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Biomass-to-Liquid (BTL)

SAF (Sustainabile Aviation Fuel) Terms: Definitionof Biomass-to-Liquid (BTL) 

Biomass-to-Liquid (BTL) refers to a technology that converts biomass feedstock, such as agricultural residues, wood chips, energy crops, or organic waste, into liquid fuels. 

The process typically involves thermochemical conversion methods, such as gasification or pyrolysis, to produce a synthesis gas (syngas) that consists of carbon monoxide, hydrogen, and other gases. 

This syngas is then further processed through a series of catalytic reactions, such as Fischer-Tropsch synthesis, to convert it into liquid hydrocarbon fuels.

BTL technology aims to provide an alternative to fossil fuels by utilizing renewable biomass resources for the production of transportation fuels. The resulting liquid fuels from BTL processes are compatible with existing infrastructure and can be used in conventional engines and vehicles without significant modifications. These fuels can include synthetic diesel, gasoline, or even aviation fuels.

The production of liquid fuels through BTL processes has several potential benefits. It can contribute to reducing greenhouse gas emissions since biomass feedstocks are considered carbon-neutral or have lower carbon footprints compared to fossil fuels. BTL also offers the advantage of utilizing various types of biomass, including agricultural and forestry residues, which can help in the efficient management of waste materials and promote sustainable land use.

However, it’s worth noting that BTL technology is still in the development and early commercialization stages. The process is complex, and there are challenges in terms of feedstock availability, technological efficiency, and economic viability. Ongoing research and development efforts aim to improve the efficiency and cost-effectiveness of BTL processes to make them more competitive with traditional fossil fuel options.

SAF (Sustainabile Aviation Fuel) Terms: Biomass-to-Liquid (BTL) Technology

Biomass-to-Liquid (BTL) technology has emerged as a promising solution in the quest for sustainable and renewable liquid fuels. BTL processes convert biomass feedstocks, such as wood, agricultural residues, or energy crops, into advanced biofuels that can be used as drop-in replacements for conventional petroleum-based fuels

This article explores the concept of Biomass-to-Liquid technology, its environmental benefits, and its potential to contribute to a greener and more sustainable energy future.

Biomass-to-Liquid (BTL) technology involves the thermochemical conversion of biomass feedstocks into liquid fuels through a series of processes, including gasification, syngas cleaning, and Fischer-Tropsch (FT) synthesis. The gasification process converts biomass into a synthesis gas (syngas), consisting of carbon monoxide (CO) and hydrogen (H2). The syngas is then cleaned and fed into the FT synthesis, where it is converted into liquid hydrocarbons, such as diesel, gasoline, and aviation fuels.

SAF (Sustainabile Aviation Fuel) Terms: Biomass-to-Liquid (BTL) Production

Biomass-to-Liquid (BTL) production involves several steps to convert biomass feedstock into liquid fuels. 

Here is a general overview of the BTL production process:

Feedstock Preparation: The first step is to collect and prepare the biomass feedstock. This can include agricultural residues (such as straw or corn stover), energy crops (like miscanthus or switchgrass), forestry residues, or organic waste. The feedstock may undergo cleaning, shredding, or drying processes to ensure it is suitable for further conversion.

Biomass Gasification or Pyrolysis: The prepared biomass is subjected to either gasification or pyrolysis, both thermochemical conversion methods. In gasification, the biomass is heated in a low-oxygen environment to produce a mixture of gases known as synthesis gas or syngas. Pyrolysis involves heating the biomass in the absence of oxygen to produce liquid bio-oil and gas by-products.

Syngas Conditioning (Gasification Only): If gasification is used, the syngas produced in the previous step undergoes conditioning to remove impurities such as tars, particulates, sulfur compounds, and nitrogen compounds. This step is crucial to ensure the quality and stability of the syngas.

Syngas Conversion (Gasification Only): The conditioned syngas is then subjected to catalytic reactions, such as the Fischer-Tropsch synthesis, where it is converted into liquid hydrocarbon fuels. Fischer-Tropsch synthesis involves a series of chemical reactions that transform the carbon monoxide and hydrogen in the syngas into longer-chain hydrocarbons.

Hydroprocessing: The liquid hydrocarbon product from the syngas conversion step may undergo additional refining processes, such as hydroprocessing. Hydroprocessing involves the removal of impurities and the adjustment of fuel properties to meet specific requirements, resulting in the production of finished liquid fuels.

Fuel Refining and Blending: The produced liquid fuels are further refined to improve their quality and ensure they meet the required specifications. This may involve processes such as distillation, hydrotreating, and blending with other compatible fuels to achieve desired performance characteristics.

Storage and Distribution: The final step involves storing the produced liquid fuels and distributing them through existing infrastructure to end-users, such as fueling stations or industrial consumers.

It’s important to note that the specific processes and technologies used in BTL production may vary depending on the feedstock, scale of operation, and desired end products. Ongoing research and development efforts aim to optimize each step of the BTL production process for improved efficiency, cost-effectiveness, and environmental performance.

Membrane technologies for hydrogen purification

SAF (Sustainabile Aviation Fuel) Terms: Membrane Technologies 

Membrane technologies play a vital role in the purification and separation of hydrogen in green hydrogen processes. Green hydrogen refers to hydrogen produced through the electrolysis of water using renewable energy sources, such as solar or wind power. 

The purification and separation of hydrogen from the electrolysis process are crucial for obtaining high-purity hydrogen for various applications.

There are several membrane technologies commonly employed for hydrogen purification and separation, including pressure swing adsorption (PSA), palladium membranes, and polymer-based membranes.

1. Pressure Swing Adsorption (PSA): PSA is a widely used technology for hydrogen purification. It utilizes adsorbents, such as activated carbon or zeolites, to selectively adsorb impurities, such as water, carbon dioxide, and methane, from the hydrogen gas stream. The impurities are then desorbed by reducing the pressure or by using a purge gas, allowing for the recovery of high-purity hydrogen.

2. Palladium Membranes: Palladium membranes are selective for hydrogen and allow the separation of hydrogen from impurities based on the difference in permeability. These membranes consist of a thin layer of palladium alloy supported on a porous substrate. When hydrogen gas is applied to one side of the membrane, hydrogen atoms diffuse through the palladium lattice, while impurities are unable to pass through. Palladium membranes can achieve high purity levels, making them suitable for applications requiring ultra-pure hydrogen.

3. Polymer-Based Membranes: Polymer-based membranes offer a cost-effective solution for hydrogen purification and separation. These membranes are typically made from materials such as polymeric blends, polyimides, or polysulfones. They operate based on the selective permeation of hydrogen through the polymer matrix, while impurities are blocked. Polymer membranes can be designed with specific pore sizes and surface chemistries to enhance hydrogen selectivity and permeability.

SAF (Sustainabile Aviation Fuel) Terms: Development of new types

In addition to these technologies, advancements in materials and membrane engineering have led to the development of new  of membranes, such as mixed matrix membranes (MMMs) and ceramic membranes, for hydrogen purification and separation. MMMs combine the advantages of both inorganic fillers and polymer matrices, allowing for improved separation performance. Ceramic membranes, on the other hand, offer excellent thermal and chemical stability, making them suitable for harsh operating conditions.

The choice of membrane technology depends on various factors, including the required hydrogen purity level, operating conditions (e.g., temperature and pressure), and the presence of specific impurities

Synthetic biology

SAF (Sustainabile Aviation Fuel) Terms: Synthetic Biology

In the realm of scientific innovation, synthetic biology has emerged as a groundbreaking discipline that combines biology, engineering, and computational sciences to design and construct novel biological systems. 

By leveraging the principles of genetics, molecular biology, and bioinformatics, synthetic biology enables researchers to manipulate living organisms, their genes, and metabolic pathways, paving the way for unprecedented advancements in medicine, agriculture, energy, and environmental sustainability. 

In this article, we delve into the exciting world of synthetic biology, its applications, and the potential it holds for revolutionizing various industries.

Understanding Synthetic Biology:

Synthetic biology can be defined as the engineering of biological systems through the design and synthesis of artificial DNA sequences, proteins, and other biological components. It encompasses a wide range of techniques and tools that enable scientists to construct biological systems with specific functions or traits. 

By utilizing the principles of genetic engineering, researchers can reprogram existing organisms or create entirely new ones to perform desired tasks or produce valuable compounds.

SAF (Sustainabile Aviation Fuel) Terms: Applications of Synthetic Biology:

Medicine and Healthcare:

Synthetic biology offers immense potential in the field of medicine. Scientists are exploring the development of novel therapies and treatments, such as engineered bacteria that can detect and target cancer cells, or the creation of synthetic organs for transplantation. Synthetic biology also plays a vital role in the production of pharmaceuticals and vaccines, making the manufacturing process more efficient and cost-effective.

Agriculture:

By engineering crops and microorganisms, synthetic biology can enhance agricultural practices. This includes developing plants with improved yields, disease resistance, and nutritional content. Additionally, synthetic biology can contribute to sustainable farming by reducing the need for pesticides and fertilizers, and by enabling the production of biofuels from non-food plant sources.

Environmental Sustainability:

Synthetic biology has the potential to address pressing environmental challenges. Researchers are investigating bioengineered solutions for waste management, such as utilizing microorganisms to break down plastic waste or convert it into biodegradable materials. Additionally, synthetic biology can aid in the production of biofuels, reducing reliance on fossil fuels and mitigating climate change.

Industrial Applications:

Synthetic biology is transforming various industries by enabling the production of valuable compounds in a more sustainable and efficient manner. It allows the creation of bio-based materials, chemicals, and enzymes through engineered microbial systems. This not only reduces reliance on petrochemicals but also minimizes the environmental impact associated with traditional industrial processes.

Challenges and Ethical Considerations:

While the promises of synthetic biology are immense, there are also ethical and safety concerns that must be addressed. The potential release of genetically modified organisms into the environment, unintentional creation of harmful pathogens, and the responsible use of synthetic biology technologies require careful regulation and risk assessment.

SAF (Sustainabile Aviation Fuel) Terms: Fact and data of Synthetic biology

Synthetic biology is a rapidly evolving field, and here are some key facts and data to provide an overview of its current status:

Market Growth

The global synthetic biology market has been experiencing significant growth in recent years. According to a report by Grand View Research, the market size was valued at USD 4.3 billion in 2020 and is projected to reach USD 47.7 billion by 2028, growing at a compound annual growth rate (CAGR) of 30.4% during the forecast period.

DNA Synthesis

DNA synthesis, a fundamental process in synthetic biology, has witnessed remarkable advancements. The cost of synthesizing DNA has significantly decreased over the years. In 2003, it cost approximately USD 12 per base pair, while by 2020, it had dropped to less than 10 cents per base pair, making large-scale DNA synthesis more accessible.

Genome Engineering:

Synthetic biology techniques have revolutionized genome engineering, allowing researchers to precisely edit and manipulate genetic information. The development of CRISPR-Cas9 technology has played a pivotal role in this field. CRISPR-based gene editing tools offer efficient and precise genome modifications, opening up new possibilities for genetic research and engineering.

Bioengineered Products

Synthetic biology has led to the creation of various bioengineered products with real-world applications. One notable example is the production of synthetic insulin using genetically modified bacteria. This innovation has transformed the treatment of diabetes, providing a reliable and cost-effective source of insulin.

Biofuels and Renewable Energy

Synthetic biology has the potential to revolutionize the production of biofuels and contribute to renewable energy sources. Researchers are exploring the use of genetically engineered microorganisms to efficiently convert plant biomass into biofuels, such as ethanol and butanol. These advancements could reduce reliance on fossil fuels and mitigate climate change.

Biopharmaceuticals

Synthetic biology plays a crucial role in the production of biopharmaceuticals. Through genetic engineering, scientists can design and engineer microorganisms to produce complex proteins, antibodies, and vaccines. This technology enables the production of therapeutics in a more scalable, cost-effective, and sustainable manner.

Environmental Applications

Synthetic biology holds promise for addressing environmental challenges. Researchers are working on developing microorganisms capable of degrading pollutants, such as plastics and oil spills. By harnessing the power of synthetic biology, it may be possible to create sustainable solutions for waste management and environmental remediation.

Regulatory Landscape

The field of synthetic biology is subject to various regulations and oversight. Different countries have implemented guidelines to ensure the safe and responsible development and use of synthetic biology technologies. Regulatory bodies assess the potential risks associated with genetically modified organisms and provide frameworks for ethical practices and risk assessment.

Collaboration and Open Access

Collaboration and open access are essential aspects of synthetic biology. Many researchers and organizations promote open-source sharing of genetic information and tools to accelerate scientific progress. This collaborative approach fosters innovation, encourages interdisciplinary research, and allows for the collective advancement of the field.

These facts and data demonstrate the growth, potential, and diverse applications of synthetic biology. As the field continues to evolve, it holds promise for addressing pressing global challenges and transforming various industries.

Synthetic biology represents a paradigm shift in our ability to engineer and manipulate biological systems. By harnessing the power of molecular engineering, it offers solutions to pressing challenges in medicine, agriculture, environmental sustainability, and industry. However, responsible and ethical implementation of synthetic biology is crucial to ensure the benefits outweigh the risks. 

With continued research, collaboration, and thoughtful consideration, synthetic biology has the potential to revolutionize multiple industries and improve the quality of life for people around the world

Solar-to-hydrogen conversion via integrated photovoltaic

SAF (Sustainabile Aviation Fuel) Terms: Solar-to-hydrogen conversion

Solar-to-hydrogen conversion via integrated photovoltaic-electrolysis systems, also known as photoelectrochemical (PEC) water splitting, is a technology that utilizes solar energy to produce hydrogen gas through a process called electrolysis. 

This approach combines the functions of a photovoltaic (PV) cell and an electrolyzer into a single device, enabling direct conversion of sunlight into hydrogen fuel.

Here’s a general overview of how the process works:

1. Photovoltaic (PV) Cell: The integrated system starts with a photovoltaic cell, which absorbs sunlight and converts it into electricity. The PV cell typically consists of semiconductor materials that generate an electric current when exposed to photons in sunlight.

2. Water Electrolysis: The electricity generated by the PV cell is then used to power an electrolyzer. The electrolyzer splits water (H2O) into its constituent elements, hydrogen (H2) and oxygen (O2), through an electrochemical reaction. This process takes place in an electrolyte solution, typically containing water and a catalyst to enhance the reaction.

3. Hydrogen Production: The generated hydrogen gas is collected and stored for later use. It can be used as a clean fuel for various applications, including fuel cells, transportation, and energy storage.

SAF (Sustainabile Aviation Fuel) Terms: The integration of PV cells and electrolysis systems

The integration of PV cells and electrolysis  into a single device offers several advantages. Firstly, it eliminates the need for separate components, reducing the overall system complexity and cost. 

Secondly, it enables the direct utilization of solar energy for hydrogen production without relying on external electricity sources. Finally, it allows for the efficient use of excess electricity produced by PV cells during peak sunlight hours, which would otherwise be wasted.

However, it’s important to note that the commercial viability and efficiency of integrated photovoltaic-electrolysis systems are still being actively researched and developed. Several technical challenges remain, including improving the efficiency of the water-splitting process, developing more durable materials for PEC devices, and reducing production costs.

Nonetheless, this technology holds great potential as a sustainable and renewable method for hydrogen production, offering a pathway towards a clean and carbon-free energy system. Ongoing research and advancements aim to address the current limitations and make solar-to-hydrogen conversion via integrated photovoltaic-electrolysis systems more practical and widely accessible

Carbon-neutral hydrogen production from biomass pyrolysis

SAF (Sustainabile Aviation Fuel) Terms: Carbon-neutral hydrogen production

Carbon-neutral hydrogen production from biomass can be achieved through a combination of biomass pyrolysis and steam reforming processes. 

Here’s how each step contributes to carbon-neutral hydrogen production:

1. Biomass Pyrolysis: Pyrolysis is a thermal decomposition process that breaks down biomass into various gaseous and liquid products through the application of heat in the absence of oxygen. Biomass, such as wood chips, agricultural residues, or dedicated energy crops, is heated to high temperatures, typically between 400 and 600 degrees Celsius, in a reactor. The absence of oxygen prevents complete combustion, leading to the production of biochar, bio-oil, and syngas.

   – Biochar: Biochar is a solid carbon-rich material that can be used as a soil amendment, promoting carbon sequestration in agricultural applications. It helps enhance soil fertility, water retention, and nutrient availability.

   – Bio-oil: Bio-oil is a liquid product obtained from biomass pyrolysis. It can be further processed and upgraded into transportation fuels or used as a precursor for the production of chemicals and materials.

   – Syngas: Syngas, also known as synthesis gas, is a mixture primarily composed of hydrogen (H2), carbon monoxide (CO), and some carbon dioxide (CO2). Syngas is the intermediate product obtained during biomass pyrolysis and serves as the starting point for subsequent hydrogen production.

2. Steam Reforming: In the steam reforming process, the syngas produced from biomass pyrolysis is further processed to generate hydrogen-rich gas. Steam reforming involves reacting syngas with steam over a catalyst at elevated temperatures. The reactions occur as follows:

   – Water-Gas Shift (WGS) Reaction: The WGS reaction converts the carbon monoxide (CO) present in the syngas to carbon dioxide (CO2) and produces additional hydrogen.

   – Methanation Reaction: The methanation reaction facilitates the conversion of any remaining carbon monoxide and carbon dioxide into methane (CH4) and water (H2O).

These reactions help increase the hydrogen content and decrease the carbon content in the gas stream, resulting in a hydrogen-rich gas suitable for various applications.

SAF (Sustainabile Aviation Fuel) Terms: The combination of biomass pyrolysis

The combination of biomass pyrolysis and steam reforming allows for the production of hydrogen while minimizing carbon emissions. 

The carbon released during biomass pyrolysis is primarily captured and stored as biochar, contributing to carbon sequestration in the soil. 

The hydrogen produced through steam reforming is considered carbon-neutral since the carbon emissions from the process are offset by the carbon capture and storage (CCS) associated with biochar production.

Carbon-neutral hydrogen production from biomass pyrolysis and steam reforming provides a pathway to generate renewable hydrogen while utilizing sustainable feedstocks and mitigating greenhouse gas emissions. It contributes to the development of a low-carbon economy and supports the transition towards a more sustainable energy future

Photocatalytic water splitting using metal-organic frameworks

SAF (Sustainabile Aviation Fuel) Terms: What is Photocatalytic water splitting

Photocatalytic water splitting using metal-organic frameworks (MOFs)

Photocatalytic water splitting using metal-organic frameworks (MOFs) is a promising approach for green hydrogen synthesis. MOFs are crystalline materials composed of metal ions or clusters coordinated to organic ligands, forming a porous structure with high surface area. These unique properties make MOFs suitable for photocatalytic applications, including water splitting for hydrogen production.

In the context of photocatalytic water splitting, MOFs can act as light-absorbing materials and catalysts to facilitate the conversion of solar energy into chemical energy in the form of hydrogen. 

SAF (Sustainabile Aviation Fuel) Terms: Outlook of Photocatalytic water splitting

Here’s how the process typically works:

1. Light Absorption: MOFs can be designed to have light-absorbing properties by incorporating light-harvesting units or photosensitizing ligands. These components absorb photons from sunlight, promoting electronic transitions and generating excited states within the MOF.

2. Charge Separation: Upon light absorption, the excited electrons and holes are generated within the MOF. Efficient charge separation is crucial to prevent recombination and maximize the utilization of photogenerated charges for the water splitting reaction. The porous structure of MOFs provides an environment where charge separation can occur.

3. Catalytic Sites: MOFs can be engineered to contain catalytic sites, typically metal centers or metal clusters, that promote the water splitting reaction. These catalytic sites facilitate the transfer of electrons and protons to drive the redox reactions involved in water splitting.

4. Water Splitting: The photogenerated electrons reduce water to produce hydrogen gas (H2), while the holes oxidize water to release oxygen gas (O2). The separated protons (H+) combine with the electrons to form hydrogen gas, which can be collected as the desired product.

SAF (Sustainabile Aviation Fuel) Terms: Photocatalytic water splitting Advance

Photocatalytic water splitting using MOFs offers several advantages for green hydrogen synthesis:

1. Abundant and Tailorable: MOFs can be synthesized using a wide range of metal ions and organic ligands, allowing for a high degree of customization. This versatility enables the design of MOFs with desired properties, such as light absorption, charge separation, and catalytic activity, tailored for efficient water splitting.

2. Stability and Recyclability: MOFs can exhibit excellent stability under photocatalytic conditions, ensuring their long-term performance. Additionally, their porous nature enables easy separation and recovery of the MOF photocatalysts, facilitating their recycling and reuse.

3. Efficiency and Selectivity: MOFs can be optimized to enhance the efficiency and selectivity of the water splitting reaction. The porous structure provides a large surface area, facilitating the exposure of catalytic sites and enhancing the contact between reactants and catalysts, leading to improved efficiency.

4. Integration with Other Systems: MOFs can be combined with other materials, such as co-catalysts or semiconductors, to form hybrid systems that synergistically enhance the water splitting performance. These hybrid systems can optimize light absorption, charge separation, and catalytic activity, further improving the overall efficiency.

However, it’s important to note that while significant progress has been made in the development of MOF-based photocatalytic water splitting, challenges remain. 

Some of these challenges include improving the stability and durability of MOFs under extended photocatalytic operation, enhancing the quantum efficiency and charge transfer kinetics, and scaling up the synthesis and production of MOFs for practical applications.

Overall, photocatalytic water splitting using MOFs is a promising avenue for green hydrogen synthesis. Ongoing research and development efforts aim to optimize the design, performance, and scalability of MOFs for efficient and sustainable hydrogen production from renewable resources

Bio-inspired catalysts for sustainable hydrogen production

SAF (Sustainabile Aviation Fuel) Terms: Bio-inspired catalysts

Bio-inspired  hold great potential for sustainable hydrogen production from water, mimicking the natural process of photosynthesis. 

These catalysts aim to replicate the efficiency and selectivity of biological systems, such as enzymes, in splitting water into hydrogen and oxygen.

One key catalyst that draws inspiration from nature is the molecular catalyst based on the earth-abundant metal complex, such as cobalt, nickel, or iron

These catalysts are designed to mimic the active sites found in metalloenzymes, such as the oxygen-evolving complex (OEC) in Photosystem II. By incorporating similar metal ions and ligands, these catalysts can efficiently catalyze the water-splitting reaction under mild conditions.

SAF (Sustainabile Aviation Fuel) Terms: Catalysts typically

Bio-inspired catalysts  consist of a molecular complex immobilized onto a support material to enhance stability and facilitate catalytic reactions. Various strategies are employed to optimize their performance, including tuning the coordination environment, incorporating proton or electron transfer pathways, and introducing redox mediators.

Another approach involves using biomimetic materials, such as metal-organic frameworks (MOFs), covalent organic frameworks (COFs), or porous coordination polymers (PCPs), as catalysts for water splitting. These materials provide a highly tunable platform for incorporating catalytic sites, optimizing their reactivity, and improving stability. By mimicking the structure and functionality of biological systems, these materials offer advantages such as high surface area, porosity, and stability.

Moreover, researchers are exploring bio-inspired catalysts based on nanomaterials, including nanoparticles, nanowires, and nanocomposites. These materials can be functionalized with earth-abundant metals or metal-free components to mimic enzyme-like activities. For example, some nanocatalysts mimic the catalytic properties of hydrogenases, which are enzymes involved in biological hydrogen production.

To further enhance the efficiency and selectivity of bio-inspired catalysts, researchers are also investigating light-driven systems. These catalysts combine light-absorbing components, such as photosensitizers or semiconducting materials, with catalytic centers to drive the water-splitting reaction using solar energy. Inspired by natural photosynthesis, these systems can utilize visible or even sunlight for efficient hydrogen production.

SAF (Sustainabile Aviation Fuel) Terms: Sustainable hydrogen production

Bio-inspired catalysts for sustainable hydrogen  offer several advantages, including the use of abundant and environmentally friendly materials, efficient utilization of solar energy, and mild reaction conditions. However, challenges remain in terms of improving the stability, scalability, and overall efficiency of these catalysts to make them viable for large-scale hydrogen production.

Ongoing research and development efforts focus on unraveling the fundamental mechanisms of biological systems, designing novel catalyst structures, and optimizing reaction conditions to achieve efficient and sustainable hydrogen production from water. The insights gained from bio-inspired catalysis have the potential to revolutionize the field of renewable energy and contribute to a more sustainable future

Hydrogen storage in nanoporous materials

SAF (Sustainabile Aviation Fuel) Terms: Hydrogen storage in nanoporous materials

Hydrogen storage in nanoporous materials is a promising approach for efficient transport and distribution of hydrogen. 

Hydrogen has a high energy density by mass, making it an attractive fuel source for various applications, including transportation. 

However, its low energy density by volume poses challenges for storage and transportation.

SAF (Sustainabile Aviation Fuel) Terms: Nanoporous

Nanoporous  offer a potential solution to overcome these challenges. These materials have a high surface area and a network of interconnected pores at the nanoscale, providing a large number of sites for hydrogen adsorption. This property allows for high storage capacity and efficient storage/release of hydrogen.

One class of nanoporous materials commonly explored for hydrogen storage is metal-organic frameworks (MOFs). MOFs are crystalline materials composed of metal ions or clusters coordinated to organic ligands. Their porous structure can be precisely engineered to optimize hydrogen storage properties. Researchers have designed MOFs with tailored pore sizes, surface areas, and adsorption energies to enhance hydrogen uptake.

Another class of materials used for hydrogen storage is porous carbon-based materials, including activated carbons, carbon nanotubes, and graphene-based materials. These materials have excellent thermal stability, good mechanical properties, and high hydrogen storage capacity due to their porous structure.

SAF (Sustainabile Aviation Fuel) Terms: Strategy to enhance hydrogen storage in nanoporous materials

Several strategies are employed to enhance hydrogen storage in nanoporous materials. One approach involves functionalizing the materials to increase hydrogen adsorption sites and improve adsorption strength. Chemical modifications, such as incorporating metal nanoparticles or introducing specific functional groups, can enhance the interaction between the hydrogen molecules and the nanoporous material.

Furthermore, researchers are exploring novel synthesis techniques to fabricate nanoporous materials with optimized properties for hydrogen storage. This includes developing methods to control the pore size, pore volume, and surface chemistry of these materials to achieve high hydrogen storage capacities and fast kinetics of hydrogen uptake/release.

Efficient transport and distribution of hydrogen can be achieved by designing storage systems based on nanoporous materials. 

These materials can be integrated into tanks or cartridges, where hydrogen is adsorbed onto the porous material at high pressure and subsequently released when needed. This approach eliminates some of the challenges associated with traditional hydrogen storage methods, such as compression and liquefaction.

Hydrogenstorage in nanoporous materials offers a promising avenue for efficient and safe storage, transport, and distribution of hydrogen. Ongoing research and development efforts aim to further improve the storage capacity, kinetics, and stability of these materials to accelerate the adoption of hydrogen as a clean and sustainable energy carrier

https://www.exaputra.com/2023/09/saf-sustainabile-aviation-fuel-terms.html

Renewable Energy

CNC Onsite Cuts Repair Costs With Uptower Machining

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Weather Guard Lightning Tech

CNC Onsite Cuts Repair Costs With Uptower Machining

Søren Kellenberger, CEO of CNC Onsite, joins to discuss uptower yaw gear repairs, flat tower flanges, and replacing 1,000 blade root bushings across 26 turbines.

Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTubeLinkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!

Allen Hall 2025: Soren, welcome back to the podcast.

Søren Kellenberger: Thank you, Allen, and, uh, nice doing it, uh, face-to-face- Yes, it’s great … and not as a team, uh, call. Right. That’s

Allen Hall 2025: true. Yeah. You’ve been doing a good bit of traveling, and you’re the new head of CNC Onsite.

Søren Kellenberger: I am, yes.

Allen Hall 2025: So congratulations on that.

Søren Kellenberger: Thank you very much.

Allen Hall 2025: And all the exciting new things that CNC Onsite [00:01:00] is doing, plus all the things you have developed and are now out in the field implementing, the, the list goes on and on and on.

I’m alwa- every time I talk to you, “Oh, we got a new-” Yeah … “machine to do something uptower.” So it’s all uptower, which is the, the beauty of CNC Onsite. You’re thinking about the operator and the cost to pull the blades off and do lifting the cell off and all those things. If we can do it uptower, we can save 30, 40, 50% of the cost of a repair.

Søren Kellenberger: Yeah.

Allen Hall 2025: That’s where CNC Onsite is just really killing it. You guys are doing great. Thank

Søren Kellenberger: you. Of course, we like what we do, but, uh, thank you.

Allen Hall 2025: Yeah. Yeah. Yeah, yeah. No, it’s good, it’s good. And, and so w- let’s talk about the things that I know about, and we’ll start there, and then we’ll go to all the new things you’re doing.

So the one that I see a lot of operators asking about is yaw tooth. Yeah.

Søren Kellenberger: Uh,

Allen Hall 2025: deformations, broken teeth on the yaw gear. That’s a big problem. And when I talk to [00:02:00] technicians, and I have them texting me about this, like, “Oh, well, I just weld on the gear back on, weld the tooth back on.” That’s a short-term solution.

That’s not gonna be long-term. The long-term solution is the CNC Onsite. Can you explain what you do to permanently fix these yaw gear problems?

Søren Kellenberger: Yeah. So what we do is actually we start by getting information about the, uh, original yaw ring, so the dimension of the teeth, and we get some load data. And, uh, then we start designing a replacement segment.

Uh, so what we ac- the process is actually that we bring a CNC controlled machine uptower, mount it on the yaw ring, and then we mill away that worn area, uh, creating a small pocket. And then those, uh, segments that we have designed, they are prefabricated. We bring them up and mount them in, in that, uh, pocket and bring the- The yaw ring back to where it’s, you can say, original design, uh, [00:03:00] that way.

Yeah

Allen Hall 2025: It’s better than the original design, ’cause you’re actually putting in better teeth than the, the manufacturer did originally.

Søren Kellenberger: True. Yeah, yeah.

Allen Hall 2025: So that happens, so you’re, you’re machining out those old teeth, broken teeth, putting the new set of teeth in th- and that all bolts in, and that’s it. That’s it.

But the, the difficulty is getting the machinery uptower to do that. That’s where a lot of your, your technology comes from, is getting this very accurate, uh, well-defined machine uptower and doing very controlled grinding and milling. Yes. So can you explain what that system looks like? If I’m gonna grind off those yaw, broken yaw teeth, how big is that kit?

Søren Kellenberger: It… Obviously, it depends a little bit on the turbine size. Sure, okay. Yeah. So, uh, it, so the, the newer five, six, uh, 10 megawatt turbines have larger teeth, so yeah, there you need a, a larger machine.

Allen Hall 2025: Okay.

Søren Kellenberger: But let’s say for, uh, Vestas three megawatt, the, the [00:04:00] complete machine weighs about 250 kilos. That’s it? So yeah.

So it, it comes up in smaller components. We just use, uh, the, the internal crane in, in the nacelle, and, uh, then we can lift the components to the yaw ring, assemble the machine, and then we are basically good to go. So it take, takes less than a day to get everything up and, uh, get set and be ready to, to machine.

Allen Hall 2025: So if you wanna fix a yaw gear problem, how long does it take from start to finish to get that done?

Søren Kellenberger: It typically, it takes one day to get everything up and get ready, and then per six teeth, which is a typical segment, it takes about a day to machine that. Okay. So, uh, let’s say you have, uh, somewhere between 10 and 15 teeth, it’s, uh, two to three segments.

So we do that in a week. Um-

Allen Hall 2025: Wow … and- ‘Cause the alternative is call a crane, have them lifting the cell off.

Søren Kellenberger: Yeah.

Allen Hall 2025: Take the yaw gear off, put a yaw gear on, if you can find a yaw gear. Yes. Put the nacelle back on. [00:05:00] Well, and I guess obviously the rotors are coming down too, so- Yeah. You’re talking about- Yes

hundreds of thousands of dollars in downtime. Yeah. It’s a big ordeal. The CNC Onsite method is so much easier.

Søren Kellenberger: We will just put our equipment in the back of our truck- … and then, uh, we’ll, we are ready to mobilize in a few days. So yeah, we can significantly, uh, bring down the downtime and, and as you said, the crane cost is of course extremely high.

And then you can add all the project management. You know, con- do I actually have my access roads, uh, still available? Right. Is the crane pad intact? And all of that stuff you need to organize. You can just forget about that and, uh- And

Allen Hall 2025: get it done …

Søren Kellenberger: get it done. Yeah.

Allen Hall 2025: Yeah. There’s, there’s a lot of owners, we, everybody knows who the machines are that have the, the, the yaw tooth problem.

Søren Kellenberger: Yeah.

Allen Hall 2025: So if you’re one of those owner operators, you better get ahold of CNC Onsite. Now, flanges on tower sections. It’s become a, a really critical issue. You hear a lot of, of [00:06:00] operators, OEMs talking about, “I’m putting together these tower sections and those flanges don’t really meet up quite right.”

Søren Kellenberger: Yep.

Allen Hall 2025: “I’m creating uneven torque patterns, bolt pat- my bolt tightening is not quite right.”

Søren Kellenberger: Yeah.

Allen Hall 2025: And it never really seats right, so you have this mechanical, built-in mechanical problem. CNC Onsite is now fixing that so those flanges are actually really flat. Really flat, yes. ‘Cause that’s what you need.

Søren Kellenberger: Yeah.

Allen Hall 2025: Yeah. They’re highly loaded.

Søren Kellenberger: If, if you want, uh… If you want your joints to be, uh, basically maintenance free, uh, we can, uh, achieve that with machining the flanges. And then, of course, you need to be in control with your bolt tightening process. Sure. But if you do those two things, you can have maintenance free bolted connections, and there’s so much money to be saved in the operations.

Um, and of course, when you have these bolts that end up fatiguing, some of them don’t get caught in time and you end up ha- having a catastrophic failure on the turbine. Uh- We’ve [00:07:00] seen that … because you have that zipper effect. Once a bolt starts breaking, the neighboring ones take that extra load and it accelerates really quickly.

Uh, yeah. Sure does.

Allen Hall 2025: Yeah. It’s a very serious situation, but it starts with this very simple solution which is just make the flange flat.

Søren Kellenberger: Yeah. But I think it’s some… a part of the issue is that those buying the towers aren’t necessarily responsible for the operational cost of maintaining that bolted connection.

So they might save a little bit of money when they buy the tower sections with rougher tolerances, but you will spend the money 10 times in the operations. Uh, and, and that’s, I think that’s where some of the operations, uh, re- the, the, those responsible for operational costs should, uh, get a little bit more CapEx spend, uh- Oh, sure.

Yeah. And, and then, uh, actually save a lot of money and, and reduce risk. Uh, it’s a huge, huge risk

Allen Hall 2025: It’s, it’s one of those lessons learned. You [00:08:00] don’t know that they should be flat. You shouldn’t know… You don’t know your flanges should be flat until you experience the problems, and then you want all your flanges flat from here on out.

Søren Kellenberger: Yeah.

Allen Hall 2025: But there’s only one way to do that really, and that’s to call CNC Onsite to come in and to make them flat.

Søren Kellenberger: Yeah.

Allen Hall 2025: Because it’s a difficult thing to do. You really need to have the machining prowess and the tight tolerances that CNC Onsite’s gonna deliver in a tool that can actually be adapted to that tower ring and make those surfaces flat.

It’s complicated. Exactly.

Søren Kellenberger: It is. Uh, but that is what we do every day, so, uh- Yes, I’ve noticed … yeah, so

Allen Hall 2025: so- You take on those challenges

Søren Kellenberger: So we are optimizing our machines to be not only fit for one-offs, but actually to go into a manufacturing, uh, process. So we have op- optimized our machines a lot with, uh, automatic alignment and, uh, stuff like that to, to really make that process, uh, easier.

Because it has been considered that when you had to machine a flange, you weren’t in [00:09:00] control with your production, uh, processes. But I think that is, um, a bit of a misinterpretation. It’s, it’s a little bit like saying when I have a casted component, I cannot get a bearing fit, uh, in my cast process. That’s not because your cast process is wrong, there’s just some limitations to what you can do.

Sure. And it’s basically the same here. Yes. And, and if you apply that con- uh, planned machining, you can gain some real benefits, uh, later on and the cost will, of course, drop dra- dramatically if you plan it, rather than call for one, uh, every time you have one that is out of tolerances and, and you can even narrow those tolerances down and get the benefits from maintenance-free bowler connections.

Allen Hall 2025: Right.

Søren Kellenberger: Uh-

Allen Hall 2025: Right, ’cause you’re gonna pay for it for the next 20, 30 years. Yeah. Yeah. That’s absolutely right. Now, you’re getting involved in some of the safety aspects of operating a turbine. Uh, some of the pins and the lockouts on the low-speed gearboxes get a little worn over time, so the hole [00:10:00] you put the pin in gets worn.

There’s a lot of loads on that and- Yeah … it starts to oblong out and eventually, if you’re trying to work on that gearbox, you’re trying to keep that and your technicians safe, which is what you’re doing- Yeah … that lockout pin doesn’t quite fit in the hole and it creates a little bit of a safety risk.

Yeah. So now CNC on-site’s coming in and saying, “Hey, wait a minute. We can realign that, clean that hole up, make that safe again.”

Søren Kellenberger: Yes.

Allen Hall 2025: Explain what that looks like and what that process is to do that.

Søren Kellenberger: Yeah. So again, it’s the same thought like with the, with the O-ring, uh, that instead of bringing a component down and trying to fix it, we have designed some machinery we can bring uptower and then make that repair.

So basically what we do is that, that we mill that hole a little bit larger and then we bring a bushing, uh, that we, uh, freeze into that hole- Okay … and to recreate that tight fit again with a, with a locking pin. Uh, so it’s, it’s not that [00:11:00] complicated, but you still need to know, of course, what you are doing.

So finding the center of the original hole is one of the critical things because you want the center of the new ring to be in that same position- Sure … to make sure it fits with the pin

Allen Hall 2025: right. So- Right. You can’t just take a drill up there and try to clean out that hole. No, no. That is not the way to do that

That,

Søren Kellenberger: that

Allen Hall 2025: won’t work. No, no . I’m sure it’s been tried, but- Yeah … no, you wanna have accurate mach- actual, uh, tight tolerance machinery up there to, to align that hole, drill it properly, put that insert back into that spot- Yeah … which is gonna be a hardened insert so it’ll last longer, right?

Søren Kellenberger: Yeah, yeah.

Allen Hall 2025: So once you do that, y- it’s a permanent fix to a otherwise nagging problem.

That’s wonderful.

Søren Kellenberger: Yeah.

Allen Hall 2025: So, th- again, that kit just goes right uptower, right up the, the lift, right up the cl- crane- Exactly … and bang, you’re done. Yeah. Okay.

Søren Kellenberger: So all our machines are designed to be able to be lifted with the internal crane-

Allen Hall 2025: Yeah …

Søren Kellenberger: of that specific nacelle.

Allen Hall 2025: Okay.

Søren Kellenberger: So obviously as the cells go bigger, they have more load cap- uh- Me too

load capacity. Yeah. So for the smaller [00:12:00] turbines, the machines come in, in a bit smaller parts- Okay … so that we are sure we stay within that 250 or 500 kilogram or even whatever the limit is of, of that- Yeah, yeah, yeah … crane. And then we can, uh, reassemble everything uptower and still do tolerances within a few hundredths of a millimeter.

And, and I think that is, that is really the core of, of what we do that, that we can achieve those workshop tolerances on site, um-

Allen Hall 2025: It’s crazy when I tell people that. I say, “Well, you know, CNC on-site, they can’t… I mean, those, those tolerances can’t be that tight.” And I say, “No, no, no, no. They’re talking about, you know, fractions of a millimeter,” which in, in American terms means fractions of a mil.

Yeah. That’s 1/1000th of an inch. That’s the tolerance you’re doing.

Søren Kellenberger: Yeah.

Allen Hall 2025: Uh, and that means quality at the end of the day. If you can machine things that tight, that means what you’re getting is gonna be right for that job. Yeah. It’s gonna fix that, fix that problem permanently, which is the goal. Yes. Don’t recreate the problem.

Just fix it once and be done. Now, blade root [00:13:00] inserts, huge issue. CNC on-site has been developing tooling to drill out those existing inserts and, and put in new inserts, and you’re having success with that.

Søren Kellenberger: Yeah.

Allen Hall 2025: That’s a… it seems like a complicated process, but you have owned that quite well. Talk about what that machinery looks like today, how you’re doing that process, and what have you learned from doing some, uh, field work.

Søren Kellenberger: It’s, uh… we actually, we’ve, we’ve developed two different machines now. Okay. So we, we have, we have one that is, uh, fully CNC controlled, uh, when you need to do a lot of bushings. Yeah. Um, that one takes a bit more, uh, time to set up, but, but, uh, each drilling process is, is really fast. Uh, and then we have developed a semi-automatic machine as well, uh, which is a little bit easier to mount, mounts directly on the blade.

And it’s, uh, really perfect when you only have smaller areas of the, the blade root where you don’t need to replace all bushings- But maybe typically it’s, it’s in the high load [00:14:00] area, which is 15 to 20 bushings maybe. Right. Something like that, right? Yes.

Allen Hall 2025: Yeah.

Søren Kellenberger: So, so there we can just mount it directly on the blade and, and then drill from, uh, from there.

Um, and it works really well. We completed, uh, the first large scale, uh, commercial, uh, project, uh, together with our good friends from, uh, We4C. Uh- Right.

Allen Hall 2025: Yes.

Søren Kellenberger: And, uh, and now we are producing, uh, two more drilling machines- Oh … uh, for, for new upcoming, uh, projects also together with, uh, the guys from, from We4C.

Allen Hall 2025: Wow.

Søren Kellenberger: So now it’s, it’s starting to, uh, to pick up. Um, it’s been a relatively long process, and I guess no one really wants to be the first mover on, uh, on new technology, right? Right. So we’ve had a lot of questions. Oh, that… And that looks interesting, but how many, uh, turbines, uh, or how many blades have you repaired?

And it’s been up until now, well, it’s only tested in the lab. Uh, but now we have the first, uh, large scale commercial, uh, project with, uh, 26, uh, turbines, [00:15:00] uh, repaired and, uh, and 1,000 bushings, uh, that were replaced, uh, across those, uh, 26 turbines. So-

Allen Hall 2025: Wow …

Søren Kellenberger: so I guess that is now large scale. Uh-

Allen Hall 2025: That’s large scale.

Yeah. Yeah. I would consider 1,000 a large scale test. Yeah. Yeah. Yes. And that brings all those turbines back to life.

Søren Kellenberger: Absolutely. They are up running, uh, full power again, so, uh, that is, uh-

Allen Hall 2025: That’s huge …

Søren Kellenberger: really nice.

Allen Hall 2025: For the operator, I’m sure they love that.

Søren Kellenberger: Yeah. And, and of course, uh, there’s, there’s been a lot of discussions about blades and, uh, bla- the, the waste, uh, issue you have on, on worn- Oh

out blades. Sure. So by being able to fix them instead of replacing them, not only is the, the cost for fixing a blade a lot lower than buying new ones, uh, but, but also from a, an environmental perspective. The not having to scrap them and create that waste is, uh, is also a nice, uh,

Allen Hall 2025: thing. Yeah, it’s one of the things that pops up more recently about replacing blades, and I think the [00:16:00] industry and the operators are pushing back on that.

Uh, because a lot of times the OEM wants to replace a blade, it’s just easier for them to do.

Søren Kellenberger: Yeah.

Allen Hall 2025: But the reality is, is that yeah, you’re creating this additional problem. What are you gonna do with the disposal of this blade? Do we really need to do that? Is it so far gone that I can’t recover it? I think a lot of times, especially with fiberglass blades- Yeah

you can bring them back to life.

Søren Kellenberger: Yeah.

Allen Hall 2025: Just with a little bit of engineering, uh, prowess and some good machinery- Yeah. You can, you can make magic happen, and that’s what CNC OnSite is doing. So that, that’s really amazing that, uh, you’re starting to get more adoption of that on, on the blade root inserts. I know across the United States there’s all kinds of issues, and you’re proving it out.

I think the adoption rate in America and all over is gonna really step up. Now, uh, you always have some cool new project, sort of top secret. What are you working on that the world needs to know about?

Søren Kellenberger: Yeah. W- I mean, we are constantly, uh, [00:17:00]expanding our, our line of services. Uh, so- Sure … so we are just out there trying to listen to what kind of issues do we see in, in the industry-

Allen Hall 2025: Yeah

Søren Kellenberger: and how can that be fixed, uh, uptower. So, so some of the, the latest, uh, innovations we’ve been doing is a, a new machine on, um… to, to do shaft milling. Uh, so that c- that can be on generator shafts, uh, for instance. There are some machines out there, but we’ve decided to go, uh, against CNC control- Okay

because it gives us a lot of, uh, opportunities both on, on speed, uh, of the process. It’s a more safe, uh, way to, uh, to do it.

Allen Hall 2025: Sure.

Søren Kellenberger: And we can actually also do different, uh, shapes on the shaft, so, so we can do more advanced, uh, repairs. Okay. We, we don’t need to stick to a certain diameter all the way. Now we can, we can mo- make grooves, and we can do, uh- Really?

all sort of sorts of stuff, uh- Oh … along that process because it’s CNC controlled.

Allen Hall 2025: Oh, sure. Okay. Um, and- Boy, okay. That makes a lot of sense. So you can actually take a, a, a basic, [00:18:00] basic, basic design of a shaft and make modifications to it- Yeah … to extend the lifetime and make it work better.

Søren Kellenberger: Yes. So typically we would mill down, uh, the shaft and- Sure

install a sleeve- Sure … to recreate a, a bearing fit, for instance.

Allen Hall 2025: Right. Yeah.

Søren Kellenberger: But we have possibilities to, uh, to create, um, grooves or anything that would do a stress relief or whatever you need, lubrication, or if you, if you want to do something, uh, afterwards, we, we can do that with, uh, with our machines.

Uh- Yeah. So yeah, we, we have some new machines for, for hollow shaft, uh, machining, so we can do stuff, uh, inside the main shaft, for instance. We can do stuff on the, the outside, as I mentioned on, on the generator shaft, but that could be on the gearbox as well. So- Sure … sometimes we see issues on the main shaft to, to gearbox, uh, connection.

Allen Hall 2025: Yeah.

Søren Kellenberger: We are able to, to fix, uh, those, uh, things uptower. Wow. And, uh, so yeah, lot of new, uh, stuff being, uh, developed.

Allen Hall 2025: That’s, that’s awesome.

Søren Kellenberger: [00:19:00] Yeah.

Allen Hall 2025: And I, I know you guys are busy, but- If somebody wants to get ahold of CNC Onsite and get work done this year, they better be making phone calls to you- … quickly. So I, I know your order book is filling up and you’re, you’re having to devote crews and machinery and time.

Yeah. How do people get ahold of you and get on that contact list and can start working the process?

Søren Kellenberger: I would say go into, uh, cnconsite.dk and, uh, there we have all our, our contacts. Uh, so just reach out. There’s a, yeah, formula you can, uh, fill in, uh, or you can find our direct contacts in our webpage, and, uh, then we can start looking at it.

So we are quite busy, but we are always- Yeah … open for, uh, discussions and, uh, yeah. That,

Allen Hall 2025: that’s a problem with being successful, is you’re just always busy running around trying to take care of problems, and that’s the thing, is that everybody I talk to that’s used CNC Onsite loves it-

Søren Kellenberger: Yeah …

Allen Hall 2025: and loves the process and loves the work you do.

So there’s gonna be a lot more phone calls and a lot more orders coming your way, and that’s- Yeah … that’s awesome. [00:20:00] Soren- Yeah … it’s so good to see you again and it’s so good to see you in person. Yeah. And congratulations on the promotion and everything that’s happening at CNC Onsite.

Søren Kellenberger: Thank you, Allen. It’s a pleasure.

CNC Onsite Cuts Repair Costs With Uptower Machining

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Renewable Energy

Is the Damage Permanent?

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Nobody knows.

Without doubt, the damage is profound.  The world has recognized that the United States is being commanded by a madman and has abandoned its place as the leader of the world.

As we look back across history, we see a certain shelf-life to democracies.  It’s easy to believe that we’re in the final days of what became of ancient Greece. It’s also possible, as numerous scholars have asserted, that we’re on the precipice of the sixth extinction.

But it’s entirely possible that the pendulum may start to rebound toward the days of America’s greatness, the time of truth and fairness.

We’ll see.

Is the Damage Permanent?

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Renewable Energy

Are You with President Trump?

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A dwindling number of hateful idiots still cling to the ideas at left.

But what was once 77 million is now approximately 45 million, and that number is falling every day, as Trump leads us deeper into corruption, economic ruin, and the revulsion of our former international allies.

Maybe we’ll see a meme like this in a month or so, when the president’s approval rating has declined into the teens, but I doubt it.

Are You with President Trump?

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