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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Informed Critical Mineral Recovery from Fossil Energy Waste Feedstocks

Critical minerals (CM), such as rare earth elements (REE), cobalt, nickel, and lithium, have important uses in modern energy and technologies, yet are vulnerable to potential supply chain disruptions. One potential domestic CM source is fossil energy wastes, such as coal combustion ash, acid mine drainage (AMD) and treatment solids (AMD solids), and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters). CM recovery from these feedstocks is promising due to their abundant quantity and fast availability as waste products. To develop informed and effective CM recovery, DOE’s National Energy Technology Laboratory (NETL) have collected and analyzed CM data for aforementioned fossil energy wastes, and utilized advanced geochemical characterization (e.g., synchrotron microprobe, sequential extraction and geochemical modeling) to identify the CM speciation and binding environments. Novel methods that recover multiple CMs while co-producing other valuable byproducts from these feedstocks have been developed. Successful examples include: (1) the discovery of easily mobile REE phases in Ca-rich coal combustion ash resulted in a patented REE recovery process from the ash feedstock while producing zeolite sorbents from the extraction wastes; (2) the successful identification of REE/Co/Ni/Zn hosting phases in acid mine drainage treatment solids (AMD solids) has informed the sequential CM recovery from AMD solids and has inspired lithium sorbent development from the extraction wastes; (3) the recovery potential of Li and other CMs in O&G produced waters and drill cuttings has been explored while the extraction residuals have been demonstrated to support plant growth as soil supplements. The innovations driven by characterization information have the potential to maximize CM recovery revenue, offset the cost of waste management and wastewater treatments while reducing the cost and environmental footprint of CM extraction.

characterization and extraction of rare earth elem↗

DOE OSTI2022

Carbon dioxide-enhanced metal release from kerogen

Heavy metals released from kerogen to produced water during oil/gas extraction have caused major environmental concerns. To curtail water usage and production in an operation and to use the same process for carbon sequestration, supercritical CO 2 (scCO 2 ) has been suggested as a fracking fluid or an oil/gas recovery agent. It has been shown previously that injection of scCO 2 into a reservoir may cause several chemical and physical changes to the reservoir properties including pore surface wettability, gas sorption capacity, and transport properties. Using molecular dynamics simulations, we here demonstrate that injection of scCO 2 might lead to desorption of physically adsorbed metals from kerogen structures. This process on one hand may impact the quality of produced water. On the other hand, it may enhance metal recovery if this process is used for in-situ extraction of critical metals from shale or other organic carbon-rich formations such as coal.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Modeling of multi-component precipitation and crystallization for zero-liquid-discharge desalination

This study proposes novel ZLD treatment trains that integrate multi-component chemical precipitation and multi-effect evaporative crystallization for efficient brine management. The methodology emphasizes sustainability by integrating CO₂ for chemical precipitation and reducing environmental impact, exemplified with two case studies: produced water that includes industrial waste heat utilization by adopting the emerging vacuum air-gapped membrane distillation (VAGMD) technology, and brackish groundwater that is abundant in sulphate which undergoes treatment by low-salt-rejection reverse osmosis (LSRRO) with interstage chemical precipitation. Here, this study is the first of its kind to simultaneously account for reducing risk of mineral scaling and effective recovery of valuable solids when incorporating VAGMD and LSRRO in ZLD treatment trains. Using Reaktoro and WaterTAP, both Python-based, open-source platforms, we model the recovery of high-purity magnesium, calcium, and sodium salts while optimizing energy consumption and operational efficiency in proposed ZLD pathways for case studies of produced water and brackish desalination brine management. Validation with experimental and reference data confirms the reliability of the models used. In both case studies, the optimized ZLD process achieves recovery rates of 97%, 99%, and 90% for Mg, Ca, and Na, with purities exceeding 99%, and brine volume reduced to less than 4% of the initial feed flow.

3D CT scans↗

DOE OSTI2024

Characterization Inform Sustainable Recovery of Critical Minerals from Fossil Energy Waste Feedstocks

Rare earth elements (REE) and other critical minerals (CM, e.g., Co, Ni, Li) have important uses in green energy and modern technologies, yet are vulnerable to potential supply chain disruptions. One potential domestic CM source is fossil energy wastes, such as acid mine drainage (AMD) and treatment solids (AMD solids), coal combustion ash, and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters). While they can contain lower CM concentrations then traditional ore, the quantity and fast availability as waste feedstock makes them a promising CM resource. To explore their promise, researchers at DOE’s National Energy Technology Laboratory (NETL) have collected and analyzed CM data for aforementioned fossil energy wastes, and utilized advanced geochemical characterization (e.g., synchrotron microprobe and sequential extraction) to identify the CM speciation and binding environments, and developed sustainable and targeted CM recovery. Successful examples include: (1) the discovery of easily mobile REE phases in Ca-rich coal combustion ash and developing a patented REE recovery process from Ca-rich Powder River Basin coal ash; (2) the successful identification of REE/Co/Ni/Zn hosting phases in acid mine drainage treatment solids (AMD solids) with diverse chemical composition (Al, Mn, or Fe-rich) informing the sequential recovery of different REE/CMs from AMD solids; (3) the recovery potential of Li and other CMs in O&G produced waters and drill cuttings. The innovations driven by characterization have the potential to offset the cost of waste management and wastewater treatments while reducing the cost and environmental footprint of CM extraction.

Stuckman, Mengling↗

DOE OSTI2024

Advanced Characterization to Inform Sustainable Recovery of Critical Minerals from Fossil Energy Waste Feedstocks

Rare earth elements (REE) and other critical minerals (CM, e.g., Co, Li) have important uses in green energy and modern technologies, yet are vulnerable to potential supply chain disruptions. One potential domestic source of CM is fossil energy wastes, such as acid mine drainage (AMD) and treatment solids (AMD solids), coal combustion ash, and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters). CM recovery from these waste feedstocks is promising due to their abundances and fast availability as waste products. On the other hand, the CM occurrence in these wastes is in small quantities compared to traditional ore bodies. Thus, novel and strategic separation and extraction processes are under exploration. Researchers at DOE’s National Energy Technology Laboratory (NETL) are collecting and analyzing CM data for aforementioned fossil energy wastes, and utilizing advanced geochemical characterization (e.g., synchrotron microprobe and sequential extraction) to understand the CM speciation and binding environments in these materials to better inform sustainable and effective recovery. Successful examples discussed in this talk include: (1) the discovery of easily mobile REE phases in Ca-rich coal combustion ash and developing a patented REE recovery process from Ca-rich Powder River Basin coal ash; (2) the successful identification of REE/Co/Ni/Zn hosting phases in acid mine drainage treatment solids (AMD solids) with diverse chemical composition (Al, Mn, or Fe-rich) informing the sequential recovery of different REE/CMs from AMD solids; (3) the recovery potential of Li and other CMs in O&G produced waters and drill cuttings. The innovations driven by characterization have the potential to offset the cost of waste management and wastewater treatments while reducing the cost and environmental footprint of CM extraction.

characterization and extraction↗

DOE OSTI2020

Susceptibility of foodborne pathogens to sanitizers in produce rinse water and potential induction of viable but non-culturable state

Not Available

Gu, Ganyu↗

DOE OSTI2021

Future of Water Infrastructure and Innovation Summit

Energy and water systems are interdependent, and the U.S. Department of Energy (DOE) has invested in energy and water for several years, including the Energy-Water Desalination Hub (led by the National Alliance for Water Innovation, NAWI), and research and development (R&D) in resource recovery from wastewater, among other areas. The Advanced Manufacturing Office (AMO) at the U.S. Department of Energy (DOE) held The Future of Water Infrastructure and Innovation Summit to inform the understanding of future opportunities in the water space. The virtual summit was held on October 27 and 28, 2020. The organizers gathered information from a diverse group of relevant water and wastewater stakeholders representing academia, industry, government, nongovernmental organizations, and local/regional utilities. Topics from Day 1 discussions included: desalination, water and wastewater treatment/recovery, produced water, industrial management of water, and hydropower, conveyance, and water systems.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Hawaii Solar Desalination Project

This project built the world’s largest Forward Osmosis (FO) solar thermal desalination plant at the NELHA Hawaii Ocean Science and Technology Park for a high visibility “on sun” demonstration of seawater desalination for agricultural applications. The project included re-commissioning an existing 2MW micro-dish solar thermal array and coupling it to a next-generation 500m3/day FO system. The purpose of the project was to validate FO at commercial scale; to verify that the water produced is safe for potential downstream agricultural users; to gather data on capital cost, energy consumption and operating expense for the technology; and to demonstrate that FO can be successfully coupled to low-grade thermal resources. The plant implemented advancements in FO component technology, including hot nano-filtration, polymeric heat exchangers, draw solutions, and improved FO membranes, and operated from June 2022 to September 2023 - producing 30gpm of permeate water. Thermal energy was below 30kWh/m 3 during operation, establishing a new benchmark in thermal desalination technology, with recovery rates at times exceeding 65%, well above what commercial RO systems can achieve. Combining the plant capital cost (CAPEX) and the operating expenses (OPEX) yields a Levelized Cost of Water (LCOW) that is competitive with existing carbon-intensive technologies such as RO. The ability of the plant to operate from a renewable resource paves the way toward a low-carbon desalination future using low-grade thermal resources.

14 SOLAR ENERGY↗

NASA NTRS1974

Domestic wash water reclamation for reuse as commode water supply using filtration: Reverse-osmosis separation technique

A combined filtration-reverse-osmosis water recovery system has been evaluated to determine its capability to reclaim domestic wash water for reuse as a commode water supply. The system produced water that met all chemical and physical requirements established by the U.S. Public Health Service for drinking water with the exception of carbon chloroform extractables, methylene blue active substances, and phenols. It is thought that this water is of sufficient quality to be reused as commode supply water. The feasibility of using a combined filtration and reverse-osmosis technique for reclaiming domestic wash water has been established. The use of such a technique for wash-water recovery will require a maintenance filter to remove solid materials including those less than 1 micron in size from the wash water. The reverse-osmosis module, if sufficiently protected from plugging, is an attractive low-energy technique for removing contaminants from domestic wash water.

Hall, J. B., Jr.↗

NASA NTRS2016

Demonstration of Robustness and Integrated Operation of a Series-Bosch System

Manned missions beyond low Earth orbit will require highly robust, reliable, and maintainable life support systems that maximize recycling of water and oxygen. Bosch technology is one option to maximize oxygen recovery, in the form of water, from metabolically-produced carbon dioxide (CO2). A two stage approach to Bosch, called Series-Bosch, reduces metabolic CO2 with hydrogen (H2) to produce water and solid carbon using two reactors: a Reverse Water-Gas Shift (RWGS) reactor and a carbon formation (CF) reactor. Previous development efforts demonstrated the stand-alone performance of a RWGS reactor containing Incofoam(TradeMark) catalyst and designed for robustness against carbon formation, two membrane separators intended to maximize single pass conversion of reactants, and a batch CF reactor with both transit and surface catalysts. In the past year, Precision Combustion, Inc. (PCI) developed and delivered a RWGS reactor for testing at NASA. The reactor design was based on their patented Microlith(TradeMark) technology and was first evaluated under a Phase I Small Business Innovative Research (SBIR) effort in 2010. The Microlith(TradeMark) RWGS reactor was recently evaluated at NASA to compare its performance and operating conditions with the Incofoam(TradeMark) RWGS reactor. Separately, in 2015, a fully integrated demonstration of an S-Bosch system was conducted. In an effort to mitigate risk, a second integrated test was conducted to evaluate the effect of membrane failure on a closed-loop Bosch system. Here, we report and discuss the performance and robustness to carbon formation of both RWGS reactors. We report the results of the integrated operation of a Series-Bosch system and we discuss the technology readiness level. 1

Abney, Morgan B.↗

NASA NTRS2016

Demonstration of Robustness and Integrated Operation of a Series-Bosch System

Manned missions beyond low Earth orbit will require highly robust, reliable, and maintainable life support systems that maximize recycling of water and oxygen. Bosch technology is one option to maximize oxygen recovery, in the form of water, from metabolically-produced carbon dioxide (CO2). A two stage approach to Bosch, called Series-Bosch, reduces metabolic CO2 with hydrogen (H2) to produce water and solid carbon using two reactors: a Reverse Water-Gas Shift (RWGS) reactor and a carbon formation (CF) reactor. Previous development efforts demonstrated the stand-alone performance of a NASA-designed RWGS reactor designed for robustness against carbon formation, two membrane separators intended to maximize single pass conversion of reactants, and a batch CF reactor with both transit and surface catalysts. In the past year, Precision Combustion, Inc. (PCI) developed and delivered a RWGS reactor for testing at NASA. The reactor design was based on their patented Microlith® technology and was first evaluated under a Phase I Small Business Innovative Research (SBIR) effort in 2010. The RWGS reactor was recently evaluated at NASA to compare its performance and operating conditions with NASA's RWGS reactor. The test results will be provided in this paper. Separately, in 2015, a semi-continuous CF reactor was designed and fabricated at NASA based on the results from batch CF reactor testing. The batch CF reactor and the semi-continuous CF reactor were individually integrated with an upstream RWGS reactor to demonstrate the system operation and to evaluate performance. Here, we compare the performance and robustness to carbon formation of both RWGS reactors. We report the results of the integrated operation of a Series-Bosch system and we discuss the technology readiness level.

Abney, Morgan B.↗

NASA NTRSDate not supplied

Development of the Miniature Total Organic Carbon Analyzer

Monitoring the Total Organic Carbon (TOC) in spacecraft potable water will be of major importance in long-duration human space exploration. In-flight analysis of potable water produced from a regenerative water processor provides immediate feedback on the quality of reclaimed water for crew health as well as water processing system health monitoring. This paper updates the progress in development of the next generation Total Organic Carbon Analyzer (TOCA) designed for the unique requirements of an exploration-class mission. The current objective is to design, build, certify, deliver, and operate a TOCA technology demonstration on the International Space Station (ISS). The next generation analyzer system technology was previously developed and selected among a feasibility study of other options. The new system provides primary advantages of reduced mass and volume through reduced system complexity and reduced need for consumables; therefore, the flight project is named MiniTOCA. The project has recently completed design of the tech demo instrument and assembled and tested a flight-like engineering development unit. The engineering unit has undergone performance testing and environmental testing which provides confidence for the project to move forward with flight unit production and certification activities. Test results are summarized in this paper. The flight unit is targeted for delivery to ISS in late 2025.

TOC↗

NASA NTRSDate not supplied

Development of the Miniature Total Organic Carbon Analyzer

TOC↗

DOE OSTI2020

Supercritical Treatment Technology for Water Purification (Annual Final Report)

This project continued the development of the Supercritical Water Extraction – Enhanced Targeted Recovery (SWEETR™) technology, a novel desalination process for treating hypersaline brines. The overall objective is to demonstrate the technical and economic feasibility of an innovative, energy efficient, and robust supercritical desalination technology to treat hypersaline solutions and separating saltwater into a pure water stream and valuable recovered solids, resulting in zero liquid discharge (ZLD). The proposed technology, focuses on innovative methods of applying supercritical water to treat highly concentrated brine solutions without incurring a high energy penalty. Integrating the technology with solar energy reduces the energy cost for the system. The results obtained during the proof-of-concept testing demonstrate that the SWEETR™ concept is technically feasible and that supercritical water treatment is a viable option with strong merit for treating high salinity waters. The strategic design of the system provides the opportunity to localize the supercritical zone, which helps reduce the overall energy cost associated with the desalination process. The process can be tuned to remove only the amount of salts required to make the treated water “fit for purpose”, providing further opportunities to minimize energy costs. The ability to destroy organic compounds associated with the water while simultaneously being able to desalinate makes SWEETR™ uniquely fitted for treating aqueous streams such as produced water from oil and gas extraction which contain small amounts of organics. Such mixed contaminant streams pose an extreme challenge for other treatment options. Future work will further develop the SWEETR™ technology to take it from the bench-scale to the pilot-scale, and ready the technology for commercial application.

04 OIL SHALES AND TAR SANDS↗

DOE OSTI2022

Oil Recovery Prediction for Polymer Flood Field Test of Heavy Oil on Alaska North Slope Via Machine Assisted Reservoir Simulation

The first ever polymer flood field pilot to enhance the recovery of heavy oils on the Alaska North Slope is ongoing. This study constructs and calibrates a reservoir simulation model to predict the oil recovery performance of the pilot through machine-assisted reservoir simulation techniques. To replicate the early water breakthrough observed during waterflooding, transmissibility contrasts are introduced into the simulation model, forcing viscous fingering effects. In the ensuing polymer flood, these transmissibility contrasts are reduced to replicate the restoration of injection conformance during polymer flooding, as indicated by a significant decrease in water cut. Later, transmissibility contrasts are reinstated to replicate a water surge event observed in one of the producing wells during polymer flooding. This event may represent decreased injection conformance from fracture overextension; its anticipated occurrence in the other production well is included in the final forecast. The definition of polymer retention in the simulator incorporates the tailing effect reported in laboratory studies; this tailing effect is useful to the simultaneous history match of producing water cut and produced polymer concentration. The top 24 best-matched simulation models produced at each stage of the history matching process are used to forecast oil recovery. The final forecast clearly demonstrates that polymer flooding significantly increases the heavy oil production for this field pilot compared to waterflooding alone. This exercise displays that a simulation model is only valid for prediction if flow behavior in the reservoir remains consistent with that observed during the history matched period. Critically, this means that a simulation model calibrated for waterflooding may not fully capture the benefits of an enhanced oil recovery process such as polymer flooding. Therefore, caution is recommended in using basic waterflood simulation models to scope potential enhanced oil recovery projects.

Keith, Cody Douglas↗

NASA NTRS1981

Hemodynamic changes during whole body surface cooling and lower body negative pressure

Six young healthy male subjects were studied to evaluate the use of whole body surface cooling (WBSC) as an antiorthostatic intervention. Previous studies have demonstrated that perfusion of an Apollo cooling garment with 16 C water produced a significant increase in stroke volume and decrease in heart rate at rest and during lower body negative pressure (LBNP). However, optimal perfusion temperatures have not been determined. The present study examined the effects of WBSC using perfusion of water at a temperature of 10 C. This perfusion temperature produced a greater decrease in mean skin temperature than water at 16 C (4 C drop compared to 2 C). The hemodynamic effects were also more prominent with 10 C water as shown by the increase in stroke volume of 11% at rest and of 35% during LBNP at -50 torr compared to control measurements at ambient temperature. Heart rates were lowered significantly (8 beats/min) and systolic arterial blood pressure was higher (8 torr). Cooling with 10 C water produced a slight increase in muscle tone, reflected by a small but significant increase (+84 ml/min) in oxygen uptake. These data suggest that WBSC is an effective nonpharmacologic means of controlling preload and deserves further investigation as an antiorthostatic intervention.

Raven, P. B.↗

DOE OSTI2020

Advanced supercritical water-based process concepts for treatment and beneficial reuse of brine in oil/gas production

Produced water generated from oil/gas reservoirs is a cost burden for oil/gas producers, with over 21 billion barrels of the waste generated in 2019. Average disposal costs range from 4.00–8.00·bbl -1 , with up to 20·bbl -1 spent on transportation alone. Dissolved solids content is a contributing factor which limits economical treatment options for this waste stream. This work proposes a novel technique that can handle high salinity waste, employing favorable properties past the critical point of water. In this study, process simulation of two supercritical water desalination (SCWD) scenarios was completed. Zero liquid discharge (ZLD) and brine concentration operating scenarios were compared, weighing the associated economics and benefits for each case. The results were shown to be economically feasible for brines with a high dissolved solids content, ranging from 3.49 to 17.28·bbl -1 in an expanded sensitivity analysis.

42 ENGINEERING↗

DOE OSTI2021

Molecular thermodynamics for scaling prediction: Case of membrane distillation

Membrane distillation (MD) for water treatment is significantly impaired by the scaling of dissolved minerals. The type and content of minerals generally measured as total dissolved solids (TDS) in hypersaline brines not only reduce the MD flux but also control the scaling behavior on the membrane surface. The scaling-induced pore blockage further reduces water flux and eventually leads to membrane wetting. The scaling problem is even more pronounced in the treatment of produced water (PW) as it contains 3–7 times higher TDS concentrations, compared to seawater. Theoretically, the necessary conditions for a salt to precipitate can be traced from its solubility product constant and activity of the constituents within the solution. Therefore, a comprehensive thermodynamic model is necessary to represent the electrolyte behavior and to predict the precipitation of different salts in a complex solution like PW. We pursued electrolyte Nonrandom Two Liquid Theory (eNRTL), a state-of-the-art electrolyte model, to address the PW fluid phase equilibria. With a fully parameterized eNRTL model, we predicted salt precipitations in two different PW samples and compared the results against the experimental findings. Furthermore, here we forecast the precipitation of salts in response to the change in PW concentration and temperature in the MD operation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗