Results for “Hydrothermal Liquefaction” — Page 8

DOE OSTI2025

Electrocatalytic benchmarking of ruthenium-based bimetallic anodes for the electrocatalytic oxidation of biomass-derived wastewater

In this paper, we report on the synthesis, characterization, and use of ruthenium oxide (RuO 2 ) doped with a secondary metal (M2) to enhance electrochemical activity and stability for the electrocatalytic oxidation (ECO) of biomass-derived wastewaters. We used different electrochemical methods such as cyclic voltammetry (CV), electrochemical surface area (ECSA), and Tafel analysis as well as physical characterization such as grazing incidence X-ray diffraction, X-ray photoelectron spectroscopy, and scanning electron microscopy to understand how the introduction of M2 affects electrochemical performance. Our results show that including an M2 improves the ECO performance regardless of the composition of the electrolyte. Specifically, we saw increase in ECSA, which could be due to enhanced charge transfer for the pH ranges evaluated. Furthermore, the introduction of organic compounds in wastewater generated during the hydrothermal liquefaction of food waste affected the ECO performance differently, depending on M2, the electrolyte composition, and anodic half-cell potential, highlighting the need to properly control the reaction conditions when testing and characterizing the electrocatalysts under different reaction regimes. We developed an in situ electrocatalytic benchmarking protocol, Boruah – Lopez-Ruiz – Strange (BLoRS), to quickly assess if the presence of M2 improves the ECO performance; thus, saving time and resources in ex situ characterization, testing, and product analysis. This foundational work provides the basis for characterization and benchmarking of electrodes of the ECO of organic compounds.

Electrocatalysis↗

DOE OSTI2026

Expanding the horizon of bio-naphtha beyond gasoline blend: property characterization and conversion opportunity assessment through technoeconomic and life-cycle analyses

Bio-naphtha, a common by-product of biorefineries, is expected to experience substantial growth in supply due to increasing demands for renewable diesel and synthetic aviation fuel (SAF). However, demand for bio-naphtha itself as a gasoline blendstock is limited because of the electrification of light-duty vehicles. This work investigated valorization opportunities for bio-naphtha from catalytic fast pyrolysis, hydrothermal liquefaction, Fischer–Tropsch synthesis, and hydrotreated esters and fatty acids pathways. These opportunities include producing polymer-grade olefin via steam cracking, SAF via steam cracking followed by olefin oligomerization, and renewable aromatics benzene, toluene, and xylene (BTX) and hydrogen via catalytic reforming. Process models were developed in Aspen Plus V14 and Aspen HYSYS V14 to calculate the mass and energy balances for each conversion step. Technoeconomic assessment and life-cycle analysis were conducted to evaluate the minimum fuel/product selling price, conversion cost, and life-cycle CO2 equivalent (CO2e) emission reduction. Technoeconomic assessment results suggest a minimum fuel/product selling price as low as $1.9/kg of olefins, $6.30/gal of gasoline-equivalent SAF, and $1.2/kg of BTX without any incentives. For all pathways, these prices are dominated by bio-naphtha feedstock costs, which account for at least 76% of the total cost. Compared with petroleum baselines, bio-naphtha-derived SAF, olefins, and BTX can achieve significant CO2e emission reductions from the use of renewable carbon resources. The results of life-cycle analysis and subsequent technoeconomic assessment, incorporating carbon credits, indicate the economic viability of using bio-naphtha for polymer-grade olefin and BTX production, with product costs comparable to market prices.

Xu, Shuang↗

DOE OSTI2025

Adsorptive denitrogenation of model aviation fuel using mesoporous silica in a packed bed adsorption system

This study aims to understand the effects of system process parameters such as flow rate, adsorbent particle size, and use of recycled adsorbent on denitrogenation performance of a model fuel using mesoporous silica gel. The goal is to reduce the nitrogen content of the model fuel from 1500 parts per million to single-digit ppm to meet ASTM specifications for drop-in fuels. This work was done with the intent of applying adsorptive denitrogenation to sustainable aviation fuel (SAF) product fractions produced via hydrothermal liquefaction (HTL). The adsorption performance of the silica is evaluated via packed column breakthrough data, with data generated from collecting from the column outlet and quantifying nitrogen content via gas chromatography. Select experiments use a significantly larger (2.5x column diameter and length) column to demonstrate linear scalability of the process. Thermogravimetric analysis data is collected to evaluate the effects of thermal calcination as a sorbent regeneration method. Effects of a more complex feed are also investigated using a known reference fuel with additional added nitrogen containing compounds. The results presented in this work successfully demonstrate up to 99.8 % removal of NCCs from a model fuel fraction at an original NCC concentration of approximately 1500 ppm to single-digit parts per million after treatment. We also examine calcination of sorbent materials to remove the adsorbed species to enable sorbent reuse and minimize waste generation and show that the calcined material can be reused up to 5 cycles with reduced adsorption capacity. Overall, this work indicates that adsorptive denitrogenation using silica gel is a viable solution to enable the integration of HTL-derived aviation fuels into existing fuel infrastructure.

Adsorption techniques↗

DOE OSTI2025

Process and environmental safety of thermochemical conversion of biomass

Biomass presents a promising opportunity for converting waste into valuable energy, fuels, and chemicals through various thermochemical processes, including hydrothermal carbonization, hydrothermal liquefaction, pyrolysis, gasification, and combustion. However, these processes operate under extreme conditions, introducing significant safety hazards that necessitate meticulous management to prevent accidents. This review discusses potential hazards, risk mitigation strategies, and safety management practices, emphasizing the importance of integrated safety measures into the design and operation of these processes. It also highlights the critical need for robust safety engineering and environmental management strategies tailored to each thermo-chemical process. As these processes transition from laboratory to industrial scale, there is an imperative to develop a clear and concise pathway for emerging industries to achieve regulatory compliance, achieve safety certification, and enable effective stewardship of potential fugitive emissions. By addressing safety and environmental concerns, stakeholders can optimize economic benefits, rural development, and achieve sustained domestic energy generation benefits offered by biomass conversion technologies. Further research on plant design optimization, operational safety, environmental evaluation standardization, and innovative waste management solutions will support the safe and effective scaling of these technologies, ultimately contributing to sustainable management and resource recovery.

09 - BIOMASS FUELS↗

DOE OSTI2021

Graphitized Biocarbon Derived from Hydrothermally Liquefied Low-Ash Corn Stover

Graphitized biocarbon can be utilized for energy storage applications such as supercapacitors. The scientific community have geared their attention to obtain such value-added product from abundantly available and low-cost biomass feedstock agricultural residues such as corn stover. Lignocellulosic components embedded within the cell wall of biomass substrates can provide a fine template for enhanced ion storage, transport, and rate capabilities, desirable for electrochemical storage. Presented is the utilization of homogenized low ash content corn stover milled and sieved to desired specifications, which underwent hydrothermal liquefaction in the presence of Ni-based catalytic salts at 275 o C. The hydrochar obtained by solid residue extracted from the reaction slurry was washed to acid neutral and subjected to catalytic activation using ZnCl 2 , followed by thermal annealing at 400 o C for morphological and pore size enhancement of the resulting biochar. Carbonization was performed on acid neutralized hydrochar at 850 °C to further enhance pore structures and increase graphitization for improved conductivity. Catalytic materials exhibited a specific capacitance of 316 F g -1 and held a 100% retention beyond 10,000 cycles. BET, Raman, XRD, cyclic voltammetry, chronopotentiometry, and EIS are discussed herein.

Biomass↗

DOE OSTI2022

Techno-economic Analysis and Life-Cycle Analysis of Renewable Diesel Fuels Produced with Waste Feedstocks

Wet waste feedstocks represent an important category of resources that could be utilized to produce biofuels. Diversion of the wet waste resources from going through conventional waste management practices to utilization as feedstocks for energy production also benefits from avoided cost and pollutant emissions of waste management and disposal. This study investigates the economic and environmental implications of producing bio-blendstocks for mixing controlled compression ignition (MCCI) engines from two waste-to-fuel pathways: hydroprocessed esters and fatty acids (HEFA) from yellow grease, and swine manure hydrothermal liquefaction (HTL) followed by biocrude upgrading. Detailed process models were developed for both pathways, which informed the techno-economic analysis (TEA) and life-cycle analysis (LCA). Conventional swine manure management practice was also modeled in detail as the business-as-usual (BAU) scenario for the swine manure HTL pathway. The estimated minimum fuel selling prices (MFSP) were $4.47/gasoline gallon equivalent (GGE) and $3.57/GGE for the yellow grease to HEFA and swine manure HTL pathways, respectively. The life-cycle greenhouse gas (GHG) emissions of the two pathways were 11.2 and -33.3 g CO2e/MJ, respectively, for the yellow grease to HEFA and swine manure HTL pathways. The credits of avoided emissions from conventional swine manure management were the main reason for the negative GHG emissions of the swine manure HTL pathway. The marginal GHG emissions abatement costs were estimated to be $100 – $253/tonne CO2e and $5 – $103/tonne CO2e for the yellow grease HEFA and swine manure HTL pathways, respectively, for a diesel price ranging between $2.0/GGE and $3.5/GGE. Since the yellow grease HEFA pathway is already commercialized, it can benefit from the $200/tonne carbon credit in the California Low Carbon Fuel Standard (LCFS) market, which could help the yellow grease HEFA pathway to achieve near-zero marginal GHG emissions abatement cost.

renewable diesel, techno economic analysis, life c↗

DOE OSTI2023

Desalting biocrude for improved downstream processing toward marine fuel application

Hydrothermal liquefaction of wet wastes (e.g., food waste and sewage sludge) offers a promising avenue for producing biocrude, but the resulting product is often contaminated with metals and water, impacting the biocrude upgrading steps to produce final fuel (e.g., jet and diesel). Here this study investigates the use of aqueous solutions of formic acid for desalting biocrudes and improving their quality. The results show that this approach significantly reduces both metal and water content, enabling mild hydrotreatment with reduced hydrogen consumption to further enhance the biocrude's quality. A preliminary technoeconomic analysis based on these experimental results shows that even without optimization, this washing process can yield biocrude with a minimum selling price of $1.87/GGE. Overall, our study demonstrates the potential for using dilute formic acid aqueous solutions to improve the quality of biocrudes, which can lead to more efficient and cost-effective conversion into biofuels.

09 BIOMASS FUELS↗

DOE OSTI2025

Direct flue gas capture for algae cultivation and subsequent valorization: evaluating life cycle emissions and costs

Algae cultivation and processing is an important pathway under discussion within the broader CO 2 capture and utilization umbrella. Here, we discuss the results of a life-cycle analysis and techno-economic analysis of a pilot-scale photobioreactor that uses flue gas directly from natural gas or biogas combustion at 3–5% CO 2 concentration. The system requires minimal freshwater use as it has been successfully run with industrial wastewater and has a much smaller areal footprint compared with open pond cultivation. Introducing the flue gas directly to the photobioreactor avoids the need for CO 2 separation and pressurization, which is undertaken in many other algae cultivation systems. For the end-use of the biomass, the default case assumes conversion of algae to liquid fuels via hydrothermal liquefaction. The results indicate that the pilot-scale system has a higher cost, and comparable greenhouse gas emissions compared to pond-based systems, especially as the grid is anticipated to evolve to a lower carbon intensity. The costs of algae biofuel production range from $\$12–16$ per GGE at the current pilot scale. Depending on whether the source of the carbon is fossil or biogenic, the net emissions are 68 g CO 2 e per MJ and −4 g CO 2 e per MJ respectively. If the marine algae species is used instead of the freshwater species, it offers an additional 16 g CO 2 e per MJ carbon fixation in the form of calcium carbonate. The findings point to broadly desirable trends in GHG emissions and costs, while the discussion aims to shed light on areas that could further improve the scalability of the system.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

A Novel Platform for Algal Biomass Production Using Cellulosic Mixotrophy (CeMix) (Final Technical Report)

This novel project, branded CeMIX for cellulosic mixotrophy, targets solutions for several technological barriers limiting the deployment of algae cultivation in sunny, arid regions (specifically the southwest United States). Opening up the region for algae cultivation could increase DOE’s resource assessments and biofuel potential for the U.S. Mixotrophic metabolism in support of liquid fuel production is completely dependent on the availability of waste organic carbon in order to avoid diversion of food resources for fuel production. The use of cellulosic sugar hydrolysate (CSH) produced via the NREL process provided a standardized carbon source for study of the underlying biochemistry and metabolic adjustments to mixotrophy. Mixotrophic metabolism uses both photosynthetic CO 2 fixation and sugar oxidation to improve biomass productivity and harvest yield. The project was high-risk, high-reward in the sense that adding organic carbon to algal cultivation is an invitation for rapid-growth, heterotrophic contaminants to overtake the culture and consume mineral nutrients needed for algal growth. To help evade this outcome the project focused on acidophilic red algae that require low pH conditions with 40-48°C optimal temperature profiles that define them as low-range thermophiles. This is the only project in the BETO portfolio to utilize extreme conditions of low pH and high operating temperatures to control pathogens and competitors in mass culture. The project yielded five major outcomes. 1) Harvest densities of 5-10 g ash-free dry weight are easily achieved, providing a 10-fold reduction in water required and dewatering demand. 2) Catabolic repression of photosynthesis in G. sulphuraria is conditionally repressed by low oxygen. 3) Mixotrophic growth on cellulosic hydrolysate consumes all C6 and C5 sugars concomitant with increases in floridean starch with little change in lipid content. Protein content can be manipulated between 35 and 54 wt% by varying the C:N molar ratio from 10:1 to 20:1, respectively. 4) Mixotrophic cultures with up to 50 mM total sugar are remarkably stable at pH 2.5 and daily average reactor temperatures of 40°C. 5) Capital costs for glass tubular photobioreactors are prohibitive for liquid fuel production using a hydrothermal liquefaction processing pathway. The economic outlook for covered raceway ponds is better with a project minimum fuel selling price at $3.32 dm 3 GE -1 .

09 BIOMASS FUELS↗

DOE OSTI2021

Evaluate Synergies of Using Hydrothermal Liquification (HTL) and Anerobic Digestion (AD) Treatment Technologies for Wastewater Resource Recovery Facilities (WRRFs)

PNNL has developed Hydrothermal Liquefaction (HTL) technology, which can directly convert sewage sludge to a biocrude oil that can be refined into renewable diesel fuel and provide a significant reduction in the volume of biosolids produced as ash with far less potential environmental impacts associated with disposal. HTL also produces an aqueous byproduct stream that requires treatment before it can be returned to the headworks of the Wastewater Resource Recovery Facilities (WRRF). The goal of this project is to evaluate synergies of using HTL and advanced AD to enable the treatment and recycle of HTL aqueous phase. This CRADA will; 1) formalize and strengthen the working relationship between PNNL and GLWA, 2) jointly evaluate HTL and AD scenarios for WRRFs and 3) help enable the implementation of HTL/AD technology at GLWA and other WRRFs.

09 BIOMASS FUELS↗

DOE OSTI2022

Corrosivity Screening of Pyrolysis Bio-Oils by Short-Term Alloy Exposures. Laboratory Analytical Procedure (LAP), Issue Date: May 12, 2022

Bio-oils contain organic acids and oxygenated compounds that can lead to corrosion issues during bio-oil processing and storage. This Laboratory Analytical Procedure (LAP) allows for rapid screening of a bio-oil's corrosivity without the need for complex equipment and long-term exposures. A robust and repeatable method for assessing the corrosivity of bio-oils is necessary in order to remove materials degradation as an obstacle to research, upgrading, use and storage of bio-oils. This LAP involves the incubation of a representative alloy, 410 stainless steel (410 SS), specimen in bio-oil over a period of 48 hours at 50 degrees C in a sealed container. The corrosive species in the bio-oil react with and deplete alloy elements such as iron (Fe) and/or chromium (Cr) from the specimen into the bio-oil solution. The depletion of Fe and Cr from the specimen results in a significant mass loss that can be recorded. The mass loss is directly correlated to the corrosivity of a bio-oil. Examples of bio-oils in scope include the ones produced by fast pyrolysis and catalytic fast pyrolysis, as well as liquids produced from hydrothermal liquefaction.

09 BIOMASS FUELS↗

DOE OSTI2023

Decarbonization of Wastewater Treatment with Microalgae Processes.

Microalgae can contribute to the decarbonization of wastewater treatment by municipalities, industries and agriculture, by substituting sunlight for energy intensive conventional treatment processes, while capturing nutrients and carbon in the algal biomass. The carbon fixed into the algal biomass can be converted to renewable natural gas (RNG) using anaerobic digestion or into renewable diesel and sustainable aviation fuel (SAF) using hydrothermal liquefaction (HTL), with greatly reduce the carbon footprints compared to conventional fuels. Bioplastics, biofertilizers and other bioproducts from microalgae biomass also provide potential benefits in greenhouse gas (GHG) reduction and domestic supply chains. Microalgae technologies can counter eutrophication caused by harmful algal blooms by recovering nutrients, N and P, from wastewaters, and even from very low nutrient concentrations found in surface waters. CO2 is required in microalgae cultivation and wastewater treatment to support maximal rates of the photosynthesis, with the CO2 obtained from the wastes themselves, other local sources or even atmospheric CO2. Greenhouse gas mitigation with microalgae processes is based on life cycle assessments, comparing such green processes with current energy intensive wastewater treatment, and nutrient reduction technologies. Microalgae technologies are specifically relevant to smaller, often disadvantaged, communities, where currently about 5,000 algae wastewater treatment ponds are operated by public utilities with many more are operated by industries. However, many, if not most, of these pond facilities require urgent technology upgrades to achieve the potential and goals of low cost GHG mitigation and efficient nutrient recycling. MicroBio Engineering Inc. is developing and has demonstrated several technologies that combine innovative carbon mitigation and decarbonization technologies for a circular economy, with longer-term potential for large-scale biofuels and biofertilizer production.

09 BIOMASS FUELS↗

DOE OSTI2023

Decarbonization of Wastewater Treatment with Microalgae Processes.

Microalgae can contribute to the decarbonization of wastewater treatment by municipalities, industries and agriculture, by substituting sunlight for energy intensive conventional treatment processes, while capturing nutrients and carbon in the algal biomass. The carbon fixed into the algal biomass can be converted to renewable natural gas (RNG) using anaerobic digestion or into renewable diesel and sustainable aviation fuel (SAF) using hydrothermal liquefaction (HTL), with greatly reduce the carbon footprints compared to conventional fuels. Bioplastics, biofertilizers and other bioproducts from microalgae biomass also provide potential benefits in greenhouse gas (GHG) reduction and domestic supply chains. Microalgae technologies can counter eutrophication caused by harmful algal blooms by recovering nutrients, N and P, from wastewaters, and even from very low nutrient concentrations found in surface waters. CO2 is required in microalgae cultivation and wastewater treatment to support maximal rates of the photosynthesis, with the CO2 obtained from the wastes themselves, other local sources or even atmospheric CO2. Greenhouse gas mitigation with microalgae processes is based on life cycle assessments, comparing such green processes with current energy intensive wastewater treatment, and nutrient reduction technologies. Microalgae technologies are specifically relevant to smaller, often disadvantaged, communities, where currently about 5,000 algae wastewater treatment ponds are operated by public utilities with many more are operated by industries. However, many, if not most, of these pond facilities require urgent technology upgrades to achieve the potential and goals of low cost GHG mitigation and efficient nutrient recycling. MicroBio Engineering Inc. is developing and has demonstrated several technologies that combine innovative carbon mitigation and decarbonization technologies for a circular economy, with longer-term potential for large-scale biofuels and biofertilizer production.

09 BIOMASS FUELS↗

DOE OSTI2023

Decarbonization of Wastewater Treatment with Microalgae Processes.

Microalgae can contribute to the decarbonization of wastewater treatment by municipalities, industries and agriculture, by substituting sunlight for energy intensive conventional treatment processes, while capturing nutrients and carbon in the algal biomass. The carbon fixed into the algal biomass can be converted to renewable natural gas (RNG) using anaerobic digestion or into renewable diesel and sustainable aviation fuel (SAF) using hydrothermal liquefaction (HTL), with greatly reduce the carbon footprints compared to conventional fuels. Bioplastics, biofertilizers and other bioproducts from microalgae biomass also provide potential benefits in greenhouse gas (GHG) reduction and domestic supply chains. Microalgae technologies can counter eutrophication caused by harmful algal blooms by recovering nutrients, N and P, from wastewaters, and even from very low nutrient concentrations found in surface waters. CO2 is required in microalgae cultivation and wastewater treatment to support maximal rates of the photosynthesis, with the CO2 obtained from the wastes themselves, other local sources or even atmospheric CO2. Greenhouse gas mitigation with microalgae processes is based on life cycle assessments, comparing such green processes with current energy intensive wastewater treatment, and nutrient reduction technologies. Microalgae technologies are specifically relevant to smaller, often disadvantaged, communities, where currently about 5,000 algae wastewater treatment ponds are operated by public utilities with many more are operated by industries. However, many, if not most, of these pond facilities require urgent technology upgrades to achieve the potential and goals of low cost GHG mitigation and efficient nutrient recycling. MicroBio Engineering Inc. is developing and has demonstrated several technologies that combine innovative carbon mitigation and decarbonization technologies for a circular economy, with longer-term potential for large-scale biofuels and biofertilizer production.

09 BIOMASS FUELS↗

DOE OSTI2021

Spill Behavior, Detection, and Mitigation for Emerging Nontraditional Marine Fuels

In this report, we describe the predicted impact of large spills or releases of alternative marine fuels. The fuels covered in this report are those that have been identified as potential future fuels for the marine shipping sector by industry experts and government agencies overseeing the development of renewable and low-carbon fuels. Several of these fuels are already in use, such as liquified natural gas, renewable diesel, ethanol, methanol, and biodiesel. Other fuels are hydrogen, dimethyl ether, ammonia, and bio-intermediates, such as catalytic fast pyrolysis biooils and hydrothermal liquefaction bio-crudes. The property databases of these fuels are extensive enough to form predictive assessments. Other potential marine fuels, such as lignin ethanol, have not been extensively evaluated and are therefore not included is this study. For each fuel chemistry, we have surmised the spill profiles and environmental impacts based on existing studies and relevant properties. The technologies used to detect spills (especially those for crude oil detection) are also reviewed for their applicability with alternative fuels, and in some instances, recommendations to improve these technologies for use with a particular fuel chemistry are put forward. Finally, current containment and remediation technologies are reviewed and assessed for their efficacy at handling these alternative fuels.

04 OIL SHALES AND TAR SANDS↗

DOE OSTI2024

Economic, Greenhouse Gas, and Resource Assessment for Fuel and Protein Production from Microalgae: 2022 Algae Harmonization Update

This report presents an updated "harmonization study" documenting the collaborative analysis of microalgae cultivation and conversion to fuels and products. Four national laboratory modeling teams reconvened to investigate the resource, economic, and environmental sustainability implications of integrated systems encompassing large-scale algae farms and conversion biorefineries. Relative to prior harmonization analyses conducted by these partners, the present effort focuses on more near-term deployment potential based on the use of nutrient-replete, high-protein algal biomass compositions (more readily achievable today without sacrificing cultivation productivity), though this also incurs challenges in lower fuel yields and accordingly higher costs and carbon intensities for the overall integrated systems. Additionally, the present assessment adds further granularity around carbon dioxide (CO 2 ) sourcing and transport via carbon capture of nearby point sources, as well as handling of high-saline cultivation media and resultant blowdown/disposal processing. Finally, this assessment focuses on conversion opportunities to produce both fuel (prioritizing sustainable aviation fuel, in this case via hydrothermal liquefaction) and protein products for the food and feed markets, recognizing growing needs for such products.

09 BIOMASS FUELS↗

DOE OSTI2023

W-SMART Phase-I Pathway Analysis: Case Study - City of Boston, MA

The purpose of this study is to synthesize stakeholder and research learnings to date by exercising PNNL’s Waste - Sustainability Monitoring of Alternative Reuse Options over Time (W-SMART) sustainability protocol for the Greater Boston region. This report serves as a foundation for future discussion and project work to characterize the costs, risks, impacts, tradeoffs, and highest uses for major waste streams. This analysis differs from previous work by 1) incorporating results of a newly completed detailed resource assessment for the Greater Boston area; (2) providing a head-to-head pathway comparison without any policy supports (e.g., carbon or energy credits); and (3) focusing on locally relevant critical waste streams and reuse strategies, by assessing the cost-effectiveness of two complimentary pathways, including (a) expanded incineration of municipal solid waste (MSW) at existing treatment sites to produce baseload electricity, and (b) the conversion of blended municipal wastewater solids (i.e., sludge) and non-residential food waste to produce liquid transportation biofuels at a proposed hydrothermal liquefaction facility in Quincy, MA. The performance of each pathway is also compared to assumed business-as-usual waste management practices as a baseline.

09 BIOMASS FUELS↗

DOE OSTI2024

Development of a Sulfur Tolerant CHG Process (CRADA 442) (Final Report)

The Pacific Northwest Laboratory (PNNL) has developed the Catalytic Hydrothermal Gasification (CHG) technology, which can convert low-value organics dispersed in aqueous streams, such as the aqueous phase byproduct from hydrothermal liquefaction (HTL) of wet wastes, to a mixture of methane, H 2 , and CO 2 . The current CHG catalyst, ruthenium (Ru) on a graphite substrate, was selected for its effectiveness as a reducing catalyst. However, the target waste aqueous feedstock, the HTL aqueous phase from wet wastes, such as sewage sludge, contains a fair amount of sulfur in both organic and inorganic forms. Like many other reduced metal catalysts, Ru is deactivated or poisoned by exposure to sulfur, among other contaminants. In general, a deactivated Ru catalyst cannot be reactivated or restored except by removing and returning it for remanufacturing. Therefore, there is an urgent need for a sulfur-resistant catalyst to enable CHG processing of the HTL aqueous waste stream. PNNL, with support from SoCalGas CRADA, has developed a sulfur resistant CHG catalyst and demonstrated a stable CHG process for converting HTL aqueous phases from wet wastes. Here, we report the major accomplishments of the project: • We have demonstrated that sulfided Ru based catalysts is stable during CHG of HTL aqueous waste stream, with a requirement of activity improvement. • We have developed a new catalyst, with 0.5-2 wt.% Ru loading, showing better activity compared to the baseline 6.7 wt.% RuSx/C catalyst. • With the new catalysts, the single-pass COD reduction is approximately 60% and two-pass COD reduction can reach approximately 85%. • The process is robust in terms of being effective across a wide range of organic species in the feedstock. • Techno-economic analysis was conducted to evaluate the economic impact of catalyst advancement and identify further improvement requirements. This type of catalyst shows great potential to be efficient and robust for CHG with low catalyst cost.

03 NATURAL GAS↗