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DOE OSTI2025

Complex carbonate phases drive geologic CO2 mineralization

Abstract Geologic carbon sequestration in mafic and ultramafic reservoirs is a scalable strategy for carbon dioxide removal, offering permanent storage via mineralization as stable carbonates. However, there is limited information on the structure and composition of key mineralization endpoints during sequestration. Here, we unravel the atomic structure, composition, and nanoscale morphology of carbonates recovered from a field-scale demonstration of CO 2 mineralization in basalt. Using transmission electron microscopy, we mapped mineralogical variations from the initial to later stages of subsurface carbonate growth and identified a previously unknown cation-ordered ankerite phase that exerts a primary control over carbonation processes. This study has provided a new understanding of subsurface carbonation pathways which will impact the parameterization of predictive geochemical models for future sequestration efforts in basalt formations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Action at a distance: The remarkable coupling of CO 2 uptake to electron transfer in specialized cyanobacterial NDH-1 complexes

Cyanobacteria achieve highly efficient photosynthesis using a CO 2 -concentrating mechanism relying on specialized Type I (NDH-1) complexes. Among these, NDH-1 3 and NDH-1 4 catalyze redox-coupled hydration of CO 2 to bicarbonate, supporting carbon fixation in carboxysomes. The mechanism of coupling electron transfer to CO 2 -hydration by these variant NDH-1 complexes remains unknown. We engineered a Synechococcus PCC7942 strain that expresses exclusively the high flux/low affinity NDH-14 complex, enabling the observation of the coupling of CO 2 hydration to cyclic electron flow in isolation from the other NDH-1 isoforms normally present in cells. We found that inhibition of the CupB protein by the carbonic anhydrase inhibitor ethoxzolamide (EZ) suppressed CO 2 uptake, slowed photosystem I rereduction, and abolished proton pumping as probed by acridine orange fluorescence. These effects were absent in strains lacking Cup proteins, confirming specificity. The results demonstrate that CO 2 hydration and electron transfer through NDH-14 are tightly coupled via proton translocation across the thylakoid membrane. These findings provide direct evidence for the bidirectional interaction in bioenergetic coupling between the plastoquinone reduction and the CO 2 uptake at the distal Zn-site over a span of ~150 Å and support a proton-removal hypothesis involving the proton transfer pathways from the Zn-site of CO2 hydration to an energetically coupled proton loading site evolutionarily repurposed from the ancestral proton pumping mechanism to enable energetic CO 2 uptake.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Biomanufacturing from gaseous C1 feedstocks: A perspective on opportunities and challenges

Single-carbon (C1) substrates including carbon dioxide, carbon monoxide, and methane are abundantly available from natural and anthropogenic sources and present potential feedstocks for biomanufacturing. Utilizing these C1 gas feedstocks in bioprocesses for sustainable production of chemicals and fuels could prove pivotal in removing excess carbon from the atmosphere. This perspective describes the spectrum and sources of CO2, CO, and CH4 and examines emerging opportunities in microbial bioconversion and bioelectrochemical processes for these feedstocks. We discuss existing challenges in bioprocess development that currently restrict the commercialization of C1 biomanufacturing technologies. We detail different aerobic and anaerobic bioconversion approaches for C1 feedstocks employing pure and mixed cultures and examine the suitability of each scenario for producing specific molecules. Beyond strain engineering and bioprocess constraints, we address often overlooked factors that limit the development of efficient and reliable bioprocesses, including technology availability for research and safety considerations. We then discuss and recommend the necessary safety features and technological research tools for developing fast, safe, and efficient bioprocesses using gaseous feedstocks to support the scale-up and commercialization of C1 biomanufacturing technologies. This perspective provides an overview of the current scientific and industrial state of the art and offers insights into future technological needs that must be addressed to realize the potential of biomanufacturing from gaseous feedstocks. Synopsis: C1 gases offer a sustainable feedstock for biomanufacturing of fuels and chemicals. This work analyzes bioconversion methods, challenges, and safety considerations, and emphasizes the need for improved technology to enable commercialization.

Biomanufacturing↗

DOE OSTI2020

Energy Performance Validation of a Gaseous Air Cleaning Technology for Commercial Buildings

The U.S. Department of Energy (DOE) Building Technologies Office Commercial Building Integration group conducts evaluations of new energy efficiency technologies as part of the High Impact Technology Catalyst program. The subject of this field validation project is an air cleaning technology that removes gaseous contaminants from indoor air to reduce outdoor air ventilation requirements. Reducing the volume of outdoor air required reduces heating, ventilating, and air conditioning (HVAC) loads and can provide significant energy savings for some buildings in certain climates. The technology, called the HLR (HVAC Load Reduction), was developed by enVerid. The technology uses a solid regenerable sorbent material that was developed by DOE's National Energy Technology Laboratory and licensed to the vendor for this application. The sorbent material was originally developed to adsorb carbon dioxide (CO2); the vendor continued to develop the sorbent and the overall system so that it can also remove volatile organic compounds (including aldehydes), carbon monoxide, ozone, and particulate matter 2.5 micrometers in diameter or smaller (PM2.5) from the air. This material has low regeneration temperature requirements, and its sorption properties are unaffected by humidity levels, both of which are beneficial for building applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Transition metal carbides and nitrides as catalysts for thermochemical reactions

Transition metal carbides and nitrides (TMCs and TMNs) have attracted much attention due to their unique physical and chemical properties brought by the incorporation of interstitial carbon and nitrogen into the crystal lattice of the parent metals. Recent advances in utilizing TMCs and TMNs have revealed their intriguing catalytic properties in many industrially important reactions, including heteroatom removal, CO 2 activation, alcohol reforming, and water–gas shift reactions. The promising activity, selectivity, and stability of TMCs and TMNs, either as catalysts or as supports for other metals, are often attributed to their strong interactions with the adsorbates, tunable surface properties, as well as the synergy with supported metals. This review summarizes the synthesis and characterization of TMC and TMN model surfaces and powder catalysts, and uses several case studies to demonstrate their unique catalytic properties in these important reactions. Finally, a discussion is also provided regarding the challenges and opportunities associated with the utilization of TMCs and TMNs in thermocatalysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

AmeriFlux FLUXNET-1F US-Tw5 East Pond Wetland

This is the AmeriFlux Management Project (AMP) created FLUXNET-1F version of the carbon flux data for the site US-Tw5 East Pond Wetland. This is the FLUXNET version of the carbon flux data for the site US-Tw5 East Pond Wetland produced by applying the standard ONEFlux (1F) software. Site Description - The Twitchell Wetland site is a 6.5 acre restored wetland on Twitchell Island, that is managed by the California Department of Water Resources (DWR) and the U.S. Geological Survey (USGS). In the fall of 1997, the site was permanently flooded to a depth of approximately 55 cm. The wetland remained fairly unvegetated in patches increasing in size towards the east. The site underwent a major disturbance in 2013 when the vegetation was removed to seed a nearby restored wetland. A flux tower equipped to analyze energy, H2O, CO2, and CH4 fluxes was installed on April 17, 2018.

Valach, Alex↗

DOE OSTI2024

An assessment of ocean alkalinity enhancement using aqueous hydroxides: kinetics, efficiency, and precipitation thresholds

Abstract. Ocean alkalinity enhancement (OAE) is a promising approach to marine carbon dioxide removal (mCDR) that leverages the large surface area and carbon storage capacity of the oceans to sequester atmospheric CO2 as dissolved bicarbonate (HCO3-). One OAE method involves the conversion of salt in seawater into aqueous alkalinity (NaOH), which is returned to the ocean. The resulting increase in seawater pH and alkalinity causes a shift in dissolved inorganic carbon (DIC) speciation toward carbonate and a decrease in the surface ocean pCO2. The shift in the pCO2 results in enhanced uptake of atmospheric CO2 by the seawater due to gas exchange. In this study, we systematically test the efficiency of CO2 uptake in seawater treated with NaOH at aquarium (15 L) and tank (6000 L) scales to establish operational boundaries for safety and efficiency in advance of scaling up to field experiments. CO2 equilibration occurred on the order of weeks to months, depending on circulation, air forcing, and air bubbling conditions within the test tanks. An increase of ∼0.7–0.9 mol DIC per mol added alkalinity (in the form of NaOH) was observed through analysis of seawater bottle samples and pH sensor data, consistent with the value expected given the values of the carbonate system equilibrium calculations for the range of salinities and temperatures tested. Mineral precipitation occurred when the bulk seawater pH exceeded 10.0 and Ωaragonite exceeded 30.0. This precipitation was dominated by Mg(OH)2 over hours to 1 d before shifting to CaCO3,aragonite precipitation. These data, combined with models of the dilution and advection of alkaline plumes, will allow the estimation of the amount of carbon dioxide removal expected from OAE pilot studies. Future experiments should better approximate field conditions including sediment interactions, biological activity, ocean circulation, air–sea gas exchange rates, and mixing zone dynamics.

Ringham, Mallory C. (ORCID:0000000348020185)↗

DOE OSTI2021

Cryogenic Carbon Capture™ (CCC) Status Report

The Cryogenic Carbon Capture™ (CCC) process separates CO2 from light gases in essentially any continuous process. CCC cools the gases to the frost or desublimation point of CO2 (-100 to -135 °C), separates and pressurizes the solids, and warms all streams to produce a CO2-depleted stream at ambient pressure and a pure (99+%) pressurized liquid CO2 stream typically to about 150 bar, both at ambient temperature. The process also recovers all gas moisture and most gas impurities less volatile than CO2 (NOx, SOx, Hg, PM, UHC, CCC, etc.) in separable streams. CCC nearly eliminates refrigeration energy for sensible temperature changes through heat integration. CCC does require energy to change the CO2 phase from a mixed vapor to a pressurized fluid, which represents the minimum energy required of any process for this separation. CCC uses additional energy for turbomachinery inefficiencies, heat losses, moisture removal and overall process pressure drop. Aside from these real-world energy demands, CCC operates near the minimum energy required to perform this gas separation by minimizing stream recycling. CCC compresses CO2 as a liquid, which is one of several reasons it costs about about half as much and consumes about half as much energy as an amine process when using flue gases with about 15% CO2. The process also has several major additional advantages, including (a) it is a bolt-on retrofit technology that does not need steam or any modification of existing equipment, (b) it recovers water and nearly all pollutants in addition to CO2 from the flue gas, (c) it enables highly efficient and cost effective energy storage at grid scale and on time scales of minutes, (d) it enables NG storage if the energy storage option is used, and (d) it has a small footprint and is minimally disruptive to existing plants, requiring only electrical power and a gas source to operate. Sustainable Energy Solutions (SES) has scaled this technology through several levels, the largest of which captures nominally 1 tonne of CO2/day and is called the skid system. Skid system field tests include utility-scale power plants, cement plants, heating plants, and other utility or industrial sites that burn natural gas, biomass, coal, shredded tires, municipal waste, and combinations of these fuels. These field tests produced 95-99% CO2 capture with CO2 purities of 99+% and initial CO2 contents that range from 4 to 28%. SES currently seeks to scale the system to merchant scale (10-80 tonnes of CO2 per day). In the process of doing so, SES has demonstrated the potential for CCC to contribute to energy storage and direct air capture in innovative and cost-effective ways. This presentation discusses the overall process and highlights results from field and in-house tests. These include (a) measured CO2 capture rates and operating conditions from in-house and field tests, and (b) predicted utility-scale costs and energy demands. This discussion also includes the application of the CCC technology to energy storage and direct air capture.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2020

Comparing energy and water use of aqueous and gas-based metalworking fluids

Gas-based metalworking fluids (MWFs) have been proposed as alternative coolants and lubricants in machining operations to mitigate concerns surrounding water use and pollution, industrial hygiene, occupational health, and performance limitations associated with water-based (aqueous) MWFs that are ubiquitously used in the metals manufacturing industry. This study compares the primary energy and water use associated with the consumptive use, delivery, and disposal of aqueous MWFs with three gas-based MWFs in the literature-minimum quantity lubricant-in-compressed air (MQL), liquid/gaseous N-2, and liquid/supercritical CO2. The comparison accounts for reported differences in machining performance in peer-reviewed experimental studies across several machining processes and materials. The analysis shows that despite the reported improvement in tool life with N-2 and CO2-based MWFs, the electricity- and water-intensive separation and purification processes for N-2 and CO2 lead to their higher primary energy and water use per volume of material machined relative to water-based MWFs. Although MQL is found to have lower primary energy use, significant consumptive water use associated with the vegetable oil commonly used with this MWF leads to higher overall water use than aqueous MWF, which is operated in a recirculative system. Gas-based MWFs thus shift the water use upstream of the manufacturing plant. Primary energy and water use of gas-based MWFs could be reduced by focusing on achieving higher material removal rates and throughput compared to aqueous MWF instead of solely targeting improvements in tool life. Additionally, the consumptive use of CO2 and N-2 MWFs could be minimized by optimizing their flow rates and delivery to precisely meet the cooling and lubrication needs of specific machining processes instead of flooding the tool and workpiece with these gases. This article met the requirements for a gold-gold JIE data openness badge described at http://jie.click/badges.

cutting fluids↗

DOE OSTI2021

Diurnal observations of basal stem CO2 efflux in three canopy dominant trees in the central Amazon

We explored mechanisms responsible for disturbance-induced shifts in carbon metabolism in forests north of Manaus, Brazil (S2º 38' 17", W60º 09' 25"), using data from a selective logging experiment (BIONTE). BIONTE (the BIOmass and NuTrient Experiment) selective logging treatments were initiated in the mid-1980s and comprised variable removal of commercial tree (not total) species basal area (T1 =32%, T2 = 42%, T3 = 69%), and control plots with no logging (T0). Raw data including tree base diameter (Db), CO2 concentration versus time inside a static stem chamber, and wood density were used to derive stem respiration rates (Rw), wood production rates (Pw), and wood carbon use efficiency (CUE). Changes in tree base diameter (Db; measured at 1.3 m height, or above the buttresses) was used to calculate wood production for individual trees (Pw). Wood density enabled calculation of stem growth rate in the same units as stem respiration (mmol C m-2 s-1). Four trees were randomly selected from five tree growth rate classes for each treatment block, for a total of 20 trees per treatment block, or 80 trees total from the BIONTE plots. Each of the 80 trees selected for the Rw study were outfitted with dendrometer bands (da Silva et al. 2002). Stem respiration was measured using the method described in Chambers et al. (2004). Briefly, an infra-red gas analyzer (LiCor 820) was operated as a closed dynamic chamber with a flow rate of 1.0 L min-1. Polyvinyl chloride (PVC) semi-cylindrical chambers (250–400 mL) were secured to the tree stem near the dendrometer bands using nylon straps. The measurement interval spanned 1–2 min, and the CO2 flux from the stem of each tree was quantified using the enclosed stem area and slope of the stem CO2 concentration versus time.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Direct air capture of CO2: from insights into the current and emerging approaches to future opportunities

The rapid development of direct air capture (DAC) technologies has become critical in order to remove CO 2 from the atmosphere and limit global warming to a maximum of 1.5°C. In this perspective, we provide a mini review of the current research on the emerging liquid- and solid-based sorbent materials to capture CO 2 , summarize the existing challenges of DAC technologies, and suggest future research directions to accelerate the development of DAC systems. In particular, the desired properties for a breakthrough sorbent that efficiently captures CO 2 from the air and releases it for sequestration are described.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Microbial electro-photosynthesis

Methods and apparatus for growing photosynthetic organisms lacking Photosystem II (PSII) function using externally supplied electrons shuttled into the organism using redox mediators to improve photosynthetic output and to produce and recover chemicals of interest. By removing PSII, all PAR photons are funneled toward Photosystem I, thereby significantly increasing the theoretical photon utilization efficiency for CO2 fixation, energy storage and the capacity to synthesize valuable chemicals. Additional genetic modification can be performed to insert or enhance specific metabolic pathways to generate products of commercial interest.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Optimal Design of Intensified Towers for CO2 Capture with Internal, Printed Heat Exchangers

Solvent-based carbon capture processes typically suffer from the temperature rise of the solvent due to the heat of absorption of CO2. This increased temperature is not thermodynamically favor-able and results in a significant reduction in performance in the absorber column. As opposed to interstage coolers, which only remove, cool, and return the solvent at discrete locations in the column, internal coolers that are integrated with the packing can cool the process inline, which can result in improved efficiency. This work presents the modeling of these internal coolers within an existing generic, equation-oriented absorber column model that can cool the process while allowing for simultaneous mass transfer. Optimization of this model is also performed, which is capable of optimally choosing the best locations to place these devices, such that heat removal and mass transfer area are balanced. Results of the optimization have shown that optimally placed cooling elements result in a significant increase in the capture efficiency of the process, compared to a similar column with no internal cooling, with a common trend being the cooling of the column in the temperature bulge region. It is observed that by optimally placing an internal cooler, the solvent flow rate can be decreased, and the CO2 lean loading can be increased while still maintaining the same efficiency. These process changes can lead to a substantial reduction in costs due to lower reboiler duty.

Summits, Stephen↗

DOE OSTI2022

Amine Oxidation Catalyzed by NO 2

Amine oxidation is a major risk in the deployment of amine scrubbing for CO2 capture from post-combustion flue gas. Oxidation probably occurs by dissolved oxygen at elevated temperature, Fe(III)/Fe(II) shuttling between the absorber and the stripper, and by NO2 in the absorber. Amine selection, dissolved oxygen removal, and solvent reclaiming mitigate oxidation due to dissolved oxygen and iron shuttle mechanism, but not by NO2. This work examines piperazine (PZ) oxidation by NO2 in a bench-scale high gas flow reactor (HGF). PZ is an effective second-generation solvent with high CO2 capacity, fast capture rate, good thermal stability, and good resistance to oxidation. Flue gas typically contains 0.5–5 ppm NO2 and 10–100 ppm NO. NO2 at 1 ppm in the flue gas appears to cause significant amine oxidation in pilot plant testing. PZ solution can easily absorb NO2, and it is hypothesized that NO2 can catalytically oxidize PZ through free-radical propagation. The issue may not be solved by a NO2 pre-scrubber since the coexistence of NO and O2 in the flue gas will keep producing non-negligible amounts of NO2 in the ductwork and the absorber after the NO2 incoming with the flue gas has been scrubbed. In addition, NO2 may not only oxidize PZ but also the intermediate degradation products, and it is unknown if the existence of dissolved iron influences the oxidation by NO2. Previous workers have also shown that NO2 is the stoichiometric source of nitrosamine. A comprehensive analysis of NO2 oxidation is needed to address solvent management and its health/environmental impact. The new high gas flow (HGF) reactor focuses only on the absorber environment and is simpler to interpret because it does not include oxidation at high temperatures and by dissolved metal catalysts from corrosion. This paper presents the results of HGF experiments and shows evidence to support a hypothesis of amine oxidation catalyzed by NO2, presents the synergic effect of NO2 and iron on amine oxidation, points out the different effects of NO2 in clean and degraded solvents, and demonstrates that NO2 not only can oxidize amines but also their degradation products.

NO2, iron, piperazine (PZ), solvent oxidation, sol↗

DOE OSTI2024

Disruptive Technology for Carbon Negative Commodity Chemicals

This project was designed to develop an economically attractive process for the carbon negative production of the commodity biochemical succinic acid. To compete against petroleum derived biochemicals, the process must deliver high raw material conversion efficiency and high volumetric productivity to reduce both recurring and capital-related costs, respectively. The proposed process introduces additional electrons sourced from hydrogen into the biosynthetic pathway so that the carbon from two CO2 molecules can be combined with each glucose to significantly increase succinic acid yields. The process also uses ultrafiltration to continuously remove the product from the bioreactor to avoid product inhibition and extend the productive life of the cell extract. Genetic deletions and specific enzyme removal during extract preparation more efficiently direct both atomic and electronic resources toward product formation. A preliminary technoeconomic analysis indicates that these process innovations made possible by cell-free production will enable large scale production with attractive ROI and profitability. This two-year project provided some 29 distinct insights, analytical advances, and process improvements that resulted in a demonstration of process feasibility. However, an estimated two to three years of additional development will be required to achieve convincing pilot scale demonstrations that will motivate large scale investments.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2025

Net-Zero Lime Kiln and Carbon Removal Facility

The final scientific/technical report for DE-FE0032248. The Project Objective for DE-FE0032248, Net-Zero Lime Kiln and Carbon Removal Facility, was to execute and complete the initial design of a commercial-scale, advanced carbon capture system that separates CO2 with at least 95% capture efficiency from process streams at the Carmeuse Kentucky (KY) lime plant that will be retrofitted to utilize sustainably sourced biomass (SSB) alone or in combination with natural gas, and/or coal, with at least a 20-year available feedstock supply and remaining asset life.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Numerical Simulation of Biogenic Fluid Catalytic Cracking (BFCC) Regenerators at Different Scales with MFIX-Exa

Catalytic Fast Pyrolysis (CFP) is a process that converts biomass into liquid intermediates suitable for transportation fuels by rapidly heating it in the presence of a catalyst, aiming to produce stable oils with reduced oxygen content. During CFP, the catalyst can become deactivated by the accumulation of coke, a carbon-rich deposit formed from the decomposition of biomass components. Unlike in petroleum refining, regenerating coked catalysts from biomass pyrolysis requires specific approaches due to the different chemical nature of the coke formed. An experimental technique, Temperature Programmed Oxidation (TPO), was used to study the de-coking process by gradually increasing temperature while monitoring the production of CO and CO2, which provides data for kinetic modeling. Utilizing data from TPO experiments, coke combustion kinetic model was developed to describe the rate of coke removal at different temperatures, allowing for simulation of regeneration processes. Then kinetic model is integrated into MFIX-Exa for the simulation of Biogenic Fluid Catalytic Cracker (BFCC) regenerator at different scales, enabling analysis of catalyst flow, temperature distribution, and regeneration efficiency under various operating conditions.

biogenic fluid catalytic cracking↗

DOE OSTI2021

Influence of Cs Loading on Pt/m-ZrO 2 Water–Gas Shift Catalysts

Certain alkali metals (Na, K) at targeted loadings have been shown in recent decades to significantly promote the LT-WGS reaction. This occurs at alkali doping levels where a redshift in the C-H band of formate occurs, indicating electronic weakening of the bond. The C-H bond breaking of formate is the proposed rate-limiting step of the formate associative mechanism, lending support to the occurrence of this mechanism in H2-rich environments of the LT-WGS stage of fuel processors. Continuing in this vein of research, 2%Pt/m-ZrO 2 was promoted with various levels of Cs in order to explore its influence on the rate of formate intermediate decomposition, as well as that of LT-WGS in a fixed bed reactor. In situ DRIFTS experiments revealed that Cs promoter loadings of 3.87% to 7.22% resulted in significant acceleration of the forward formate decomposition in steam at 130 °C. Of all of the alkali metals tested to date, the redshift in the formate ν(CH) band with the incorporation of Cs was the greatest. XANES difference experiments at the Pt L 2 and L 3 edges indicated that the electronic effect was not likely due to an enrichment of electronic density on Pt. CO 2 TPD experiments revealed that, unlike Na and K promoters, Cs behaves more like Rb in that the decomposition of the second intermediate in LT-WGS, carbonate species, is hindered due to (1) increased basicity of Cs, (2) the tendency of Cs to cover Pt sites that facilitate CO 2 decomposition, and (3) the tendency of Cs to increase Pt particle size as shown by EXAFS results, resulting in fewer Pt sites that facilitate CO2 decomposition. As such, the LT-WGS rate was hindered overall and the rate-limiting step shifted to carbonate decomposition (CO 2 removal). Like its Rb counterpart, low levels of added Cs (e.g., 0.72%Cs) were found to improve the stability of the catalyst relative to the unpromoted catalyst; the stability comparison was made at similar CO conversion level as well as similar space velocity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗