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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
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↗
DOE OSTI2025

Heterogeneity of the Dominant Causes of Performance Loss in End-of-Life Cathodes and Their Consequences for Direct Recycling

Recycling Li-ion batteries from electric vehicles is critical for reducing costs and supporting the development of a domestic battery supply chain. Direct recycling of cathodes, like LiNixMnyCozO2 (NMC), is attractive due to its low cost, energy use, and emissions compared to traditional recycling techniques. However, a comprehensive understanding of the active material properties at end-of-life is needed to guide direct recycling processes and the performance-dependent reuse applications. Here, NMC material from an end-of-life commercial pouch cell is characterized and bench-marked against pristine non-cycled counterparts with respect to capacity, impedance, crystallography, morphology, and microstructure to identify major degradation modes and understand variability in the end-of-life material. The spatial heterogeneity of each property throughout the cell is also quantified. While the degraded material demonstrated similar capacity as the pristine, its impedance and rate capability are severely diminished. Furthermore, samples from the periphery of the electrode layers showed more severe performance loss compared to samples extracted from central regions. The dominant culprit of performance loss is the material microstructure, where the magnitude of particle cracking showed the strongest correlation to the impedance components that are most unfavorably impacted. This work suggests severe cracks in cathode active materials are the primary challenge that direct recycling methods must overcome.

25 ENERGY STORAGE↗
DOE OSTI2023

Dual Recycling of Depolymerization Catalyst and Biodegradable Polyester that Markedly Outperforms Polyolefins

Chemically recyclable, circular polymers continue to attract increasing attention, but rendering both catalysts for depolymerization and high-performance polymers recyclable is a more sustainable yet challenging goal. Here we introduce a dual catalyst/polymer recycling system in that recyclable inorganic phosphomolybdic acid catalyzes selective depolymerization of high-ceiling-temperature biodegradable poly(δ-valerolactone) in bulk phase, which, upon reaching suitable molecular weight, exhibits outstanding mechanical performance with a high tensile strength of ≈66.6 MPa, fracture strain of ≈904 %, and toughness of ≈308 MJ m –3 , and thus markedly outperforms commodity polyolefins, recovering its monomer in pure state and quantitative yield at only 100 °C. In sharp contrast, the uncatalyzed depolymerization not only requires a high temperature of >310 °C but is also low yielding and non-selective. Importantly, the recovered monomer can be repolymerized as is to reproduce the same polymer, thereby closing the circular loop, and the recycled catalyst can be reused repeatedly for depolymerization runs without loss of its catalytic activity and efficiency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Chemically Recyclable and Tunable Polyolefin-Like Multiblock Copolymer Adhesives

Adhesives are important in creating multilayer products, such as in packaging and construction. Most current hot-melt adhesives such as poly(ethylene-co-vinyl acetate) (EVA) and polyurethanes lack chemical recyclability and do not easily de-bond, complicating recycling. Here, we achieved tunable adhesive properties of chemically recyclable polyolefin-like multiblock copolymers through regulating the incorporation of crystalline hard blocks, amorphous soft blocks, and ester content highlighted by adhesive strengths up to 6.80 MPa. We further demonstrated applications of these adhesives in multi-layer films and showed that the adhesives can be readily de-bonded, recovered, and chemically recycled. Overall, this study into structure-property relationships, including effects of crystallinity, soft-block incorporation, and ester content of the multiblock copolymers on adhesive properties, has resulted in a modular hot-melt adhesive platform that exhibits chemical recyclability for virgin-quality adhesive re-generation, reprocessability for repeated reuse of the recovered adhesive, and tunability for designing adhesives with a wide range of low to high (up to ~80% stronger than EVA) adhesion strengths.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Simulation of the impact of particle recycling on the plasma in MPS-LD device based on the BOUT++ LPD module

A linear plasma device (LPD) module has been developed under the BOUT++ framework to simulate plasma transport in the MPS-LD. However, previously, the LPD module used a simplistic neutral particle model that only includes particle density and velocity, which prevents the full understanding of the plasma-neutrals interactions. In this work, we further optimize the neutral model by using a more complete neutral fluid model containing the continuity equation, momentum equation, and energy equation. The reactions such as charge exchange, excitation, and radiation collisions are included. Since the neutral particle source is mainly provided by particle recycling from the target, a particle recycling model is employed, which includes both fast reflection and slow thermal release. The upgraded LPD module is applied to simulate the argon (Ar) discharge experiment of MPS-LD, and the benchmark against experiment measurement and SOLPS-ITER simulation results are presented. Good agreements are obtained, showing the validation of the upgraded module. After that, the impact of particle recycling on Ar plasma is investigated. It is found that a higher recycling coefficient (R) promotes the achievement of high-density plasma at the target. In conclusion, the recycled Ar atoms change target plasma pressure as well as plasma-neutral collisions, which both contribute to plasma momentum loss, thus promoting the rollover of ion flux to the target.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Direct Recycling of Blended Cathode Materials by Froth Flotation

We report that direct Li-ion battery recycling involves separating cathode active materials in the solid phase while preserving their electrochemical performance. To reuse the recycled ones in new batteries, it is necessary to separate individual cathode components, which would typically occur prior to the rejuvenation and any compositional reformulation processes. Herein, a froth flotation process is developed to separate pristine lithium nickel-manganese-cobalt oxide (LiNi 0.333 Mn 0.333 Co 0.333 O 2 , NMC111) and lithium manganese oxide (LMO) materials. The flotation results show that with multiple stages of the separation processes, a satisfactory separation is achieved with 95% grade or above of NMC111 in the froth product and 95% grade of LMO in the tailing product. The electrochemistry results show that the flotation chemicals have negligible impact on the electrochemical performance of recycled active materials, whereas the NMC111 exhibits a minor capacity fade after being in contact with deionized water at 2% solid concentration. An improvement in both the rate and cycling performance is achieved at 10% solid concentration or higher. It is found that there is little compositional and structural change to the aqueous recycled NMC111 powders. An effective and low-cost separation method for direct recycling mixed cathode compositions is demonstrated.

25 ENERGY STORAGE↗
DOE OSTI2024

Recycling Perspectives of Electric Arc Furnace Slag in the United States: A Review

This article presents a comprehensive review of electric arc furnace (EAF) slag recycling in the United States, examining its classification and the associated challenges and opportunities of its industrial use. The study affirms EAF slag's nonhazardous status. Here, the main challenges identified in EAF slag applications include substantial variations in composition and volume instability during/after hydration. Analysis of the U.S. recycling practices reveals that EAF slag is predominantly reused, with minimal landfill disposal. However, its prevalent use as a low value-added aggregate in construction applications underscores the industry's ongoing challenge to get additional value from EAF slag recycling. Despite these challenges, the study highlights a great potential for increased value extraction from EAF slag recycling. Beyond conventional applications as a clinker material for the cement industry, the review explores modern technologies for steelmaking slag recycling, revealing options for recovering valuable metals such as Cr, V, Mo, and Fe through methods such as leaching, reduction, and oxidation.

42 ENGINEERING↗
DOE OSTI2017

Effects of Diisocyanate and Polymeric Epoxidized Chain Extenders on the Properties of Recycled Poly(Lactic Acid)

Increasing demand in the use of poly(lactic acid) (PLA) leads to a debate about using potential foodstuffs for plastic production and a moral issue when starvation problem is taken into account. One of the solutions is recycling of PLA; however, recycling results in property losses during melt processing due to low thermal stability of PLA. This study focuses on using chain extenders to offset thermal degradation of recycled PLA. The effects of a diisocyanate and a polymeric epoxidized chain extender on the properties of the recycled poly(lactic acid) were investigated. In order to mimic the recycling process, PLA was subjected to thermo-mechanical degradation using a laboratory scale compounder. Chain extender type, loading and mixing time were investigated. On-line rheology and intrinsic viscosity measurements of PLA before and after chain extension confirmed that the molecular weight increased. Dynamic mechanical analysis, rheology and tensile tests revealed that the chain extenders led to a significant increase in modulus, strength and melt-viscosity. It was found that diisocyanate had slightly higher and faster chain extension reactivity than polymeric extender. Differential scanning calorimetry results showed an increase in the crystallization temperature due to the branched and extended chain structure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Hybrid network via instantaneous photoradiation: High efficient design of 100% bio-based thermosets with remoldable and recyclable capabilities after UV curing

Conventional thermoset materials cannot be remolded and recycled due to the covalent bonds existing in the network. The reversible nature of secondary interactions between monomeric units renders supramolecular structure reconfigurable abilities upon exposure to appropriate stimuli. This feature is quite useful in the design of novel thermoset materials with remoldability and recyclability, but its widespread adoption is limited due to the low strength and high cost of supramolecular structure. Here, we present a new class of thermoset with a distinct recycling mechanism and structural design. It is strong, transparent, recyclable, 100% biorenewable, creep resistance after thermal treatment, and produced in a ultrafast, scalable and cost-effective manner. These characteristics come from a purpose-designed hybrid network via a ultraviolet radiation in seconds. As a result, this technology provides a new way to obtain thermosets with remoldability and recyclability. It is green and efficient, not limited in lab, and can be scaled up for industry.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Recyclability of reversible polymer networks over a Dozen reprocessing cycles

Reversible polymer networks capable of reversible reactions along their backbone provide a promising strategy for addressing waste management challenges associated with conventional thermoset products. However, reversible polymer networks cannot be recycled infinitely. Unavoidable side reactions eventually cause significant degradation of mechanical properties or loss of recyclability. This study aims to answer a simple yet critical question on reversible polymer network systems: how many reprocessing cycles can be achieved before profound mechanical degradation or a loss of recyclability? The recyclability of Diels–Alder (DA) network samples was evaluated by repeating consistent reprocessing cycles until they were no longer reprocessable. To enhance their recyclability, the chemical structure of the maleimide precursor was tailored to mitigating side reactions by maleimide homopolymerization. Remarkably, by employing a maleimide precursor with alkyl substitutions on its phenyl group, the DA network system attained 12 reprocessing cycles using injection molding at 160 °C without significant degradation of mechanical properties. However, the 13th reprocessing cycle did not succeed. Rheological analysis revealed the accumulation of non-reversible bonds within the network structure during repeated reprocessing, despite fairly consistent mechanical properties under operating conditions. This study demonstrates that the rational design of the maleimide precursor is an effective means to enhance the reprocessability of DA networks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Substitution of virgin carbon fiber with low-cost recycled fiber in automotive grade injection molding polyamide 66 for equivalent composite mechanical performance with improved sustainability

Recycled carbon fiber has historically proven challenging to integrate into composite manufacturing due in no small part to the low-density, randomly oriented, discontinuous fiber format that results from typical recycling. Discontinuous fiber requires the use of alternative technologies than those traditionally applied to continuous fiber (e.g., hand lay-up, winding). Extrusion compounding is one such applicable technology, but material transfer into the system requires alternative feeding equipment or the use of an altered procedure as trialed in this research. In this study, an injection molding compound for automotive applications was prepared with recycled carbon fiber and compared against an existing commercial compound. Input fibers and molded compound were evaluated for mechanical performance, while relevant variables such as compounded fiber alignment and aspect ratio were compared to the existing baseline material to confirm a like-for-like composite material structure. Overall, analysis indicates that recycled fiber performs similarly to virgin fiber reinforcement, demonstrating that recycled fiber may be a viable drop-in replacement for short-fiber discontinuous applications.

42 ENGINEERING↗
DOE OSTI2023

A decision support tool for e-waste recycling operations using the hen-and-chicks bio-inspired optimization metaheuristic

E-waste from end-of-life electrical and electronic devices is one of the fastest growing waste streams from households and businesses. E-waste recycling yields environmental sustainability and economic benefits. Due to continuous changes in e-waste types and compositions, recycling businesses face challenges to optimize their operational configuration to achieve better economic and environmental performance. To help e-waste recyclers mitigate this problem, we have developed a modular decision support tool called the Comprehensive Manufacturing Assessment Tool (CMAT) that can simulate both e-waste recycling operations and economics. This tool can give valuable insights regarding the profitability of the entire operation and different e-waste types. In addition, a new bio-inspired metaheuristic optimization algorithm, hen-and-chicks optimization (HACO), was developed to assign manpower to different workstations to maximize operational efficiencies. According to the results of our case study, laptops, desktops, and computer peripherals are the three electronic waste products that produce the most profit. Our examination of the sensitivity of material prices shows that the price of steel has the most significant influence on total profit, because it is the most widely used material in the majority of electronic devices. We have released the decision support tool as open-source software under a general public license. It could be customized for other recycling industries beyond e-waste to achieve business sustainability by making their operations more efficient.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Achieving low-temperature hydrothermal relithiation by redox mediation for direct recycling of spent lithium-ion battery cathodes

Lithium-ion battery (LIB) recycling is an urgent need to address the massive generation of spent LIBs from portable devices and electrical vehicles. However, the large-scale recycling is hampered by economic and safety issues associated with today's recycling processes. In this study, we demonstrate a safe and energy efficient direct regeneration process based on low-temperature hydrothermal relithiation (LTHR) at low pressure for spent LiNi x Co y Mn z O 2 (0 < x,y,z <1, x + y + z = 1, or NCM) cathode materials. A low concentration of low-cost redox mediator is employed to improve the relithiation kinetics of spent NCM materials, enabling full relithiation temperature to be reduced from 220 °C to 100 °C or below. Correspondingly, the pressure incurred in the relithiation process can be reduced from ~25 bar to 1 bar, offering significantly improved operation safety. Specifically, three NCM materials, including chemically delithiated NCM111, cycled (degraded) NCM111, and cycled NCM622, were successfully regenerated with complete recovery of composition, crystal structure, and electrochemical performance, achieving the same effectiveness as that achieved at high temperature process. Meanwhile, the total energy consumption of spent cell recycling and the greenhouse gas emission is also reduced. This work provides a facile and scalable way to more sustainable LIB recycling with high economic return, high operation safety and low cost.

25 ENERGY STORAGE↗
DOE OSTI2018

Soil contamination from lead battery manufacturing and recycling in seven African countries

Highlights: • Soil lead contamination was found at lead battery recycling facilities in Africa. • Mean lead concentrations were 2600 mg/kg in soil on the outside of plants. • Lead pollution at these sites poses significant health risks to the public. • Lead contamination at these plants suggest that extensive remediation is warranted. Lead battery recycling is a growing hazardous industry throughout Africa. We investigated potential soil contamination inside and outside formal sector recycling plants in seven countries. We collected 118 soil samples at 15 recycling plants and one battery manufacturing site and analyzed them for total lead. Lead levels in soils ranged from < 40–140,000 mg/kg. Overall mean lead concentrations were ~23,200 mg/kg but, average lead levels were 22-fold greater for soil samples from inside plant sites than from those collected outside these facilities. Arithmetic mean lead concentrations in soil samples from communities surrounding these plants were ~2600 mg/kg. As the lead battery industry in Africa continues to expand, it is expected that the number and size of lead battery recycling plants will grow to meet the forecasted demand. There is an immediate need to address ongoing exposures in surrounding communities, emissions from this industry and to regulate site closure financing procedures to ensure that we do not leave behind a legacy of lead contamination that will impact millions in communities throughout Africa.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Class-based separations of mixed solid–liquid systems with condensable solvent washing and extraction: The dilemma of pizza box recycling

As primary feedstocks deplete across the world, raw material extraction becomes increasingly expensive. Awareness of the environmental impact of primary extraction has motivated the development of energy- and reagent-efficient methods for material reuse. This work confronts an emblematic challenge of modern recycling: the soiled pizza box. While the fibers constituting corrugated cardboard are generally recyclable, pizza contaminants such as sauces and oils complicate their reuse, resulting in municipal prohibitions on the recycling of used pizza boxes in cardboard recycling streams and a representative of 275 kg/year per US household of food waste that is directed to landfill. This challenge is common to many materials, and engineering strategies must be developed to tackle complex/mixed feedstocks. To address the mixed composition of the pizza box (and similar materials), an environmentally benign, non-toxic organic solvent is applied to remove and fractionate components from mixed materials. The solvent employed in this process, dimethyl ether (DME), is a condensable hygroscopic gas, which facilitates its removal and recovery for reuse. Further, the results of this study indicate that 1) DME is capable of solubilizing and extracting components from soiled cardboard and other materials, (resulting in cardboard drier than new/unused cardboard) facilitating its recycling, and 2) the DME-soluble components of the system phase separate into aqueous and fatty acid/oil fractions (potentially ~27.5 kg/year per US household). Condensable solvent-driven washing and extraction enable the efficient separation of multiple intermediate product streams, suggesting a pathway to enable technology development necessary for achieving clean production in a circular economy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Impact of automated battery sorting for mineral recovery from lithium-ion battery recycling in the United States

The United States has identified several lithium-ion battery materials as critical for reaching the national emission reduction targets that have been set in accordance with the 2015 Paris Agreement. However, with few natural resources available domestically, there is a rapidly growing focus on the development of a domestic recycling industry to recover these materials from end-of-life batteries. Here, we use the Lithium-Ion Battery Resources Assessment (LIBRA) system dynamics model to evaluate the impact of automated battery sorting technology in terms of the shares of cobalt and nickel that are recovered through recycling. Findings show that automated sorting has clear benefits over manual sorting methods by helping recyclers selectively process high-cobalt batteries. By maximizing cobalt recovery, recycling becomes more profitable and drives greater investment in recycling capacity, resulting in a higher share of nickel and cobalt recovered from EOL batteries over time.

25 ENERGY STORAGE↗
DOE OSTI2018

The Case for Recycling: Overview and Challenges in the Material Supply Chain for Automotive Li-Ion Batteries

Lithium ion batteries (LIB) continue to gain market share in response to the increasing demand for electric vehicles, consumer electronics, and energy storage. The increased demand for LIB has highlighted potential problems in the supply chain of raw materials needed for their manufacture. Some critical metals used in LIB, namely lithium, cobalt, and graphite are scarce, are not currently mined in large quantities, or are mined in only a few countries whose trade policies could limit availability and impact prices. The environmental and social impacts of mining these materials have also drawn attention as production ramps up to meet the increased demand. Closed-loop systems with recycling at the end-of-life provide a pathway to lower environmental impacts and a source of high value materials that can be used in producing new batteries. Because environmental regulations concerning end-of-life batteries are not fully developed or implemented, most of these batteries currently end up in the landfills, with a very small number of spent batteries sent to the existing recycling facilities. However, with proactive regulations, an increasing supply of spent batteries, and innovations in recycling technologies, end-of-life batteries could supply a significant fraction of the materials needed for manufacturing of new LIB. This paper reviews the current state of the LIB manufacturing supply chain, addresses some issues associated with battery end-of-life, and sheds light on the importance of LIB recycling from the environmental and value chain perspectives. We also discuss the expected benefits of recycling on the global LIB supply chain.

25 ENERGY STORAGE↗
DOE OSTI2012

Experimental investigation of the quality characteristics of agricultural plastic wastes regarding their recycling and energy recovery potential

Highlights: Black-Right-Pointing-Pointer Definition of parameters characterising agricultural plastic waste (APW) quality. Black-Right-Pointing-Pointer Analysis of samples to determine APW quality for recycling or energy recovery. Black-Right-Pointing-Pointer Majority of APW samples from various countries have very good quality for recycling. Black-Right-Pointing-Pointer Upper limit of 50% w/w soil contamination in APW acceptable for energy recovery. Black-Right-Pointing-Pointer Chlorine and heavy metals content in APW below the lowest limit for energy recovery. - Abstract: A holistic environmentally sound waste management scheme that transforms agricultural plastic waste (APW) streams into labelled guaranteed quality commodities freely traded in open market has been developed by the European research project LabelAgriWaste. The APW quality is defined by the APW material requirements, translated to technical specifications, for recycling or energy recovery. The present work investigates the characteristics of the APW quality and the key factors affecting it from the introduction of the virgin product to the market to the APW stream reaching the disposer. Samples of APW from different countries were traced from their application to the field through their storage phase and transportation to the final destination. The test results showed that the majority of APW retained their mechanical properties after their use preserving a 'very good quality' for recycling in terms of degradation. The degree of soil contamination concerning the APW recycling and energy recovery potential fluctuates depending on the agricultural plastic category and application. The chlorine and heavy metal content of the tested APW materials was much lower than the maximum acceptable limits for their potential use in cement industries.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗