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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Harvesting Energy from Wastewater by Converting Sewage

This project aims were to develop and demonstrate a scalable, integrated process to convert sewage sludge into renewable natural gas (RNG), enabling wastewater treatment plants (WWTPs) to become net energy producers. The system proposal integrates autothermal hydrothermal liquefaction (AT-HTL), supercritical salt precipitation (SCSP), and hydrothermal gasification (HTG), collectively forming the Supercritical Sludge-to-Gas (SC-S2G) platform. Initially, batch hydrothermal liquefaction reactions were used to screen sewage sludge using AT-HTL (later termed RI-HTL) conversion to biocrude, aqueous and char phases compared to hydrothermal liquefaction (HTL). Significant improvement in biocrude yield using peroxide addition at O:C ratio of 0.05 and under conditions of 300°C for 10 minutes gave 57% biocrude yield and 85% fluid carbon yield (biocrude plus aqueous), while minimizing the loss of carbon to char solids (~7%). Hence, RI-HTL was shown to be effective for conversion of real sewage sludge. The corrosion of the alloy reactor tubes or vessels is an important factor when developing a process that includes an oxidant and a chemically complex feed like sewage sludge. We investigated the corrosion rates on metal alloys at 350°C for 240 hours. Corrosion rates of 0.21 and 0.26 mpy for 304L and 316L stainless steel were measured respectively. The corrosion information obtained in this investigation was utilized by PNNL for design, materials sourcing and construction of the pilot scale continuous flow system.

09 BIOMASS FUELS↗
DOE OSTI2024

Pilot microbial electrolysis cell closes the hydrogen loop for hydrothermal wet waste conversion to jet fuel

The global shift toward net-zero emissions necessitates resource recovery from wet waste. In this study, we demonstrate the first feasibility of combining pilot-scale microbial electrolytic cells (MECs) with hydrothermal liquefaction (HTL) for simultaneous post-hydrothermal liquefaction wastewater (PHW) treatment and efficient hydrogen (H₂) production to meet biocrude upgrading requirements. Long-term single reactor operation revealed that fixed anode potential enabled rapid startup, and low catholyte pH and high salinity were effective in suppression of cathodic methanogenesis and acetogenesis – resulting in high current density of 16.6 A m –2 and 9.3 A m –2 when feeding synthetic wastewater and PHW respectively. Additionally, the anode biofilm exhibited spatial variations in response to local environmental conditions. In conclusion, onsite parallel or serial operations of multiple MECs showed good performance using actual PHW with a record-high H 2 production rate of 0.5 L L R day –1 for MEC over 10 liters scale, and the optimal chemical oxygen demand (COD)-to-H 2 yield reached 0.127 kg-H 2 per kg-COD, supporting a self-sufficient, closed-loop upgrade to jet fuel.

08 HYDROGEN↗
DOE OSTI2023

MHTLS Cross-flow Heat Exchanger Temperature Performance Data

The presentation and supporting information provide data on the performance of an engineering-scale cross-flow heat exchanger used in hydrothermal liquefaction (HTL). Temperature profiles are provide for the process of waste water treatment sludges and a food waste. The data can be used to model larger-scale heat exchangers used in HTL.

Bioenergy Technologies Tags Heat Exchanger HTL MHT↗
DOE OSTI2021

Development of Algal Biomass Yield Improvements in an Integrated Process (Final Report)

This project built on the success of Global Algae Innovations Algae Biomass Yield Phase 1 project to accelerate the commercialization of algal biofuels through development of an integrated, economical, photosynthetic, open raceway system to produce algal oil. Two parallel pathways to a biofuel were investigated. In the algal crude oil pathway, highlighted in blue, the dewatered algal biomass slurry is used as a feed to hydrothermal liquefaction to produce an algae crude oil and recycle aqueous stream. In the algal lipid oil pathway, highlighted in green, the algal biomass slurry is dried, and the oil is extracted to produce an algal lipid oil biofuel intermediate and a high protein algae meal co-product. Upgrading to drop-in fuels has been demonstrated for the biofuel intermediates in both pathways. Since the algal lipid oil pathway requires lipid accumulation, the productivity is generally lower than the algal crude oil pathway, but the required productivity for economical algal biofuel production is also lower because the coproduct value is greater. The outdoor cultivation was performed at the Kauai Algae Farm. The project team has expertise across the full breadth strain development, advanced algal cultivation, open raceway contamination control, CO 2 supply, harvesting, dewatering, extraction, hydrothermal liquefaction, technoeconomic analysis and life cycle analysis: Hildebrand laboratory at Scripps Institution of Oceanography – diatom strain development. Mayfield laboratory at UCSD - green algae strain development. TSD Management Associates- CO 2 supply, algal harvesting and dewatering, and algal drying and extraction. Qualitas - large-scale test site for algal harvesting technology. Texas A&M University - algal drying and extraction technology. Pacific Northwest National Laboratory - hydrothermal liquefaction technology. GE Water and Power - membrane technology. National Renewable Energy Laboratory - algal techno-economic analysis. Phase 1 of the project resulted in tremendous productivity and pre-processing improvements in an integrated, large-scale, low-cost cultivation and pre-processing process that moved algal technology closer to economic viability for biofuels than ever before. Phase 2 accomplishments further facilitate development of a commercial algal biofuel industry by adding: several top performing strains and strain development tools including breeding; open-pond cultivation innovations that achieved a 30% improvement in overall productivity, an 83% reduction in cost, and a 95% reduction in energy use relative to conventional technology; further improvements in harvesting that led to the Zobi harvester ® as a universal, economical, low energy, commercially available microalgae harvesting solution; breakthroughs in drying and extraction including a new low energy drying process and several new low energy extraction unit operations that together with the Zobi harvester ® achieve a 90% reduction in cost and 97% reduction in energy use relative to conventional technology. These improvements are sufficient to enable economical production of algae biofuel and protein meal co-product if the process were scaled up to a commercial-scale 5,000-acre algae farm.

09 BIOMASS FUELS↗
DOE OSTI2022

Techno-economic analysis of cellulosic ethanol conversion to fuel and chemicals

In this paper, we describe multiple scenarios investigated to assess the techno-economic results of producing fuels from corn stover-derived ethanol and the impact of co-producing higher-value, ethanol-derived n-butanol and 1,3-butadiene to improve economic feasibility. An alternative approach that produces only chemicals from the lignocellulosic-derived ethanol while producing fuels from the residual cell mass, unconverted sugars and lignin using hydrothermal liquefaction and hydrotreating also is described. Our results indicate that the hydrothermal liquefaction pathway has cost advantages relative to pathways that burn lignin from the corn stover conversion process to make ethanol when the associated ethanol stream is used to make only chemicals.

09 BIOMASS FUELS↗
DOE OSTI2020

Restoring Pre-Industrial CO2 Levels While Achieving Sustainable Development Goals

Unless humanity achieves United Nations Sustainable Development Goals (SDGs) by 2030 and restores the relatively stable climate of pre-industrial CO2 levels (as early as 2140), species extinctions, starvation, drought/floods, and violence will exacerbate mass migrations. This paper presents conceptual designs and techno-economic analyses to calculate sustainable limits for growing high-protein seafood and macroalgae-for-biofuel. We review the availability of wet solid waste and outline the mass balance of carbon and plant nutrients passing through a hydrothermal liquefaction process. The paper reviews the availability of dry solid waste and dry biomass for bioenergy with CO2 capture and storage (BECCS) while generating Allam Cycle electricity. Sufficient wet-waste biomass supports quickly building hydrothermal liquefaction facilities. Macroalgae-for-biofuel technology can be developed and straightforwardly implemented on SDG-achieving high protein seafood infrastructure. The analyses indicate a potential for (1) 0.5 billion tonnes/yr of seafood; (2) 20 million barrels/day of biofuel from solid waste; (3) more biocrude oil from macroalgae than current fossil oil; and (4) sequestration of 28 to 38 billion tonnes/yr of bio-CO2. Carbon dioxide removal (CDR) costs are between 25–33% of those for BECCS with pre-2019 technology or the projected cost of air-capture CDR.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

A Review on Lignin Liquefaction: Advanced Characterization of Structure and Microkinetic Modeling

Lignin liquefaction microkinetics is a move toward a more first principles (i.e., ab initio) based understanding at the molecular level in reaction engineering. While the microkinetic modelling of reactions to obtain kinetic rate parameters of chemical reactions have been widely used in the field of gas phase combustion and heterogeneous catalysis, this approach has not been as thoroughly developed in the area of biomass thermochemical reactions (e.g., lignin pyrolysis, hydrothermal liquefaction). The difficulties in establishing the structure of complex heterogeneous materials, like lignin, is perhaps the main challenge in developing rational microkinetic descriptions of biomass thermochemical reactions. In this manuscript we review the current state of the art and the challenges to develop microkinetic models for lignin liquefaction technologies (e.g., pyrolysis, hydrothermal liquefaction, solvolysis). A general strategy for the development of microkinetic models for lignin liquefaction technologies is discussed. Here, the first hurdle is to obtain sufficiently rich experimental data of lignin underlying polymeric structure and methodologies to use this data to build realistic lignin structural representations. Some analytical techniques for lignin structural characterization and their associated data, as well as a correlation for calculating the degree of macromolecular lignin branching are discussed. The presence of small lignin oligomeric structures and the role of these structures in lignin pyrolysis is also addressed. The ways in which elementary deconstruction and repolymerization reactions occur within this structure to form a liquid intermediate, and how these deconstruction products continue to interact with each other until they are removed from the liquid intermediate is thoroughly discussed. Further, experimental work with model compounds and the effect of reaction parameters (e.g., temperature, pressure, vapor residence time) are reviewed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Techno-economic analysis of bioplastic and biofuel production from a high-ash microalgae biofilm cultivated in effluent from a municipal anaerobic digester

Rotating Algae Biofilm Reactors (RABRs) are a promising technology for efficient treatment of wastewater and production of algae-based bioproducts. However, RABR-grown algae can contain a high content of ash (30–60 wt%, dry basis), which influences the technical and economic feasibility of bioproduct conversion processes. In this report, experimental studies and economic analysis were conducted to compare different processes for bioproduct conversion of a high-ash microalgae biofilm grown using a RABR treating 0.6 million gallons per day of anaerobic digestion centrate at the Central Valley Water Reclamation Facility in Salt Lake City, UT. Process and economic models were developed and compared for three conversion processes: 1) the production of bioplastics, 2) the production of bioplastics with a lipid-extraction pretreatment, and 3) the production of biocrude via hydrothermal liquefaction. Techno-economic analysis was performed for each conversion process, including three cases for algae productivity: 231, 391, and 577 metric tons per year (dry basis). The calculated value for the minimum plastic selling price (MPSP) of bioplastics produced from algae ranges from $\$4050$ to $\$3520$ per metric ton based on the baseline and final productivity cases of the RABR, respectively. The extraction of lipids in addition to bioplastic production results in an MPSP of $\$4570$ to $\$4000$ per metric ton for the same productivity cases. The relatively small production scale and complex processing for hydrothermal liquefaction results in a minimum fuel selling price of the biocrude of $\$5.32$ per gallon of gasoline equivalent. In conclusion, the conversion process for bioplastic production from whole algae has the highest income:expense ratio and the most cost-competitive pricing of the three modeled processes.

09 BIOMASS FUELS↗
DOE OSTI2021

Greenhouse Gas Impact of Algal Bio-Crude Production for a Range of CO2 Supply Scenarios

Refined bio-crude production from hydrothermal liquefaction of algae holds the potential to replace fossil-based conventional liquid fuels. The microalgae act as natural carbon sequestrators by consuming CO2. However, this absorbed CO2 is released to the atmosphere during the combustion of the bio-crude. Thus, the life-cycle greenhouse gas (GHG) emissions of refined bio-crude are linked to the production and supply of the materials involved and the process energy demands. One prominent raw material is CO2, which is the main source of carbon for algae and the subsequent products. The emissions associated with the supply of CO2 can have a considerable impact on the sustainability of the algae-based refined bio-crude production process. Furthermore, the diurnal algae growth cycle complicates the CO2 supply scenarios. Traditionally, studies have relied on CO2 supplied from existing power plants. However, there is potential for building natural gas or biomass-based power plants with the primary aim of supplying CO2 to the biorefinery. Alternately, a direct air capture (DAC) process can extract CO2 directly from the air. The life-cycle GHG emissions associated with the production of refined bio-crude through hydrothermal liquefaction of algae are presented in this study. Different CO2 supply scenarios, including existing fossil fuel power plants and purpose-built CO2 sources, are compared. The integration of the CO2 sources with the algal biorefinery is also presented. The CO2 supply from biomass-based power plants has the highest potential for GHG reduction, with a GHG footprint of −57 g CO2 eq./MJ refined bio-crude. The CO2 supply from the DAC process has a GHG footprint of 49 CO2 eq./MJ refined bio-crude, which is very similar to the scenario that considers the supply of CO2 from an existing conventional natural gas-based plant and takes credit for the carbon utilization.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Results of the International Energy Agency Bioenergy Round Robin on the Analysis of Heteroatoms in Biomass Liquefaction Oils

A round robin study evaluating the analysis of biomass liquefaction oils (BLOs) from fast pyrolysis and hydrothermal liquefaction (HTL) was performed, involving fifteen laboratories in seven countries in order to assess the current status of analytical techniques for the determination of nitrogen, sulfur, and chlorine content in BLOs and evaluate potential differences in origin (i.e. fast pyrolysis vs HTL). The BLOs were produced from a range of feedstocks including pine, mixed softwoods, forest residues, micro-algae, miscanthus, and wheat straw to cover a variety in nitrogen, sulfur, and chlorine content and speciation. Nine samples were distributed, comprised of eight separate BLOs and one blind duplicate produced by five producers. The samples were analyzed for water, carbon, hydrogen, nitrogen, sulfur, and chlorine content. No analytical test method was mandated; laboratories were encouraged to utilize whichever method they determined would be most applicable, relying on the existing body of BLO literature as a guide. The results of this round robin study are presented in this paper. The results of the carbon, hydrogen, and water measurements as reference analyses had relative standard deviations (2.9%, 3.5, and 5.6%, respectively) that were comparable to those found in past round robin studies on fast pyrolysis bio-oil. The analysis of nitrogen, sulfur, and chlorine showed higher levels of variability. Laboratories mostly chose the same method for water, carbon, hydrogen and nitrogen determination whereas there were a variety of methods chosen for sulfur and chlorine determination. The results suggest that specific analytical methods for the determination of nitrogen, sulfur, and chlorine should be further refined to ensure reproducible and accurate results for BLO analysis due to their importance on emissions, material selection, and catalyst activity.

Biomass, IEA Bioenergy, pyrolysis, hydrothermal li↗
DOE OSTI2022

Economic and Environmental Analysis to Evaluate the Potential Value of Co-Optima Diesel Bioblendstocks to Petroleum Refiners

The U.S. petroleum refining sector is undergoing a period of historic transformation, catalyzed by the decarbonization of the U.S. economy. Diesel-boiling-range bioblendstocks have gained traction, owing to their superior fuel properties and environmental performance as compared to traditional petroleum fuels. This work couples refinery linear programming models with life cycle assessment to quantify the potential economic and environmental benefits, and trade-offs, of blending diesel-boiling-range bioblendstocks at petroleum refineries. Linear programming models were developed in Aspen Process Industry Modeling Systems (PIMS) for three representative petroleum refinery configurations of differing complexity. Seven diesel-boiling-range bioblendstocks: 4-butoxyheptane, 5-ethyl-4-propylnonane, soy biodiesel, sludge hydrothermal liquefaction diesel, polyoxymethylene ethers, renewable diesel, and hexyl hexanoate, were investigated to identify key fuel properties that influence refineries' economics and to track the effect of adding bioblendstocks on refinery-wide cradle-to-gate greenhouse gases (GHG) emissions. These analyses considered blending levels from 10 to 30 vol% and fuel demand projections over the period 2040 to 2050. This analysis determines that bioblendstock sulfur content and cetane number are the primary fuel attributes with the potential to provide value to refiners. Life cycle assessment results indicate that the use of diesel-boiling-range bioblendstocks can reduce cradle-to-gate refinery GHG emissions by up to ~ 40 % relative to conventional refinery operations when considering carbon uptake in the supply chain of the bioblendstock. Refinery-wide marginal GHG abatement costs range from 120 to 3,600 USD2016/metric tons carbon dioxide equivalent avoided across the scenarios evaluated. Reducing the price of bioblendstocks is identified as a key to their adoption.

ADVANCED PROPULSION SYSTEMS,BIOMASS FUELS,ENERGY P↗
DOE OSTI2021

Tailored Bioblendstocks With Low Environmental Impact To Optimize MCCI Engines

This project seeks to overcome impediments to expansion of algae cultivation and conversion into fuels to displace petroleum and reduce greenhouse gas (GHG) emissions. The overall objective of the project is to develop and demonstrate a microalgae bio-blendstock with greater than 60% greenhouse gas reduction relative to petroleum diesel, reduce sooting propensity, increase cetane number, improve engine thermal efficiency relative to a baseline diesel engine operating on conventional fuel. These objectives are being accomplished by: Applying cultivation of algae polycultures to achieve robustness and productivity, Converting whole algae to bio-hydrocarbons via Hydrothermal Liquefaction (HTL) to make a biocrude and up-grading the biocrude via hydroprocessing to obtain tailored bioblendstocks for diesel fuel, Optimizing diesel (MCCI) combustion through blending model compounds into diesel fuel to represent the tailored bioblendstocks through experiments and numerical simulation.

09 BIOMASS FUELS↗
DOE OSTI2022

Improving the Economic Viability of Biological Utilization of Coal Power Plant CO 2 by Improved Algae Productivity and Integration with Wastewater Treatment

The overall goal of this project was to improve the cost-effectiveness of systems using algae to capture and beneficially utilize CO 2 from the flue gas of coal-fired power plants. Algal biomass cultivation is an attractive alternative for carbon capture and utilization because it can uptake more CO 2 per land area than any other photosynthetic crop. Also, the resulting biomass can be used to make valuable large-market commodity products, such as biofuels and animal feed. However, the use of algal carbon capture has been limited by several factors including: (1) high costs for growing algae (>$\$1,300$/ton), (2) large land requirements for algae cultivation, and (3) environmental concerns about the large amount of water and nutrient inputs needed for growing algae. This project has taken direct aim at resolving these key limitations and demonstrated several viable approaches to improve the economic and environmental feasibility of algal carbon capture. In particular, this project demonstrated a significant increase in average annual algal productivity from baseline values of 8 g/m 2 -day to above 20 g/m 2 -day. This supports a much lower projected cost of algae production (<$\$500$/ton) and reduces land requirements by more than 50%. Additionally, this project confirmed the ability to grow multiple algae species with wastewater nutrients, which facilitates the potential for substantial new revenue streams for algae cultivation based on tipping fees for nutrient laden wastewater. This study highlighted that there is more potential value in wastewater nutrient treatment credits than in the primary commodity products made from algae. The use of wastewater inputs also mitigates the concerns associated with the large amount of water needed for growing algae. The algal biomass grown for this project using wastewater and simulated flue gas inputs were characterized for potential use as an animal feed ingredient. The algae had a protein content in the range of 35-40%, which is between some common commodity animal feed products— distiller’s grains (~25-30% protein) and soybean meal (45-50% protein). In-vitro digestion tests using cattle rumen fluids, showed that this algae biomass was best suited for use as “bypass protein”, which is digested in the animal intestine. Based on the protein content and amino acid profile of the algae grown in this study, it was estimated to have market value in the range of $\$190$-$\$280$/ton. There is potential for higher value feed products if the algae content of omega-3 fatty acids or antioxidants is accounted for. This project also did small scale demonstration of forward osmosis algae dewatering and nanofiltration of hydrothermal liquefaction aqueous products, which were shown to improve the cost and energy balance for producing algal products. When all the improvements demonstrated in this study were included in techno-economic analysis, it showed there was a viable pathway to profitable algal CO 2 utilization with a payback period in the range of six to ten years.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

SCALEABLE HYDROTREATING OF HTL BIOCRUDE TO PRODUCE FUEL BLENDSTOCKS

Hydrothermal liquefaction (HTL) offers an attractive route to produce fuel blendstocks from wet wastes. Scaleable hydrotreating data for the conversion of HTL biocrude to fuels is critical to the commercialization of HTL. Herein, we demonstrate pore diffusion limitations for the hydrotreating of HTL biocrudes. We demonstrate scale-able hydrotreating of HTL biocrude to produce a high cetane diesel fuel and demonstrate the hydrotreating limitations.

Biofuel, hydrotreating, HTL biocrude, hydrothermal↗
DOE OSTI2021

Extended catalyst lifetime testing for HTL biocrude hydrotreating to produce fuel blendstocks from wet wastes

This paper presents the upgrading of HTL (Hydrothermal Liquefaction) bio oil produced by from various sources such as sewage sludge and food wastes. The HTL oil was hydrotreated over a CoMo/Al2O3 (guardbed) and NiMo/Al2O3 (mainbed) catalysts at WHSV 0.5hr-1, 400°C and 1500 psi. The steady state densities (at 40°C) were 0.79 and 0.81 g/ml for HTL biocrude derived from sewage sludge and food waste, respectively. After 1500 hours of steady state operation, variations in process conditions that affect the hydrotreating performance had been identified in the following order; Pressure>WHSV>Temperature. Pressure had huge impact on the hydrotreating performance. The hydrotreating efficiency was reestablished to base line conditions with minimal deactivation of catalyst at 2000 hours run time.

Hydrothermal Liquefaction, HTL, Hydrotreating, Bio↗