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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Impact of Modifications in Continuous Recycling System for U/Pu and U/TRU with Fast and Thermal Reactors on Fuel-Cycle Performance and Waste Characterization

This paper studies the impact of modifications in continuous U/Pu and U/TRU recycling systems on fuel-cycle performance and waste characterization. The continuous recycling systems considered in this paper are multi-stage scenarios consisting of sodium-cooled fast reactors (SFR) and mixed-oxide (MOX) fueled pressurized water reactors (PWR). The study was performed by introducing a series of fuel-cycle cases that slightly differ in their fuel-cycle scenarios, core designs, and types of heavy metals (HM) recycled (Pu or TRU). The major exchange in the fuel-cycle scenarios considered here occurs in the PWR-MOX stage such that one set of cases recycles its discharged Pu/TRU and fabricate MOX fuel by topping Pu/TRU recovered from SFR blankets, and the other uses only recovered Pu/TRU from SFR blankets, and its discharged Pu/TRU is sent to SFR metallic fuel fabrication. All analyses performed in this paper also take into account 1% of annual growth in electric power production. Therefore, the design of reactor cores and fuel-cycle systems must be able to produce additional Pu/TRU in order to cover additional reactors built for the 1% growth in each year.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Self Configuring Digital Twin for Optimizing E-Waste Recycling

Electronic waste recycling industry needs a decision support tool for optimizing their processes to become cost competitive. We developed a software called CMAT, Comprehensive Manufacturing Assessment Tool. The aim of CMAT is to provide the e-waste recycling companies with a fully customizable decision support framework that analyzes the optimal supply chain configurations. The software optimizes the logistics operations, helps to identify the best recycling process configuration, and generates valuable insights regarding the economic performance of different categories of e-waste. The ultimate purpose of the tool is to assist the users developing a digital twin of their processes and to provide insights on questions pertinent to the e-waste recycling industry including how to increase efficiency and reduce costs, energy consumption, and greenhouse gas emissions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Effectiveness of actinide management in fast reactors over a finite recycling period - 15123

Long-lived nuclear waste primarily consists of transuranic (TRU) isotopes. Full recycling of TRU isotopes can, in theory, lead to a reduction in repository radiotoxicity to reference levels in as little as ∼500 years provided reprocessing and fuel fabrication losses are limited. However, over a limited time frame, the radiotoxicity of the 'final' core can dominate over reprocessing losses, leading to a much lower reduction in radiotoxicity compared to that achievable at equilibrium. In this paper, the fuel cycle code ORION is used to model the recycle of light water reactor (LWR)-produced TRUs in sodium-cooled fast reactors (SFRs). With full actinide recycling, at least 6 generations of SFRs are required in a gradual phase-out of nuclear power to achieve transmutation performance approaching the theoretical equilibrium performance. Break-even SFRs are much less effective from a point of view of reducing waste radiotoxicity. Thorium (Th)-burner fuel cycles are found to result in slightly lower radiotoxicity than U-burner fuel cycles for the same number of generations. Closed break-even Th fuel cycles require ∼3 generations of operation before their waste radiotoxicity benefits result in decay to the reference level in ∼1000 years, provided that Pa is recycled. While this is a very long time frame, it is substantially better than the time frame required by other strategies. The integrated decay heat over the scenario time frame is substantially higher for break-even Th-SFRs than break-even U-SFRs as a result of much higher {sup 90}Sr production. As decay heat affects repository sizing, this weakens the argument for the Th cycle. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Optimization of Material Recycling During the Decommissioning Process of Nuclear Power Plants - 16123

The German Government decided in 2011 to phase out nuclear power. Therefore, in the near future there will be several nuclear power plants queued up, in parallel, for dismantling. In nuclear decommissioning there is no standardized procedure available, so that a high level of optimization potential can be assumed. We present the results of a preliminary study, in which the optimization potential of metal recycling during the dismantling process should be estimated. The project can be roughly divided into four sections: - Determination of the metal inventory of an exemplarily selected plant; - Analysis of the recycling routes of scrap metal fractions and assessment of the potential for optimization of each process step during the dismantling; - Conduction of activation calculations to uncover the potential of interim storage allowing for radioactive decay; - In collaboration with the Institute of Process Metallurgy and Metal Recycling at the RWTH Aachen, appropriate process steps and process chains of an optimized metal recycling for each of the resulting scrap metal fractions are identified. The paper and the presentation summarize the status and the results of the project implementation and will address for the optimization potentials for decommissioning projects. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Direct Recycling of Spent NCM Cathodes through Ionothermal Lithiation

Ionic liquids (ILs) are a family of nonconventional molten salts that offer many advantages, such as negligible vapor pressures, negligible flammability, wide liquidus ranges, good thermal stability, and much synthesis flexibility. The unique solvation environment of these ILs provides new reaction or flux media for controlling formation of solid-state materials with a minimum perturbation of morphologies. A successful lithiation via ionothermal synthesis using a cost-effective Li halide as Li source and recyclable ILs as solvents is reported in this study for the direct recycling of LiNi 1/3 Co 1/3 Mn 1/3 O 2 (NCM 111) cathodes. In addition, the ionic liquids can be readily recycled and reused after ionothermal lithiation. The lithiation of spent cathodes can enable the direct recycling of spent cathode materials in lithium-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2024

Closed‐Loop Recycling of Mixed Plastics of Polyester and CO 2 ‐Based Polycarbonate to a Single Monomer

Abstract Physical blending is an effective strategy for tailoring polymeric materials to specific application requirements. However, physically blended mixed plastics waste adds additional barriers in mechanical or chemical recycling. This difficulty arises from the intricate requirement for meticulous sorting and separation of the various polymers in the inherent incompatibility of mixed polymers during recycling. To overcome this impediment, this work furthers the emerging single‐monomer – multiple‐materials approach through the design of a bifunctional monomer that can not only orthogonally polymerize into two different types of polymers – specifically lactone‐based polyester and CO 2 ‐based polycarbonate – but the resultant polymers and their mixture can also be depolymerized back to the single, original monomer when facilitated by catalysis. Specifically, the lactone/epoxide hybrid bifunctional monomer (BiL O ) undergoes ring‐opening polymerization through the lactone manifold to produce polyester, PE(BiL O ), and is also applied to ring‐opening copolymerization with CO 2 , via the epoxide manifold, to yield polycarbonate, PC(BiL O ). Remarkably, a one‐pot recycling process of a BiL O ‐derived PE/PC blend back to the constituent monomer BiL O in >99 % selectivity was achieved with a superbase catalyst at 150 °C, thereby effectively obviating the requirement for sorting and separation typically required for recycling of mixed polymers.

Shi, Changxia↗
DOE OSTI2024

Closed‐Loop Recycling of Mixed Plastics of Polyester and CO 2 ‐Based Polycarbonate to a Single Monomer

Abstract Physical blending is an effective strategy for tailoring polymeric materials to specific application requirements. However, physically blended mixed plastics waste adds additional barriers in mechanical or chemical recycling. This difficulty arises from the intricate requirement for meticulous sorting and separation of the various polymers in the inherent incompatibility of mixed polymers during recycling. To overcome this impediment, this work furthers the emerging single‐monomer – multiple‐materials approach through the design of a bifunctional monomer that can not only orthogonally polymerize into two different types of polymers – specifically lactone‐based polyester and CO 2 ‐based polycarbonate – but the resultant polymers and their mixture can also be depolymerized back to the single, original monomer when facilitated by catalysis. Specifically, the lactone/epoxide hybrid bifunctional monomer (BiL O ) undergoes ring‐opening polymerization through the lactone manifold to produce polyester, PE(BiL O ), and is also applied to ring‐opening copolymerization with CO 2 , via the epoxide manifold, to yield polycarbonate, PC(BiL O ). Remarkably, a one‐pot recycling process of a BiL O ‐derived PE/PC blend back to the constituent monomer BiL O in >99 % selectivity was achieved with a superbase catalyst at 150 °C, thereby effectively obviating the requirement for sorting and separation typically required for recycling of mixed polymers.

Chemistry↗
DOE OSTI2023

Effect of recycled fibers and shredded intermediates variation on the mechanical properties and energy absorption of fiber‐reinforced composite panels

Abstract The global composite industry generates large quantities of waste which mostly ends up in landfills due to a lack of established end‐use applications for multiple waste streams. The scrap from end‐of‐life (EoL) includes manufacturing waste such as dry chopped fiber tows, loose fibers, shredded fibers from fabric textile operations, cured/semi‐cured prepregs, and fully cured composite structure waste from aircraft, automobiles, wind blades, boats, and pressure vessels. In this work, different composite waste streams were reduced to shredded intermediates, followed by simple blending, and subjected to wet compression molding to produce composite panels. The panels/plaques were tested for mechanical properties (flexure and impact), fiber‐matrix wet‐out, and property bounds. It was found that wet‐compression molding was a viable and scale‐able approach to produce recycled panels from EoL composites shredded scrap. Furthermore, full‐scale size panels for use in truck bodies and intermodal shipping container flooring were manufactured and their impact resistance was tested using a drop weight impact test. They were tested both for high‐ and low‐velocity load. In the case of high‐velocity load, the average impact load was 14,673 N; the average absorbed energy was 101.6 J; the average elastic energy was 11.7 J and the impact resistance was 1065 J/m. In the case of the low‐velocity drop weight impact test, it was found that the average impact load was 7877.358 N; the average absorbed energy was 9.718 J; the average elastic energy was 9.14 J, and the impact resistance was 184.1 J/m. The shredded composite was shown to be a candidate material for the manufacture of truck bodies and intermodal containers’ flooring panels. Highlights By using shredded intermediates from different composite waste streams, it is possible to manufacture composite panels. Wet–compression process is an appropriate technique for manufacturing recycled fiber composite panels. Regardless of the source of scrap, the mechanical properties of the produced composite panels were improved. The recycling process technology can be transformed to commercial scale to produce full‐size transportation flooring panels. A product pathway is established in consideration of lower cost and improved recyclability.

Vaidya, Uday↗
DOE OSTI2025

Friction-based recycling: an evaluation of friction extrusion for fabricating Ti-6Al-4 V wire fabricated from machining chip feedstock

Abstract Titanium and its alloys are used in aviation and automobile industries due to their remarkable strength to weight ratio, but machining loss commonly is high with ~ 80 wt% of the material being converted to scrap. Recycling post-consumer Ti scrap directly into solid bulk products is a potential solution for repurposing valuable material. Further, eliminating fresh Ti sponge during recycling might lead to lower energy and greenhouse gas emissions. In this study, a solid-phase process known as friction extrusion was utilized to recycle Ti-6Al-4 V machining chips into solid wires which could be used as feedstock in additive manufacturing. The friction consolidation technique was first used to convert chips with varying degrees of oxygen content into solid billets for its use as feedstock material in subsequent friction extrusion. The extrudates were fabricated above the beta transition temperature, which was achieved by selecting the rotation rate and feed rate, to process the billets near 1000 °C using a tungsten-lanthana extrusion die. This work presents the first occurrence of friction extruded titanium alloy wires. The effect of friction extrusion on microstructural features, tensile properties, and texture are reported. Overall, the friction extrusion method is capable of directly recycling Ti-6Al-4 V scrap into extruded wire.

Friction Extrusion↗
DOE OSTI2019

Kinetics of Recycling CF/EP Composites by Thermal Excitation of Cr{sub 2}O{sub 3}

Recycling high performance carbon fibers (CFs) by thermal excitation of Cr{sub 2}O{sub 3} semiconductor was proposed. The kinetic model of decomposition of epoxy resin was established and the method for solving kinetic parameters was proposed. The influences of temperature and treatment time on the decomposition rate of epoxy resin were investigated. The kinetic equation was established and the accuracy was verified experimentally. The morphology of the recycled CF was observed and monofilament tensile strength was determined. Results indicated that temperature and treatment time had positive correlation with decomposition rate of the epoxy resin. The reaction order n was 1.5, with excitation energy E of 85.03 kJ·mol{sup −1} and pre-exponential factor k{sub 0} of 1.26 × 10{sup 6} min{sup −1}. The established kinetic equation could be used to estimate the temperature and treatment time. Prolongation of treatment time could improve the monofilament tensile strength. The monofilament tensile strength of the recycled CF at 480 °C for 30 min was 102.72% of that of the original CF, indicating that surface heat treatment was performed on CF during the recycling process.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A fast computational framework for the design of solvent-based plastic recycling processes

Multicomponent plastics cannot be processed using mechanical recycling technologies, hindering efforts to deal with plastic waste. Multicomponent plastics include multilayer plastic films, which are widely used for food and healthcare packaging. Multilayer films combine several layers (potentially dozens) of different polymers to protect products from external factors (e.g., oxygen, water, temperature, shock, and light). Solvent-based separation processes have emerged as a promising alternative to recycle these complex materials. For instance, the Solvent-Targeted Recovery and Precipitation (STRAP TM ) process uses sequential solvent washes to selectively dissolve and separate constituent polymers from multicomponent plastic waste, including films. STRAP TM process design (separation sequence, type of solvents, and operating conditions) changes significantly depending on the design of the multilayer plastic film (e.g., number, types, and proportions of polymers). The ability to quickly quantify the economic and environmental benefits of diverse STRAP TM process designs is essential to accelerate the development of sustainable recycling processes and more recyclable multilayer film products. In this work, we present a fast computational framework that integrates molecular-scale models, process modeling, and techno-economic and life cycle analysis to quickly evaluate STRAP TM designs. The computational framework is general and can be used to study the processing of complex multilayer plastic waste streams that contain many layers. Furthermore, we highlight the different uses of the framework via targeted case studies.

Computational framework↗
DOE OSTI2023

Recyclability of additively manufactured bio-based composites

As the flexibility, efficiency, and application space of additive manufacturing continues to grow, many have begun to investigate more sustainable feedstocks as well as options for the end of life of additively manufactured parts. This study examines the effects of mechanical recycling on additively manufactured parts from bio-based feedstock. Here, articles were printed on the Big Area Additive Manufacturing (BAAM) system at the Oak Ridge National Laboratory using poly (lactic acid)/wood flour (PLA/WF) pellets. These parts were shredded and granulated, and the granulate was fed directly back into the BAAM system for re-printing, skipping the costly and energy-intensive steps of extrusion and pelletization. The chemical, mechanical, thermal, and rheological changes to PLA/WF before and after recycling were investigated. Additionally, the energy savings from directly printing granulate on the BAAM system without extrusion and pelletization is reported. It is shown that PLA/WF is an excellent candidate for recycling of large format additively manufactured parts, and value of these parts can be reclaimed while saving cost and energy through mechanical recycling.

42 ENGINEERING↗
DOE OSTI2017

Reduced alkali-silica reaction damage in recycled glass mortar samples with supplementary cementitious materials

Recycling waste glass aggregate into concrete can reduce environmental impacts but also may lead to serious alkali silica reaction (ASR) damage. This study aims to characterize ASR damage development in the mortar samples containing reactive glass aggregates and investigate the damage reduction effect of the waste supplementary cementitious materials (SCMs), including recycled glass powders and fly ash. The recycled glass aggregate mortar samples with/without SCMs were prepared in this study. The length change tests were first conducted with the prepared mortar samples based on the ASTM C1260 standard. The results demonstrated the added SCMs can largely decrease early-age ASR expansion rate. The optical microscope and Scanning Electron Microscope (SEM) with Energy Dispersive X-ray Spectroscopy (EDS) were further conducted to characterize the ASR damage in mortar samples and investigate the damage mitigation mechanism with added SCMs. The combined SEM imaging and chemical analysis indicated added SCMs can decrease both the alkali and calcium content of the generated ASR gel. In addition, the ASR damage development inside mortar samples were monitored with dynamic micron X-ray CT (μCT) over a reaction period of 63 hour at the temperature of 80°C. The scanning patterns demonstrated the ASR damage can be easily developed from the area with initial cracks and sharp corners. In conclusion, the images of glass power and fly ash samples showed significantly reduced ASR damage. This study showed that adding of SCMs can largely reduce ASR deterioration and thus facilitate the recycling glass particles into concrete.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Techno-economics of hydrocarbon fuel production and recyclables recovery from landfill-destined municipal solid waste: AI-enhanced materials recovery facility design

Sustainable aviation fuels (SAF) production from cellulosic paper fractions of municipal solid waste (MSW) destined for landfills has strong potential to advance environmental, social, and economic sustainability across the aviation and waste sectors. This study proposes an artificial intelligence-enabled material recovery facility (AI-MRF) design to efficiently characterize, separate, process, and convert recovered paper waste from MSW into intermediate chemicals and SAF. The AI-MRF, designed to process 233,091 metric tons of MSW annually, integrates smart manufacturing technologies including AI, visual and hyperspectral imaging, multi-sensor data, and traditional sorting systems. Well-characterized and sorted cellulosic paper waste was utilized for chemical and fuel production scenarios, while clean plastics, metals, and glass were considered for recycling. Conversion of paper waste into intermediate sugars achieved a net present value (NPV) of up to $\$67$ million. For sugar-to-SAF production scenarios, the minimum fuel selling price (MFSP) was calculated at $\$6.11$ per gasoline gallon equivalent (GGE) when excluding recyclable revenue, and $\$4.03$ per GGE when halving recyclable revenue. The MFSP was further reduced to $\$1.96$ per GGE when accounting for SAF sales and recyclables. Nationally, this approach could yield about 2 billion GGE of hydrocarbon fuel annually from available MSW in the United States.

09 BIOMASS FUELS↗
DOE OSTI2024

Covalent adaptable polymer networks with CO 2 -facilitated recyclability

Cross-linked polymers with covalent adaptable networks (CANs) can be reprocessed under external stimuli owing to the exchangeability of dynamic covalent bonds. Optimization of reprocessing conditions is critical since increasing the reprocessing temperature costs more energy and even deteriorates the materials, while reducing the reprocessing temperature via molecular design usually narrows the service temperature range. Exploiting CO 2 gas as an external trigger for lowering the reprocessing barrier shows great promise in low sample contamination and environmental friendliness. Herein, we develop a type of CANs incorporated with ionic clusters that achieve CO 2 -facilitated recyclability without sacrificing performance. The presence of CO 2 can facilitate the rearrangement of ionic clusters, thus promoting the exchange of dynamic bonds. The effective stress relaxation and network rearrangement enable the system with rapid recycling under CO 2 while retaining excellent mechanical performance in working conditions. This work opens avenues to design recyclable polymer materials with tunable dynamics and responsive recyclability.

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

Advances in ionic liquid recycling for lignocellulosic biomass pretreatment

Ionic liquids (ILs) are promising solvents for the pretreatment of lignocellulosic biomass due to their ability to disrupt cellulose, hemicellulose, and lignin structures. However, large-scale implementation requires the development of efficient recovery and recycling methods. This review provides a comprehensive analysis of the recyclability potential of ILs used in biomass pretreatment, emphasizing their mechanisms, recent innovations, and ongoing challenges. We begin by discussing the structural diversity and tunability of ILs, which underlie their effectiveness in biomass deconstruction. The distinct roles of IL anions and cations in dissolving specific biomass components are systematically presented and compared. Advances in IL recycling techniques, including antisolvent precipitation methods, membrane separation, and distillation, are critically examined, with attention to how mechanistic insights can inform the design of more efficient and selective recovery strategies. Despite progress, significant challenges remain to scaling up IL-based biomass processing, including high cost, environmental concerns, and impact of biomass-derived impurities (e.g., lignin residues, sugars, proteins) on IL purity and functionality after reuse. We also review the applicability of different ILs based on life cycle assessments and techno-economic analyses. Lastly, we identify critical research gaps and propose future directions, including the design and development of next-generation ILs with improved recyclability, reduced toxicity, and enhanced economic viability for industrial-scale applications.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Ionic liquid-enhanced recycling of lithium-ion battery black mass via heavy liquid centrifugal separation

Direct recycling of lithium-ion batteries (LIBs) is of great significance to supply chain security and environmental protection by restoring spent battery materials to their original purpose without destroying their chemical structure. One of the key processes for direct recycling is to separate valuable anode and cathode active materials from black mass. This study evaluates ionic liquid-enhanced Heavy Liquid Centrifugal Separation (HLCS) as an efficient method for separating LIB black mass into its constituent anode and cathode materials. The optimized HLCS process achieved a separation efficiency of over 95%, yielding a graphite-rich upper layer and an NMC-rich lower layer. Characterization by thermogravimetric analysis (TGA), X-ray diffraction (XRD), and inductively coupled plasma-optical emission spectroscopy (ICP-OES) confirmed the purity and structural integrity of the recovered fractions. The addition of N-methyl-2-pyrrolidone and ionic liquid 1-ethyl-3-methylimidazolium bromide decoupled entangled particles, while subsequent treatment of the anode layer with 1-(2,3-dihydroxypropyl)-3-methylimidazolium chloride further enhanced separation purity. The recycled graphite exhibited comparable battery performance to pristine graphite. These results demonstrate HLCS as a promising LIB recycling strategy, advancing sustainable battery manufacturing.

Adigun, Babafemi [Univ. of Tennessee, Knoxville, T↗
DOE OSTI2014

Modulating resonance behaviors by noise recycling in bistable systems with time delay

In this paper, the impact of noise recycling on resonance behaviors is studied theoretically and numerically in a prototypical bistable system with delayed feedback. According to the interior cooperating and interacting activity of noise recycling, a theory has been proposed by reducing the non-Markovian problem into a two-state model, wherein both the master equation and the transition rates depend on not only the current state but also the earlier two states due to the recycling lag and the feedback delay. By virtue of this theory, the formulae of the power spectrum density and the linear response function have been found analytically. And the theoretical results are well verified by numerical simulations. It has been demonstrated that both the recycling lag and the feedback delay play a crucial role in the resonance behaviors. In addition, the results also suggest an alternative scheme to modulate or control the coherence or stochastic resonance in bistable systems with time delay.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗