Hydrothermal liquefaction of wastewater-grown algae to produce synthetic aviation fuel: A combined experimental study and techno-economic assessment

Kumar, Abhishek; Watkins, Jacob D.; Cronin, Dylan; Schmidt, Andrew J.; Santosa, Daniel M.; Yang, Zhibin; Heyne, Joshua; Valdez, Peter J.

doi:10.1016/j.ecmx.2025.101096

Hydrothermal liquefaction of wastewater-grown algae to produce synthetic aviation fuel: A combined experimental study and techno-economic assessment

Journal Article · Wed Jun 11 00:00:00 EDT 2025 · Energy Conversion and Management: X

DOI:https://doi.org/10.1016/j.ecmx.2025.101096· OSTI ID:2586720

Kumar, Abhishek ^[1]; Watkins, Jacob D.; Cronin, Dylan ^[1]; Schmidt, Andrew J. ^[1]; Santosa, Daniel M. ^[1]; Yang, Zhibin ^[2]; Heyne, Joshua ^[3]; ^[1]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)
Washington State University, Richland, WA (United States)
Pacific Northwest National Laboratory (PNNL), Richland, WA (United States); Washington State University, Richland, WA (United States)

Large-scale algae farms may someday become a consistent source of biomass feedstock for biofuels. Near-term supplies of algal biomass are available at certain water resource recovery facilities as algae cultivation is used as a method for nutrient recovery from specific effluent streams. Algae grown as a service shifts the value to the service rather than its sole use as a feedstock, which could enable the provision of algal biomass at low to no cost to biofuel producers. Hydrothermal liquefaction (HTL) can readily upgrade wet feedstock slurries, such as algae, to produce a carbon-enriched biocrude. The HTL biocrude can be hydrotreated and distilled, producing a variety of distillate fuels, including synthetic aviation fuel (SAF). We present a pathway, showing the experimental production of SAF from wastewater-grown algae via HTL, along with a techno-economic assessment to identify opportunities for process improvements. Critical quality attributes of the SAF, such as density, viscosity, surface tension, and freeze point, were estimated within the expected fuel experience ranges when compared against petroleum jet fuel. The average minimum fuel selling price of fuels from wastewater-grown algae for breakeven economics was $$\$$9.04$ per gasoline gallon equivalent (GGE). The sale of co-products such as struvite fertilizers and cement additives can add revenue to reduce the net cost. Ultimately, the selling price is influenced by the scale of the HTL processing facility. Adjusting estimations in the process scale, algae yield, and capital cost estimation can lower the price to $$\$$6.51$/GGE or raise it to $13.07/GGE.

View Accepted Manuscript (DOE)

Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC06-76RL01830

OSTI ID:: 2586720

Report Number(s):: PNNL-SA--210146

Journal Information:: Energy Conversion and Management: X, Journal Name: Energy Conversion and Management: X Vol. 27; ISSN 2590-1745

Publisher:: Elsevier BVCopyright Statement

Country of Publication:: United States

Language:: English

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