Robust optimization of flexible diafiltration systems for critical mineral separations

Yao, Jason [Carnegie Mellon University (CMU)]; Dougher, Molly [University of Notre Dame] (ORCID:0000000315677084); Lee, Andrew [NETL Site Support Contractor, National Energy Technology Laboratory]; Garciadiego, Alejandro [NETL Site Support Contractor, National Energy Technology Laboratory] (ORCID:0000000300973307); Tarka, Thomas [NETL] (ORCID:0000000261054366); Dowling, Alexander [University of Notre Dame] (ORCID:0000000193837499); Gounaris, Chrysanthos [Carnegie Mellon University (CMU)] (ORCID:0000000157792510)

doi:10.1016/j.ceja.2026.101282

DOE OSTI · 3684012

Robust optimization of flexible diafiltration systems for critical mineral separations

Yao, Jason [Carnegie Mellon University (CMU)]·Dougher, Molly [University of Notre Dame] (ORCID:0000000315677084)·Lee, Andrew [NETL Site Support Contractor, National Energy Technology Laboratory]·Garciadiego, Alejandro [NETL Site Support Contractor, National Energy Technology Laboratory] (ORCID:0000000300973307)·Tarka, Thomas [NETL] (ORCID:0000000261054366)·Dowling, Alexander [University of Notre Dame] (ORCID:0000000193837499)·Gounaris, Chrysanthos [Carnegie Mellon University (CMU)] (ORCID:0000000157792510)

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Abstract

This paper provides major contributions in expanding the literature for membrane process design with critical mineral recovery applications and showcasing the importance of robust design techniques for reducing risks of underperformance in such systems. Here, a membrane process flowsheet featuring PrOMMiS membrane models for recovering lithium/cobalt from spent batteries is showcased, uncertainty in membrane sieving and localized fouling are considered, and robust designs are obtained using the PyROS toolset. This paper is intended for a general audience of researchers working in critical minerals, membranes, and optimization related areas.

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36 MATERIALS SCIENCE 42 ENGINEERING non-linear robust optimization process design under uncertainty

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Yao, Jason [Carnegie Mellon University (CMU)], Dougher, Molly [University of Notre Dame] (ORCID:0000000315677084), Lee, Andrew [NETL Site Support Contractor, National Energy Technology Laboratory], Garciadiego, Alejandro [NETL Site Support Contractor, National Energy Technology Laboratory] (ORCID:0000000300973307), Tarka, Thomas [NETL] (ORCID:0000000261054366), Dowling, Alexander [University of Notre Dame] (ORCID:0000000193837499), Gounaris, Chrysanthos [Carnegie Mellon University (CMU)] (ORCID:0000000157792510). 2026-06-05. Robust optimization of flexible diafiltration systems for critical mineral separations. https://doi.org/10.1016/j.ceja.2026.101282

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