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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels (2019 State of Technology)

Each year, the DOE Bioenergy Technologies Office (BETO) assesses progress in their research and development efforts toward sustainable production of renewable fuels. Technical and cost targets were previously established for the wet waste hydrothermal liquefaction and biocrude upgrading pathway and summarized in a design report. The present report summarizes the research and associated techno-economic analysis (TEA) in support of the 2019 state of technology (SOT) assessment for this pathway. Data from Pacific Northwest National Laboratory’s Conversion hydrothermal liquefaction (HTL) program for wet waste was used to update the pathway techno-economic analysis (TEA) for the fiscal year 2019 State of Technology (2019 SOT). An overview of the current process model, experimental data and plant economics for the SOT is presented.

09 BIOMASS FUELS↗
DOE OSTI2025

Upgrading biocrude oil into sustainable aviation fuel using zeolite-supported iron-molybdenum carbide nanocatalysts

Food waste is an underdeveloped source for production of sustainable aviation fuel (SAF). Now, there is no certified conversion process of food waste for SAF by American Society for Testing and Materials (ASTM). We report the use of zeolite-supported molybdenum carbide nanocatalysts in upgrading biocrudes, produced from food wastes through HTL, into SAF precursors. Our data show a complete removal of oxygen from the biocrude through hydrodeoxygenation and a higher heating value of 46.5 MJ/kg, which is comparable to that of Jet A (46.1 MJ/kg). The prescreening tests (tier alpha and beta) show the average carbon number of the distillation cut (150° to 230°C) of upgraded fuel is 10.6, close to the value of 11.4 for average conventional jet fuel, and the specifications of properties including surface tension, viscosity, heating value, flash point, and freezing point were found to meet the standards of SAF. The metal carbide nanocatalysts were reusable in upgrading tests, and the activity of deoxygenation was retained.

10 SYNTHETIC FUELS↗
DOE OSTI2022

Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels: 2021 State of Technology

Each year the U.S. Department of Energy Bioenergy Technologies Office (BETO) assesses progress in their research and development efforts toward sustainable production of renewable fuels (DOE 2016) through the annual state of technology (SOT) assessment. The SOT assessment evaluates the impact of the year’s research progress on the modeled minimum fuel selling price (MFSP) for selected biofuel conversion pathways and measures the current state of the technology relative to defined goal case projections. Supply chain sustainability analysis to track and guide research toward improved greenhouse gas (GHG) emissions, energy usage, water usage and other environmental metrics for the pathway is performed by Argonne National Laboratory (Cai et al. 2018, 2020). Technical and cost targets for a projected goal case set for the year 2022 were previously established for the wet waste hydrothermal liquefaction (HTL) and biocrude upgrading pathway and summarized in a design report (Snowden-Swan et al. 2017). Process performance advancements made for HTL and biocrude hydrotreating have resulted yearly reductions in the modeled MFSP relative to the initial SOT (2018) (Snowden-Swan et al. 2020, 2021). This report summarizes the research and associated techno-economic analysis (TEA) for the pathway 2021 SOT. Methods and economic assumptions for the nth plant analysis used for the TEA are consistent with the design report (Snowden-Swan et al. 2017), with the exception of updates in the modeled cost year (2016) and income tax rate (21%).

09 BIOMASS FUELS↗
DOE OSTI2022

Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels: 2022 State of Technology

Data from Pacific Northwest National Laboratory’s (PNNL) conversion hydrothermal liquefaction (HTL) program for wet waste was used to update the pathway techno-economic analysis (TEA) for the fiscal year 2022 State of Technology (2022 SOT). Figure S.1 shows the modeled minimum fuel selling price (MFSP) for the 2022 SOT, along with the previous years’ SOTs (Snowden-Swan et al. 2020, 2021, 2022). These costs are for a HTL plant scale of 110 dry ton/day sludge feed and a larger centralized upgrading plant scale of 38 million gallons/year biocrude feed, commensurate with the design case. All costs were updated to 2020 dollars. Corresponding cost breakdowns and technical parameters for each case are given in Appendix B. In previous years’ analyses options with and without ammonia (NH 3 ) stripping treatment of the HTL aqueous phase recycle stream were included in the analysis to account for cases with direct recycle of untreated HTL aqueous phase back to the wastewater treatment plant. In the FY21 SOT assessment however, system boundaries for the analysis were adjusted to reflect separate ownership/operatorship for the HTL plant and with that, nutrient surcharge fees associated with disposal of the aqueous phase wastewater to a municipal sewer system were incorporated to provide an improved accounting of true disposal costs for a standalone plant. With these changes, there is no significant cost difference between the case including ammonia removal and the case excluding ammonia removal and therefore the “no NH3 removal” options will not be included in the 2022 and future SOTs.

09 BIOMASS FUELS↗
DOE OSTI2023

Microalgae Hydrothermal Liquefaction and Biocrude Upgrading: 2022 State of Technology

A preliminary techno-economic analysis (TEA) was developed for the fiscal year (FY) 2022 state of technology (SOT) assessment to evaluate the benefits and risks of using demonstrated, high-productivity algae strains for fuels generation, including sustainable aviation fuel (SAF). In 2022, the marine algal strain, Picochlorum celeri, which demonstrated the highest outdoor biomass productivities reported to date in the DOE-funded open-pond raceway testbed at the Arizona Center for Algae Technology and Innovation (AzCATI), was tested for continuous hydrothermal liquefaction (HTL) processing at PNNL. HTL testing results demonstrated a biocrude yield of 0.33 g/g algae on an ash-free dry weight (AFDW) basis from P. celeri. The hydrotreatment testing of the HTL biocrude from P. celeri was also conducted to investigate the production of jet fuel from marine algal biomass. To the best of our knowledge, this is the first report of jet fuel production from autotrophically grown marine algal biomass. The current hydrotreating testing demonstrated approximately 22.7 wt% of the hydrotreated oil within the typical boiling-point range of jet fuel (150–250 °C). Initial testing of the jet fuel cut (JFC) showed that the physical properties under investigation were within typical ranges for petroleum-based jet fuels. The experimental work of this study closes the gap between outdoor algae cultivation and algae conversion to critical transportation fuels using the same algae strain for both cultivation and conversion testing. The continuous HTL and the upgrading testing described herein demonstrate the potential of producing sustainable aviation fuel (SAF) from algae cultivated in open-pond systems using the primary inputs of sunlight and carbon dioxide.

09 BIOMASS FUELS↗
DOE OSTI2021

Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels: 2020 State of Technology

Data from Pacific Northwest National Laboratory’s conversion hydrothermal liquefaction (HTL) program for wet waste was used to update the pathway techno-economic analysis (TEA) for the fiscal year 2020 State of Technology (2020 SOT). The modeled fuel blendstock MFSP for the 2020 SOT is estimated at $4.50/GGE (with ammonia stripping of the AP), a reduction of $0.61/GGE, or 12%, relative to the 2019 SOT (Snowden-Swan et al. 2020). Progress in the HTL area includes increased reactor LHSV from 3.6 to 4.0 and a newly designed staged approach for the sludge pumping and heating, resulting in a 1 cent and 26 cent reduction in modeled MFSP, respectively. The newly designed heat exchanger configuration is less material and capital intensive than the previous SOT, and provides a system design that is more scalable with regard to practical fabrication limitations. Further improvements may be possible with the use of core inserts to enhance tube velocity and heat transfer rates. Biocrude hydrotreating research progress improved weight hourly space velocity (WHSV) from 0.67 to 0.72 hr-1 in the guard bed and from 0.39 to 1.02 hr-1 in the main hydrotreating bed, a 7% and 162% improvement, respectively. Hydrotreating performance was not sacrificed at the higher throughput rates and catalyst activity remained stable over the run. The demonstrated increase in WHSVs reduced the modeled MFSP by $0.34/GGE.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels

Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.

09 BIOMASS FUELS↗
DOE OSTI2024

Supporting data for Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels

Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.

Li, Shuyun↗
DOE OSTI2023

Uncertainty analysis for techno-economic and life-cycle assessment of wet waste hydrothermal liquefaction with centralized upgrading to produce fuel blendstocks

Wet waste hydrothermal liquefaction is a promising technology for producing transportation fuels with much lower greenhouse gases emissions than petroleum-based fuels. However, its techno-economic and life cycle assessment are primarily based on laboratory scale testing data, subject to considerable uncertainties, and even bias, due to knowledge gaps. Here, a preliminary uncertainty analysis of key economic measures was conducted based on the 2019 state-of-technology model for biocrude production. Building on the preliminary analysis, this work presents a comprehensive uncertainty analysis in both economic and environmental measures of the entire supply chain of wet waste hydrothermal liquefaction to fuel blendstocks including biocrude upgrading based on the 2021 state-of-technology model. The analysis includes the most recent developments in hydrothermal liquefaction and biocrude upgrading technologies and Monte Carlo simulation based on an integrated model system including an improved reactor yield model, reduced-order process model, discounted cash flow economic model and simplified life-cycle assessment model. The estimated biocrude yield ranges from 42.2% to 52.4% with a median of 47.3%. The estimated fuel yield ranges from 34.7% to 42.7% with a median of 38.7%. The estimated minimum fuel selling price ranges from $\$ $2.28/gge to $\$ $3.45/gge with a median of $\$ $2.80/gge. Relative to petroleum-derived diesel, the estimated reduction in supply chain greenhouse gas emissions ranges from 73.4% to 81.8% with a median of 77.7%. Compared to the 2019 state-of-technology analysis, a significant improvement in biocrude selectivity and economic measures and reduction in uncertainties were achieved due to the incorporation of additional continuous experimental data sets, technology development and de-risking, and improvement in model accuracy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Pilot-scale hydrotreating of catalytic fast pyrolysis biocrudes: process performance and product analysis

Catalytic fast pyrolysis (CFP) is a technology option for producing advanced biofuels from hydrocarbon-rich biocrude intermediates. The relatively high oxygen content of biocrudes compared to petroleum intermediates increases hydrogen consumption and the lower thermal stability accelerates catalyst deactivation and reactor fouling hindering the adaptation of hydrotreating technology for biocrude upgrading into biofuels. In this study, four chemically different biocrude feeds were upgraded in a pilot scale hydroprocessing unit at similar process conditions using a commercial hydrodeoxygenation (HDO) catalyst. The biocrude feeds and hydrotreated products were characterized using standard ASTM procedures and advanced analytical techniques (GCxGC-FID and GCxGC-MS). HDO catalyst activity was monitored by changes in physical properties and chemical composition of the upgraded products as a function of time on stream. Aliphatic acids, ketones, aldehydes, and furan derivatives were completely converted during the hydrotreating tests while the concentration of aromatics, aliphatic hydrocarbons and phenolics increased during the hydrotreating tests. The oxygen content, nitrogen content, specific gravity, viscosity and the heavy end of the boiling point range (determined by simulated distillation) of the upgraded products increased with increasing time on stream during hydrotreating. The deactivation rate was the lowest for the biocrude feed that contained the most aliphatic and aromatic hydrocarbons and was the highest for the biocrude feed that had the most anhydrosugars. Overall, the HDO deactivation rate correlates with the total amount of oxygen in the feed (17 wt% to 29 wt%, on a wet basis).

09 BIOMASS FUELS↗
DOE OSTI2021

Microalgae Conversion to Biofuels and Biochemical via Sequential Hydrothermal Liquefaction (SEQHTL) and Bioprocessing: 2020 State of Technology

A preliminary techno-economic analysis (TEA) was developed for the fiscal year 2020 state of technology (SOT) assessment to evaluate the benefits and risks for a large-scale microalga hydrothermal liquefaction (HTL) system based on most recent testing results. The focus of the study is directed toward the conversion system, which consists of five processes: two-stage sequential HTL (SEQHTL), biocrude upgrading to final fuels, bioprocessing for co-product generation, hydrogen generation, and steam cycle. In this system, algae biomass with corn stover supplement during the lower algae productivity seasons (winter, fall, and spring) to match the maximum algae seasonal production rate in summer is employed to maintain a constant plant capacity in all the seasons. Algae only (summer season) or algae/corn stover blended feedstock (other seasons) are sent to a two-stage SEQHTL process. In stage I, the carbohydrates in the feedstock are extracted and separated from the residual solid. The residual solid from stage I is further converted to biocrude in the SEQHTL stage II step. The biocrude is upgraded to final fuel products in an upgrading process. The extract stream from HTL stage I is sent to the bioprocessing section for co-product generation via fermentation of carbohydrate. Lactic acid (LA) is assumed to be the co-product based on current bioprocessing testing results.

09 BIOMASS FUELS↗
DOE OSTI2020

Algae/Wood Blends Hydrothermal Liquefaction and Upgrading: 2019 State of Technology

The fiscal year (FY) 2019 State of Technology (SOT) Assessment for a microalgae and woody biomass blend feedstock hydrothermal liquefaction (HTL) and biocrude upgrading system has been completed and reported here. This study is a preliminary economic analysis for this system. Inputs from the 2019 NREL open pond algae cultivation model provided microalgae seasonal flowrates and dewatered algae feedstock price. These inputs have been coupled with modeled experimental data from PNNL for algae/wood blends processed via HTL to assess the cost impacts. The TEA results demonstrated a 28% reduction in the conversion cost only from $1.22/gge in 2018 to $0.88/gge in 2019.

09 BIOMASS FUELS↗
DOE OSTI2023

Pilot-Scale Continuous Plug-Flow Hydrothermal Liquefaction of Food Waste for Biocrude Production

Pilot-scale hydrothermal liquefaction (HTL) of biowaste is a critical step toward commercialization of the HTL technology. Despite many HTL studies conducted with wet biomass, including food waste, few were performed with a pilot-scale continuous plug-flow reactor (PFR), with the biocrude yield and quality analysis based on dewatering (ASTM D2892 Annex X1). This paper describes the development and performance evaluation of a mobile pilot-scale HTL continuous PFR, with a processing capacity of 60 L/h of wet feedstock and 6 L/h of biocrude production. The reactor system was designed for reaction conditions of up to 325 °C and 17.25 MPa. The reactor has a volume of 28.88 L with an additional counterflow heat exchanger volume of 18.07 L. Two types of food wastes, from a food processing plant and grocery store, were processed at 280 °C for 30 min, producing biocrude oil yields of 52.19 and 47.06 wt %, energy recoveries of 68.17 and 70.77%, and carbon recoveries of 66.91 and 64.78%, respectively. Furthermore, due to its high feedstock capacity and reaction volume, large amounts of biocrude oil and post-HTL wastewater (PHW) were obtained from this pilot-scale reactor to allow downstream research on upgrading biocrude oil for transportation fuel as well as PHW treatment and nutrient recovery.

09 BIOMASS FUELS↗
DOE OSTI2022

Hydrothermal Liquefaction and Upgrading of Wastewater-Grown Microalgae: 2021 State of Technology

The fiscal year (FY) 2021 State of Technology (SOT) Assessment for the hydrothermal liquefaction (HTL) of wastewater (WW)-grown microalgae and biocrude upgrading system was completed and reported here. An industrial partner, Gross-Wen Technologies (GWT), provided algae feedstock cultivated on a revolving algal biofilm (RAB) system by using the primary effluent from a water resource recovery facility (WRRF). This provided algae was tested at PNNL for HTL processing. The experimental results provided the major design basis of the HTL process of the SOT baseline case. The primary effluent of the Metropolitan Water Reclamation District (MWRD) of Greater Chicago was assumed to be the nutrients source for algae growth and the algae yield data per gallon wastewater provided by GWT were used to estimate the total algae production rate and thus the HTL conversion plant scale. Considering different cultivation technologies and wastewater streams with different flow rates and nutrients contents can be used to produce algae, this SOT assessment just provided an example case study for WW-grown algae based HTL conversion to fuels systems. A preliminary economic analysis was developed based on process simulation results. Sensitivity analysis was implemented to evaluate cost impacts of plant scales, potential cost improvements and other key factors.

54 ENVIRONMENTAL SCIENCES↗
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↗