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DOE OSTI2023

Design of Multi-Stage Solvent Extraction Process for Separation of Rare Earth Elements

Flowsheet design and stage determination for the separation of rare earth elements (REEs) using solvent extraction (SX) is a challenging task because of the chemical similarity of the REEs. Low separation factors between the elements and complex equilibrium chemistry provide unique challenges to designing an efficient flowsheet for the separation of elements. The multi-stage nature of the SX process adds further complexity, making the assessment of products for a proposed design and stage combination difficult. Therefore, to develop a SX flowsheet, it is essential to quantify the performance for various design and separation conditions. This paper attempts to address the challenge by utilizing an equilibrium and process modeling approach. Results from a bench-scale study performed on a 10 g/L rare earth salt mixture were used in studying the extraction/stripping behavior and developing equilibrium models. DEHPA with TBP as a phase modifier was used as an extractant, while hydrochloric acid was utilized as a stripping agent. The results obtained were used in developing extraction/stripping models, which were integrated into a process framework of a SX train in a Matlab/Simulink environment. The models were programmed as a function block routine and used for developing a flowsheet, which was simulated for differing separation and design conditions. To identify optimum stage combinations, a particle swarm optimization (PSO) routine was developed and implemented for each SX train. Recovery and purity of elements of interest were used as objective function criteria. The stage combination leading to the minimization of the objective function was used to identify the optimum stage combination for a series of SX trains to attempt a balance of purity and recovery. The models and optimization method were implemented to separate a feed mixture containing REEs, which indicated that 99.52 and 85.41 percent purity is achievable for Yttrium and Lanthanum separation using 8-12-3 and 10-3-5 stage combination for loading, scrubbing, and striping. The model also indicated difficult separability between neodymium, praseodymium, and cerium.

Srivastava, Vaibhav (ORCID:0000000212645987)↗

DOE OSTI2020

Methods and materials for determination of distribution coefficients for separation materials

Methods and materials for determining the affinity of separation materials for targeted species are described. A composite separation medium is described that combines a separation material such as an ion exchange material or a sorbent with an SERS substrate. Methods and materials can be utilized to determine the distribution coefficient of a species for a separation material after running a single separation protocol followed by examination of the separation material of the protocol according to SERS. Disclosed methods can be utilized to determine the affinity of existing separation materials for targeted species as well as to determine the affinity of newly engineered separation materials to characterize species.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Separator Effect on Zinc Electrodeposition Behavior and Its Implication for Zinc Battery Lifetime

We report uncontrolled zinc electrodeposition is an obstacle to long-cycling zinc batteries. Much has been researched on regulating zinc electrodeposition, but rarely are the studies performed in the presence of a separator, as in practical cells. Here, we show that the microstructure of separators determines the electrodeposition behavior of zinc. Porous separators direct zinc to deposit into their pores and leave “dead zinc” upon stripping. In contrast, a nonporous separator prevents zinc penetration. Such a difference between the two types of separators is distinguished only if caution is taken to preserve the attachment of the separator to the zinc-deposited substrate during the entire electrodeposition–morphological observation process. Failure to adopt such a practice could lead to misinformed conclusions. Our work reveals the mere use of porous separators as a universal yet overlooked challenge for metal anode-based rechargeable batteries. Countermeasures to prevent direct exposure of the metal growth front to a porous structure are suggested.

25 ENERGY STORAGE↗

DOE OSTI2022

Separating Oil-Water Mixtures Using Bump Arrays

Particle separation is an important process step across many fields. One technique being applied for separating solids such as blood components or sand particles from carrier fluids is the use of arrays of aligned posts called deterministic lateral arrays to bump particles to one side in the flow stream to enhance separation. This technique may be useful for separation of deformable particles. The ability to efficiently separate two-phase industrial (oil/water) mixtures is key for future use of valuable resources. Over 1 trillion gallons of petroleum production water could be reclaimed annually for reuse in the drought-ridden western US states. The ability to reclaim this petroleum production water may be critical for the Central High Plains (Colorado, Kansas, Oklahoma, Texas, and New Mexico). Trends in just the High Plains area already lost 20 to 25% of the irrigated farming area due to insufficient ground water storage to irrigate, and farmland losses are expected to grow to 40%. Proving this technology is key to reuse of petroleum production water for crop irrigation or to replace water from currently failing aquifers in rich agricultural lands of the Central High Plains. We conducted experiments applying mesofluidic separation for flowing two-phase (oil/water) mixtures. Experiments were conducted using oils of differing viscosities with water as the carrier fluid; separation was achieved over a range of oil-water concentrations. We describe the results of these experiments in this paper.

oil-water separation, micelle, droplet separation,↗

DOE OSTI2023

Simple Bioparticle Filtration Device Based on an Ultralow-Fouling Zwitterionic Polyurethane Membrane for Rapid Large-Volume Separation of Plasma and Viruses from Whole Blood

Plasma separation from whole blood is oftent required as an essential first step when performing blood tests with a viral assay. However, developing a point-of-care plasma extraction device with a large output and high virus recovery remains a significant obstacle to the success of on-site viral load tests. Here, we report a portable, easy-to-use, cost-efficient, membrane-filtration-based plasma separation device that enables rapid large-volume plasma extraction from whole blood, designed for point-of-care virus assays. The plasma separation is realized by a low-fouling zwitterionic polyurethane-modified cellulose acetate (PCBU-CA) membrane. The zwitterionic coating on the cellulose acetate membrane can decrease surface protein adsorption by 60% and increase plasma permeation by 46% compared with a pristine membrane. The PCBU-CA membrane, with its ultralow-fouling properties, enables rapid plasma separation. The device can yield a total of 1.33 mL plasma from 10 mL whole blood in 10 min. The extracted plasma is cell-free and exhibits a low hemoglobin level. In addition, our device demonstrated a 57.8% T7 phage recovery in the separated plasma. The results of real-time polymerase chain reaction analysis confirmed that the nucleic acid amplification curve of the plasma extracted by our device is comparable to that obtained by centrifugation. With its high plasma yield and good phage recovery, our plasma separation device provides an excellent replacement for traditional plasma separation protocols for point-of-care virus assays and a broad spectrum of clinical tests.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Important Role of Ion Flux Regulated by Separators in Lithium Metal Batteries

Abstract Polyolefin separators are the most common separators used in rechargeable lithium (Li)‐ion batteries. However, the influence of different polyolefin separators on the performance of Li metal batteries (LMBs) has not been well studied. By performing particle injection simulations on the reconstructed three‐dimensional pores of different polyethylene separators, it is revealed that the pore structure of the separator has a significant impact on the ion flux distribution, the Li deposition behavior, and consequently, the cycle life of LMBs. It is also discovered that the homogeneity factor of Li‐ion toward Li metal electrode is positively correlated to the longevity and reproducibility of LMBs. This work not only emphasizes the importance of the pore structure of polyolefin separators but also provides an economic and effective method to screen favorable separators for LMBs.

25 ENERGY STORAGE↗

DOE OSTI2025

Nanofiltration Membranes for Li + /Mg 2+ Separation: Materials and Mechanisms

Nanofiltration (NF) membranes have garnered significant interest for Li + /Mg 2+ separation, a crucial step in lithium extraction from brines. The state-of-the-art commercial LiNE-XD membrane exhibits a Li + /Mg 2+ separation factor (SF Li/Mg ) of 42 at pH 3.3, due to the positive charges on the membrane surface and its strong size-sieving ability. Membranes with higher separation factors at a broad pH range are being pursued to improve separation efficiency. This work aims to provide a timely and comprehensive assessment of advanced NF membranes with superior Li + /Mg 2+ separation properties, as well as their structure and property relationships for designing next-generation membranes. We describe transport mechanisms for ions in NF membranes and discuss governing parameters and models employed to quantify the Li + /Mg 2+ separation. High-performance membrane materials are exhaustively introduced, including commercial and modified polyamides, two-dimensional materials, metal–organic frameworks, crown ethers, and their blends. Finally, we critically compare these membranes in an upper bound plot and highlight the opportunities and challenges of NF membranes for practical Li + /Mg 2+ separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Unconventional desalination: The use of cyclone separators in HDH desalination to achieve zero liquid discharge

Research in water desalination technologies is constantly growing to meet global demands for freshwater. Though acting to meet these demands, the rapid growth and spread of desalination technologies poses environmental issues due to the increasing brine concentrates that are ultimately discharged back to nature. This article presents a cyclone separator to transform a humidification-dehumidification (HDH) cycle to a dual-product cycle to produce freshwater and solid salt crystals for highly saline streams. A desalination cycle equipped with a cyclone separator is used to treat water with 3.5%–81% salinity. The separation efficiency is well above 99% and can produce potable water from hyper saline feed in a once-through process. Further, the cyclone separator performance was tested under different conditions including humidity ratios, relative humidities, and feed stream's salinities. The cyclone separator is self-cleaning and overcomes salt scaling. This behavior is a direct function of the walls' temperature and the carrier air dew point. Self-cleaning capability allows the cyclone separator to treat feed water of extreme salinities (up to 810,000ppm) down to freshwater salinity with zero liquid discharge. The cyclone separator was utilized in a novel HDH desalination technology to treat different salinities. The product was freshwater of salinity <500ppm.

42 ENGINEERING↗

DOE OSTI2020

On electrolyte wetting through lithium-ion battery separators

The wettability by electrolyte is a critical characteristic of lithium-ion battery separators since electrolyte absorption is essential for ionic transport. Most importantly, fast absorption of electrolyte facilitates the electrolyte filling and wetting processes during the battery assembly. However, theoretical or experimental investigation of separator wettability has rarely been reported, and thus very little quantitative data can be found in the existing literature. Here, innovative experimental techniques and associated analytical models have been developed to fully characterize the electrolyte wetting behavior through battery separators. Both in-plane and through-plane imbibition processes are investigated. The results show that, electrolyte needs significantly longer time to wet separators than it does for commercial electrodes. The wetting rate depends significantly on the pore size, porosity, and micro-structure of the separators. Electrolyte in-plane wetting is only observed in the separators manufactured by the wet process. Increasing separator porosity and pore size is shown to be substantially increasing through-plane wetting rate. In addition, ceramic coating is shown to increase in-plane wetting but retard through-plane wetting.

25 ENERGY STORAGE↗

DOE OSTI2024

Toward sustainable electrochemically mediated separations driven by renewable energy

Environmental pollution, water scarcity, resource shortage, and fossil fuel reliance have all represented threats to a sustainable future. Separation processes play a pivotal role in improving sustainability in fields such as industrial processes, resource recycling, wastewater treatment, and water desalination, among others. Electrochemical systems have gained increased attention as effective separation platforms, not only in performance but also as a potentially energy-efficient approach. However, the reliance on non-renewable energy sources, such as fossil fuels, for electricity generation limits the advancement toward a fully sustainable separation process. Integration of separation processes with eco-friendly renewable energy sources can increase overall sustainability and decrease carbon footprint. Here, in this review, we provide an overview of electrochemical separations and recent efforts to integrate them with renewable energy sources such as heat and solar energy. We discuss electrochemical separations, including electrosorption and electrodialysis, and research to transition these processes to thermoelectrochemical (TEC) and photoelectrochemical (PEC) platforms. Finally, we discuss current challenges and future prospects in direct integration of renewable energy sources with separation processes.

electrochemistry↗

DOE OSTI2017

Mechanical behavior and failure mechanisms of Li-ion battery separators

We determine and compare anisotropic mechanical properties for three types of commercially available Li-ion battery separators: Celgard 2325, Celgard PP2075 dry-processed polymer separators, and DreamWeaver Gold 40 non-woven separator. Significant amount of anisotropy of properties was determined, with the Young's modulus being different by up to a factor of 5 and ultimate strength being different by a factor of 10 between orthogonal directions within a polymer separator layer. Strain rate sensitivity was investigated by applying strain rates ranging from 1•10 -4 s -1 to 0.1 s -1 . Significant strengthening was observed and the strain rate strengthening coefficients were determined for both elastic modulus and yield stress in case of polymer separators. Digital image correlation technique was used to measure and map the strains over the specimen's gage section. A significant strain concentration in bands running perpendicular to the tensile axis was observed in polymer separator samples oriented in transverse direction. Such localized necking allows for extremely high strains close to 300% to develop in the material. Furthermore, the failure mode was remarkably different for all three types of separators which adds additional variable in safe design of Li-ion batteries for prevention of internal short circuits.

25 ENERGY STORAGE↗

DOE OSTI2017

Strain distribution and failure mode of polymer separators for Li-ion batteries under biaxial loading

Deformation of polymer separators for Li-ion batteries has been studied under biaxial tension by using a dome test setup. This deformation mode provides characterization of separator strength under more complex loading conditions, closer representing deformation of an electric vehicle battery during crash event, compared to uniaxial tension or compression. Two polymer separators, Celgard 2325 and Celgard 2075 were investigated by deformation with spheres of three different diameters. Strains in separators were measured in situ by using Digital Image Correlation (DIC) technique. The results show consistent rupture of separators along the machine direction coinciding with areas of high strain accumulation. The critical first principal strain for failure was independent of the sphere diameter and was determined to be approximately 34% and 43% for Celgard 2325 and Celgard 2075 respectively. These values can be taken as a criterion for internal short circuit in a battery following an out-of-plane impact. A Finite Element (FE) model was built with the anisotropic description of separator behavior, derived from tensile tests in orthogonal directions. In conclusion, the results of simulations predicted the response of separator rather well when compared to experimental results for various sizes of rigid sphere.

25 ENERGY STORAGE↗

DOE OSTI2021

Al 2 O 3 /TiO 2 coated separators: Roll-to-roll processing and implications for improved battery safety and performance

Heat generation is one of the major concerns with lithium-ion batteries (LIB) while charging them at higher currents, which could inadvertently impact the rate performance and reduce the safety of the cell. Polymer separator is one of the least thermal conductive components of a LIB. In addition, commercial separators for LIB are made from polyolefin membranes that tend to shrink and curl at higher temperatures due to their lower melting temperature (~130 °C). Developing separators with improved thermal stability and higher electrolyte uptake is essential for enhancing the safety as well as the performance of the LIB. In this work, a thin layer of ceramic coatings (Al 2 O 3 and TiO 2 ) is applied on propylene (PP) membrane to improve the thermal stability and electrolyte affinity without compromising the rate performance. A slurry with 100% Al 2 O 3 coated on the polypropylene separator exhibited the best improvement in thermal stability ( shrinkage of 0.6% vs 6.0% for uncoated membrane) and excellent rate performance with 92% capacity retention at 2C. The Al 2 O 3 coated separator demonstrated excellent electrolyte wettability compared to the uncoated membrane. The cross-plane thermal conductivity of the ceramic coated separators is analyzed to understand their heat transfer behavior. The thermal conductivity of the separator is improved by ~3.2 times with the Al 2 O 3 coating.

25 ENERGY STORAGE↗

DOE OSTI2024

Static and Dynamic Thermomechanical Properties of Phase-Separated Epoxy Networks with Tuned Microstructures

Here, polymerization-induced phase separation is a useful method for the construction of heterogeneous epoxy networks with properties exceeding their homogeneous counterparts. In this work, we examine the static and dynamic thermomechanical properties of phase-separated epoxy networks salient to their application as encapsulants. Three heterogeneous epoxy-amine networks with nano-, meso-, and macro-phase-separated morphologies comprised of hard and soft domains are compared to a rigid, unstructured network. The glass transition profiles of the heterogeneous networks are complex, spanning many decades in the frequency domain. The nanophase-separated morphology leads to higher coefficient of thermal expansion, yet surprisingly is characterized by reduced residual stress. Under both quasi-static and dynamic compression (strain rates of order 10 –3 and 10 3 s –1 , respectively), the nanophase-separated network also exhibits higher modulus and strength. In split-Hopkinson bar experiments, the energy dissipation characteristics of the epoxy networks were nearly identical. Curiously, however, the Hugoniot response of the macro-phase-separated network determined by ballistic shockwave analysis indicates a remarkable ability of this material to mitigate shockwave propagation in comparison to many homogeneous and heterogeneous polymer materials. Collectively, this work reveals several previously unreported phenomena with respect to structure–property relationships in phase-separated epoxy networks, illustrating the potential value of systematically tuned microstructures for optimization of application-specific physical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Supramolecular Assembly of Lanthanide-Binding Tag Peptides for Aqueous Separation of Rare Earth Elements

Selective and eco-friendly separation and purification methods for rare earth elements (REEs) are necessary to meet the increasing demand for these valuable metals, which are extensively used in modern electronics and clean energy technologies. Mining feedstocks consist of REE mixtures as stable trivalent cations (Ln 3+ ) that are difficult to separate due to their identical charge and similar size. Lanthanide-binding tags (LBTs), peptide chelates that coordinate Ln 3+ in binding pockets, show promise as selective, high-affinity extractants. We demonstrate that the LBT variant LBTLLA 5– , designed for high selectivity for Tb 3+ , is an effective extractant, forming complexes with REEs in solution that subsequently organize into self-assembling structures rich in Ln 3+ . These structures condense into aggregates that can be separated, enabling an efficient, all-aqueous, eco-friendly separation process. The self-assembled structures are studied using dynamic light scattering, ζ-potential measurements, transmission electron microscopy, anomalous small-angle X-ray scattering, inductively coupled plasma optical emission spectroscopy, and ultraviolet–visible absorption spectroscopy, which confirm LBTLLA 5– peptide-REE ion binding and the further assembly of micron-scale structures rich in REEs. Molecular dynamics simulations reveal the interactions promoting aggregation as well as the integrity of the binding pocket upon self-assembly. We find that LBTLLA 5– :Ln 3+ complexes recruit excess cations within the macrostructures, and we demonstrate that aggregation and selective separation can be controlled by manipulating the metal-peptide ratio in solution. Furthermore, we demonstrate separation from equimolar mixtures of REE pairs Tb 3+ -Lu 3+ and Tb 3+ -La 3+ , supporting the application of LBT peptides as a platform for the selective separation of REEs.

LBT peptides↗

DOE OSTI2022

Modeling Isotope Separation in Electrochemical Lithium Deposition

Naturally occurring Li consists of two stable isotopes, 6 Li with an abundance of about 7.5%, and 7 Li making up the remainder with 92.5%. The development of a 6 Li enrichment technique, in terms of technical reliability and environmental safety to reach 6 Li future requirements, represents a key step in the roadmap for nuclear fusion energy supply worldwide. This paper uses finite element analysis-based models to simulate electrochemical Li isotope separation, which is an attractive method in terms of simplicity, safety, and scalability. In the model, we quantitatively analyze how different electrochemical factors including thermodynamics, charge-transfer kinetics, and diffusivities affect the separation process (separation factor), together with cell parameters, such as cell length and current density. The maximum separation factor of 1.128 could be obtained with the cell under the optimal thermodynamic, kinetic, and diffusive conditions, which is among the highest separation factors ever reported. Furthermore, these results will assist in designing the actual isotope separation setup with large separation factor and appropriate timing for sample collection.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2018

Surface-Engineered Inorganic Nanoporous Membranes for Vapor and Pervaporative Separations of Water–Ethanol Mixtures

Surface wettability-tailored porous ceramic/metallic membranes (in the tubular and planar disc form) were prepared and studied for both vapor-phase separation and liquid pervaporative separations of water-ethanol mixtures. Superhydrophobic nanoceramic membranes demonstrated more selective permeation of ethanol (relative to water) by cross-flow pervaporation of liquid ethanol–water mixture (10 wt % ethanol feed at 80 °C). In addition, both superhydrophilic and superhydrophobic membranes were tested for the vapor-phase separations of water–ethanol mixtures. Porous inorganic membranes having relatively large nanopores (up to 8-nm) demonstrated good separation selectivity with higher permeation flux through a non-molecular-sieving mechanism. Due to surface-enhanced separation selectivity, larger nanopore-sized membranes (~5–100 nm) can be employed for both pervaporation and vapor phase separations to obtain higher selectivity (e.g., permselectivity for ethanol of 13.9 during pervaporation and a vapor phase separation factor of 1.6), with higher flux due to larger nanopores than the traditional size-exclusion membranes (e.g., inorganic zeolite-based membranes having sub-nanometer pores). The prepared superhydrophobic porous inorganic membranes in this work showed good thermal stability (i.e., the large contact angle remains the same after 300 °C for 4 h) and chemical stability to ethanol, while the silica-textured superhydrophilic surfaced membranes can tolerate even higher temperatures. These surface-engineered metallic/ceramic nanoporous membranes should have better high-temperature tolerance for hot vapor processing than those reported for polymeric membranes.

09 BIOMASS FUELS↗

DOE OSTI2025

Interphase Engineering Enabled by Using a Separator with Electrochemically Active Carbazole Polymers for Lithium-Ion Batteries

Separators are generally considered inert components in lithium-ion batteries. In the past, some electroactive polymers have been successfully applied in separator modifications for overcharge protection or as acid scavengers. This study highlights the first use of two “electroactive” carbazole polymers (copolymer 9-phenyl-9H-carbazole-phenyl [PCP] and poly(9-vinylcarbazole) [PVC]), which were each applied separately as coatings on the cathode-facing side of commercial Celgard 2325 separators, respectively, to enhance the cycling performance of 0.3Li 2 MnO 3 ·0.7LiMn 0.5 Ni 0.5 O 2 //graphite (LMR-NM//Gr) full cells through interphase engineering. The team observed an irreversible polymer oxidation process of the carbazole-functionalized polymers—occurring only during the first charge—for the modified separator cells, and the results were confirmed by dQ/dV analysis, cyclic voltammetry measurements, and nuclear magnetic resonance characterizations. During this oxidation, carbazole polymers participate in the process of interphase formation, contributing to the improved cycling performance of LMR-NM//Gr batteries. Particularly, oxidation takes place at voltages of ~4.0 and ~3.5 V when PCP and PVC are used as separator coatings, which is highly irreversible. Further postmortem examinations suggest that the improvements using these modified separators arise from the formation of higher-quality and more inorganic SEI, as well as the beneficial CEI enriched in LixPOyFz. These interphases effectively inhibit the crosstalk effect by reducing TM dissolution.

carbazole↗