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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Numerical implementation of the MOOSE subchannel module (SCM) algorithm

The subchannel module of moose (SCM), previously referred to as Pronghorn-SC, is a subchannel code designed to resolve single-phase flow fields and calculate the relevant flow variables, in nuclear reactor fuel-pin assemblies. The assemblies it models are: water-cooled, with bare fuel-pins in a square ducted, quadrilateral lattice and liquid-metal/water-cooled, with bare/wire-wrapped fuel pins in a hexagonal ducted, triangular lattice. Previous publications have presented the development, validation and verification of SCM. This work presents an comparative overview of the different solvers implemented within SCM. This includes the solver algorithm description, and a performance comparison. The two test cases chosen to demonstrate the solver performance were taken from the PSBT enthalpy mixing benchmark and the ORNL-19 pin benchmark.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Design and performance of a variable gap system for thermal conductivity measurements of high temperature, corrosive, and reactive fluids

We report high-temperature fluids such as molten salts, liquid metals, and gasses are being proposed for many advanced energy systems including thermal energy storage devices, concentrating solar plants, and advanced nuclear reactor designs. However, the chemical behavior and thermophysical properties of many of these fluids have not been well characterized, which hinders the design, modeling, safety analysis, and deployment of these systems. Thermal conductivity is a property that is especially limited by existing measurement capabilities, which are subject to errors caused by convection, material interaction, radiative heat transfer, and instrument degradation. Therefore, there is a lack of standard, systematic measurement techniques for high-temperature, reactive, and corrosive fluids. In this work, the development of a variable gap thermal conductivity measurement system is detailed. The system is designed to measure the thermal conductivity of highly corrosive and reactive fluids, and survive operation between 100 °C and 800 °C. The effects of convection are minimized by limiting the thickness of the specimen to thin sizes (<0.3 mm). Corrections for radiative heat transfer were included in the working equations to consider specimens with varying optical properties. The design, construction, instrumentation, operating principles, and data analysis techniques are discussed in detail. The system was tested up to 500 °C using helium gas and molten KNO 3 -NaNO 3 to verify the measurement technique and determine the sources of error. At 300 and 400 °C KNO 3 -NaNO 3 , results showed maximum relative error of 6% when compared to results in the literature. The helium results were within 13% of those in the literature at 300 and 400 °C. Higher errors were observed at 500 °C for both fluids, and the sources of these errors are discussed.

42 ENGINEERING↗
DOE OSTI2023

FOR-868 Microreactor Applications Research Validation and Evaluation (MARVEL) Project

The Microreactor Applications Research Validation and Evaluation (MARVEL) reactor will offer experimental capabilities that are not currently available at DOE’s national laboratories. The test bed will perform R&D on the fundamental features, operations, and behaviors of microreactor technologies and help industry partners quickly test, develop, and demonstrate their technologies. The liquid- metal cooled microreactor will produce energy using small amounts of high- assay, low-enriched uranium (HALEU) from available research materials. Its design is primarily based on existing technology and will be built using off-the- shelf components to the extent practical. The reactor will be built inside the Transient Reactor Test (TREAT) Facility Micro-Reactor Experiment Cell (T- REXC), a separate project governed by the requirements of FOR-684, “Transient Reactor Test (TREAT) Facility Micro-Reactor Experiment Cell (T REXC),” and outside the scope of this document.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1987

Analysis of closed cycle megawatt class space power systems with nuclear reactor heat sources

The analysis and integration studies of multimegawatt nuclear power conversion systems for potential SDI applications is presented. A study is summarized which considered 3 separate types of power conversion systems for steady state power generation with a duty requirement of 1 yr at full power. The systems considered are based on the following conversion cycles: direct and indirect Brayton gas turbine, direct and indirect liquid metal Rankine, and in core thermionic. A complete mass analysis was performed for each system at power levels ranging from 1 to 25 MWe for both heat pipe and liquid droplet radiator options. In the modeling of common subsystems, reactor and shield calculations were based on multiparameter correlation and an in-house analysis for the heat rejection and other subsystems.

Juhasz, A. J.↗
DOE OSTI2023

Magnetohydrodynamics in free surface liquid metal flow relevant to plasma-facing components

Abstract While flowing Liquid Metal (LM) Plasma-Facing Components (PFCs) represent a potentially transformative technology to enable long-pulse operation with high-power exhaust for fusion reactors, Magnetohydrodynamic (MHD) drag in the conducting LM will reduce the flow speed. Experiments have been completed in the linear open-channel LMX-U device [Hvasta et al 2018 Nucl. Fusion 58 01602] for validation of MHD drag calculations with either insulating or conducting walls, with codes similar to those used to design flowing LM PFCs for a Fusion Nuclear Science Facility [Kessel et al 2019 Fusion Sci. Technol . 75 886]. We observe that the average channel flow speed decreased with the use of conducting walls and the strength of the applied transverse magnetic field. The MHD drag from the retarding Lorentz force resulted in an increase of the LM depth in the channel that ‘piled up’ near the inlet, but not the outlet. As reproduced by OpenFOAM and ANSYS CFX calculations, the magnitude and characteristics of the pileup in the flow direction increased with the applied traverse magnetic field by up to 120%, as compared to the case without an applied magnetic field, corresponding to an average velocity reduction of ∼45%. Particle tracking measurements confirmed a predicted shear in the flow speed, with the surface velocity increasing by 300%, despite the 45% drop in the average bulk speed. The MHD effect makes the bulk flow laminarized but keeps surface waves aligned along the magnetic field lines due to the anisotropy of MHD drag. The 3D fringe field and high surface velocity generate ripples around the outlet region. It was also confirmed that the MHD drag strongly depends on the conductivity of the channel walls, magnetic field, and volumetric flow rate, in agreement with the simulations and a developed analytical model. These validated models are now available to begin to determine the conditions under which the ideal LM channel design of a constant flow speed and fluid depth could be attained.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Investigation of γ - ( U , Z r ) structural properties and its interfacial properties with liquid sodium using ab initio molecular dynamics

In this study, the elastic properties, structural parameters, sound velocity, and Debye temperature of γ–(U,Zr) were computed using ab initio molecular dynamics (AIMD) at temperatures between 1000 K and 1400 K and for Zr content between 0 at. % and 100 at. %. UZr is used as a metallic fuel for Sodium Fast Reactors (SFRs). The study of the mechanical and thermal behavior of these alloys leads to a better data-informed fuel design. The bulk modulus, shear modulus, Young's modulus, and Poisson's ratio were calculated from the elastic constants and their dependence on Zr content and temperature was investigated, comparing the results with previous computational work and the available experimental data in the literature. Interfacial properties between UZr (up to 32 at. % which typically exists in nuclear fuel) and liquid sodium are also of interest due to the presence of a sodium bond between the fuel and the cladding in metallic nuclear fuel. The interfacial energy between γ–(U,Zr) and liquid sodium, the surface tension of liquid sodium, and the work of adhesion were computed at different temperatures and Zr concentrations. It was demonstrated that γ–(U,Zr) is completely wetted by liquid sodium at all the investigated temperatures and Zr concentrations. Finally, this work provides the basis for the determination of interfacial resistances in SFRs and their implementation into heat transfer fuel performance simulations, which will be the subject of future work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Undercooling minimization in ultrasound coupled DTA measurements of molten salts

Molten salts are ionic liquids that are used for the electrolytic pyroprocessing of metals and as heat transfer fluids in very high temperature processes. Recently, halide-based molten salt reactors (MSR) have gained momentum for high density and environmentally responsible electricity generation. The function of these reactors and their fuel cycle depend on a knowledge of the halide salt’s thermodynamic properties [1]. Therefore, high accuracy phase equilibria of MSR relevant base halide and actinide containing salts are needed. Modern thermal analysis of the phase transitions of halide salts is usually done during heating at relatively high scan rates with commercial devices. Normally such measurements are adequate for pure or pseudo-binary salts. However, as the number of components in the mixture increases, accurately resolving the liquidus becomes increasingly difficult. Reversing the scanning mode greatly increases the sensitivity of phase transition measurements but can decrease accuracy due to undercooling [2] — a common occurrence in molten halide systems [3]. This work presents the development of a differential thermal analysis (DTA) cell intended for use in radiological gloveboxes. Non-contact ultrasonic agitation of the halide salt is implemented to limit kinetic limitations on crystallization during cooling to minimize undercooling [4]. Measurements on halide salts are also presented to elucidate the effect of non-contact mixing on undercooling. Reference [1] S. Boyd and C. Taylor, “3 - Chemical fundamentals and applications of molten salts,” in Molten Salt Reactors and Thorium Energy, T. J. Dolan, Ed., Woodhead Publishing, 2017, pp. 29–91. doi: 10.1016/B978-0-08-101126-3.00003-8. [2] K. Nitsch, A. Cihlár, and M. Rodová, “Molten state and supercooling of lead halides,” J. Cryst. Growth, vol. 264, no. 1, pp. 492–498, Mar. 2004, doi: 10.1016/j.jcrysgro.2004.01.011. [3] L. Rycerz, “Practical remarks concerning phase diagrams determination on the basis of differential scanning calorimetry measurements,” J. Therm. Anal. Calorim., vol. 113, no. 1, pp. 231–238, Jul. 2013, doi: 10.1007/s10973-013-3097-0. [4] Md. H. Zahir, S. A. Mohamed, R. Saidur, and F. A. Al-Sulaiman, “Supercooling of phase-change materials and the techniques used to mitigate the phenomenon,” Appl. Energy, vol. 240, pp. 793–817, Apr. 2019, doi: 10.1016/j.apenergy.2019.02.045.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Comparison of Approaches for CO 2 Sequestration as Solid Carbon Products

The growing global climate crisis linked to the rising atmospheric CO 2 levels calls for urgent and innovative solutions. Fixing CO 2 as valuable solid carbon products, such as carbon nanofibers or nanotubes (CNFs or CNTs), offers a promising way to potentially achieve net-negative CO 2 emissions. However, direct CO 2 -to-solid carbon faces significant thermodynamic and kinetic constraints, especially under mild reaction conditions. This mini-review compares three emerging approaches for CO 2 conversion into solid carbon: 1) using molten salt at high temperatures to produce CNFs or CNTs, 2) converting CO 2 to amorphous carbon with pyrophoric liquid metals at near room temperature, and 3) employing an electrocatalytic-thermocatalytic tandem process to produce CNFs at relatively mild temperatures. We examine the underlying principles, thermodynamic driving forces, and recent advances of each approach, and discuss the challenges and opportunities in catalyst development, reactor design, and energy management. We aim to highlight CO 2 fixation, facilitate net-negative CO 2 emissions, and stimulate more innovations for both environmental and economic benefits.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Microreactor Optimization Using Simulation And Economics (mouse)

Microreactor Optimization Using Simulation and Economics (MOUSE) is a tool that integrates both nuclear microreactor design and reactor economics to provide comprehensive evaluations and optimizations. This tool enables stakeholders to explore the interplay between technical and economic variables, guiding them towards effective and competitive microreactor solutions. For the reactor core simulations, MOUSE leverages the OpenMC Monte Carlo Particle Transport Code to perform detailed core simulations for various microreactor designs. The included OpenMC models are 2D core designs of a Liquid Metal Thermal Microreactor (LMTR), a Gas-Cooled TRISO-Fueled Microreactor (GCMR), and a Heat Pipe Microreactor. Beyond core design, MOUSE includes simplified calculations for: - Calculating the masses of heat exchangers within the system. - Mechanical power of pumps. - Estimating the area occupied by various buildings within the nuclear plant. For the economic analysis, MOUSE provides detailed bottom-up cost estimates, encompassing a wide range of costs including preconstruction costs, direct costs, indirect costs, training costs, financial costs, operation & maintenance (O&M) costs, and fuel costs. These cost estimations are developed using data from the MARVEL project and additional literature sources, enabling the calculation of total capital costs and levelized cost of energy for both first-of-a-kind and nth-of-a-kind microreactors. MOUSE also enables analysis of the cost drivers and competitiveness in the electricity market. MOUSE allows users to modify a wide array of technical and economic parameters to evaluate different scenarios and their impacts. Examples of these parameters include: Fuels, coolants, or reflector materials Enrichment levels Control drum materials and geometry Fuel pin geometry and materials Moderator pin geometry and materials Reactor core and reflector dimensions Packing factor for the TRISO particles Nuclear reactor power and reactor burnup Number of sensors Shielding thickness Reactor vessel and guard vessel dimensions Operational staff requirements Number of emergency shutdowns Levelization period Interest rate Construction duration Since MOUSE is powered by the WATTS toolkit, it supports optimization studies, parametric analyses, and uncertainty calculations/propagation. The optimization techniques enable users to identify optimal design and economic configurations. The parametric analysis tools allow users to explore the sensitivity of various parameters, while uncertainty propagation helps quantify the impact of uncertainties on overall performance and cost. User Interface and Workflow: Currently, MOUSE is a command-line-based tool. Users can input various reactor design or economic parameters, modify the designs, run simulations, and visualize results through comprehensive data visualization and reporting capabilities. The typical workflow involves setting up the reactor model, defining economic parameters, running simulations, and analyzing the results to make informed decisions. By combining advanced design calculations with detailed economic modeling, MOUSE provides a robust framework for optimizing nuclear microreactor technologies, enhancing their competitiveness, and guiding stakeholders towards innovative and cost-effective solutions.

Hanna, Botros [Idaho National Laboratory (INL), Id↗
DOE OSTI2024

Performance Investigation of High-temperature Latent Heat Storage for Integration with Advanced Nuclear Reactors

Integrating thermal energy storage (TES) with advanced nuclear reactors enhances the flexible use of nuclear energy, facilitating its expansion beyond conventional electricity generation. High-temperature TES, capable of storing heat above 400 degree C, emerges as a vital carbon-free energy solution for decarbonizing industrial sector, especially when combined with low-emission energy sources like advanced nuclear reactors. Idaho National Laboratory (INL) has recently developed a novel design for high-temperature latent heat storage system, called Heat pipe Integrated Thermal Battery (HITB), and efforts are underway to experimentally demonstrate the concept. HITB employs liquid-metal heat pipes to establish thermal linkage between TES and nuclear systems without direct fluid exchange, minimizing the potential risk of the integrated systems such as cross-contamination. HITB is designed to achieve high charging and discharging efficiency as well as high energy storage density by employing metal alloys as Phase Change Material (PCM). Initial proof-of-concept experiments are being undertaken using an aluminum alloy (Al59%-Mg35%-Zn6%). This paper discusses current progress of the HITB project at INL, seeking to develop high-temperature TES for versatile integration with advanced nuclear reactors, and shares insights from the performance evaluations via numerical modeling and analysis.

25 ENERGY STORAGE↗
DOE OSTI2021

Material Control & Accountancy for Molten Salt Reactors (FY2021 Report)

There is significant domestic and international interest, investment, and research and development momentum to pursue advanced nuclear reactor technologies. Molten salt reactor (MSR) concepts display the largest variability in fuel type and design features among the current advanced concepts. MSRs have been proposed with various core designs, sizes (power), and fuel cycles. Salt-fueled molten salt systems represent the only advanced reactor type with fuel that is not in a solid form during operation. These “liquid-fueled” MSRs are unique from perspectives of fuel fabrication, spent irradiated fuel and waste components, licensing, and material control and accountability (MC&A) including the potential of fissile material holdup. The liquid fuel salt is the defining distinction in comparison to other advanced reactors that propose TRI-structural ISOtropic particle fuel pebbles, various coolant options (e.g., molten salts or metals, high temperature gas), or small modular alternatives using solid fuel variants including both light water reactors and non-light water reactors. MSRs are appealing to the nuclear energy industry because of the diverse reactor characteristics they can support including various neutron energy spectra, fueling requirements, fuel cycles, and/or fuel utilization. However, because of the significant deviation and diversity of a salt-fueled system compared to traditional solid fuel light water-cooled reactors (LWRs), the history, regulatory licensing framework, modeling capabilities, and supporting engineering technology are either lacking or, in some cases, nonexistent. Therefore, the research community is actively supporting advanced MSR development on many of these fronts in particular to assist MSR vendors with licensing requirements. ORNL is leading the research and development of respective MC&A approaches for salt-fueled MSRs. This report summarizes the research performed at Oak Ridge National Laboratory (ORNL) under the US Department of Energy, Office of Nuclear Energy, Advanced Reactor Safeguards (ARS) program to investigate safeguards and security by design concepts, licensing and regulatory considerations, and dynamic system-level modeling to understand radioisotope concentrations for salt-fueled MSRs. The report builds upon the previous research and literature, identifies the MC&A challenges inherent to a salt-fueled MSR, reviews current regulatory frameworks for LWRs and their applicability towards salt-fueled MSRs, summarizes the status and progress of an MSR dynamic modeling tool, and discusses a prospective MC&A approach based on the Molten Salt Demonstration Reactor (MSDR) model.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Conceptual core design of the molten metal fueled microreactor with self-regulating capability

The microreactor concept has received significant attention in the United States for its lower capital investment, siting flexibility and high mobility. A microreactor aims to provide reliable electricity in remote communities, mining areas, or isolated islands, which will save the high fuel transportation cost. Thus, minimizing the staff level for operating and maintaining a microreactor is desirable. The objective of the study is to design a self-regulated Molten Metal fueled microReactor core (MMR) and to demonstrate the self-regulating capability of the MMR core. The control of the reactor is solely relying on reactivity feedbacks from fuel temperature perturbation. Molten UMn (liquid form at the temperature over 720°C) was utilized as the fuel material in MMR due to the larger thermal expansion coefficient compared to the conventional solid fuel. The MMR core has a fast neutron spectrum, which corresponds to a small burnup reactivity swing. The core design parameters were selected based on DAKOTA, REBUS, and ANLHTP calculations. The MMR is designed to run for 10 years at a power level of 15 MWth. Furthermore, no refueling is needed during the reactor lifetime. The system dynamic analyses were performed, and it was found that the reactor can be self-regulating within a temperature range of 800 ± 80°C for a loss of heat sink transient.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Exploring Fission–Fusion Synergies to Accelerate Compatibility Understanding

To address the significant commercial interest in fusion energy, it will be necessary to accelerate the compatibility research associated with liquid breeders including Li, eutectic Pb–Li and LiF-BeF 2 (FLiBe) molten salt. Particularly for FLiBe, compatibility understanding is limited especially for fusion relevant materials such as reduced activation ferritic-martensitic steels, SiC and V alloys. The historical knowledge associated with molten salt reactors (MSRs) and recent work to commercialize MSRs can benefit fusion research. Recent experimental and modeling work has improved understanding and this knowledge can be applied to fusion relevant materials. For liquid metals (LMs), the comparisons to Li and Pb–Li are less direct but nevertheless can help guide the pathway toward commercialization. For Pb–Li, Al-rich coatings have been shown to inhibit dissolution and potentially increase operating temperatures. For commercialization, the experience with sensors and on-line cleanup can help guide future developments. Thus, it is worth considering the potential for fission-related research with LMs and molten salts to help accelerate fusion research.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Simulation of Liquid Lithium Divertor Geometry Using SOLPS-ITER

Here, plasma-facing component (PFC) geometries are evaluated for a Fusion Nuclear Science Facility (FNSF) design to find solutions that are compatible with flowing liquid lithium components while satisfying requirements from the perspective of plasma and neutral particle transport. Flowing liquid metal (LM) divertor systems offer important advantages due to continual regeneration of the surface material, but may require modifications from standard optimized tokamak divertor designs. Scrape Off Layer Plasma Simulator for the International Thermonuclear Experimental Reactor (SOLPS-ITER) simulations are used to compare standard vertical target, open, and balanced baffled geometries. It is found that the open geometry offers little control of neutral particles and has narrow operating windows where the divertor fluxes can be lowered to acceptable levels, while maintaining the required upstream density. The addition of neutral baffles allows greater control over the divertor conditions with less impact on the upstream density. The divertor neutral pressure in the baffled geometry is slightly higher than the open divertor, but not as large with a vertical target. A first-pass coupling of the SOLPS solution with sheath and implantation/erosion models to compute the lithium emission shows that the lithium is largely confined to the near-surface region due to the small ionization mean free path and large main ion flow toward the surface. The lithium source was varied by three orders of magnitude. At the highest rate, when the sourced lithium approaches the level of the main ion recycling flux, a high core lithium concentration (~10%) is observed with only moderate power dissipation to affect the divertor plasma.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Monitoring of Temperature Measurements for Different Flow Regimes in Water and Galinstan with Long Short-Term Memory Networks and Transfer Learning of Sensors

Temperature sensing is one of the most common measurements of a nuclear reactor monitoring system. The coolant fluid flow in a reactor core depends on the reactor power state. We investigated the monitoring and estimation of the thermocouple time series using machine learning for a range of flow regimes. Measurement data were obtained, in two separate experiments, in a flow loop filled with water and with liquid metal Galinstan. We developed long short-term memory (LSTM) recurrent neural networks (RNNs) for sensor predictions by training on the sensor’s own prior history, and transfer learning LSTM (TL-LSTM) by training on a correlated sensor’s prior history. Sensor cross-correlations were identified by calculating the Pearson correlation coefficient of the time series. The accuracy of LSTM and TL-LSTM predictions of temperature was studied as a function of Reynolds number (Re). The root-mean-square error (RMSE) for the test segment of time series of each sensor was shown to linearly increase with Re for both water and Galinstan fluids. Using linear correlations, we estimated the range of values of Re for which RMSE is smaller than the thermocouple measurement uncertainty. For both water and Galinstan fluids, we showed that both LSTM and TL-LSTM provide reliable estimations of temperature for typical flow regimes in a nuclear reactor. The LSTM runtime was shown to be substantially smaller than the data acquisition rate, which allows for performing estimation and validation of sensor measurements in real time.

Pantopoulou, Stella↗
DOE OSTI2023

Multi-Sourced Collaboration for the Production and Refining of Rare Elements and Critical Metals (Final Technical Report)

The project objective was to develop a feasible and cost-effective method for recovering rare earth elements (REEs) and critical materials (CMs) from coal and coal byproducts, resulting in high-purity individually separated REEs and CMs. The targeted REEs included Y, Pr, Nd, Gd, Dy, and Sm, with a purity of over 99.5%, while the CMs included Co, Mn, Ga, Sr, Li, Ni, Zn, and Ge, with a purity of over 90%. The project aimed to design a prototype facility capable of producing 1-3 tonnes/day of high-purity REO mixes. The work was divided into four designated circuits: 1) REE extraction and concentration, 2) REE separation and purification, 3) RE metal production, and 4) CM production. To achieve these goals, the project involved 11 tasks, including technology reviews, research, process flow diagram development, mass balance estimation, and preliminary technical-economic analysis. The project team included researchers from the University of Kentucky, University of Alabama and Virginia Tech as well as process specialists from Argonne National Laboratory. MP Materials provided technical support regarding rare earth markets and processing while Alliance Coal performed resource assessment. The project included a market analysis for Nd/Pr, Tb, Dy, Gd, Y, Co, Mn, Li, Sr, Ga, Ni, Zn, and Ge. These analyses provided insights into the supply and demand trends as well as historic and future projections of market price relative to purity requirements for these elements. Two coal resources were selected for the project: the West Kentucky No. 13 (Baker) Seam and an undisclosed lignite resource in the Illinois coal basin. The estimated quantities of REEs in these resources were calculated based on production samples and drilling data. It was estimated that there is adequate supply for an operation producing one metric ton daily of higher purity mixed rare earth oxides (MREO) for approximately 20 years at a site located in western Kentucky. In Circuit 1, project data was obtained from a pilot heap leach and REE concentration facility. It was concluded that the existing circuit, which generated a MREO concentrate, two types of CM mixed products, and Li- and Sr-containing waters, would be suitable feed for circuits 2-4. Data from the first-of-its-kind coal coarse refuse heap leach pilot pad played a crucial role in estimating reliable elemental concentrations of the pregnant leaching solution (PLS). The average total REE concentration in the PLS was found to be 28.6 ppm. In Circuit 2, several concepts were explored including a novel process referred to as solvent-assisted chromatography (SAC). This concept involved a novel columnar reactor that incorporated multiple mixer/settlers, thereby enabling the operation of counter-flowing aqueous and organic phases. Unfortunately, due to project time constraints, a complete fundamental modeling analysis could not be completed to fully evaluate the technology. Molten salt electrowinning was considered as an alternative for circuit 3 following circuit 2 purification circuit utilizing the novel SAC process. A mass and energy balance of Nd reduction to metal in a fluoride containing molten salt electrolyte was conducted. Comparisons were made with the current state of Asian molten salt electrorefining, and potential improvements in siphoning rare earth metals (REM) from the reactor were presented. A cost estimate was performed for the production of 1 tonne per day, which yielded a total of $2.29 million for the nine electrowinning (EW) cells required. The selected option for circuits 2 and 3 was a plasma distillation process, which initially separates rare earth elements (REEs) from other elements. This is followed by selective electrowinning in various ionic liquids. The selection was made on the basis of thermodynamic modeling and experimental data previously published by a project partner. The combination offers an innovative approach to integrated refining and RE metal production. For Circuit 4, an extensive literature review was conducted for the processing of the CMs. The ultimate decision was to utilize a combined plasma and ionic liquid process as well to produce individual high-purity concentrates of Zn, Ni, Co, Mn, and Mg. A separate flowsheet for Li and Sr was recommended, which would yield carbonates of these elements. Due to the lack of suitable experimental data at this time, a process recommendation could not be provided but several methods have been proposed for consideration. Lastly, a techno-economic analysis (TEA) was conducted to assess the effectiveness of the proposed process for further investigation. The TEA results revealed a capital expense (CapEx) of $737 million and an annual operational expense (OpEx) of $220 million. Due to the selected elements, the hypothetical heap leach pad can produce 1 metric tonne per day of REO equivalent, but a conscious decision was made to only treat targeted REEs, resulting in the production of 0.4 metric tonne of REM. An estimated annual revenue of $90.87 million was projected based on standard market pricing information provided by the funding agency. During the TEA, ten different modules were evaluated for costing purposes. The precipitation circuit was identified as the largest single operational expense, followed by the Mg/Mn process due to the amount of treated metal. In terms of capital expenditures, the heap leach process incurred the highest cost, followed by the Mg/Mn process. The scalability of the plasma process is a crucial consideration since the reactors cannot be scaled beyond the largest demonstrated size due to their reliance on surface area of the slag and vapor phase. The purity estimate for the REEs are generally 98%±2% to produce a metal. The purity level being lower than the project objective was due to the lack of specific experimental data needed to tighten the tolerance of the estimates. Based on literature and previous experience, the CMs are estimated as follows; Ga (95%+, metal), Sr (95%+, carbonate), Li (95%+, carbonate), Ni (98%±2%, metal), Zn (95%+, metal sponge), Ge (95%+, metal), Co (98%±2%, metal), and Mn (98%±2%, metal).

01 COAL, LIGNITE, AND PEAT↗