouse gas (GHG) emissions from the provision of CO 2 for twelve hours of the day from a range of sources operating on a twenty-four-hour basis. Twelve CO 2 supply cases spanning from fossil fuel power plant stack gases to direct air capture (DAC) systems are modeled. The results are compared in a life cycle assessment (LCA) framework. The CO 2 supply from the combustion or gasification of biomass has GHG emissions of –1.62 gCO 2 eq./g CO 2 delivered and is the case with the lowest carbon footprint for supplied CO2. The emissions for all the CO 2 supply cases were found to be negative, either because of capturing more CO 2 from the atmosphere than is released from the CO 2 production process, or because of production of excess electricity that is exported to the grid (replacing emissions from grid electricity). A purpose-built Natural Gas Combined Cycle (NGCC) power plant CO 2 source has the highest GHG emissions of -0.40 gCO 2 eq./gCO 2 delivered of the cases considered because of nighttime emissions and natural gas supply chain losses. The impact of a diurnal cycle can be mitigated by using capture and refrigeration systems as part of the CO 2 management system. The results are sensitive to the GHG emissions of the grid electricity, which is imported or exported in different cases. The results provide a benchmark for the comparison of different CO 2 supply options for the establishment of a sustainable algal biorefinery.

42 ENGINEERING↗

Drivers of Water Use in the Agricultural Sector of the European Union 27

Population growth and the uncertain hazards that accompany climate change have put increasing pressure on the management and sustainability of water. It has a direct impact on agriculture and its domestic and international supply chain linkages. As one of the largest agricultural producers in the world, the European Union (EU) is particularly sensitive to changes in water availability. Therefore, here we perform a structural decomposition analysis based on the recently released EXIOBASE 3 database to examine in depth how changes in water input coefficients, in final demand and in technology have affected changes in water use across crops. Crop production consumes 99% of the direct water in agriculture. Our results show that the largest EU crop producers have experienced an increase in water use that is mostly driven by changes in technology. On the other hand, several Mediterranean countries, where water scarcity has been a problem for years, have decreased their water consumption mostly thanks to an improvement in their water intensity. Results by crop are consistent with those at the aggregated level except for vegetables of which water use changes have been primarily driven by changes in final demand and water intensity.

54 ENVIRONMENTAL SCIENCES↗

PV DMFA [SWR-21-105]

The Photovoltaic Dynamic Material Flow Assessment (PV DMFA) model (also referred to here as “The model”) is a computational framework written in Python based on utility-scale PV electricity generation to quantify time-series stocks and flows of PV materials primarily in crystalline silicon PV technologies. The model evaluates cradle-to-cradle life cycle of utility-scale solar PV systems in the United States in the period 2000-2100. PV DMFA serves as a sustainability analysis tool to assess the impacts of different material circularity practices (i.e., reduce, reuse/refurbish, remanufacture, and recycle), PV module design shifts and sensitivity of material processing and technology related parameters to material installations, waste creation and raw material depletion in PV material supply chains. This tool enables advanced planning for future material needs and informs sustainable pathways for PV material management in the circular economy. This tool could be helpful to a wide range of stakeholders; Particularly, researchers and manufacturers looking for technoeconomic and/or environmental life cycle analysis (LCA) feedback for renewable energy (RE) systems.

Khalifa, SherifA.↗