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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Compatibilization Strategy and Mechanism for Co-stabilizing Commingled Plastics and Pyrolyzed Rubber in Asphalt

Hot mix asphalt mixture is considered the ideal approach to reuse waste plastics in high-value applications because of its very high amount of usage in highway construction. However, the differences in polarity and density between polymers and asphalt lead to polymer coalescence and therefore the poor storage stability of modified asphalt. These challenges are exalted when recycling commingled plastics. This study introduced an innovative compatibilization strategy and mechanism for co-stabilizing commingled plastics and pyrolyzed rubber in asphalt. Commingled plastics were first grafted with maleic anhydride for surface activation, followed by reactive kneading with pyrolyzed rubber and crosslinking agent to form an integrated thermoplastic elastomer (ITPE) for asphalt modification. The mechanical, thermal, and interfacial behaviors of the ITPE were evaluated through tensile testing, thermogravimetric analysis, and scanning electron microscopy. The storage stability and rheological properties of the modified binder blends were evaluated through the cigar tube test and dynamic shear rheometer testing. Results demonstrated a successful formation of imide bonds in the ITPE, which can improve the strength, ductility, and thermal stability of rubber–plastic composites. Appropriate utilization of crosslinking agents can improve both rutting and fatigue resistance of ITPE-modified asphalt with good storage stability because of the co-existence of rigid plastic and soft rubbery regimes and the formation of a crosslink network. Furthermore, excessive content of crosslinker led to severe phase separation and reduced storage stability of modified binder blends. Extra crosslinker tended to float in asphalt because of its low density and caused an excessive formation of the crosslink network in the top section of the asphalt.

asphalt binder modifiers↗
DOE OSTI2024

ChemPren: a new and economical technology for conversion of waste plastics to light olefins

With the ever-increasing demand for plastics, sustainable recycling methods are key necessities. Here, the current plastics industry can manage to recycle only 10% of the 400 million metric tons of plastic produced globally. Waste plastics, in the current infrastructure, land up mostly in landfills. Although a lot of research efforts have been spent on processing and recycling co-mingled mixed plastics, energy-efficient sustainable and scalable routes for plastic upcycling are still lacking. Catalytic valorization of waste plastic feedstock is one of the potential scalable routes for plastic upcycling. Silica-alumina based materials, and zeolites have shown a lot of promise. A major interest lies in restricting catalyst deactivation, and refining product selectivity and yield for such catalytic processes. This article highlights ChemPren technology as a clean energy solution to waste plastic recycling. Co-mingled, mixed plastic feedstock along with spray dried, attrition resistant, ZSM-5 containing catalysts is preprocessed with an extruder to form optimally sized particles and fed into a fluidized bed reactor for short contact times to produce selectively and in high yields ethylenes, propylenes and butylenes. This techno-economic perspective indicates that the ChemPren technology can produce propylene at $\$$0.16 per lb, whereas the current selling price of virgin propylene is $0.54 per lb. This technology can serve as a platform for mixed plastic upcycling, with more advancements necessary in the form of robust and resilient catalysts and reactor operation strategies for tuning product selectivity.

25 - ENERGY STORAGE↗
DOE OSTI2024

Mixed polyester recycling can enable a circular plastic economy with environmental benefits

The mixed and varied nature of fossil-based and bio-based plastic waste requires complex and costly separations to enable compatibility with recycling technologies. A circular plastic economy based on mixed polyesters through cleaving ester bonds to produce monomers, while re-utilizing bio-based monomers to produce high-quality sustainable plastics, charts an exciting solution. However, the feasibility of such a circular economy solution remains underexplored. Here, in this study, we conducted a techno-economic analysis and life-cycle assessment of three polyester depolymerization recycling processes-methanolysis, glycolysis, and acid hydrolysis-for a mixed feedstock (polyethylene terephthalate [PET], polylactic acid [PLA], and polybutylene adipate terephthalate [PBAT]). Methanolysis outperforms glycolysis and hydrolysis economically and environmentally due to more efficient downstream separations, generating products with a 31% decrease in selling price and 21%-46% reduction in acidification, carcinogenic toxicity, fossil-fuel depletion, global warming potential, particulate formation, and smog formation compared to conventional polyester manufacturing. This study highlights the viability of a circular plastic economy for mixed polyesters via a single chemical recycling process.

09 BIOMASS FUELS↗
DOE OSTI2025

Upcycling of polyethylene terephthalate to high-value chemicals by carbonate-interchange deconstruction

Condensation thermoplastics have become ubiquitous. The emergence of chemical upcycling could transform them into valuable feedstocks for chemical manufacturing at their end-of-life. However, current solvolysis processes suffer equilibrium limitations due to the liberation of reactive byproducts. We report a carbonate interchange deconstruction (CID) methodology for poly(ethylene terephthalate) (PET), where carbonates act as both latent nucleophiles and byproduct sequestering agents. High product selectivity (>95%) is achieved regardless of the targeted terephthalate product, originating from removal of ethylene glycol from the reaction equilibrium via its conversion into various oligoethers. CID is robust to the impurities present in post-consumer waste plastics and significantly reduces solvent demand, with just 10 mL of dimethyl carbonate successfully converting ca. 5 g of mixed PET waste into highly pure dimethyl terephthalate in excellent isolated yield (92%). CID opens a new upcycling paradigm wherein CO2, embedded in carbonates, is leveraged to choreograph the selectivity of an otherwise equilibrium-controlled polymer upcycling process.

Galan, Nick [ORNL]↗
DOE OSTI2025

Repurposing Post-Consumer Polyethylene to Access Cross-Linked Polyethylene with Reprocessabilty, Recyclability, and Tunable Properties

Polyethylene (PE) is the most widely produced plastic but accumulation and resistance to degradation has significantly contributed to the plastic waste crisis. Upcycling has presented promising solutions to transform PE waste into value-added products. In this study, mixed post-consumer PE was successfully repurposed into reprocessable and chemically recyclable cross-linked polyethylene (XLPE). This process involved converting PE into telechelic oligomers, followed by repolymerization using a hybrid cross-linking system consisting of a dynamic cross-linker 2,4,6-triethoxy-1,3,5-triazine (TETA) and non-dynamic cross-linker tris(6-isocyanatohexyl)isocyanurate (Tri-HDI). In the resulting XLPE, TETA facilitated iterative reprocessing with minimal property degradation across cycles, whereas Tri-HDI helped preserve functional performance throughout service life. Compared to PE, XLPE exhibited enhanced mechanical properties, reduced creep deformation under application-relevant temperatures, and high temperature structural stability. Notably, copolymerizing PE oligomers with commercial macrodiols was employed to create composite XLPEs, enabling tuning material properties. After use, XLPE can be efficiently and selectively depolymerized under mild conditions, even when mixed with commercial insulator cables. This depolymerization allows for the recovery of the constituent building blocks, enabling purification and subsequent repolymerization for reuse. This approach demonstrates the potential of repurposing plastic waste into sustainable materials and fostering the development of a circular economy.

INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMI↗
DOE OSTI2026

Artificial intelligence-driven municipal solid waste sortation and its significance on downstream waste valorization in the United States: Techno-economic and life cycle assessment

Municipal solid waste (MSW) generation is quickly increasing due to population growth, industrialization, and urbanization. Current sorting technologies, e.g., optical sorters have low sortation efficiency and produce contaminated sorted materials unsuitable for downstream valorization. This study evaluates a novel artificial neural network (ANN)-based MSW sortation system through sorting efficiencies, economic performance, and environmental impacts. ANN system can sort up to 8 plastic types and all organic waste (i.e., food, yard, and paper waste) with 99% and 93% recovery efficiency, respectively, compared to optical sortation which could separate only polyvinyl chloride (PVC) plastic ultimately producing mixed plastics (except PVC) and organics streams as products. Nonetheless, their sortation costs are similar, $28.7 for ANN-based sortation and $28 for optical sortation per metric ton (Mt) of MSW at processing capacity of 94,860 metric tons (Mt)/yr of MSW in the United States. Additionally, ANN system produced high purity feedstocks for downstream valorization. A biochar pyrolysis plant modeled to process 3.6 and 14 Mt/h of sorted yard waste outperformed biochar production from mixed organic fraction (MOF), achieving 8% lower production cost and 34% lower global warming impact (1.37 kg CO 2 eq. per kg) compared to biochar derived from mixed organic feedstock (2.08 kg CO 2 eq.).

09 BIOMASS FUELS↗
DOE OSTI2026

Upcycling Real‐World Post‐Consumer Polyolefins Plastics Into Light Olefins Via Microwave‐Assisted Processing

The rapid accumulation of plastic waste, particularly post-consumer polyolefins (POs) pose severe environmental and economic challenges worldwide. Recycling of post-consumer POs remains inefficient due to difficulties in separating mixed plastics, complex additives compositions, and high processing costs, resulting in recycling rates of less than 9%. To address these critical issues, this study utilized an innovative microwave-assisted catalytic upcycling approach for the efficient upcycling of complex post-consumer POs mixtures into valuable light olefins. Using the microwave-assisted catalytic upcycling approach, gas yields reached up to 80 wt.% from post-consumer POs mixtures, accompanied by a high selectivity (>70 wt.%) toward valuable light olefins. The upcycling of POs under microwave conditions is fully invested, including additives in real-word plastics, mixtures of different POs, reusability of catalyst, and more. The microwave-assisted catalytic upcycling approach offers an efficient, scalable, and cost-effective solution for upcycling post-consumer plastic mixtures, thereby advancing the principles of a circular economy.

42 ENGINEERING↗
DOE OSTI2025

Conversion of Compositionally Diverse Plastic Waste over Earth-Abundant Sulfides

Chemical deconstruction of polyolefin plastic wastes via hydroconversion is promising for mitigating plastic accumulation in landfills and the environment. However, hydroconversion catalysts cannot handle complex feedstocks containing multiple polymers, additives, and heteroatom impurities. Here, we report a single-step strategy using earth-abundant metal sulfide catalysts to deconstruct these wastes. We show that NiMoS x /HY catalysts deconstruct polyolefin feedstocks, achieving ~81–94% selectivity to liquid products. Postsynthetic zeolite modification enhances the catalyst’s activity by >2.5 times, achieving over 95% selectivity to liquid fuels with controllable product distribution in the naphtha, jet fuel, and diesel range. The catalyst is resilient to increasingly complex feedstocks, such as additive-containing polymers and mixed plastics composed of polyolefins and heteroatom-containing polymers, including poly(vinyl chloride). As a result, we extend the strategy to single-use polyolefin wastes that can generate toxic byproducts, such as HCl and NH 3 , and eliminate their emissions by integrating reaction and sorption in a one-step process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

A better fate for PVC

Here, a critical component of plastics waste, polyvinyl chloride, is tough to recycle efficiently and sustainably owing to its high chlorine content. Now, research shows how to convert polyvinyl chloride mixed with polypropylene, at room temperature, into chlorine-free hydrocarbons.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Polymer grafted aramid nanofiber reinforces immiscible waste polypropylene/poly(ethylene terephthalate)

Polypropylene (PP) and poly(ethylene terephthalate) (PET) are plastics commonly used for packaging because of their excellent barrier and mechanical properties. The properties of these plastics are often diminished after mechanical recycling, inevitably causing down-cycling. Furthermore, this problem is exacerbated when different kinds of polymers mix. Aramid nanofibers have the potential to improve the mechanical properties of polymers due to their excellent mechanical properties but their poor dispersion in polymers is a challenge. Grafting polymers onto nanofibers can help address this challenge. In this work, different loading levels (1%, 2%, and 5%) of polymer grafted aramid nanofibers (ANFs) are blended with waste PP/PET (90/10), simulating a PP waste stream containing traces of PET contaminants. Scanning electronic microscopy, rheology, and differential scanning calorimetry results show the affinity of PP functionalized aramid nanofibers (PP_ANF) towards the PP matrix. At 1 wt% of the nanofiber, the size of the PET droplets in the PP matrix of the PP_ANF blend range from 0.2 to 2.0 μm while that of unmodified ANF and PET_ANF blends are in the range of 0.1–6.2 and 0.5–7.4 μm, respectively. In summary, polymer grafted ANFs have the tendency of improving properties of its like polymers due to similarity in the grafting polymer and the polymer matrix.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Counterintuitive Compatibilization of Poly(-Valerolactone) and Poly(L-Lactic Acid) by Statistical Copolymers toward Compostable and Recyclable Packaging

Poly(δ-valerolactone) (PVL) and poly(l-lactic acid) (PLLA) are bioderivable, compostable, and chemically recyclable plastics with synergistic properties for addressing plastic waste accumulation in receiving environments. Though recyclable-by-design polymers often fall short of competing with incumbent materials, blending affords a means to leverage individual component strengths toward ideal tunable properties. Polymer blends are often immiscible, but a range of methodologies are available to promote mixing. Here, we report on the compatibilization of 9 immiscible PVL and PLLA blends with three different compatibilization agents: thermoplastic starch, synthesized PVL-co-PLLA statistical copolymers (SCPs), and synthesized PVL-b-PLLA block-type copolymers. Resulting degrees of compatibilization are observed through scanning electron microscopy, corroborated by thermal and mechanical analyses monitoring performance as a function of microdomain size. Small-angle and wide-angle X-ray scattering experiments are conducted to observe the influence of compatibilizers on individual crystalline phases to further elucidate material behavior. Molecular dynamics simulations provide key insights into the interfacial interactions between homopolymers and compatibilizers. Finally, a suite of end-of-life avenues is established by biodegradation in industrial composting conditions, chemical recycling by deconstruction to hydroxymethyl esters, and direct chemical depolymerization to lactone precursors in mixed feed. Overall, we highlight several promising blends and the counterintuitive SCP compatibilization phenomenon toward high-performance, sustainable materials.

Compatibilization, copolymer compatibilizer, bio-b↗
DOE OSTI2025

Hyperspectral imaging for real-time waste materials characterization and recovery using endmember extraction and abundance detection

Hyperspectral imaging, combined with advanced spectral unmixing techniques and artificial intelligence, offers a powerful solution for improving material identification and classification. Here, this study evaluates the effectiveness of the pixel purity index and the sequential maximum angle convex cone algorithms in extracting and validating spectral signatures from pure samples of paper components (cellulose and lignin) and plastic (polypropylene). Principal-component analysis showed that both algorithms captured nearly all relevant variance for the tested materials. Spectral signatures were compared using the spectral angle mapper, revealing high similarity in the short-wave infrared region and greater variability in the visible near-infrared range. The methodology was then applied to a disposable coffee cup to detect and quantify mixed materials, accurately estimating material abundance and object area with less than 1% error. This approach enhances material classification, supporting product verification, quality control, and automated sorting for sustainable waste management and resource recovery.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Closing the loop on plastics: Biological and hybrid routes for converting plastic waste to polyhydroxyalkanoates

Polyhydroxyalkanoate (PHA) production from plastic-derived substrates offers a promising route to mitigate plastic pollution while reducing dependence on conventional PHA feedstocks. Plastic waste represents an abundant carbon source for microbial fermentation, but efficient conversion remains limited by incomplete deconstruction, inhibitory intermediates, low carbon recovery, and challenges in process integration. Plastic-derived streams contain diverse compounds, including fatty acids, hydrocarbons, fatty alcohols, aldehydes, esters, and aromatic compounds generated during depolymerization. These intermediates can be metabolized by selected microorganisms, particularly Pseudomonas species with versatile fatty-acid and hydrocarbon pathways, as well as Cupriavidus necator and mixed microbial cultures. Unlike reviews that address plastic upcycling or PHA biosynthesis separately, this review focuses on the deconstruction–fermentation interface that governs plastic-to-PHA conversion. It consolidates current progress in plastic deconstruction, substrate conditioning, microbial metabolism, fermentation control, polymer recovery, and techno-economic and life-cycle considerations. Here, by emphasizing substrate composition, biological compatibility, plastic‑carbon recovery, and final polymer quality, the review identifies priorities for scalable and environmentally sustainable PHA production from plastic-derived substrates.

42 ENGINEERING↗
NASA NTRS2008

Development of an Inline Urine Monitoring System for the International Space Station

Human exposure to microgravity during spaceflight causes bone loss. Calcium and other metabolic byproducts are excreted in urine voids. Frequent and accurate measurement of urine void volume and constituents is essential to determining crew bone loss and the effectiveness of countermeasures. Previous US Space Shuttle (SS) Urine Monitoring System (UMS) technology was unable to accurately measure urine void volumes due to cross contamination between users and fluid system instabilities. Currently, urine voids must be collected manually in a flexible plastic bag containing a known tracer quantity. The crew member must completely mix the bag then withdraw a representative syringe sample for later ground analysis. The current bag system accuracy is highly dependent on mixing technique. The International Space Station (ISS) UMS has been developed as an automated device that collects urine from the Waste and Hygiene Compartment (WHC) urinal funnel interface, separates the urine, measures the void volume, and allows for syringe sampling. After operations, the ISS UMS delivers the urine to the WHC for normal processing then flushes its plumbing with a small water volume. The current ISS UMS design incorporates an innovative rotary separator that minimizes foaming, greatly reduces cross contamination between urine voids (< 0.5 ml urine), and provides accurate volume measurements (< +/- 2% error for 100 to 1000 ml void volumes). The system performance has been validated with extensive ground tests and reduced gravity aircraft flights. The lockersized ISS UMS is currently being modified to interface with the ISS Node 3 WHC Russian ACY hardware. The operation principles, characteristics, and results are outlined in the paper.

Broyan, James Lee, Jr.↗
DOE OSTI2026

Universal Approach for the Depolymerization of Polyamides via Photothermal Conversion

Polyamides (PAs) exhibit excellent chemical stability and mechanical resistance, yet these same characteristics lead to their widespread accumulation in the environment as pollution. In this work, we developed an inclusive and operationally simple photothermal strategy to recycle PAs, overcoming the high energy barriers necessary to break down these materials. PAs can be depolymerized using photothermally mediated ring-closing depolymerization and acidic hydrolysis to afford cyclic and linear monomers using carbon black as a photothermal agent (PTA) under visible light irradiation. We showed that polyamide 6 is efficiently depolymerized to ε-caprolactam with 74% yield in 10 min. Similarly, in 1 h, the photothermal acidic hydrolysis of polyamide 6,6 afforded hexamethylene diamine and adipic acid with 97 and 96% yields, respectively. This method was further applied to a variety of aliphatic and aromatic PAs and mixed PA waste. Both photothermally promoted processes effectively depolymerize pigment-containing postconsumer waste by leveraging existing black pigments as PTAs. Here, photothermal conversion provided a general and rapid route for PA depolymerization under visible light irradiation, enabling high monomer yields with inexpensive reagents and a general tolerance to additives, demonstrating this approach’s potential for a circular plastic economy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2009

Development of an In-line Urine Monitoring System for the International Space Station

Exposure to microgravity during space flight causes bone loss when calcium and other metabolic by-products are excreted in urine voids. Frequent and accurate measurement of urine void volume and constituents is thus essential in determining crew bone loss and the effectiveness of the countermeasures that are taken to minimize this loss. Earlier space shuttle Urine Monitoring System (UMS) technology was unable to accurately measure urine void volumes due to the cross-contamination that took place between users, as well as to fluid system instabilities. Crew urine voids are currently collected manually in a flexible plastic bag that contains a known tracer quantity. A crew member must completely mix the contents of this bag before withdrawing a representative syringe sample for later ground analysis. The existing bag system accuracy is therefore highly dependent on mixing technique. The International Space Station (ISS) UMS has been developed as an automated device that collects urine from the Waste and Hygiene Compartment (WHC) urinal funnel interface, separates the urine, measures void volume, and allows for syringe sampling. After the ISS UMS has been used by a crew member, it delivers urine to the WHC for normal processing. The UMS plumbing is then flushed with a small volume of water. The current ISS UMS design incorporates an innovative rotary separator that minimizes foaming, consequently greatly reducing cross-contamination among urine voids (less than 0.5 mL urine) while also providing accurate volume measurements (less than 2 percent error for 100 to 1,000 mL void volumes). ISS UMS performance has been validated through extensive ground tests and reduced-gravity aircraft flights. The locker-sized ISS UMS is currently undergoing a design modification that will permit it to interface with the ISS Node 3 WHC Russian toilet (ACY) hardware. The operating principles, characteristics, and results of this design modification are outlined here.

Broyan, James Lee, Jr.↗
NASA NTRS1994

Chemical recycling of scrap composites

There are no well-developed technologies for recycling composite materials other than grinding to produce fillers. New approaches are needed to reclaim these valuable resources. Chemical or tertiary recycling, conversion of polymers into low molecular weight hydrocarbons for reuse as chemicals or fuels, is emerging as the most practical means for obtaining value from waste plastics and composites. Adherent Technologies is exploring a low-temperature catalytic process for recycling plastics and composites. Laboratory results show that all types of plastics, thermosets as well as thermoplastics, can be converted in high yields to valuable hydrocarbon products. This novel catalytic process runs at 200 C, conversion times are rapid, the process is closed and, thus, nonpolluting, and no highly toxic gas or liquid products have been observed so no negative environmental impact will result from its implementation. Tests on reclamation of composite materials show that epoxy, imide, and engineering thermoplastic matrices can be converted to low molecular weight hydrocarbons leaving behind the reinforcing fibers for reuse as composite reinforcements in secondary, lower-performance applications. Chemical recycling is also a means to dispose of sensitive or classified organic materials without incineration and provides a means to eliminate or reduce mixed hazardous wastes containing organic materials.

Allred, Ronald E.↗
DOE OSTI2026

Improbability of Post-Closure Criticality in Compacted Criticality Control Overpacks after Room Closure at Waste Isolation Pilot Plant

As part of its periodic re-certification of the Waste Isolation Pilot Plant (WIPP), an operating repository in bedded salt for the disposal of transuranic (TRU) waste from atomic energy defense activities, the United States Environmental Protection Agency expects a re-evaluation of features, events, and processes, such as post-closure nuclear criticality. Although salt creep beneficially encapsulates the TRU waste in the closed WIPP repository, the spacing between an array of waste packages is disrupted as the salt creep closes disposal rooms and containers lose structural integrity. For most TRU waste, the possibility of post-closure criticality is exceedingly small either because the salt neutronically isolates TRU waste canisters or because closure of a disposal room from salt creep does not sufficiently compact the low mass of fissile material. The criticality evaluation was updated, however, because of the introduction of criticality control overpack (CCO) containers, which may dispose up to 380 fissile gram equivalent plutonium-239 in each container. The criticality potential is evaluated through high-fidelity geomechanical modeling of a disposal room filled with CCO containers during two representative conditions: (1) large salt block fall, and (2) gradual disposal room closure from salt creep. Geomechanical models of roof fall demonstrate three tiers of CCO containers are not greatly disrupted. Geomechanical models of gradual room closure from salt creep (without brine seepage and subsequent gas generation to permit maximum room closure) were used to predict irregular arrays of closely packed CCOs after 1000 years, when room closure has asymptotically approached maximum compaction. Models of spheres or cylinders with 380 fissile gram equivalent of plutonium (as oxide) at the predicted irregular compacted spacing demonstrate that an array of CCO containers is not critical when surrounded by salt and magnesium oxide, provided the mass of hydrogenous material shipped in CCO containers (usually plastics) is controlled or boron carbide (a neutron poison) is mixed with the fissile contents.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗