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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Comparative life cycle assessment of bioenergy in Japan from residual biomass-based wood pellets produced in the US Pacific Northwest

The US Pacific Northwest (PNW) faces an increase in wildfires due to forest overcrowding and climate change, posing significant environmental and public health risks. Traditional methods of managing surplus biomass, including prescribed burning, have increased air pollution and global warming. While in the PNW, residual woody biomass is being treated as waste, Japan’s growing demand for bio-based energy presents an opportunity to export value-added biomass as energy pellets. This study investigates whether producing wood pellets from the residual woody biomass from forest operations and sawmills for electricity generation in Japan is truly environmentally beneficial. Accordingly, we conducted a cradle-to-grave Life Cycle Assessment (LCA) to evaluate the environmental impact of residual pellets vs. coal for electricity generation. The assessment covered feedstock production, pellet processing, transportation, and combustion phases. Our findings indicate that replacing coal-based electricity in Japan with PNW residual pellet-based electricity can lower the Global Warming Potential (GWP) by about 90% for every unit of electricity displaced. Furthermore, the results show that repurposing the otherwise burnt harvest slash residues for pellet production would improve local air quality by reducing PM 2.5 and smog in the PNW. However, substituting coal with residual pellets marginally increased carcinogenic and ecotoxicity-related emissions. Based on these results, we conclude that substituting coal with residual wood pellets for electricity generation, particularly harvest-slash residual pellets, is environmentally beneficial across most impact categories, including the GWP. This research underscores how an export‑oriented pellet industry can help address the environmental challenges within the regional US wood products industry and global renewable energy supply.

Velappan, Hemalatha [Univ. of Washington, Seattle,↗
DOE OSTI2025

Component Identification of Solid Biomass Fuels Using Reflected Light Microscopy: Interlaboratory Study 2

As nations transition toward sustainable energy systems, biomass has become a vital component of global energy portfolios. Derived from organic materials such as wood, agricultural residues, forestry byproducts, and organic waste, biomass is a renewable energy source with significant environmental and economic benefits. Responsible biomass energy production can improve waste management, reduce emissions of greenhouse gases, and mitigate environmental pollution. However, as the diversity of biomass-derived fuels increases, robust quality assessment methods are essential to ensure their efficiency, safety, and minimal environmental impact. Reflected light microscopy (RLM) is one such technique with the potential to complement conventional physico-chemical analyses by enabling a rapid identification of material constituents and impurities. To refine this methodology and evaluate the reproducibility of solid biomass component identification using RLM, an interlaboratory study (ILS) was conducted. The study involved the recognition of 58 components across 45 photomicrographs, with the participation of 65 scientists and students from 25 countries. The participants faced high difficulty identifying some of the marked components, and as a result, the percentage of correct answers ranged from 19.0 % to 98.3 %, with an average correct identification rate of 62.7 %. The most challenging aspects of the identification process included distinguishing between woody and non-woody (agro) biomass, accurately identifying petroleum-derived materials, and differentiating agro biomass from inorganic matter. The results suggest that while RLM is an important tool for characterizing solid biomass, further development of methodology guidelines and training are necessary to enhance its effectiveness. Future research should prioritize preparing detailed, image-rich, microscopic morphological descriptions of biomass fuel components, which could improve the accuracy and reliability of using RLM in biomass fuel characterization.

09 BIOMASS FUELS↗
DOE OSTI2026

Evaluation of a Smoke Opacity Sensor for Improving Residential Wood Heater Combustion

Residential wood heating lacks real-time particulate matter (PM) monitoring technologies capable of measuring emissions directly from flue gases. This study evaluates the performance of the Octoring, an opacity-based smoke sensor developed to monitor wood heater emissions and provide feedback for improved combustion. The device was tested on catalytic and non-catalytic cordwood heaters and a pellet heater during startup, high-burn, and low-burn phases. Performance was assessed against reference particle instruments and gravimetric measurements using concordance, correlation, and agreement analyses. Results show that temperature-dependent drift is the primary limitation affecting sensor accuracy, with systematic drift observed across ambient and combustion conditions. Agreement with reference instruments ranged from poor to good depending on operating conditions, with the strongest performance observed during pellet heater high-burn operation. These findings establish a performance baseline for opacity-based sensing technologies and identify key areas for further development before practical deployment in residential wood combustion monitoring systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends with Washed and Unwashed Legacy Coals and Other Waste Fuels to Generate White Hydrogen

The objective of this effort, primarily funded by the United States Department of Energy (DOE), and led by the Electric Power Research Institute, Inc. (EPRI), with support by Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), has been to qualify coal, biomass, and plastic waste blends based on performance testing of selected fuel pellet compositions in a pilot-scale updraft moving-bed (UDMB) gasifier. The testing provided relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are the focus. The gasifier used for testing is HMI’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips (biomass). However, mixtures of these fuels with plastic wastes have not been prepared and gasified together. The three feedstocks were densified and pelletized by California Pellet Mill (CPM) to meet the feedstock size required by Sotacarbo’s 30mm ID UDMB gasifier, under contract to HMI. The technical tasks and results from this two-year research project included: (1) Feed Procurement and Preparation: Nine different tri-fuel pellets were prepared from varying compositions of fresh mined PRB coal, corn stover biomass, and car fluff waste plastics. Tri-fuel pellets were produced by CPM and shipped to Sotacarbo’s test facility in Carbonia, Sardinia, Italy. (2) Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different UDMB gasification tests to be performed in Sotacarbo’s 12-inch ID pilot scale gasifier, the process monitoring instrumentation used, and the extractive samples recovered for analysis of the total gasification process mass and energy balance. (3) Gasifier Testing: Nine different gasification runs were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstock compositions generated from varying mixtures of PRB coal, biomass, and plastic wastes. The testing generated performance data on gasification reaction efficiency and performance, yielding relevant data for models used to scale up the gasifier design. This task also included work to refurbish and reassemble the pilot gasifier at Sotacarbo and perform a baseline 100% PRB coal run. (4) Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results are reported in the project’s final report, published in March 2024. The results show that all tri-fuel pellets gasified well and maintained structural integrity throughout the gasification process. The syngas generated can be shifted to hydrogen by using commercial syngas shifting technologies. (5) High Fidelity computational fluid dynamics (CFD) Simulation: The National Energy Technology Laboratory (NETL) team performed CFD simulations of the UDMB gasifier for two of the tri-fuel pellets gasified in Sotacarbo’s pilot scale gasifier. The kinetic mechanisms for the pyrolysis of each constituent, PRB coal, corn stover biomass, and waste plastics are based on thermogravimetric analysis performed by Sotacarbo. The gasification model was validated by comparing the predicted syngas composition at the exit of the gasifier with the measured syngas composition. In addition, the reactor’s measured internal temperature profile agreed well with the predicted internal reactor temperature profile. These results validate that the model can be used to predict the performance of the updraft moving bed gasifier for different feedstocks and operating conditions. This paper summarizes the results of the completed work in which the pelletizing procedure was validated to ensure the viability of the tri-fuel pellets for the gasification runs performed at Sotacarbo’s 30 mm UDMB gasifier. The gasification performance data from this series of nine runs will enable modeling of a full-scale HMI industrial scale gasifier supporting both combined heat and power, and Hydrogen production from coal (both fresh mined and legacy) combined with various biomass and waste plastics. Additionally, plans and progress on a follow-up project, being executed by the same project team, will be presented. In this project, a total of twenty (20) different feedstocks are being prepared from varying compositions of biomass (both woody biomass and corn stover) with a mixture of legacy coal waste, plastic waste, and refuse-derived fuel (RDF). The testing will provide information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design to 50 megawatt electric (MWe) (equivalent hydrogen production). Tests will also be performed on a bench-scale fluidized-bed gasifier for comparison purposes. The results of this testing will be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends.

08 HYDROGEN↗
DOE OSTI2025

Fluidized Bed Gasification For Conversion of Biomass and Waste Materials to Renewable Hydrogen

This project was undertaken in order to study the potential for hydrogen production, at low cost, from mixtures of biomass and municipal solid waste (MSW). This approach allows for the production of hydrogen with a very low fossil carbon burden, while taking advantage of tipping fees (associated with MSW) to improved process economics. The team sourced three primary feedstocks (wood, MSW, and waste plastics) and characterized them comprehensively using established techniques with a long track record in the field of gasification. All three primary feedstocks were highly reactive and lost most of their mass during initial devolatilization. The production of tars, including heavy tars, was quite high, and was most problematic in the case of the MSW and Waste Plastics feedstocks. Little practical difference was identified between the MSW and Waste Plastics materials, and the addition of bed-forming materials (dolomite and brown alumina) to the feedstocks was found to reduce production of tars during devolatilization under thermogravimetric analysis and/or Fischer Assay conditions. A series of four tests in a lab-scale bubbling-fluidized-bed gasifier, at 50 psig of pressure and about 825 C, confirmed these findings. Pellet feedstocks, broken into fragments, were used for these tests, and pellets comprised of 50% MSW and 50% biomass were found to be the best option in terms of fossil carbon burden, economic potential, and gasification characteristics. Tests were then undertaken in a pilot-scale gasifier facility based on the GTI U-Gas fluidized-bed gasification technology. The feedstock handling train of the 20 TPD U-Gas pilot-scale gasifier located in Des Plaines, IL, was operated under simulated gasification conditions, and the 50/50 pellets were found to be very robust and unproblematic. An improved design for the forward end of the feedstock injection screw of the gasifier was developed and installed. The design approach was based on improved passive cooling of the front-most shroud at the end of the screw, since this approach was found in comprehensive modeling studies to be more than sufficient to accomplish the project objectives associated with this phase of the work, while also avoiding thermal gradients that could have caused heat-stress-induced damage to the refractory around the feedstock inlet if an active cooling approach had been applied. Careful technoeconomic analysis (TEA) of two possible 1000 TPD facilities was carried out. The TEA of conversion of MSW with corn stover in one case, and MSW with woody feedstock in the other case, showed that both had the potential to provide hydrogen at about $1/kg (minimum selling price, 2018 dollar basis). Of the two TEA cases, the one that was based on the conversion of wood in the southeastern USA was found to have slightly better economic potential. The other TEA case was based on a real location in Nebraska and called for corn stover feedstock conversion along with MSW. An underserved communities outreach program plan was developed in cooperation with personnel from the Nebraska Public Power District.

08 HYDROGEN↗
DOE OSTI2026

Assessing Options for Particulate Measurement Tools to Advance Wood Heaters (CRADA Final Report)

For approximately 40 years, particulate matter (PM) from residential wood heaters has been certified in North America using an EPA dilution tunnel with a filter-based gravimetric measurement. While reasonably repeatable, this approach reports only a single value for the entire burn sequence and does not provide information on PM at different points within the sequence, which would support improved wood heater designs. PM monitors that report with high time resolution offer a potential solution, but their performance for various types of heaters and across heater operating conditions has not been extensively evaluated. In this 18-month collaborative project, the Hearth, Patio & Barbecue Association (HPBA) and Lawrence Berkeley National Laboratory (LBNL) tested five continuous PM instruments spanning three measurement principles—light-scattering, inertial mass (TEOM), and triboelectric—against gravimetric and size-resolved references on three residential heater types (cordwood, catalytic cordwood, and pellet) across startup, high-burn, and low-burn operating phases.

42 ENGINEERING↗
DOE OSTI2025

Enhancing the flowability of woody biomass slurries in wet biorefineries

Feeding wet lignocellulosic biomass (e.g., softwood and hardwood) slurries into high-pressure, high-temperature reactors at an industrially relevant scale presents significant challenges, such as process equipment plugging. Here, in this study, we investigate the possibility of improving the flowability of biomass slurries in an industrial scale wet biorefinery by tuning the physical and chemical characteristics of the biomass particles. To understand the effects of the chemical characteristics of woody biomass on flowability, cellulose pulp particles are produced from pulp sheets via knife milling, pelletizing, and crumbling. These cellulose pulp particles are processed for acid hydrolysis dehydration (AHDH) at one –tonne-per day pilot scale. The levulinic acid yield (a product of cellulose AHDH) and the flowability of the biomass particles are compared using market pulp, 1 mm crumbled pine softwood, a blend of 2 mm hammer-milled pine softwood with 10 wt.% bark, and 2 mm hammer-milled hardwood material with 10 wt.% bark (to represent forest residues). The results indicate that the presence of hemicellulose and lignin influences the flowability of lignocellulosic feedstocks. Crumbled wood particles show poor flowability at the pilot scale, while the presence of fine materials (less than 0.7 mm) and bark improves the flowability of biomass slurries without affecting the organic acid yields (based on C6 carbohydrate content).

09 - BIOMASS FUELS↗
DOE OSTI2026

Design and scale-up of 3D printed bat houses with biomass-derived polymer composites

Biomass (e.g., pine sawdust, especially high–ash content pine sawdust) is commonly disposed of as waste. Combining biomass with polymers to make composite feedstocks for 3D printing has been explored as a method to reduce or repurpose the biomass waste. Although not all biocomposite properties are known, the wood-based polylactic acid (PLA) composite has promising qualities for applications in ecological settings. In this work, pine wood–PLA composite feedstock was used to 3D print supplemental roost structures for endangered tree-roosting bats, which often face a paucity of suitable naturally occurring roosts. This material combination was selected because it is estimated to degrade faster than the synthetic material systems that are used widely in supplemental bat roosting structures to aid in the conservation of tree roosting bats. The layered, rough surface created by the 3D printing process serves as a surface that bats can grip while roosting. Computer-aided design (CAD) models were generated based on natural roost structures, and a full-size bat house was successfully additively manufactured using a pellet-fed large-scale 3D printing system. The 3D printed hexagon exhibited a tensile strength of 22–23 MPa and a Young’s modulus of 3202–3218 MPa in the x-direction. It has been demonstrated that the 3D printed bat house can be installed on a tree in a stable fashion. This successful demonstration of a bat roost manufactured using a bioderived composite should promote its use in other fish and wildlife structures and broader industrial applications such as construction and automobiles.

3D printing↗
DOE OSTI2024

Material property characterization of 3D printed polypropylene wood plastic composites

Abstract Wood flour (WF) at 10 wt.% and 20 wt.% loadings was used as a reinforcing filler to enhance the applicability of polypropylene (PP) for 3D printing. After performing printability tests of PP wood plastic composites (WPCs), the mechanical properties of both injection‐molded and 3D‐printed PP WPC specimens were explored. Test specimens were prepared from 3D printed hexagons for analyzing the mechanical properties. Adding WF to neat PP increased the storage modulus and the glass transition temperature while decreasing the degree of crystallinity and the coefficient of thermal expansion, while enhancing the printability of neat PP. The tensile strength, tensile modulus of elasticity, flexural strength, and flexural modulus of elasticity of injection‐molded neat PP improved by up to 21%, 59%, 30%, and 56%, respectively, with 20 wt.% WF. However, the impact strength of injection‐molded neat PP decreased by 85%, with 20 wt.% WF. After 3D printing, the tensile strength and tensile modulus of elasticity of printed neat PP increased by up to 84% and 60%, respectively, with 20 wt.% WF. The flexural strength and flexural modulus of elasticity of neat printed PP remained unchanged compared to those of PP filled with 20 wt.% WF, while the impact strength decreased by 87%. Highlights WF was used as a reinforcement in polypropylene designed for 3D printing A pilot‐scale, pellet‐fed 3D printer was used to print hollow hexagons, and then test specimens were fabricated from these hexagons for mechanical properties The tensile and flexural properties of 3D printed neat polypropylene improved, while the impact strength decreased after adding 20 wt.% WF to the neat PP.

Hwang, Sungjun↗
DOE OSTI2026

Overview of ST40 results and future: expanding the physics basis of high-field spherical tokamaks

The goal of the ST40 programme is to explore the physics of high-field spherical tokamaks (STs), to validate empirical and theoretical models and, hence, to build confidence in predictions required to support the design of future generations of STs. ST40 is a compact high-field ST that has achieved the following parameters: R 0 = 0.4–0.55 m, I p = 0.20–0.85 MA, B t (R= 0.4 m) = 0.7–2.1 T, κ ⩽ 1.9, and A = 1.6–1.9. Highlights of recent experimental results include (i) H-mode and confinement studies at B t ⩽ 2.1 T, (ii) observation of bifurcation of the scrape-off-layer power fall-off width, λ q , into a ‘wide’ branch that follows existing H-mode scalings and a ‘narrow’ branch that exhibits λ q values that are up to 10 times lower than the predictions of established scalings, (iii) development of high-performance scenarios with plasma current, I p , up to 0.85 MA, (iv) development of highly non-inductive scenarios with high β p , and (v) the first ST40 experiments utilising the newly commissioned impurity powder dropper. The work on all these topics has been supported by a number of advancements in ST40 hardware and software, from plasma control to data analysis and interpretation. At the end of 2025, ST40 embarked on a major upgrade to further expand its capabilities by introducing, among other improvements, all-metal plasma-facing components, 1 MW of electron cyclotron heating, a pellet injector, and a pair of lithium evaporators for wall conditioning.

confinement↗