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Researchers from DOE's Feedstock-Conversion Interface Consortium and Feedstock Logistics Program describe sources of feedstock variability and why it matters for biorefinery operations.
We developed an CFD aided ML-based tool for rapid assessment and optimization of different compositions of biomass in a fluidized bed reactor. First, we use CFD to simulate fluidized bed reactors with known inlet biomass mixtures and obtain corresponding syngas yields. A lumped kinetic mechanisms represents the conversion of cellulose, hemicellulose, and lignin, as well as subsequent cracking of tars into non-condensable gases (H 2 , CO, CO 2 , CH 4 ). We use Bayesian analysis/optimization to obtain the ideal operational and mass flow conditions for hydrogen production.
There is an urgent need to accelerate energy crop development for the production of renewable transportation fuels from biomass. Our interdisciplinary team developed mobile, ground-based and aerial phenotyping platforms and advanced remote sensing data analysis tools to acquire and process imagery from different types of cameras (e.g. RGB, multispectral, hyperspectral, and thermal sensors) and LiDAR point cloud data in large-scale sorghum field trials during phase 1 of the project. Phase 2 focused on Technology to Market activities to deliver these systems to the market place coupled with targeted research programs to address specific limitations or challenges for these systems.
During the years of 2018 through 2023, The Washington State University Energy Program (WSU EP) operated the Northwest Combined Heat and Power Technical Assistance Partnership under contract to the US Department of Energy’s Advanced Manufacturing Office (AMO), a part of DOE’s larger Office of Energy Efficiency and Renewable Energy. This contract provided direction and funding for providing technical outreach, information and technical/economic analysis services in support of expanding development of Combined Heat and Power (CHP) over a four state region in the Pacific Northwest. The states served included Alaska, Idaho, Oregon and Washington. During the duration of this contract, the WSU EP delivered performed specific assigned tasks and provided services of various generally prescribed types, with the overall goal of increasing adoption of CHP as an efficient heat and power supply in the region. Indications – though not formally evaluated to our knowledge – are that this goal was achieved. Over many years, the WSU team has provided support for CHP developments in these states under similar previous Department of Energy contracts, and many such projects have been built. While the early-phase outreach, education and techno-economic assessments that the NW CHP TAP provides rarely immediately result in project construction, there is no doubt that the WSU EP team has had substantial influence in the construction of a number of important CHP projects in the region. Examples of projects implemented directly under the current team’s guidance and services during this contract cycle include an 875 kilowatt biomass fueled CHP system installed at the University of Idaho, and 5 megawatt natural gas fueled CHP system at the University of Montana ( UM Breaks Ground on New Power Facility, Slashes Emissions 30% (umt.edu) ). Many other CHP systems recently installed are also either directly or at least partially the result of information and technical services provided by the team. Finally, though much more difficult to quantify and less glamorous, the team has helped countless organizations to understand CHP and determine whether and how CHP may be a fit for them, before they consider paying for engineering services. Whether the ultimate outcome has been to include CHP or not, the expert skills provided by the NW CHP TAP team have provided real value to these organizations considering this relatively complex technology. Over the duration of the contract our team provided 71 Initial Technical Assessments and 17 Advanced Technical Assessments; 53 End-User Engagements and 33 Stakeholder Engagements of various types; 42 Technical Profiles (Project Profiles, Program Profiles and Policy Profiles), and produced 14 technical articles for the Department of Energy. Unfortunately, these quantities provide no measure of the value that the team has provided. Only our clients can judge that, and we are confident that they are pleased with the benefits we have offered them.
Efficient Biomass Separation Object detection of anatomical parts (Cob, Stalk, Husk) in IR images enables precise separation, improving preprocessing (e.g., drying, grinding) for biofuel production. Detailed Biomass Characterization with Hyperspectral Data Hyperspectral imaging captures spectral signatures of biomass, allowing for the identification of specific traits like moisture content, lignin levels, and nutrient composition, leading to optimized treatments for each biomass part. Enhanced Feedstock Quality By leveraging hyperspectral data, feedstock can be processed based on its chemical composition, improving conversion efficiency and biofuel yield. Automation for Large-Scale Operations Automated object detection and hyperspectral data analysis reduce manual labor, ensuring accurate sorting and faster processing, making large-scale biofuel production more efficient. Maximized Biomass Utilization Accurate identification of biomass properties minimizes waste and ensures that each part is processed according to its highest biofuel potential.
In recent years, researchers at the National Renewable Energy Laboratory (NREL) and the University of California Berkeley (UC Berkeley) have independently developed catalysts that convert methanol and dimethyl ether into alkylate-like hydrocarbons with a high-octane value, and both have developed intellectual property around these chemical transformations. Both UC Berkeley and NREL wish to see their technologies commercialized to address a number of domestic and international energy challenges. The technologies developed by NREL and UC Berkeley are complimentary but neither have moved beyond the laboratory scale due to remaining challenges with the catalyst activity and selectivity, and/or with the reaction engineering associated with maximizing the yield of the high-value product. NREL and UC Berkeley wish to collaboratively through a shared resources CRADA to solve issues related to the scale-up and process integration of their high-octane hydrocarbon technologies, thus enabling future licensing of the technology to an industry partner.
The University of Utah, in partnership with Idaho National Laboratory (INL), evaluated Sorption-Enhanced Gasification (SEG) as a transformative pathway for producing hydrogen with the potential for negative CO 2 emissions. SEG integrates gasification, water-gas shift, and in-situ carbon capture within a dual fluidized bed reactor to enable efficient clean hydrogen production. Key challenges related to biomass variability and process complexity were addressed through feedstock engineering, reaction optimization, and process validation. A co-pelletized biomass–limestone feedstock was developed to simplify feeding and introduction of makeup limestone. Kinetic and sorbent studies identified optimal operating conditions and confirmed the suitability of low-cost limestone, while catalysts were developed to reduce tar formation. Reactor modeling and techno-economic analysis indicated that SEG can achieve competitive hydrogen production costs, particularly when combined with carbon incentives, supporting its potential for scale-up and carbon-negative operation.
This report presents an assessment of the cost and performance of gasification systems fed with alternative solid feedstocks. Three gasification plant configurations with carbon capture and storage (CCS) fed with biomass, municipal solid waste (MSW), and mixed plastic waste (MPW) were analyzed and compared using standard technoeconomic analysis techniques.
One dominant challenge facing the development of biorefineries is achieving consistent system throughput with highly variant biomass feedstock quality and handling performance. Current handling unit operations are adapted from other sectors (primarily agriculture), where some simplifying assumptions about granular mechanics and flow performance do not translate well to a highly compressible and anisotropic material with nonlinear time- and stress-dependent properties. This work explores the shear and frictional properties of loblolly pine at multiple experimental test apparatus and particle scales to elucidate a property window that defines the shear behavior over a range of material attributes (particle size, size distribution, moisture content, etc.). In general, it was observed that the bulk internal friction and apparent cohesion depend strongly on both the stress state of the sample in granular shear testers and the overall particle size and distribution span. For equipment designed to characterize the quasi-static shear stress failure of bulk materials ranging from 50 to 1,000 ml in test volume, similar test results were observed for finely milled particles (50% passing size of 1.4 mm) with a narrow size distribution (span between 10 and 90% passing size of 0.9 mm), while stress chaining and over-torque issues persisted for the bench-scale test apparatus for larger particle sizes or widely dispersed sample sizes. Measurement of the anisotropic particle–particle friction ranged from coefficients of approximately 0.20 to 0.45 and resulted in significantly higher and more variable friction measurements for larger particle sizes and in perpendicular alignment orientations. To supplement these laboratory-scale properties, this work explores the flow of loblolly pine and Douglas fir through a pilot-scale wedge-shaped hopper and a screw feeder. For the gravity-driven hopper flow, the critical arching distance and mass discharge rate ranged from approximately 10 to 30 mm and 2 to 16 tons/hour, respectively, for both materials, where the arching distance depends strongly on the overall particle size and depends less on the hopper inclination angle. Comparatively, the auger feeder was found to be much more impacted by the size of the particles, where smaller particles had a more consistent and stable flow while consuming less power.
Volatile products from thermal decomposition of lignocellulosic biomass have been well characterized, but the solid- and liquid-phase reactions during the early stages of decomposition are largely unknown. Here the initial solid-phase biomass thermal deconstruction reactions were analyzed in situ and with high particle heating rates, delineating how these processes occur. A variety of instrumentation was used to quantify the extent and relative rates of deconstruction, demonstrating that biopolymers resist the thermally energetic conditions to differing degrees, even when ensconced in biomass cell walls. Hemicellulose and the more frangible lignin components decompose and volatilize more readily than cellulose, which temporarily enriches biomass with cellulose. These chemical changes manifest in larger cell wall structural and mechanical property transformations. In all, this investigation concludes that these solid-phase reactions strongly influence the production rates of volatile species and will require additional study before these processes can be modeled precisely to improve yields of desired product.
This study demonstrates a failure identification methodology applied to a preprocessing facility generating conversion-ready feedstocks from biomass meeting conversion process critical quality attribute (CQA) specifications. Failure Modes and Effects Analysis (FMEA) was used as an industrially relevant risk analysis approach to evaluate a logging residue preprocessing system to prepare feedstock for pyrolysis conversion. Risk evaluations considered both system-level and operation unit-level assessments considering process efficiency, product quality, cost, sustainability, and safety. Key outputs included estimations of semi-quantitative risk scores for each failure, identification of the failure impacts, identification of failure causes associated with material attributes and process parameters, ranking success rates of failure detection methods, and speculation of potential mitigation strategies for decreasing failure risk scores. Results showed that deviations from moisture specifications had cascading consequences for other CQAs along with process safety implications. Failures linked to fixed carbon specifications carried the highest risk scores for product quality and process efficiency impacts. As increased throughput can be inversely related to meeting product quality specifications; achieving throughput and other material-based CQAs simultaneously will likely require system optimization or prioritization based on system economics. Ultimately, this work successfully demonstrates FMEA as a risk analysis approach for other bioenergy process systems.
Five economically advantaged biomass feedstocks identified in the US Department of Energy's 2016 Billion Ton Study were gasified and the syngas reformed at the bench scale to study the feedstock price-performance relationship. The distribution of reformed syngas compositions, heating values, and yields were similar across the different feedstocks and blends thereof, which ranged from inexpensive residual wastes to more expensive and higher quality biomass, revealing that feedstock performance was mostly insensitive to its price. Custom blended feedstocks produced syngas with characteristics resembling linear combinations of syngas from single-component feedstocks, supporting the ability to customize and predict blended properties based on single-feedstock data. A techno-economic analysis of specific feedstock costs for producing high-octane gasoline showed that miscanthus and forest residues were the most cost-effective with gas yields consistent with experimental gasification data. A field-to-wheels life-cycle assessment of greenhouse gas emissions showed that forest residues was the most environmentally benign feedstock of those studied.
ESSS is the marketer of a software that Yidong Xia and his team used in a recent study. Yidong published an article mentioning the software, Rocky DEM, and the company asked if they could interview Yidong and write what they call a case study and a blog post for their website. They are both fairly similar, just from different angles.
Objective: The objective of this task is to identify the costs of sorting municipal solid wastes (MSW) into different product streams that would be suitable for inclusion in potential low-cost feedstock blends. Expected Outcome: Progress Milestone – Complete a MSW sorting process model that includes unit operations of shredding, screening, sieving, air classification, magnetic separation and eddy current separation in conjunction with a MSW sorting equipment supplier. This model will be scalable such that it can be utilized in both large urban areas and rural areas.
Research on harvesting, collection, and storage has matured, and our understanding of feedstock supply challenges has led us to the point of our current goals. The goals of this project include using storage time to collect impactful data of critical feedstock properties in storage and to characterize the feedstock before delivery. This data will inform delivery scheduling of biomass and relevant compositional information to minimize variations in the material quality, which are critical to the preprocessing and conversion performance.
The overall objective is to solve the particle attrition issue during biomass grinding and pelleting and to enable pelleting as a viable option for production of on-spec material or conversion-ready cellulosic feedstocks.
The project goal includes developing model pathways to improve sustainability of feedstock supply chains to reduce access costs and the environmental footprint. The project aims to harness synergies of production and collection practices and current systems to improve economic and environmental outcomes.
To evaluate the re-design and reconfiguration of a dual-fluidized bed (DFB) gasification system into a recirculating pyrolysis reactor, Computation Fluid Dynamic (CFD) simulations of the system were conducted. The Barracuda Virtual Reactor® computational particle fluid dynamic code was used to perform simulations of the pyrolysis process. Modeling of the chemical reaction kinetics for both gas phase and solid particle phase were included. The recirculating pyrolysis reactor shown in Fig. 1a is based on a bubbling-bed biomass pyrolyzer and a riser combustor to convert the remaining char. The operational differences in the re-configuration of the DFB gasification system into a recirculating pyrolysis system for the production of bio-oil are (1) replacement of a low-surface area inert bed material with a high-surface-area bed material that has acidic properties to provide catalytic activity for the production of bio-oil with reduced oxygen content, (2) lower temperature and residence time for bio-oil production from pyrolysis, (3) replacement of the fluidization gas in the bubbling bed pyrolyzer from steam to nitrogen, and (4) the reduction of pyrolyzer freeboard volume. The bed material used for catalytic pyrolysis is Sasol 300 (300-micron dia., bulk density 0.94 kg/l, and surface area 130 m2/g) and is a theta-alumina with mild acidity. This is in comparison with previous standard bed material Carbo HSP (430-micron dia., bulk density 2.01 kg/l, and surface area 0.03 m2/g) used for gasification. For bio-oil production, pyrolysis in the bubbling bed requires temperatures in the range of 550 C in comparison with gasification temperatures near 850 C. To attain this lower temperature requires management of the energy mass balances, with control of the bed material recirculation rate between bubbling bed pyrolyzer and riser combustor, the introduction of a nitrogen purge in the pyrolyzer, and adjusting the pressure balance between the two vessels. To extract bio-oil from the pyrolysis reactor with a snorkel, two different freeboard configurations were evaluated. In Fig. 1 b the existing high freeboard configuration is shown and in Fig. 1 c the reduced freeboard design is presented. The introduction of a nitrogen purge for the high free board configuration provided the highest bio-oil production from the CFD simulations. To decrease the bed-material circulation rate, primary and secondary air on the combustor side were reduced, and the pressure on the combustor was slightly increased. A portion of the biomass and bio-oil was observed to be transported to the combustor, leading to a smaller pyrolysis yield. The control of the pyrolyzer temperature is performed by controlling the circulation rate. Good fluidization of the bubbling bed and cascade PID control are required to keep the temperature from oscillating due to large time delay experienced when changing primary and secondary air. (a) (b) (c) Figure 1. (a) Dual Fluidized Bed pyrolysis system configuration, (b) mole fraction of nonpolar biooil in high freeboard configuration, and (c) mole fraction of nonpolar bio-oil in low freeboard configuration with nitrogen purge introduced in both configurations.