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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Sustainability-inspired cell design for a fully recyclable sodium ion battery

Large-scale applications of rechargeable batteries consume nonrenewable resources and produce massive amounts of end-of-life wastes, which raise sustainability concerns in terms of manufacturing, environmental, and ecological costs. Therefore, the recyclability and sustainability of a battery should be considered at the design stage by using naturally abundant resources and recyclable battery technology. Herein, we design a fully recyclable rechargeable sodium ion battery with bipolar electrode structure using Na 3 V 2 (PO 4 ) 3 as an electrode material and aluminum foil as the shared current collector. Such a design allows exceptional sodium ion battery performance in terms of high-power correspondence and long-term stability and enables the recycling of ~ 100% Na 3 V 2 (PO 4 ) 3 and ~ 99.1% elemental aluminum without the release of toxic wastes, resulting in a solid-component recycling efficiency of >98.0%. The successful incorporation of sustainability into battery design implies that closed-loop recycling and the reutilization of battery materials can be achieved in next-generation energy storage technologies.

25 ENERGY STORAGE↗
DOE OSTI2021

Recycling lead and transparent conductors from perovskite solar modules

Abstract Perovskite photovoltaics are gaining increasing common ground to partner with or compete with silicon photovoltaics to reduce cost of solar energy. However, a cost-effective waste management for toxic lead (Pb), which might determine the fate of this technology, has not been developed yet. Here, we report an end-of-life material management for perovskite solar modules to recycle toxic lead and valuable transparent conductors to protect the environment and create dramatic economic benefits from recycled materials. Lead is separated from decommissioned modules by weakly acidic cation exchange resin, which could be released as soluble Pb(NO 3 ) 2 followed by precipitation as PbI 2 for reuse, with a recycling efficiency of 99.2%. Thermal delamination disassembles the encapsulated modules with intact transparent conductors and cover glasses. The refabricated devices based on recycled lead iodide and recycled transparent conductors show comparable performance as devices based on fresh raw materials. Cost analysis shows this recycling technology is economically attractive.

14 SOLAR ENERGY↗
DOE OSTI2019

Closed Loop Recycling of Electric Vehicle Batteries to Enable Ultra-high Quality Cathode Powder

The lithium-ion battery (LIB) recycling market is becoming increasingly important because of the widespread use of LIBs in every aspect of our lives. Mobile devices and electric cars represent the largest application areas for LIBs. Vigorous innovation in these sectors is spurring continuous deployment of LIB powered devices, and consequently more and more LIBs will become waste as they approach end of life. Considering the significant economic and environmental impacts, recycling is not only necessary, but also urgent. The WPI group has successfully developed a closed-loop recycling process, and has previously demonstrated it on a relatively small scale 1 kg spent batteries per experiment. Here, we show that the closed-loop recycling process can be successfully scaled up to 30 kg of spent LIBs from electric vehicle recycling streams, and the recovered cathode powder shows similar (or better) performance to equivalent commercial powder when evaluated in both coin cells and single layer pouch cells. All of these results demonstrate the closed-loop recycling process has great adaptability and can be further developed into industrial scale.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A green closed-loop process for selective recycling of lithium from spent lithium-ion batteries

As the economy started to recover from the COVID pandemic, the price of Li 2 CO 3 skyrocketed to its highest. This situation has aggravated concerns about the supply chain for lithium-ion batteries (LIBs). Recycling spent LIBs is a potential solution to alleviate the bottleneck of the supply chain and prevent environmental pollution, and has attracted lots of attention. However, lithium recycling is generally disregarded because of the complex recycling process and its low recycling efficiency. Here, in this work we developed a sustainable lithium recovery process, which can selectively leach and recover lithium with formic acid before recycling valuable metals. With the reported method, lithium can be 99.8% recovered from layered oxide cathode materials with 99.994% purity. In addition, this lithium recovery process is affordable, compared to the typical hydrometallurgical process, by saving 11.15% per kilogram of spent LIBs. Therefore, this research provided a new solution to eliminating the effects of lithium ions on valuable metal separation and the co-precipitation reaction and precluding the influence of other metal ions on lithium recovery. Finally, this simplified lithium recovery process provides new opportunities for sustainable recycling of LIBs and economical restoration of the lithium supply chain.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Active Recycling Control Through Lithium Injection in EAST

The coating of tokamak walls with thin layers of lithium has been demonstrated to reduce plasma recycling from the plasma-facing surfaces and to improve overall plasma performance. These effects, including reduced divertor D α emission, the elimination of edge-localized modes, and increased energy confinement have been observed in multiple experiments when lithium coatings are applied before plasma discharges. However, this coating technology does not extrapolate to future long-pulse devices, since the lithium coatings will be passivated by the continual plasma flux onto the surface. In order to provide active conditioning capability, a new technology has been developed that is capable of injecting lithium powder into the scrape-off layer plasma during plasma discharges, where it quickly liquefies and turns into an aerosol. The use of this “lithium dropper” is under study at the Experimental Advanced Superconducting Tokamak (EAST), where the potential benefits of real-time wall conditioning via lithium injection are being tested. Here, we present an analysis of the recycling characteristics during EAST experiments testing active lithium injection in order to assess recycling reduction and control. Lithium aerosol was injected from the top of the machine, with one system dropping lithium near the X-point and another into the low-field side divertor leg. The injection of lithium into the SOL reduced divertor recycling, as evidenced by reduced D α emission with ion flux measured by probes relatively unchanged. This effect is strongest in the active divertor, confirming the lithium is transported to strongly plasma-wetted areas. Furthermore, quantitative analysis of the recycling changes using the SOLPS edge plasma and neutral transport code indicated a ~20% reduction in recycling coefficient with lithium injection.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Recovery of postconsumer mechanically recycled polymers

Mechanical recycling plays a key role in reducing landfill bound plastics that pollute our environment. This process converts plastic waste into marketable pellets by sorting, cleaning, grinding into flakes, compounding in the molten state, and ultimately pelletizing. A primary restriction for the widescale usage of mechanical recycling is the highly variable quality and mechanical properties of the plastic waste feedstock. Degradation can occur during the plastic life cycle with the consumer, during the mechanical processing itself, or during the complex sorting process required to produce the feedstock. This study explores how rheological characterization can mitigate the batch-to-batch variability and identify a potential application for each batch. Shear and extensional rheology of “application-specific” virgin high-density polyethylene (HDPE) and virgin polypropylene (PP) was used as the control for this categorization process. Recycled HDPE and PP from three different streams were then measured and compared to the results from the control study. Rheological measurements proved to be very effective at providing sufficient differentiation to categorize the recycled polymer as suitable for different applications such as injection molding, blow molding, or thermoforming. Finally, the usage of an additional step to sort the recycled polymers by their initial use application was found to achieve a remarkably consistent recovery of application-specific material properties. Furthermore, this secondary sorting could provide significant added value for mechanically recycled polymers.

Differential scanning calorimetry↗
DOE OSTI2024

Manufacture and testing of biomass-derivable thermosets for wind blade recycling

Wind energy is helping to decarbonize the electrical grid, but wind blades are not recyclable, and current end-of-life management strategies are not sustainable. Here, to address the material recyclability challenges in sustainable energy infrastructure, we introduce scalable biomass-derivable polyester covalent adaptable networks and corresponding fiber-reinforced composites for recyclable wind blade fabrication. Through experimental and computational studies, including vacuum-assisted resin-transfer molding of a 9-meter wind blade prototype, we demonstrate drop-in technological readiness of this material with existing manufacture techniques, superior properties relative to incumbent materials, and practical end-of-life chemical recyclability. Most notable is the counterintuitive creep suppression, outperforming industry state-of-the-art thermosets despite the dynamic cross-link topology. Overall, this report details the many facets of wind blade manufacture, encompassing chemistry, engineering, safety, mechanical analyses, weathering, and chemical recyclability, enabling a realistic path toward biomass-derivable, recyclable wind blades.

17 WIND ENERGY↗
DOE OSTI2024

End-of-Life Plastics Management: A Review: Mechanical recycling, pyrolysis and hydrocracking methods

End-of-life plastics present a significant challenge to achieving a sustainable economy. It is crucial to develop environmentally friendly technologies to process the waste streams beyond landfilling. This review provides a detailed overview of end-of-life plastics management, covering mechanical recycling, pyrolysis and hydrocracking methods. Mechanical recycling is the predominant technique employed on a large scale in recycling end-of-life plastics, and this review discusses the technoeconomic assessment and life cycle assessment (LCA) of mechanical recycling. This review also summarises key studies concentrating on chemical recycling techniques for handling end-of-life plastics. Among these, pyrolysis and hydrocracking are discussed in depth. Recent advancements and fundamentals of these two techniques are covered, highlighting their significance in tackling the plastic waste challenge. The prospects of scaling up pyrolysis and hydrocracking technologies are interpreted in terms of technical and economic feasibility. The discussion concludes with recommendations for future research to commercialise chemical recycling of end-of-life plastics.

Chemistry↗
DOE OSTI2021

Evaluations of the Fates of Alkali Metals, Actinides, Mercury, and Iodine During DWPF Recycle Diversion

The fates of alkali metals, actinides, mercury, and iodine in the Defense Waste Processing Facility Recycle Diversion process (as currently conceptualized) have been evaluated through paper studies based on available knowledge of the chemistry, physical properties, solubility, and volatility of the various species involved. The effect of pH in the range from 9 to 13 has been discussed. Recommendations for additional studies to close technology gaps have been provided, many of which are contingent upon the results of pending testing and sample characterization efforts. There is uncertainty in the amounts of soluble actinides passing through the process filter, though the bulk of the actinides should be captured on the filter with the Recycle Collection Tank solids and the total amounts of actinides should be relatively low. The Recycle Collection Tank pH could impact the fraction of actinides reaching the evaporator, but the primary factors determining the actinide fate are expected to be the amount of CO 2 sorption from air sparging or, for certain actinides (such as plutonium), oxidation and/or sorption to MnO 2 solids from permanganate additions to destroy the glycolate anion. Process optimization could minimize the amounts of actinides passing the filter. Depending upon the levels of mercury observed in recycle stream samples and because of the volatility of mercury, the evaporator should be designed with the capability to remove dense mercury phases from the condensate to avoid exceeding ETP WAC limits. The facility design must be adequate to transfer dense mercury phases and testing to confirm mercury transfer is needed. Simulant containing mercury is recommended for both filtration and evaporation testing. OLI Modeling of the various recycle streams is recommended to provide insight on the fate of iodine. Iodine-spiked simulants are recommended for upcoming evaporation tests. The pro) ect should consider the likelihood and impact of NAS scale formation in the evaporators. Process optimization may be needed to minimize the accumulation of NAS scale and possibly the sorption of actinides in the evaporator. Actual waste testing of the Recycle Diversion filtration and evaporation should include the analysis of actinides, mercury, and iodine to determine their partitioning.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Infinitely Recyclable Network Polymers, Enabling Sustainable Manufacturing (CRADA Final Report)

This FLO Materials project was aimed at commercializing a new, infinitely recyclable material that can enable closed-loop lifecycles for hard-to-recycle plastics and plastic products. Four hundred million metric tons of virgin plastic is produced each year, yet less than 10% of this material is recycled. In the US alone, 2% of energy consumption is dedicated to the manufacture of virgin plastics, polymer resin, and synthetic rubbers. By keeping plastic materials in circulation longer, we can reduce waste, lower manufacturing costs, cut energy and oil consumption, and drastically reduce greenhouse gas (GHG) emissions. Specifically, FLO’s innovation overcomes the complications associated with salvaging difficult-to-recycle plastics (i.e., contaminated thermoplastic linear polymers, thermoset cross-linked network polymers), which represent at least 20% of total polymer global production, with a recycling rate of near 0%. Chemical recycling of these new polymers through depolymerization allows all additives to be easily removed at room temperature and the recovered monomers to be remanufactured into next generation materials with 100% recovery of mechanical performance and aesthetic quality.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effects of Mechanical Recycling on Carbon Fiber-Based Hybrid Composites

Carbon fiber (CF) reinforced composites are high-performing, highly utilized material systems historically used in aerospace. As the cost of CF decreases, other industries, such as automotive and energy generation, seek to adopt CF composites into their applications. A sudden increase in CF demand may create supply chain issues if the adoption happens without scaling up of the CF production. A solution for reducing the reliance on CF is to substitute some portion of the CF content with another fiber type without significantly reducing the material properties. When multiple reinforcing fillers are introduced into a composite system, the materials system is often referred to as a hybrid composite and in this case a CF-based hybrid composite. To further relieve reliance on CF and with sustainable manufacturing becoming more prominent in industry, mechanical recycling can be employed to replace all or a percentage of the virgin material content. Utilizing recycled content in place of virgin content will further aid in reducing the reliance on virgin CF and decrease overall material costs. Here, the effects of utilizing mechanically recycled feedstocks on the mechanical properties of injection molded samples are explored to understand the feasibility of re-manufacturing recycled CF-based hybrid composites. By determining the mechanical properties and mechanisms in which the properties change through varying recycled content, the assessment of how the material will perform in other manufacturing processes can be inferred. As a result, industry will gain better insight into utilizing mechanically recycled feedstocks to reduce their reliance on the CF supply chain.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The Isotopic Limit of Recycling

Despite advances in recycling technologies and practices, the world still mostly operates on a once-through materials use cycle. The once-through approach to the materials supply chain cannot work into perpetuity. The vast majority of current recycling efforts focus on mechanical or chemical separation-based techniques and are often subsequently limited on the number of times a component can be recycled or upcycled. By looking at things from a particle physics and nuclear history perspective, we propose a thought experiment to determine the physical limit of recycling and propose subsequent limits and standards to evaluate all recycling efforts. This uncommon approach to analysis demonstrates that the current limits to recycling are not physical in nature but engineering.

Lang, Eric↗
NASA NTRS1988

Isotopic constraints on crustal growth and recycling

The Sm-Nd isotopic data on clastic and chemical sediments are used with the present-day age distribution of continental crustal rocks to estimate the rates of crustal accretion, growth and recycling throughout earth's history. A new method for interpreting Nd model ages on both chemical and clastic sediments is proposed. A general relationship is derived between the mean crustal residence time of material recycled from the crust to the mantle (i.e., sediments), the mean age of the crust, and the crustal growth and recycling rates. This relationship takes into account the fact that the age distribution of material in the continental crust is generally different from the age distribution of material recycled into the mantle. The episodic nature of the present-day age distribution in crustal rocks results in similar episodicity in the accretion and recycling rates. The results suggest that by about 3.8 Ga ago, about 40 percent of the present continental volume was present. Recycling rates were extremely high 3-4 Ga ago and declined rapidly to an insignificant value of about 0.1 cu km/a during most of the Phanerozoic. The Nd model age pattern on sediments suggests a fairly high rate of growth during the Phanerozoic.

Jacobsen, Stein B.↗
NASA NTRSDate not supplied

Should Oxygen, Hydrogen, and Water on the Moon Be Provided by Earth Supply, Life Support Recycling, or Regolith Mining?

The water needed for space life support has so far been provided by either direct supply from Earth on most missions or by life support wastewater recycling on the International Space Station (ISS). With the recent large reduction in launch cost, Earth resupply has become more attractive, but recycling always costs less than resupply for a large enough crew on a long enough mission. Water is also needed to make up recycling losses and oxygen and hydrogen are needed for propulsion fuel. This paper compares the costs of oxygen, hydrogen, and water on the moon for Earth supply, lunar recycling, and lunar mining. While Earth supply is the most expensive by far, lunar recycling and mining costs are not much different. Life support wastewater provides a large but limited supply, so lunar mining will always be needed. Minor cost reductions may make mining less expensive than recycling.

Harry W Jones↗
DOE OSTI2022

Recycling Measurements for the Lithium Tokamak Experiment

The lithium tokamak experiment (LTX) is a spherical torus designed to investigate a low-recycling wall regime for magnetically confined plasmas. Traditional measurements of recycling using Dα emission are not feasible in LTX due to reflections off the plasma-facing-components: stainless-steel shell, liquid lithium layer, and molybdenum limiters. Since lithium has low VUV reflectivity, LTX will use Lyman-α emission to measure particle recycling. LTX will use 10- and 20-channel AXUV diode arrays with Lyman-α filters to view recycling off the inboard and outboard shells. A single detector views recycling off a limiter. Measurements will be used with neutral modeling to calculate recycling and neutral deposition. To investigate the performance of an AXUV diode with directly-deposited filter, measurements were obtained with this detector and a visible detector viewing a calibration plasma then compared with emission calculated using a collisional-radiative model.

Physics - Plasma physics↗
DOE OSTI2013

Hanford Low-Activity Waste Processing: Demonstration of the Off-Gas Recycle Flowsheet - 13443

Vitrification of Hanford Low-Activity Waste (LAW) is nominally the thermal conversion and incorporation of sodium salts and radionuclides into borosilicate glass. One key radionuclide present in LAW is technetium-99. Technetium-99 is a low energy, long-lived beta emitting radionuclide present in the waste feed in concentrations on the order of 1-10 ppm. The long half-life combined with a high solubility in groundwater results in technetium-99 having considerable impact on performance modeling (as potential release to the environment) of both the waste glass and associated secondary waste products. The current Hanford Tank Waste Treatment and Immobilization Plant (WTP) process flowsheet calls for the recycle of vitrification process off-gas condensates to maximize the portion of technetium ultimately immobilized in the waste glass. This is required as technetium acts as a semi-volatile specie, i.e. considerable loss of the radionuclide to the process off-gas stream can occur during the vitrification process. To test the process flowsheet assumptions, a prototypic off-gas system with recycle capability was added to a laboratory melter (on the order of 1/200 scale) and testing performed. Key test goals included determination of the process mass balance for technetium, a non-radioactive surrogate (rhenium), and other soluble species (sulfate, halides, etc.) which are concentrated by recycling off-gas condensates. The studies performed are the initial demonstrations of process recycle for this type of liquid-fed melter system. This paper describes the process recycle system, the waste feeds processed, and experimental results. Comparisons between data gathered using process recycle and previous single pass melter testing as well as mathematical modeling simulations are also provided. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Impact of electric vehicle battery recycling on reducing raw material demand and battery life-cycle carbon emissions in China

The rapid growth of electric vehicles (EVs) in China challenges raw material demand. This study evaluates the impact of recycling and reusing EV batteries on reducing material demand and carbon emissions. Integrating a national-level vehicle stock turnover model with life-cycle carbon emission assessment, we found that replacing nickel-cobalt-manganese batteries with lithium iron phosphate batteries with battery recycling can reduce lithium, cobalt, and nickel demand between 2021 and 2060 by up to 7.8 million tons (Mt) (67%), 12.4 Mt (96%), and 37.2 Mt (93%), respectively, significantly decreasing reliance on import. Moreover, battery recycling coupled with reuse can reduce carbon emissions by up to 6,532-6,864 Mt (36.0-37.9%), depending on four recycling methods employed. However, this reuse strategy delays battery recycling and risks lithium supply shortage, necessitating trade-offs between carbon reduction and material supply. Future technologies, such as lithium-sulfur and all-solid-state batteries, despite their energy efficiency, might exacerbate lithium shortage, underscoring the crucial need for increased lithium supply.

25 ENERGY STORAGE↗
DOE OSTI2024

Winding Down: End of Service and Recycling for Wind Energy [Slides]

In this webinar hosted by the U.S. Department of Energy's WINDExchange initiative, experts from the National Renewable Energy Laboratory introduce attendees to key concepts in end-of-service processes for wind energy technologies and infrastructure, including decommissioning, repowering, and recycling. As wind energy projects across the United States become older, decisions about end-of-service options and component processing are of growing importance to project owners and operators, state and local decision-makers, and neighboring communities. There is also concern about the blade waste that must be processed, with a number of recycling solutions being developed to meet this need. This webinar introduces the processes and activities involved at the end of a wind energy project's lifespan; discusses the impacts these activities have on communities, landowners, the wind energy industry, and other stakeholders; explains different blade recycling methods; and discusses the future of recycling in the wind energy industry.

17 WIND ENERGY↗