Matthew Wiatrowski

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.

The development of microalgal biorefineries, utilizing high-value coproducts, offers a strategy to lower production costs, while the use of saline-tolerant microalgal species contributes to reducing freshwater consumption.

Fast pyrolysis of woody materials is a technology pathway for producing renewable fuels and chemicals. This is a presentation of isolating needles, bark, and stemwood from a single tree as well as isolating stemwood and whole tree samples from the same species of tree with different ages and pyrolyzing each individually as well as in mixtures. This gives insight into the role of tree anatomical fractions on the resulting intermediate oil product as well as into interactions between these components. The highest carbon content oil (45.1 wt% as received) was produced from a one-to-one mixture of stemwood and needles, followed by the pure stemwood (43.4–43.8 wt% as received), while the lowest oil carbon content was from a one-to-one blend of bark and needles (26.7 wt% as received). The pyrolysis oil yield (combining oil and aqueous where separation occurred) varied from 54 wt% as received (needles) to 72.3 wt% as received (stemwood). When comparing trees of different ages, we find the change in the ratio of the anatomical fractions is a dominant factor in the product composition and yields, while the product composition and yields vary slightly with tree age when only the stemwood is pyrolyzed. Here we present the bench-scale pyrolysis, yields, and product characterization of loblolly pine feedstocks (13- vs. 23 year-old, residues, air-classified residues, whole tree, needles, bark, and stemwood).

We develop a catalytic process comprising exclusively of flow reactions for conversion of wet waste-derived volatile fatty acids to sustainable aviation fuel (SAF) and key aromatic building blocks (benzene, toluene, ethylbenzene, and xylene; BTEX). Acids are upgraded via sequential ketonization and either cyclization of light (C_3-7) ketones to BTEX and an aromatic SAF blendstock or hydrodeoxygenation of C₈₊ ketones to an alkane SAF blendstock. The enabling step investigated in this work is light ketone cyclization over H/ZSM-5, which was chosen through screening upgrading of 4-heptanone over solid acidic and basic catalysts. We then determined the reaction network of 4-heptanone upgrading by analyzing selectivity trends with conversion and concluded that the reaction should be run at full conversion. Finally, we demonstrated the entire acid upgrading process by converting commercial food waste-derived carboxylic acids to SAF blendstocks and BTEX. We blended the C₉₊ aromatic and alkane products to create one SAF blendstock and show that this mixture can be blended 50/50 with Jet A and meet all critical property standards. Techno-economic analysis and life cycle assessment show that utilizing a food waste feedstock for the process can be economically feasible with current policy incentives and reduce greenhouse gas emissions by more than 250%.

To reach the goals set by the US Department of Energy's Sustainable Aviation Fuel (SAF) Grand Challenge, currently available feedstocks may be insufficient. Giving priority to developing, prototyping and reducing the cost of algal feedstock before investing and lining up locations is important. As the production of algal feedstocks advances, a simplified conversion approach using more mature technologies can help reduce the investment risk for algae‐based fuels. Reducing process complexity to the steps described here [namely, conversion of lipids to HEFA (hydroprocessed esters and fatty acids) fuels and relegating the remainder of the biomass to anaerobic digestion or food/feed production] enables the near‐term production of algal SAF but presents challenging economics depending on achievable cultivation costs and compositional quality. However, these economics can be improved by present‐day policy incentives. With these incentives, the modeled algae‐to‐HEFA pathway could reach a minimum fuel selling price as low as $4.7 per gasoline gallon equivalent depending on the carbon intensity reduction that can be achieved compared with petroleum. Uncertainty about algal feedstock production maturity in the current state of technology and the future will play a large role in determining the economic feasibility of building algae‐to‐HEFA facilities. For example, if immaturity increases the feedstock price by even 10%, SAF production in 2050 is about 58% of the production which could have been achieved with mature feedstock. Additionally, growth in this conversion pathway can be notably boosted through the inclusion of subsidies, and also through higher‐value coproducts or higher lipid yields beyond the scope of the process considered here.

The TEA and LCA impacts of utilizing low-cost feedstocks in a high-temperature conversion process are of great interest. Here, we investigate the conversion cost impacts of two underutilized feedstocks from the commercial pine industry; 13-year-old whole trees, representing trees removed for the purpose of pre-commercial thinning, and 23-year-old pine residues, representing a waste stream produced from the deconstruction of mature trees for other purposes. Experimental fast pyrolysis data for each feedstock was used in tandem with results from supply and preprocessing analyses in order to evaluate the field-to-fuel economics. A low difference in MFSP was found between the conversion costs for the two feedstocks, with residues demonstrating a net benefit of $0.27/GGE compared to the whole tree thinnings, driven primarily by feedstock supply costs. This suggests that both whole tree thinnings and pine residues may be viable feedstock options for CFP conversion. Life cycle inventories were also generated for each case, enabling a field-to-fuel quantification of the cost and carbon cycle associated with each feedstock.