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DOE OSTI2023

Next Generation Feedstocks for the Emerging Bioeconomy

The Next Generation Feedstocks for the Emerging Bioeconomy project, led by the University of Illinois Urbana-Champaign, was designed to accelerate the development of sustainable, cost-competitive biomass feedstocks that can be grown on marginal lands, which are not suitable for row crop production. By focusing on advanced bioenergy-type switchgrass cultivars and related perennial grasses, the project directly supported the U.S. “Billion-Ton Vision,” which aims to expand biomass production to displace fossil fuels while providing environmental and economic benefits. The project improved understanding of perennial bioenergy crop performance at a large scale in marginal environments.

09 BIOMASS FUELS↗

DOE OSTI2024

Bioenergy and Climate Change in Ukraine: How climate can impact the sustainability of bioenergy production

The Russian invasion has exacerbated Ukraine’s energy security issues, prompting a shift toward diversifying energy supply sources. Additionally, strategic documents aim to align Ukraine’s energy system with EU climate requirements, focusing on reducing reliance on fossil fuels and advancing decarbonization efforts. This report focuses on the expansion of bioenergy as an alternative source of energy in Ukraine. Current assessments suggest that Ukraine has substantial bioenergy potential, primarily from agricultural residues and energy crops. However, the challenges posed by climate change and the ongoing war might impact the outcome of these projections. This report highlights the importance of integrating climate factors into energy modeling using tools like the integrated assessment models to provide a comprehensive understanding of Ukraine’s bioenergy potential under various climate scenarios. It also emphasizes the need for climate-smart agriculture and forestry practices to mitigate risks, enhance energy efficiency, and support resilient crop supplies. Recommendations for stakeholders include diversification of the energy supply sources, developing adaptation strategies, diversifying bioenergy feedstocks, and ensuring robust decision-making to navigate the impacts of climate change on Ukraine’s energy system.

09 BIOMASS FUELS↗

DOE OSTI2025

Technical and Economic Assessment and Gap Analysis of Advanced Nuclear Reactor Integration with a Reference Methanol Synthesis Plant

Efforts continue to identify the most-economic methods to decarbonize several sectors of the United States (U.S.) economy. Industrial processes such as synfuel synthesis and high value commodity chemicals rely heavily on energy-dense and easily stored and transported fossil fuels, which power and feed their operations. Steam methane reforming (SMR) is a widely used process for producing methanol. In this process, methane (CH 4 ) from natural gas (NG) reacts with steam (H 2 O) over a catalyst at high temperatures (700°1,000°C) to produce syngas, a mixture of hydrogen (H 2 ) and carbon monoxide (CO). The syngas is then converted into methanol (CH 3 OH) through a second catalytic reaction. This method is known for being an efficient and commonly employed pathway for industrial methanol production. The high-temperature heat needed for SMR, which is currently used in the natural-gas-to-methanol process, cannot be supplied by small modular nuclear reactor (SMNR) direct heating; the temperatures required for the SMR process exceed those of the main steam produced by near-market high-temperature gas reactors (HTGRs). For the conventional methanol process, this leaves possible nuclear-integration opportunities that include: (1) blending nuclear hydrogen into the SMR NG fuel, or (2) assessing alternative synthesis routes leveraging nuclear capabilities and steam electrolysis outputs. In the reference methanol plant, SMR provides the methanol-synthesis reactor with H 2 and co. In Case (2), the state-of-the-art reverse water gas shift (RWGS) pathway achieves the same, sourcing carbon from an industrial CO 2 source.

08 - HYDROGEN↗

DOE OSTI2024

Energy Requirements for Integration of Nuclear Reactors with Iron and Steel Plants

This report identifies energy needs of heavy energy users within the domestic iron and steel industry and suggests solutions for integrating nuclear energy. The iron and steel industry, composed of several types of plants which perform different processes with varied energy demands and vectors, is a heavy consumer of electric power and fossil fuels including coke and natural gas. Almost all major process temperatures exceed the temperatures of direct heat available from advanced reactors, and so electricity and hydrogen were considered instead. Reference units were adopted and estimated energy demands computed for the blast furnace (BF), direct reduced iron (DRI) unit, electric arc furnace (EAF), and reheat furnaces. By utilizing production capacity data from industry reports, the ranges of power demands were estimated, including for hydrogen production by high temperature steam electrolysis (HTSE). For the EAF and DRI unit, more detailed integration studies with thermodynamic modeling were also conducted and determined a possible solution with a specific reactor design and number of modules. Furthermore, because many unit processes are co-located, entire plants were considered by adding the energy demands of the unit processes to form four hypothetical reference plants. The range of power needs for the reference plants is compatible with multi-unit banks of microreactors at the low end, and would create a need for multiple larger-capacity SMRs at the high end (1 GWe plus 0.14 GWt). Although the overall power need at the high end is well-matched with one present-day large reactor offering (1.1 GWe), redundancy considerations may require a minimum of two reactors, potentially eliminating the single large reactor from consideration. Auxiliary or house loads would increase the reference plant estimates. Finally, the report provides total estimated energy needs under integration of all U.S. units of each process (BF, DRI, EAF, and reheat furnaces), representing a national potential for nuclear energy in the industry. U.S. iron and steel plants may be candidates for integration with nuclear reactors via electricity and hydrogen, and many sites have energy requirements that correspond well to the capacities of several advanced nuclear power designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Midwest ZEVI 2030 Charging Roadmap for I-80 Corridor

Zero-emission Medium Duty and Heavy Duty vehicles (MD-HD ZEVs) hold great promise for reducing operational costs through use of more energy eAicient propulsion technology while reducing reliance on fossil fuels. Consistent with the Department of Energy’s focus on energy innovation, ZEVs and the necessary charging and refueling infrastructure to support them represent an important area of focus for technological advancement. Widespread adoption of MD-HD ZEVs can also provide benefits by improving air quality, and lowering carbon emissions in the transportation industry. Powertrain technologies are in production today to reduce tank-to-wheel and well-to-wheel emissions of commercial vehicles to zero or near-zero emissions, but significant development remains to bring down the cost and address the operational limitations of these technologies, particularly for larger vehicles. ZEV technologies have an opportunity to be an important part of a fleet’s mix of powertrains as capital and operational costs come down. However, the greatest challenge preventing widespread adoption of ZEVs may be the lack of adequate charging and hydrogen (H₂) fueling infrastructure.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

CRADA Number NFE-22-09315 with Captis Aire LLC (CRADA Final Report)

Our goal is to provide an economically and environmentally advantageous capture technology to clean the air at industrial manufacturing facilities, especially wood products manufacturing facilities. There are hundreds of wood products manufacturing sites at which this capture technology could be implemented and thousands more sites in the broader 104 industries subject to the clean air act. This work is critical because when implemented at just 50 wood products sites it could capture over 100 million pounds per year of pollutants (wastes) that could be converted into over 90 million pounds per year of valuable products rather than burning them as waste. These pollutants, primarily turpentine or terpenes, can be used to provide a wide variety of products including biofuels, flavors, fragrances, and more. Versus the baseline technology, the technology could reduce energy use including fossil fuels by more than 10 trillion BTUs per year and drive down operational costs for our customers by up to $150 million per year.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Evaluating Polymer Properties with Different Additives for Carbon Capture and Other Applications

Anthropogenic climate change is one of this generation’s most pressing concerns, with the potential to completely alter the delicate balance we’ve struck with nature. Already, global temperatures have risen 1.29°C, leading to disrupted weather systems, extinctions, increased risks of wildfires, and sea level rise, to name a few effects. Carbon dioxide emission from the combustion of fossil fuels and other industrial activity is a large driver of this phenomenon, as it absorbs heat before it can be radiated away from Earth, trapping it. Carbon dioxide has reached unprecedented levels in our atmosphere, showing a 50% increase from preindustrial averages to a whopping 430 ppm. Thus, reducing the amount of carbon dioxide via carbon capture technology is an important endeavor that serves to benefit everyone. The Microencapsulated CO 2 Sorbent (MECS) team at Lawrence Livermore National Laboratory (LLNL) has turned to microencapsulation to approach this endeavor. Microcapsules provide an attractive approach to carbon capture, combining large surface areas for more efficient mass transfer, regenerative abilities, reduced solvent loss, and improved handling. Additionally, while existing carbon capture technology relies on industrial plants, capsules could present a modular approach to carbon capture, reducing the need for extensive physical infrastructure. The MECS team’s design consists of a polymer membrane that contains a liquid carbon sequestering sorbent, aqueous sodium carbonate. The carbon capturing reaction occurs in three distinct steps, the first of which is the dissolution of carbon dioxide into the sorbent solution and its conversion into carbonic acid (H 2 CO 3 ), shown in equations 1 and 2 respectively. Because this step hinges upon the ability of carbon dioxide to reach the solution inside the capsule, it is necessary that the microcapsule shell is permeable to carbon dioxide gas. The MECS team produces these microcapsules using the in-air droplet encapsulation apparatus (IDEA) shown in figure 1, which can produce uniform micron-scale droplets at speeds much faster than traditional single-dispersal microfluidic-based techniques. The IDEA Is 100 times faster than these current techniques and can reach up to 1000 times their speed when incorporating a multi-nozzle design. Additionally, because droplets are produced in-air via vibration, IDEA can decrease post-processing times and material waste by 99% and can fabricate microgels that are 10 to 100 times more viscous than can be produced via traditional microfluidics. While this design represents a breakthrough in the throughput, efficiency, and tunability of microcapsule production, it imposes a major constraint on the microcapsule curing process. Because microcapsule shells are crosslinked with UV light while falling 30 cm through the air, this gives them a reaction window of approximately 0.2 seconds. Thus, the system and shell formulations must be optimized such that the shells can be fully crosslinked within this very narrow window, prompting investigations into curing behavior.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Heat Pumps and Energy Recovering Ventilators in Northern Alaska

The intended purpose of this project was to bring alternative heat and ventilation options to rural communities off the road system in Northwestern Alaska. Most of the residents of these communities are reliant upon kerosene or other fossil fuels to provide heat to their homes. Our intention was to offer an alternative to using those sources by providing heat pumps to 45 homes in the communities of Elim and Koyuk. When projecting energy use for these units based on the fuel prices at the time, it was discovered that energy costs for heat pumps would equal or slightly exceed the costs of existing kerosene units. Secondly, as part of our E&l grant we installed 45 energy recovery ventilators (ERV’s) in those same homes. This was important given our experience over the years with moisture and comfort issues in most homes within this region. Exhaust-only systems are rarely used due to the high heating costs. Additionally, exhaust-only systems have a potential risk of back drafting due to tight building construction. Balanced systems like this eliminate that risk while improving indoor air quality. Another benefit to these types of systems is the fact that they help transfer heat from a single heat source equally throughout the building. Our overall goal was to offer new technology options to improve these structures and the families that reside in them where, given their location and extreme seasonal temperature swings, they have historically never been offered.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Energy Impacts of Electric Aircraft: An Overview

Commercial aviation represents approximately 2% of the global emissions of greenhouse gases, yet presently relies exclusively on fossil fuels as a source of energy. This paper evaluates to what extent an all-electric aircraft can provide an alternative. First, three classes of aircraft are modeled at various timelines in the future: 50/100/150 passenger capacity in 2030/2040/2050. Technology is assumed to improve over time, especially with regards to battery specific energy, resulting in aircraft with increased range. A database of all domestic flights in the US in 2019 is then used to filter and aggregate flights suited for replacement by electric aircraft. In the short term (2030), no viable aircraft can meet the requirements of each class. By 2040, a third of the flights can be done by an all-electric aircraft, but only short ones, as the range does not exceed 500 mi, resulting in 3% of total passenger-miles. By 2050, owing to the most optimistic technology assumptions, a quarter of all passenger-miles can be flown by electric airplanes. The resulting displaced jet fuel is also calculated.

Aviation sustainability↗

DOE OSTI2021

An experimental database of cell performance for vanadium redox flow battery

The continual growth in energy demand has resulted in the deployment of renewable energy generators to reduce the impact of fossil fuel dependence. However, these generators often suffer from intermittency and require energy storage when there is over-generation and the subsequent release of this stored energy at high demand. One promising energy storage technology which can provide a solution to improve energy management and grid stability, is the redox flow battery. Among the numerous flow battery systems, vanadium redox flow battery is the most iconic solution to large scale energy storage, giving a more efficient link between energy production, especially from renewables, and energy demand. The aim of the current database is to characterize the performance of the cell design and to provide training/validation data for physical model or data-driven model. The database includes hundreds of experimental cell performance data of vanadium redox flow battery with various current densities for multiple charge-discharge cycles. All the cell parameters, chemical parameters, material parameters, operation parameters and thermodynamic parameters of the cell system are listed. Coulomb, voltaic and energy efficiencies are also provided. The database will be helpful for researchers in the field of redox flow batteries.

Gao, Peiyuan↗

DOE OSTI2024

Modeling-Based Design and Optimization of a Gradient Composite Transition Joint

An innovative additively manufactured gradient composite transition joint (AM-GCTJ) has been designed to join dissimilar metals, to address the pressing issue of premature failure observed in conventional dissimilar metal welds (DMWs) when subjected to increased cyclic operating conditions of fossil fuel power plants. The transition design, guided by computational modeling, developed a gradient composite material distribution, facilitating a smooth transition in material volume fraction and physical properties between different alloys. This innovative design seeks to alleviate structural challenges arising from distinct material properties, including high thermal stress and potential cracking issues resulting from the thermal expansion mismatch typically observed in conventional DMWs. In this study, we investigated the creep properties of transition joints comprising Grade 91 steel and 304 stainless steel through a combination of simulations and creep testing experiments. The implementation of a gradient composite design in the plate transition joint resulted in a significant enhancement of creep resistance when compared to the baseline conventional DMW. For instance, the creep rupture life of the transition joint was improved by > 400% in a wide range of temperature and stress testing conditions. Meanwhile, the failure location shifted to the base material of Grade 91 steel. Such enhancement can be primarily attributed to the strong mechanical constraint facilitated by the gradient composite design, which effectively reduced the stresses on the less creep-resistant alloy in the transition zone. Beyond examining plate joints, it is crucial to assess the deformation response of tubular transition joints under pressure loading and transient temperature conditions to substantiate and demonstrate the effectiveness of the design. The simulation results affirm that the tubular transition joint demonstrates superior resistance compared to its counterpart DMW when subjected to multiaxial stresses in tubular structures. In addition, optimization of the transition joint’s geometry dimensions has been conducted to diminish the accumulated deformation and enhance the service life. Lastly, the scalability and potential of the innovative transition joints for large-diameter pipe applications are addressed.

Zhang, Wei↗

DOE OSTI2016

Data-driven reinforcement learning–based real-time energy management system for plug-in hybrid electric vehicles

Plug-in hybrid electric vehicles (PHEVs) show great promise in reducing transportation-related fossil fuel consumption and greenhouse gas emissions. Designing an efficient energy management system (EMS) for PHEVs to achieve better fuel economy has been an active research topic for decades. Most of the advanced systems rely either on a priori knowledge of future driving conditions to achieve the optimal but not real-time solution (e.g., using a dynamic programming strategy) or on only current driving situations to achieve a real-time but nonoptimal solution (e.g., rule-based strategy). This paper proposes a reinforcement learning–based real-time EMS for PHEVs to address the trade-off between real-time performance and optimal energy savings. The proposed model can optimize the power-split control in real time while learning the optimal decisions from historical driving cycles. Here, a case study on a real-world commute trip shows that about a 12% fuel saving can be achieved without considering charging opportunities; further, an 8% fuel saving can be achieved when charging opportunities are considered, compared with the standard binary mode control strategy.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Enhancing NDE Reliability for Grade 91 Steel Welds: Ultrasonic Imaging and Microstructural Correlations

Ensuring the integrity of Grade 91 (9Cr-1Mo-V) steel welds is vital for the safe and reliable operation of fossil fuel–fired and nuclear power plants. Here, this study applies an imaging technique for the ultrasonic characterization of two Grade 91 steel welds created with cold metal transfer and flux-cored arc welding processes. Ultrasonic immersion testing in the through-transmission configuration was employed to generate shear waves, which helped identify the weld metal, heat-affected zone, and base metal regions. These weld microstructures were also correlated to their ultrasonic images using metallography, ultrasonic amplitude, hardness measurements, and grain size. The findings from this study can assist practitioners in developing new nondestructive evaluation technologies, improving the inspection reliability of creep strength–enhanced ferritic steel welds by potentially identifying weld microstructure regions susceptible to creep-type failures.

Grade 91 steel↗

DOE OSTI2015

Efficient Eucalypt Cell Wall Deconstruction and Conversion for Sustainable Lignocellulosic Biofuels

In order to meet the world’s growing energy demand and reduce the impact of greenhouse gas emissions resulting from fossil fuel combustion, renewable plant-based feedstocks for biofuel production must be considered. The first-generation biofuels, derived from starches of edible feedstocks, such as corn, create competition between food and fuel resources, both for the crop itself and the land on which it is grown. As such, biofuel synthesized from non-edible plant biomass (lignocellulose) generated on marginal agricultural land will help to alleviate this competition. Eucalypts, the broadly defined taxa encompassing over 900 species of Eucalyptus, Corymbia, and Angophora are the most widely planted hardwood tree in the world, harvested mainly for timber, pulp and paper, and biomaterial products. More recently, due to their exceptional growth rate and amenability to grow under a wide range of environmental conditions, eucalypts are a leading option for the development of a sustainable lignocellulosic biofuels. However, efficient conversion of woody biomass into fermentable monomeric sugars is largely dependent on pretreatment of the cell wall, whose formation and complexity lend itself toward natural recalcitrance against its efficient deconstruction. A greater understanding of this complexity within the context of various pretreatments will allow the design of new and effective deconstruction processes for bioenergy production. In this review, we present the various pretreatment options for eucalypts, including research into understanding structure and formation of the eucalypt cell wall.

09 BIOMASS FUELS↗

DOE OSTI2024

Bioenergy cropping systems shape ant community composition and functional roles

The adoption of biomass crops grown for energy is a likely source of major landscape change in coming decades during the transition from fossil fuels. There are a wide range of cropping systems that have not been widely deployed yet but could become commonplace, and our knowledge of their ecological attributes and biodiversity impacts is limited. Ants are prominent and functionally important components of grassland and agricultural ecosystems. Given their outsized influences on ecosystem structure and function, we sought to understand how ant communities are likely to be shaped by a range of bioenergy cropping systems. We characterized ant communities in a long-term experimental array in Michigan, USA containing ten dedicated bioenergy crops including annual monocultures, simple monoculture or near-monoculture perennial grasses, and complex polyculture systems. Community composition differed strongly among cropping systems, and ants were more abundant, species-rich, and functionally diverse in complex systems than in simpler systems, particularly annual crops. Our results illustrate the divergent effects that bioenergy crop adoption could have for ant communities and the important functions they carry out in agroecosystems.

Haan, Nathan L.↗

DOE OSTI2018

Hot Water Extraction Improves the Characteristics of Willow and Sugar Maple Biomass With Different Amount of Bark

Shrub willows are being developed as a short rotation woody crop (SRWC) that can grow on marginal agricultural land. Willow has a high net energy ratio (energy produced/ fossil fuel energy consumed), low greenhouse gas footprint and high carbohydrate production potential. Willow biomass can be combined with forest biomass, but willow often has a higher proportion of bark that creates challenges because it increases the ash content and decreases the melting point. Hot water extraction is a pretreatment that has been shown to improve the quality of chipped material while producing a marketable stream of byproducts. This study evaluated how the amount of bark (0%, 33%, 66% and 100%) on three willow cultivars and sugar maple impact the output of hot water extraction in terms of mass removal and extract composition, as well as its influence on the heating value, ash and elemental content. The hot water extraction process resulted in ash content up to 50% for sugar maple and willow, but there was variation among the willow varieties. The heating value after hot water extraction was about 5% higher because of the removal of mostly hemicelluloses, which have relatively low heating value. HWE led to significant reductions of calcium, potassium, magnesium and sulfur contents. The hot water extraction provides a fermentable sugar stream and other coproducts after multiple separation and treatment steps, and improves the characteristics of willow and sugar maple biomass for combined heat and power. This paper demonstrates how biomass with higher bark content can generate a useable sugar stream while improving the quality of the biomass for combined heat and power by managing its ash content while simultaneously producing other valuable products.

09 BIOMASS FUELS↗

DOE OSTI2021

Low-Cost Radiant Heater for Rapid Response, High-Temperature Heating

High-temperature processing has an irreplaceable role in many research and industrial applications. Despite remarkable development spanning over a century, the pursuit of even higher thermal flux density and more rapid thermal transients has not slowed down. As part of the ongoing energy evolution, many industrial applications are transitioning from direct combustion of fossil fuels as primary energy sources to increasing electrification, capable of adapting to renewable power grids. Thus, there is an emerging need for electrical heaters that can replace burners and supply the heat demand, especially at the highest temperatures. In this study, we report on a radiant heater design that can achieve cyclic heating/cooling rates of up to 400 K min –1 and a temperature range in excess of 1,800 K, comparable to those of commercial infrared gold image furnaces, at high surface and volumetric power densities. The heater consists of a modular unit of incandescent tungsten filament and is enclosed in an evacuated ceramic envelope, chemically inert, tolerant of thermal shock, and impervious to gasses. The material and manufacture cost of such heaters, which is estimated at ~$0.05/W, is less than 0.03% of that for infrared gold image furnaces, which is at >$2/W. Tests of more than 10,000 demanding cycles (high temperature and high heating/cooling rate) over 350 h of total operational time and in different temperature ranges confirm the robust performance of radiant heater prototypes. The design is widely applicable to high-temperature reactor and furnace designs. In thermochemistry research and practice, these radiant heaters could offer multiple benefits compared to solar simulators, lasers, infrared gold furnaces, ceramic heaters, or direct concentration of solar input.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Determining the Adsorption Energetics of 2,3-Butanediol on RuO 2 (110): Coupling First-Principles Calculations With Global Optimizers

As climate change continues to pose a threat to the Earth due to the disrupted carbon cycles and fossil fuel resources remain finite, new sources of sustainable hydrocarbons must be explored. 2,3-butanediol is a potential source to produce butene because of its sustainability as a biomass-derived sugar. Butene is an attractive product because it can be used as a precursor to jet fuel, categorizing this work in the alcohol-to-jet pathway. While studies have explored the conversion of 2,3-butanediol to butene, little is understood about the fundamental reaction itself. We quantify the energetics for three pathways that were reported in the literature in the absence of a catalyst. One of these pathways forms a 1,3-butadiene intermediate, which is a highly exothermic process and thus is unlikely to occur since 2,3-butanediol likely gets thermodynamically trapped at this intermediate. We further determined the corresponding energetics of 2,3-butanediol adsorption on an ensemble of predetermined binding sites when it interacts with a defect-free stoichiometric RuO 2 (110) surface. Within this ensemble of adsorption sites, the most favorable site has 2,3-butanediol covering a Ru 5–coordinated cation. This approach is compared to that obtained using the global optimization algorithm as implemented in the Northwest Potential Energy Surface Search Engine. When using such a global optimization algorithm, we determined a more favorable ground-state structure that was missed during the manual adsorption site testing, with an adsorption energy of -2.61 eV as compared to -2.34 eV when using the ensemble-based approach. We hypothesize that the dehydration reaction requires a stronger chemical bond, which could necessitate the formation of oxygen vacancies. As such, this study has taken the first step toward the utilization of a global optimization algorithm for the rational design of Ru-based catalysts toward the formation of butene from sustainable resources.

09 BIOMASS FUELS↗