Unlocking the biofuel power of cover crop in Washington State: Enhancing potential through hydrothermal liquefaction

This study evaluates cover crops in Washington State (WA) as a renewable feedstock for hydrothermal liquefaction (HTL), supported by techno-economic (TEA) and life cycle (LCA) analysis. In the Pacific Northwest, fallow land is the common winter practice, generating no income for farmers. Over three years, field trials at two representative sites—Puyallup (cool, wet) and Othello (irrigated, no-till)tested triticale, hairy vetch, crimson clover, winter pea, and fava bean preceding cash crops. Biomass yields, composition, soil impacts, and net revenue were assessed across removal treatments. HTL conversion produced 32–37 wt% biocrude, lower than 48 wt% for sewage sludge, with modeled cradle-to-grave carbon intensities of 26–31 g CO 2 e/MJ and minimum fuel selling prices (MFSP) of $6.75–$7.18 per gallon gasoline equivalent (GGE), comparable to other lignocellulosic feedstocks. No significant changes were observed in soil carbon, nitrogen, or subsequent cash crop yields after cover crop removal. Farmer profitability was possible, particularly for triticale and hairy vetch at $60 per dry ton. To address seasonal variability, blending with wastewater sludge was evaluated. All scenarios delivered >70 % carbon intensity reductions relative to fossil fuels, and with Renewable Identification Number (RIN) credits, MFSPs below $2.5/GGE were achievable. These results demonstrate that cover crops can generate new revenue streams for farmers while serving as a flexible, low-carbon feedstock. Integrating cover crops with waste biomass offers a practical pathway to expand the bioeconomy and support year-round renewable fuel production. • Cover crop biomass removal can provide biofuel feedstock without reducing cash crop yields. • Triticale offers the highest yields; hairy vetch provides stable yields, low costs, and N-fixation benefits. • Hydrothermal liquefaction of cover crops yields 32–37 wt% biocrude, with MFSP of $6.8–$7.2/GGE and reduced below $2.5/GGE through sludge blending and RIN credits. • Life cycle analysis shows low carbon intensity for cover crop–sludge blends, supporting >70% GHG reductions. • Adoption on 3 % of WA cropland could yield 28 million gge/year SAF.