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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Development of Process Flowsheets for the Recovery of Metals by Solvent Extraction to Recycle Battery Materials: Evaluation of Application of AMUSE Code. Final CRADA Report

RSR Technologies (RSRT) wished to investigate the use of the AMUSE solvent extraction code, housed at Argonne National Laboratory (ANL) to evaluate the recycling of battery cells for the reclamation of metal values. The modeling studies were undertaken by the group at ANL to evaluate several separation schemes for battery metals using solvent extraction. These studies would develop a framework to be experimentally validated at RSRT at its facility in Dallas, TX. The AMUSE code modeling work would speed the development of recovery flowsheets for spent batteries.

25 ENERGY STORAGE↗
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 OSTI2025

Screening green solvents for multilayer plastic film recycling processes

Multilayer (ML) plastic films are essential packaging materials that help protect products from diverse external factors; however, only 5% of all ML films are recycled in the United States. Solvent-based technologies are a promising alternative for recycling ML films because they enable recovery of constituent polymer resins. For example, the Solvent Targeted Recovery and Precipitation (STRAPTM) process sequentially dissolves and separates polymer components using a series of targeted solvent washes. A crucial design aspect of this process is the impact of selected solvents on human health and on the environment. Here, this work introduces a computational framework that integrates molecular modeling, process modeling, techno-economic analysis (TEA), and life-cycle analysis (LCA) to quickly screen green solvents for solvent-based ML recycling processes. Initial screening for solvents based on selectivity is performed by estimating temperature-dependent solubilities using molecular-scale models. Subsequent screening uses basic estimates of energy use and octanol-water partition coefficients (logP) as key measures of health, safety, and environmental hazards. Detailed process modeling, TEA, and LCA are used on a reduced set of promising solvents identified in early screening steps to more accurately determine how solvent selection and associated operating conditions impact overall economics and environmental impacts. The framework is used for the identification of green solvents (from a database of 1,000 solvents) that separate an industrial ML film composed of polyethylene (PE), ethylene vinyl alcohol (EVOH), and polyethylene terephthalate (PET). Our analysis shows the effectiveness of the framework and reveals fundamental trade-offs between solvent greenness, solubility, and economics. Our work emphasizes the importance of taking a holistic systems view during solvent design and aims to inform the development of new processes for ML film recycling and the identification of new ML films that are easier to recycle.

economics↗
DOE OSTI2025

Toward a sustainable circular economy of multilayer plastic films: Life cycle and techno-economic assessment with a focus on end-of-life treatment and multiple recovery cycles

This study presents a life cycle assessment (LCA) and techno-economic analysis (TEA) of end-of-life technologies for treating polyethylene–polyamide barrier film waste, focusing on quality degradation across recovery cycles. Novel treatment methods are experimentally validated, while others are drawn from literature and industry consultations. A displacement approach, assuming no quality loss, is first applied. Results show that solvent-based recycling via the solvent-targeted recovery and precipitation (STRAP) process outperforms alternatives across environmental indicators, reducing global warming potential (GWP) by 40% compared to landfilling. Incineration performs worst in most categories, particularly eutrophication (80% higher than landfilling), due to nitrogen emissions. Experimentally validated downcycling (pelletizing) proves more economically viable. The assumption of infinite recoverability is overly optimistic. To address this, we propose a mathematical framework accounting for a finite number of recovery cycles. This refined model shows reduced GWP and cost savings for solvent recovery, making its benefits less pronounced than initially estimated. Sensitivity and uncertainty analyses reveal strong dependence on recovered material quality and solvent recovery efficiency, underscoring the need for optimized process design. Finally, hotspot analysis identifies greenhouse gas emissions from the polyamide supply chain as the dominant GWP contributor. In conclusion, the results underscore potential trade-offs across pathways and show that solvent-based recovery’s sustainability depends heavily on process conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Electrochemical Deconstruction of Ortho-Phthalate Plasticizers and Recovery of Plasticizing Moieties

Electrochemical methods for the direct reduction of alkyl esters have been understudied but provide a potential advantage for addressing specific waste streams given that such strategies often require only a minimal chemical profile. One such waste stream that could benefit from electrochemical remediation is poly(vinyl chloride) (PVC) plastics. PVC recycling often faces challenges due to the complexity of such waste. Solvent-based recycling methods pose several advantages for addressing post-use PVC; however, such methods are complicated by the high amounts of toxic legacy plasticizers (ortho-phthalates) present in PVC. A potential solution to addressing such phthalates is to address them electrochemically, coupled with recovery of the resulting valuable products. Presented herein is an optimized electrochemical method for ester activation that is leveraged to separate and recover the aromatic and alkyl components of ortho-phthalate plasticizers. The resulting aliphatic alcohols may be reused to prepare other non-toxic plasticizers. This electro-degradation method is demonstrated on six phthalates that have been identified to pose health concerns in addition to plasticizers recovered from commercial samples of PVC.

di-(2-ethylhexyl) phthalate↗
DOE OSTI2024

An Explainable Classification Framework for Determining and Understanding the Suitability of Solvent Extraction for Bioproduct Recovery

Lignocellulosic biomass is an abundant feedstock for producing sustainable fuels and chemicals. However, a key challenge in most biomass utilization strategies is the recovery of products from a dilute, typically aqueous, phase. In this respect, liquid–liquid extraction, which relies on a solvent to transfer a product of interest from one liquid phase to another (solvent-rich) phase, is a technology that can reduce the energy requirements for product recovery. To reduce solvent consumption, liquid–liquid extraction needs to be combined with another separation method (e.g., distillation) to recycle the solvent. Despite the research on solvent extraction, there are limited system-wide methods that allow us to determine when extraction is well suited to carry out a specific separation. Accordingly, we present a classification framework to predict whether extraction, coupled with distillation, is feasible and more economical than distillation. Our framework is based on features such as feed composition, liquid–liquid equilibrium constants, relative volatilities, and solvent price, and leads to trained classifiers that show good prediction accuracy. We further study how specific features influence the suitability of extraction. Furthermore, to showcase the applicability of the framework, we use it to analyze the separation of acetic acid from water.

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

DOE-GENIORS Dynamic Irradiation Testing

As part of the homogeneous actinides recycling strategy, the EURO-GANEX process is one of the most promising options to achieve the goal of minor actinides recovery. Improvements made to EURO-GANEX system have resulted in the emergence of the so-called New EURO-GANEX process, where the composition of the solvent has been modified by replacing TODGA and DMDOHEMA with cis-mTDDGA in the organic phase and SO3-Ph-BTP with PyTri-Diol in the aqueous phase in order to resolve important issues. The objective of this work is twofold: evaluate the gamma radiolytic resistance of the new EURO-GANEX process by dynamic irradiation conditions simulating the three main steps of the process, and validate the design of CIEMAT Náyade, CEA Marcel and INL irradiation loop devices since each of them mimics different aspects of the real process. Náyade and the INL loops could irradiate the organic and aqueous phases together, whereas in the CEA loop, the irradiated solvent is recycled continuously inside a platform with several stages of mixer-settlers containing aqueous flows simulating the three main steps of the process. The extraction performances and changes in the composition of the solvent have been analyzed during the irradiation experiment by different techniques: gamma spectrometry and ICP-MS/OES for cations or radioactive tracer extraction, and HPLC-MS to identify and quantify the degradation compounds. Despite some differences between the three-irradiation facilities, this inter-institutional study shows that these three comparative tools provide similar trends in the radiolytic stability of a liquid-liquid extraction system. Favourable extraction results for the different steps are obtained according to the static irradiation studies found in literature. However, the degradation of cis-mTDDGA is appreciable leading to degradation compounds, some of which form precipitates and produce important changes in viscosity, important aspects that must be addressed prior to the successful industrial application of the new EURO-GANEX process.

38 - RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCL↗
DOE OSTI2023

Interinstitutional Study of the New EURO-GANEX Process Resistance by Gamma Irradiation Test Loops

As part of the homogeneous actinides recycling strategy, the EURO-GANEX process is one of the most promising options to achieve the goal of minor actinides recovery. However, EURO-GANEX also has various drawbacks that are being addressed. Improvements made to EURO-GANEX system have resulted in the emergence of the so-called New EURO-GANEX process, where the composition of the solvent has been modified by replacing TODGA and DMDOHEMA with cis-mTDDGA in the organic phase and SO3-Ph-BTP with PyTri-Diol in the aqueous phase in order to resolve important issues. The objective of this work is twofold: evaluate the gamma radiolysis resistance of the new EURO-GANEX process by dynamic irradiation conditions simulating the three main steps of the process and validate the design of CIEMAT Náyade, CEA Marcel and INL irradiation loop devices since each of them mimics different aspects of the real process. Náyade and the INL loops could irradiate together the organic and aqueous phases, whereas in the CEA loop, the irradiated solvent is recycled continuously inside a platform with several stages of mixer-settlers containing aqueous flows simulating the three main steps of the process. The extraction performances and changes in the composition of the solvent have been analysed during the irradiation experiment by different techniques: gamma spectrometry and ICP-MS/OES for cations or tracers extraction, and HPLC-MS to quantify the degradation and evaluate the degradation compounds. Additionally, in spite of some differences between the three-irradiation facilities, this inter-institutional study shows that they are three comparative tools, which provide results on the stability towards radiolysis of a liquid-liquid extraction system. Favourable extraction results for the different steps are obtained according to the static irradiation studies found in literature. However, the degradation of cis-mTDDGA is appreciable leading to degradation compounds, some of which form precipitates and produce important changes in viscosity, important aspects that must be addressed prior to the successful industrial application of the new EURO-GANEX process.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2025

Distillable amine-based solvents for effective pretreatment of multiple biomass feedstocks

Exploring the potential of advanced distillable solvents as efficient biomass pretreatment agents is critical for biorefineries, enhancing fermentable sugar yields while enabling solvent recovery and recycling without suffering significant losses. Here, we employ distillable amine-based solvents for pretreating a wide range of lignocellulosic feedstocks, aiming to facilitate the industrial release of fermentable sugars from diverse feedstocks through enzymatic hydrolysis. Twenty-two diverse feedstocks, sourced from different geographical regions and representing various biomass categories, were surveyed for chemical (mainly carbohydrates and lignin) and lignin (S, G, and H units) profiles. Several solvents, including ethanolamine, ethanolammonium acetate, butylamine, butylammonium acetate, and triethylamine, were tested for the pretreatment of eight selected biomasses. Among these solvents, butylamine emerged as the most effective due to its favorable sugar release, excellent solvent removal rate, and low boiling point, facilitating solvent recovery and recycling. Extending butylamine pretreatment to all 22 feedstocks demonstrated desirable sugar yields and highly efficient solvent removal in the majority of the biomass sources tested. Agricultural residues and their mixtures showed particularly favorable sugar release. Despite minimal changes in cellulose crystallinity, XRD characterization of sorghum, poplar, and pine before and after butylamine pretreatment showed a decrease in intensity and a slight shift of certain peaks, indicating alterations in cellulose structure. Fourier-transform infrared spectroscopy and thermogravimetric analysis analyses suggested disruption of biomass linkages in hemicellulose and lignin, enhancing enzymatic digestibility. Scale-up experiments of the mixed agricultural feedstocks in a 1 L Parr reactor achieved over 90% glucose liberation and more than 99% butylamine removal, highlighting the scalability of the method. The resulting hydrolysates supported the growth of diverse bacterial and fungal strains, indicating downstream compatibility with commercial fermentation processes. This study presents butylamine as an effective, recoverable pretreatment solvent for a wide range of lignocellulosic feedstocks, offering a promising solution to key biorefinery challenges. The demonstrated scalability and compatibility with various biomass types and blends underscore its potential for industrial application, advancing sustainable biofuel and biochemical production.

biomass composition↗
DOE OSTI2025

Innovative use of CaO in combination with amino acid salt to convert CO 2 as CaCO 3 nanoparticles under mild pH and low temperature

The increasing demand for sustainable CO 2 management has driven the development of innovative methods that can convert point source CO 2 into value-added products. In this study, CaO in combination with amino acid salt was used to convert CO 2 into CaCO 3 nanoparticles. Different from the conventional method where CO 2 diffusion presents a major challenge in reacting with CaO to form CaCO 3 , amino acid salt solvent was applied to absorb CO 2 first and then rapidly reacted with CaO to form CaCO 3 nanoparticles (∼50 nm) at a low temperature (e.g., 60 °C). Our experiments showed that at a glycine (Gly)/NaOH ratio of 2:1 or 3:1, the solution pH values during the CO 2 absorption and conversion were about 8–9 at 60 °C, while at a ratio of 1:1, the solution pH values were about 9–11; without Gly, the solution pH values were about 12. Gly-optimized solvent substantially reduced corrosion risk to reactors. In addition, the use of amino acid (i.e., Gly) led to much smaller CaCO 3 particles, distinctly different chemical phases, and fundamentally different chemical reactions. Moreover, in the presence of Gly, the solution pH was completely reversed and the solution was regenerated for cyclic use when CaO was added. The solvent was recyclable and reusable, highlighting the cost-effectiveness and sustainability of this approach. The Gly-modulated CaCO 3 nanoparticles may have significant potential for industrial applications in the biomedicine, construction, plastics, and rubber industries.

36 MATERIALS SCIENCE↗
DOE OSTI2026

A mathematical design framework for membrane pre-concentration in energy-efficient recovery of fermentation products

Due to the dilute nature of products manufactured via fermentation and cell-free bioprocessing, dewatering is a common unit operation in downstream processing (DSP) for bioproduct recovery, but it is typically energy intensive. To improve DSP energy efficiency for bio-based small molecules, integrating high-pressure membrane pre-concentration is a promising process option. However, this approach is typically constrained by a tradeoff between concentration factor (CF) and product recovery (PR), namely increasing the CF typically results in greater product loss, and vice versa. Here we developed a model that enables process design guidelines to: (i) identify scenarios in which the additional energy consumption and product loss from membrane pre-concentration are justified for use in DSP, and (ii) determine the optimal CF that minimizes process specific energy consumption. We compared the energy consumption of high-pressure membrane-integrated processes to evaporation-only processes and applied the model to an experimental case study for the separation and purification of butyric acid from Clostridium tyrobutyricum fermentation using an in situ product recovery (ISPR) process. The model estimated that integrating a tangential-flow reverse osmosis (RO) pre-concentration unit could reduce process energy consumption up to 45%. The use of advanced membrane pre-concentration technologies, such as negative rejection membranes and organic solvent reverse osmosis (OSRO), have the potential to further reduce the overall process specific energy consumption up to 96%, projected based on modeling. Overall, membrane pre-concentration, especially when strategically integrated prior to an evaporation step with optimized process conditions, holds significant potential for improving DSP energy efficiency, particularly in applications requiring substantial solvent removal for product recovery from dilute mixtures.

09 BIOMASS FUELS↗
DOE OSTI2025

Molecular Level Understanding of Polyethylene Terephthalate (PET) Depolymerization in Base/Alcohol Hybrid Systems

Polyethylene terephthalate (PET) depolymerization in base/alcohol hybrid systems represents a promising low-energy approach for chemically recycling PET waste into valuable monomers. This study investigates the mechanistic pathways of PET depolymerization in NaOH/alcohol solutions, emphasizing the competing roles of hydroxide and alkoxide species. Utilizing a combination of experimental techniques, density functional theory (DFT) calculations, and molecular dynamics (MD) simulations, we explore how factors such as base concentration, alcohol chain length, and pKa values of alcohols influence PET depolymerization efficiency and pathways. Our findings indicate that alkoxide ions (RO⁻) exhibit notably higher reactivity than hydroxide ions (HO⁻), favoring an alcoholysis pathway in the base/alcohol hybrid system. Experimental results across a series of C1 to C5 alcohols show that longer-chain alcohols, particularly 1-butanol, achieve higher PET conversion, although this does not align solely with simple nucleophilicity trends of alkoxides. While DFT calculations reveal comparable activation energies for various alkoxides in PET depolymerization, MD simulations underscore the significant role of alcohol chain length, with longer-chain alcohols forming more stable or frequent interactions with PET. Additionally, the alkoxide concentration, influenced by the alcohol’s pK a , directly impacts PET conversion. These suggest that PET depolymerization is governed by a balance between alkoxide concentration and alkoxide-PET interactions, rather than activation energies or nucleophilicity alone. From a practical perspective, incorporating long-chain alcohols as cosolvents may enhance process efficiency but increases raw material costs by approximately 30%. However, long-chain alcohols present a safer and more sustainable alternative to hazardous cosolvents such as dichloromethane. This work offers a molecular-level understanding of PET depolymerization in base/alcohol systems and provides insights into optimizing these systems for more efficient and sustainable PET recycling processes.

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

Recent advances in biomass pretreatment using biphasic solvent systems

The complexity and recalcitrance of lignocellulosic biomass seriously hinder its subsequent conversion to liquid fuels. To achieve high-value utilization of lignocellulosic biomass, the physical–chemical barrier should be overcome through appropriate pretreatment techniques to improve the accessibility of cellulose for efficient enzymatic hydrolysis. With the rapid emergence of novel pretreatment solvents, biphasic solvent pretreatments represent a nascent and green pretreatment method that has shown outstanding advantages and broad application prospects in the biorefinery of lignocellulosic substrates due to its ability to provide economically viable biomass upgrading, the separation process for products in the solvent phase, and the reutilization of solvents. Herein, different types of biphasic solvents (e.g., 2-methyltetrahydrofuran, methyl isobutyl ketone, 1-butanol, phenoxyethanol, ionic liquids, and deep eutectic solvents) were reviewed systematically, including the fundamental designs of biphasic solvents for biomass pretreatment, their effect on the fractionation of individual biomass components (e.g., carbohydrate and lignin) and the enzymatic hydrolysis performance, and the coproduction of furan and hydroxymethylfurfural. Finally, the main pros and cons of these different biphasic solvent systems are summarized, and the future development direction is also proposed. Finally, this review can provide a reference for designing and selecting effective biphasic pretreatment methods for various types of lignocellulosic biomass.

09 BIOMASS FUELS↗
DOE OSTI2022

Process Scale-Up of an Energy-Efficient Membrane Solvent Extraction Process for Rare Earth Recycling from Electronic Wastes

This study reports the process scale-up and long-term performance of an energy-efficient and cost-effective membrane solvent extraction (MSX) process for separation and recovery of high purity rare earth oxides (REOs) from scrap permanent magnets (SPMs). Here, the rare earth elements (REEs), including dysprosium, neodymium, and praseodymium, are recovered from SPMs using a neutral extractant, tetraoctyl diglycolamide (TODGA) embedded in a microporous polypropylene hollow fiber membrane module. The MSX process performance is demonstrated with bench scale module with membrane surface area of 1.4 m 2 to industrial scale modules with membrane surface area of up to 20 m2 to enable the processing of up to 1 ton month –1 of SPMs. The purity and the yield of the recovered REOs are >99.5 wt% and >95%, respectively. The average extraction rate of REOs is >10 g m –2 hr –1 . A skid of MSX system is assembled with a membrane area of 40 m 2 . The MSX skid successfully recovers REOs with a capacity of 300 kg REOs/month. Finally, it is determined that the organic phase containing the extractant maintains its performance up to 250 h. The results suggest that the MSX process is an economically viable and environmentally friendly process for separation and recovery of REOs from electronic wastes.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Delamination recycling of multilayer plastic films: Solvent-assisted separation pathways and recovery of solid polyolefins

Multilayer plastic films are excellent packaging materials due to the bound layers of multiple polymers, with each different polymer contributing to the film properties. Desirable properties lead to continuously growing demand for multilayer films. Multilayer plastic films are typically single-use and, as such, their increased production and disposal have led to waste management problems. Multilayer films are not currently recyclable primarily due to the multiple bound polymers. This work advances delamination as a recycling process to separate and sequester valuable polymers from multilayer films, facilitating the incorporation of these polymers into the circular economy. We effect delamination in a physical process that preserves targeted polymers as solid film, hence retaining their embodied energy. This work documents three different pathways of inducing delamination of multilayer films, with appropriate solvents disrupting adhesion between adjacent layers or dissolving a minor component of the film in less than an hour and at temperatures below 90°C, and where all initial polyethylene is maintained in its solid form throughout the process and is recovered at high purity. Solvent-based delamination is exemplified on commercial multilayer films with majority polyethylene (PE), and polyethylene terephthalate (PET) or ethylene vinyl alcohol copolymer (EVOH) or nylon also present. Solvent-based delamination is an energy-efficient and environmentally friendly recycling process that improves upon dissolution-precipitation recycling, since delamination involves very little dissolution and no precipitation, and is superior to pyrolysis which breaks down the polymers, while delamination keeps polymer chains intact. Furthermore, delamination recycling can contribute to the sustainable use of multilayer films as they continue to protect our food and medicine.

Chemical Recycling↗
DOE OSTI2026

Delamination of Multilayer Plastic Films to Recover Polyethylene with Favorable Mechanical Properties

Multilayer plastic films play a critical role in packaging, with each polymer layer contributing specific properties to the multilayer film. Multilayer plastic films are not currently recyclable due to the bound polymers. With multilayer film production of about 20 million metric tons in 2024 and rising, endof- life treatment becomes pressing. This work presents a scalable solvent-based delamination recycling process that is applied to commercial postindustrial multimaterial films to unbind the materials within a multilayer film by dissolving only the adhesive layer and recover polyethylene (PE) as an intact solid film. Solventbased delamination is a simple process that allows the complete recovery of materials and solvents used in the process. The delaminating solvent, 88% formic acid in water, induces delamination of PE/PEI/PET and PE/PU/PET films at 70 °C in under an hour. Recovered PE has no contamination detected by Fourier transform infrared spectroscopy and mechanical properties on par with those of virgin resin. The recovery of high-quality solid PE film fit for reprocessing, at low operating temperatures and with closed-loop solvent reuse, promotes delamination as a low energy consumption and environmentally friendly recycling process. PE recovered from delamination can be reused in equivalent products, promoting circularity of multimaterial films.

chemical recycling↗
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↗