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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

The Energy Costs of Dewatering Feedstock Microalgae Species Using Conventional Implementations of Ultrasonic and Crossflow Filtration Technologies

The use of microalgae as a feedstock for biofuels and other products continues to be explored, but large-scale biomass production faces persistent high costs. One major cost contributor is the energy required for harvesting and dewatering, a challenge resulting from the dilute nature of microalgae cultures as well as the properties of microalgae cells. This study investigated the energy demands of concentrating three diverse microalgae species (Nannochloropsis salina, Scenedesmus obliquus, and Chlorella luteoviridis) exhibiting different settling velocities, a key harvesting property, using conventional ultrasonic and crossflow membrane filtration. Membrane-free ultrasonic filtration removed 60-80% of the microalgae largely in steady-state operations, increasing concentrations 20-100 times, while consuming 1-6 kWh/m3 - similar to centrifugation. In contrast, crossflow membrane filtration retained nearly 100% of the microalgae, increasing concentrations over 20-fold, but consumed 158 kWh/m3 - over 10 times the energy of centrifugation. Both approaches exceeded the 10% energy target suggested in the 2010 National Algal Biofuel Technology Roadmap. This study also highlights potential sources of energy savings. For ultrasonic filtration, attention to an innovative, dynamic property of the ultrasonic chamber called the Energy Efficiency Factor, could lead to energy reductions by no more than 10-fold and improve the favorability of two of the microalgae species studied. For membrane filtration, a dead-end configuration could reduce energy consumption by no more than 1000-fold, making it favorable for all three species. This study not only highlights the need to further increase the energy content of microalgae cultures, but also the critical importance of continued development of ultrasonic filtration and other harvesting technologies to achieve low-cost, energy-sustainable algal biofuels.

09 BIOMASS FUELS↗
DOE OSTI2025

Two novel Patescibacteria: Phycocordibacter aenigmaticus gen. nov. sp. nov. and Minusculum obligatum gen. nov. sp. nov., both associated with microalgae optimized for carbon dioxide sequestration from flue gas

The functional roles of bacterial symbionts associated with microalgae remain understudied despite the importance of microalgae in biotechnology and environmental microbiology. 16S rRNA gene sequencing was conducted to analyze bacterial communities associated with two microalgae optimized for growth with flue gas containing 5%–10% CO 2 . Two dominant bacteria with no taxonomic classification beyond the class level (Paceibacteria) were discovered repeatedly in the most productive algal cultures. Long-read metagenomic sequencing was conducted to yield high-quality metagenomes, from which two novel species were discovered under the Seqcode (seqco.de/r:ywe1blo2), Phycocordibacter aenigmaticus gen. nov. sp. nov. and Minusculum obligatum gen. nov. sp. nov. The genus Phycocordibacter gen. nov. was proposed as the nomenclatural type of the family Phycocordibacteraceae fam. nov. and the order Phycocordibacterales ord. nov. Both bacteria possessed features typical of Patescibacteria such as reduced genomes (<800 kbp), lack of complete glycolysis and tricarboxylic acid (TCA) cycle pathways, and inability to synthesize amino acids. Instead, they rely on the reductive pentose phosphate pathway (Calvin cycle) for essential biosynthesis and redox balance. P. aenigmaticus may also rely on elemental sulfur oxidation (sdo), partial nitrite reduction (nirK), and sulfur-related amino acid metabolism (SAMe → SAH). Both bacteria were found in high relative abundance in cultures of Tetradesmus obliquus HTB1 (freshwater) and Nannochloropsis oceanica IMET1 (marine), suggesting a tight association with microalgae in various environments. The absence of full metabolic pathways for energy production suggests extreme metabolic limitations and obligate symbiosis, most likely with other bacteria associated with the microalgae.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Life-cycle analysis of microalgae-based polyurethane foams

Polyurethane plastics are essential in many consumer and commercial products such as insulation, furniture, automotive interiors, and clothing. Pathways for producing polyurethane from microalgae offer an opportunity to reduce greenhouse gas emissions and other environmental impacts and can incorporate processes that avoid the use of toxic isocyanates typically used in conventional polyurethane production processes. In this study, the greenhouse gas emissions, fossil energy, and water consumption of biobased polyurethane and biobased non-isocyanate polyurethane were evaluated via life-cycle analysis using the R&D Greenhouse Gases, Regulated Emissions, and Energy Use in Technologies model. Microalgae-based polyurethane foam was found to achieve greenhouse gas emission reductions of up to 79% compared with conventional polyurethane foam production. The greenhouse gas reductions for the non-isocyanate microalgae polyurethane pathway are slightly lower at 58% compared with conventional polyurethane foam. However, it offers additional benefits by reducing toxicity potential compared to the isocyanate polyurethane pathway. The analysis also included a biorefinery-level analysis to evaluate the impact of incorporating polyurethane production into fuel-processing microalgae biorefineries. The sensitivity analyses conducted in this study reveal that improved algae cultivation strategies can lead to decreases of up to 127% and 80% in GHG emissions from the baseline process of Bio-PU and Bio-NIPU, respectively. Likewise, implementation of renewable electricity can result in up to 128% and 74% lower GHG emissions compared to the baseline production of Bio-PU and Bio-NIPU, respectively. Finally, the analysis evaluated different coproduct handling methods including displacement and allocation (based on mass, energy, and market-value). The results suggest that it is important to consider both the displacement and allocation methods as these led to significant differences in the environmental impacts.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Development and Validation of a Process Model and Open-Source Process Simulator for Microalgae-Based Tertiary Phosphorus Recovery

Microalgae-based tertiary wastewater treatment has the potential to meet stringent effluent phosphorus limits, with the added benefit of producing a marketable feedstock. However, the lack of validated mechanistic models and their implementation in process simulators have limited the adoption of this technology. In this study, an updated lumped pathway metabolic model (Phototrophic-Mixotrophic Process Model, PM 2 ), including both photoautotrophic and heterotrophic metabolisms of microalgae, was developed to predict effluent phosphorus concentration and biomass yield in response to dynamic influent and varying environmental conditions. The model was implemented in QSDsan – an open-source, Python-based design and simulation platform – for robust simulation under uncertainty. A global sensitivity analysis was performed to prioritize model parameters for calibration. The model was then calibrated and validated using batch experimental data and 45 days of continuous online monitoring data from a full-scale (568 m 3 ·d -1 ) microalgae-based tertiary wastewater treatment plant (EcoRecover process). In particular, along with dynamic influent composition, temperature and light intensity data with diel variation were provided as model inputs to reflect the microalgal behavior under day-night cycling. Overall, the QSDsan-based microalgae process simulator was able to predict effluent phosphorus within 0.02–0.04 mg-P·L -1 , while also capturing the general trends of state variables according to nutrient availability.

Lumped pathway metabolic model↗
DOE OSTI2026

Microalgae Commodities Production with a Direct Air Capture Process (Final Technical Report)

This report documents the work performed under Award Number DE-EE0009276, "Microalgae Commodities Production with a Direct Air Capture Process," to advance the technology for large-scale, low-cost microalgae biomass production in the United States. The project's overarching goal was to decouple microalgae production from enriched CO 2 point sources, such power plant flue gases, which otherwise limit the national resource potential for algal biomass.

09 BIOMASS FUELS↗
DOE OSTI2025

Charting the state of GEMs in microalgae: progress, challenges, and innovations

Genome-scale metabolic models (GEMs) provide a systems-level framework for understanding and engineering microalgal metabolism. This review explores the evolution of GEMs in microalgae, highlighting advances in light modeling, automation, and multi-omics integration. Special emphasis is placed on Chlamydomonas reinhardtii as a model species. Limitations of current models, particularly for microalgae, are discussed, alongside promising developments in dynamic modeling and machine learning. Together, these innovations chart a path toward more predictive, adaptable GEMs that can accelerate biotechnological applications of microalgae in sustainable production systems.

Plant Sciences↗
DOE OSTI2025

Ultrastructure of the Endoplasmic Reticulum in Eukaryotic Microalgae

ABSTRACT The endoplasmic reticulum (ER) is a large and highly dynamic component of the eukaryotic endomembrane system. In eukaryotic microalgae, it plays six distinct roles: (1) It envelopes the chromatin to form thenucleus. (2) It forms cisternae in the cytoplasm, some of which scaffold the synthesis of proteins destined for incorporation into membranes or for secretion. (3) It associates withGolgicisternae to scaffold the synthesis of glycosylated proteins. (4) It associates with theplasma membraneto mediate the synthesis and secretion of hydrophobic molecules. (5) It mediates the synthesis of cytoplasmiclipid bodies. (6) In lineages harboring complex plastids of red algal ancestry, it forms thechloroplast ER, which envelops the primary chloroplast envelope. In this review, these systems are illustrated using the quick‐freeze deep‐etch electron microscopy (QFDEEM) technique, which lifts up the topological configurations adopted by this gossamer system. A key finding is that in all the complex microalgae examined except dinoflagellates, the inner nuclear envelope membrane associates directly with the plastid‐contiguous membrane of the chloroplast ER at foci designated as chloroplast‐nuclear junctions. These junctions may play a role in regulating the maintenance and physiology of the complex organelles.

Microbiology↗
DOE OSTI2025

Evaluation of microalgae cultivation at air-CO 2 equilibrium pH for improving carbon utilization efficiency

Microalgae are often cultivated at near-neutral pH to optimize growth. However, this results in significant CO 2 loss through outgassing in open-pond cultivation systems, leading to low CO 2 utilization efficiency and higher biomass production costs. One potential solution is algal cultivation at air-CO 2 equilibrium pH, which minimizes CO 2 outgassing but may inhibit growth due to stresses at higher pH levels. In this study, we evaluated the viability of this approach by growing Picochlorum celeri and Tetraselmis striata under outdoor relevant conditions at equilibrium pH. Compared to pH 7 cultures, biomass productivity declined by 35 % for P. celeri and 57 % for T. striata. Although CO 2 outgassing could be minimized, the significant loss in productivity led to a higher overall minimum biomass selling price (MBSP). Increased ammonia toxicity at the higher pH was found to be one of the growth-limiting factors and was mitigated by reducing ammonium fertilizer concentration. This adjustment resulted in a more moderate productivity decline of 13 % (instead of 35 %) for T. striata, and consequently, a lower MBSP was achieved. These findings suggest that equilibrium pH cultivation may be a viable method for reducing CO 2 loss without significantly compromising biomass productivity. Depending on the strain, strategies to mitigate stressors, such as ammonia toxicity, may be necessary.

09 BIOMASS FUELS↗
DOE OSTI2025

Integration of CO 2 capture and microalgae cultivation: demonstration assessment of outdoor Scenedesmus acutus cultivation using gaseous ammonia as a nitrogen source

Towards the goal of integrating CO 2 capture using aqueous ammonia with its utilization for algae cultivation, Scenedesmus acutus (UTEX B72) was grown in 1100 L open raceway ponds using CO 2 and NH 3 supplied from gas cylinders. CO 2 /NH 3 mole ratios of 7 and 10 were employed, the gas mixture acting as a surrogate for the output from a CO 2 scrubbing system using aqueous ammonia. Compared to Scenedesmus acutus grown in open ponds using gaseous CO 2 and NaNO 3 as the N-source, the ponds supplied with gaseous CO 2 and NH 3 displayed higher productivity at both CO 2 /NH 3 ratios, with the higher ratio providing the best growth. Depending on the culturing conditions and CO 2 /NH 3 ratio, CO 2 utilization ranged up to 15.8% and NH 3 utilization to 23.0%. These rather low values reflect the fact the high CO 2 /NH 3 feed rate used, resulting in a substantial release of NH 3 from the ORPs (~45%). Finally, these findings demonstrate the suitability of gaseous NH 3 as a N-source for microalgae cultivation, while highlighting the need for a control strategy that closely balances the CO 2 /NH 3 supply with the algae growth rate. The produced algae biomass possessed a high protein and low ash content, rendering it particularly suitable for use as a bioplastic feedstock.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Technology Case Study: Techno-Economic and Life Cycle Analysis for Microalgae Conversion Pathways to Fuels and Products

This technology case study report details the cost and sustainability prospects for an emerging feedstock - microalgae - converted to fuels and products via a fractionation and upgrading approach termed combined algae processing (CAP). Detailed techno-economic analysis (TEA) and life cycle analysis (LCA) are conducted for the conversion of farmed algae biomass, with two primary scenarios considering the conversion of either high-compositional-quality biomass enriched in lipids (high-lipid [HL]) or lower-quality biomass enriched in protein (high-protein [HP]). Each scenario employs a different biorefinery configuration tailored towards extracting the maximum value from the given biomass composition. The HL scenario produces fuels and non-isocyanate polyurethane (NIPU) as the primary products, while the HP scenario products fuels and a residual solid coproduct which can be used as a co-feed for producing thermoplastics. The results for the HL scenario were particularly promising, with a minimum fuel selling price (MFSP) of $\$$3.68 per gasoline gallon equivalent (GGE) and fuel GHG emissions translating to 54%-76% reduction compared to petroleum fuels depending on the coproduct handling method used. In contrast, the HP scenario faced more challenges in producing biofuels economically, projecting an MFSP of $\$$7.92/GGE despite significant revenues from the residual algae solids. LCA results for the HP case reflected a 24% reduction potential in biorefinery-level GHG emissions. However, these GHG reductions were primarily associated with the thermoplastic coproduct, which accounted for 93% of all biorefinery outputs by mass. Using a process-level allocation method, carbon intensity results were less promising, indicating a net increase in fuel GHG emissions versus petroleum fuels and highlighting the reliance of this scenario on the thermoplastic coproduct.

09 BIOMASS FUELS↗
DOE OSTI2026

Effects of Media Nutrient Variation on Microalgae Productivity and Economics During Semi-Continuous Cultivation

The development of large-scale microalgae growth for biofuel production is currently limited by the cost of biomass production. However, new approaches to infrastructure and cultivation practices are bringing the field closer to realization. Macronutrients in the cultivation media contribute significant costs, especially since their concentrations have not been optimized for specific strains and conditions. Environmental photobioreactors (ePBRs) were used to simulate cultivation under outdoor conditions, during which the nitrogen and phosphorus levels in the media were varied. The growth of two potential biofuel production strains, Picochlorum celeri and Tetraselmis striata, with varying nutrient inputs during summer and winter scripts, respectively, was studied. This study demonstrated that nitrogen and phosphorus in f/2 media could be reduced by more than 60% from the standard formulation, while maintaining growth rates in a semi-continuous harvesting approach. Experiments comparing the standard and reduced nutrient input concentrations were also conducted for both species in 820 L outdoor raceway ponds, in Mesa, AZ. P. celeri grown in these ponds in October had a growth rate of 10.6 ± 0.7 g/m 2 /day and 10.6 ± 0.3 g/m 2 /day for the standard and low-nutrient P. celeri ponds, respectively. T. striata grown in April–May had a growth rate of 16.6 ± 1.4 g/m 2 /day for the standard nutrient input ponds and 17.4 ± 1.1 g/m 2 /day for the low-nutrient input ponds, and in October 14.5 ± 0.6 g/m 2 /day for standard nutrient ponds and 14.4 ± 0.6 g/m 2 /day for low-nutrient ponds. These outdoor data therefore confirmed the indoor ePBR data. Techno-economic analysis shows that, if high growth rates can be attained at lower nutrient concentrations, a reduction of at least 60% in nutrient costs can be achieved. Such results highlight the importance of managing macronutrient media inputs, as these have a considerable contribution to biomass production costs in large-scale facilities. The analysis also points to the importance of maintaining high spent medium recycling rates in an industrial deployment, so as to minimize the losses of nitrogen and phosphorus compounds.

09 BIOMASS FUELS↗
DOE OSTI2025

Optimized Illuminance Operation-A Light-Driven Dilution Strategy to Improve Microalgae Biomass Productivity

Periodic dilution is a necessary operation to avoid light limitation due to self-shading as the culture grows dense. However, environmental conditions are constantly changing in outdoor cultivation systems, making it difficult to determine the optimal dilution rate. To address this challenge, this study evaluated a dilution approach based on light penetration to optimize illuminance (OptiLum) in the culture. Biomass concentration was controlled via sensor-feedback directed dilution to ensure that light reaching the bottom of the culture was maintained above the compensation intensity. Under replicated outdoor pond conditions, by keeping the entire culture within a net-positive photosynthetic zone, the OptiLum operation improved the biomass productivities of two top-performing strains, Picochlorum celeri and Tetraselmis striata, by 95 % and 86 %, respectively, compared to conventional semi-continuous batch cultivation. The dilution rate varied daily and was dynamically adjusted based on the light status within the culture, which is concurrently influenced by weather, culture density, and growth rate. The techno-economic analysis showed that the OptiLum operation could reduce biomass production cost by as much as 24 % and 33 % for P. celeri and T. striata, respectively, assuming a low-cost dewatering approach with initial gravity settling of biomass can be realized for both strains. However, a more costly two-stage dewatering strategy, comprising only membranes and centrifuges, may be necessary for non-settling strains, such as P. celeri, which would alternatively increase production costs by 23 % for the OptiLum case. The results demonstrated that the proposed OptiLum operation is a promising approach to improve biomass productivity and lower production cost via weather-responsive and self-adjusting dilution.

09 BIOMASS FUELS↗