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At least 433 records · Page 24

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Lunar Water Extraction Via Lunar Auger Dryer ISRU (LADI)

In 2009, the Lunar Reconnaissance Orbiter (LRO) and Lunar Crater Observation and Sensing Satellite (LCROSS) provided definitive proof of water in the Lunar’s southern permanently shadowed region (PSR)1. Both the 2020 NASA Technology Taxonomy2 and the Lunar Surface Innovation Initiative (LSII) team identified capability gaps in icy regolith transfer and reactor processing in Permanently Shadowed Region (PSR) environmental conditions. A water processing plant operating inside the PSR can continuously process water (and volatiles) for both breathable air and propellant. NASA’s Johnson Space Center (JSC) fabricated a unique breadboard test stand for validating the feasibility of this concept,developed a lunar auger dryer sizing tool, and identified the physical flow and thermal models required to design an Engineering Development Unit (EDU) for environmental testing. Over the two years this project was active, models were developed including: a) a sizing tool that scales the auger parameters based on production targets, b) accurate thermal models in both lab and lunar conditions, c) a Discreet Element Model (DEM) for observing particle effects in low-g, and d) incorporated these subsystem models into a MATLAB parametric Modular Open System Approach (MOSA) system model. These models were validated by testing the auger in both a mechanical and thermal system configuration. The results of this testing increased the Technology Readiness Level (TRL) of the Lunar Auger Dryer ISRU (LADI) system to TRL 4.

Lunar↗

DOE OSTI2025

SEM/EBSD Characterization of Baffle-Former Bolts Designated for High Energy X-ray Microscopy Studies at the Advanced Photon Source

This report documents the microstructural and surface characterization of two high-fluence baffle-former bolts (BFBs) harvested from a commercial pressurized water reactor (PWR) after nearly four decades of service. These bolts experienced extreme conditions including high neutron fluence, elevated temperatures, corrosive primary water, and sustained mechanical loads, all of which contribute to degradation mechanisms such as irradiation-assisted stress corrosion cracking (IASCC). Using scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD), the study assessed bulk and near-surface microstructures, grain boundary characteristics, and in-service oxide layers. The results revealed significant differences between bolts exposed to 41 dpa and 29 dpa, including differences in recrystallization extent, deformation structures, and oxidation morphology. These findings establish critical baseline data for integration with advanced synchrotron-based high-energy X-ray microscopy (HEXM) and computational crystal plasticity models. Ultimately, the work supports improved mechanistic understanding and predictive capability regarding the long-term performance of reactor core internal components.

Lach, Tim [Oak Ridge National Laboratory (ORNL), O↗

DOE OSTI2022

Quantifying transport and electrocatalytic reaction processes in a gastight rotating cylinder electrode reactor via integration of Computational Fluid Dynamics modeling and experiments

Understanding the complexity of the multiple processes of mass, momentum, charge, and heat transport, and how these affect reaction kinetics at the electrode/electrolyte interface is one of the major challenges in the field of energy and catalysis. The rapid and rational scale-up of electrocatalytic systems to industrial scales require a detailed understanding of nonlinear transport-reaction processes, accessible only through the building of multi-physics models that capture with high fidelity the complexity of real-world devices. The gastight rotating cylinder electrode (RCE) reactor is a promising lab-scale tool that can decouple transport from intrinsic kinetics to generate data for first-principle models useful in the design of industrial, electrochemical reactors. Computational Fluid Dynamics (CFD) studies have previously been used to investigate the bulk flow in RCE reactors for simple corrosion and electroplating processes. However, the quantification of changes in local concentration within the viscous layer where catalysis takes place requires capturing the correct flow conditions inside the hydrodynamic boundary layer near the surface of the electrode. Further, this requires simulations with spatial resolution in the nm and μm scale and temporal resolutions between ms and s scales that are similar to the timescales for reactions on the electrode surface. In this study, experimental electrocatalysis is combined with CFD modeling to elucidate and parameterize the hydrodynamics in a gastight RCE reactor. CFD simulations of the electrochemical ferricyanide reduction reaction under mass transport limited conditions are used to evaluate the validity of the CFD model parameters by comparing calculated dimensionless mass transport descriptors to dimensionless correlations obtained experimentally. Justifications for assumptions and details of the simulation methods used in this study are presented to provide a detailed understanding of the effect that each model parameter has on the ability to accurately simulate electrocatalysis in RCE systems. The simulation methodology reported here is a first step towards the development of multi-scale models for the study of transport dependent electrocatalytic processes, such as the electrochemical transformation of CO 2 to fuels and chemicals.

42 ENGINEERING↗

NASA NTRS1990

Analysis of a Mars-stationary orbiting microwave power transmission system

To determine the feasibility of providing efficient RF power transmission from a Mars-stationary orbit to the surface of the planet, an assessment was made focussing on RF propagation in the 2.45- to 300-GHz range. The proposed orbiting system configuration provides for power generation by either photovoltaic array or nuclear reactor, the conversion of the dc output to RF, and subsequent propagation of RF energy from the orbiting array to the Martian surface. On the planet, a rectenna array will convert RF to dc power to be distributed for planetary power needs. Total efficiency of the energy conversion chain from dc to RF in orbit through RF to dc on the planetary surface was derived for several representative frequencies in the range of study. Tradeoffs between component efficiency and transmitting antenna requirements were considered for each of these frequencies. Rectenna element power density thresholds and desired received power levels were used to determine receiving antenna criteria. Recommendations are presented for research into developing technologies which may afford enhanced viability of the proposed microwave power transmission system.

Long, Kenwyn J.↗

DOE OSTI2020

The Evaluation of Chemical Decontamination for Contaminated Carbon Steel Scrap by Multiphase Treatment Process - 20249

There is a significant growth in the field of decommissioning of nuclear facilities due the fact that for a lot of them their end of life is nearing. In Taiwan, the government plans to steadily reduce the dependence on nuclear power and moves gradually towards a nuclear-free homeland. Therefore, the development of decommissioning technology becomes the significant issue for the next coming years. The decommissioning of a nuclear power plant is a long process and practical work including radiological surveys, decontamination, dismantling, and the subsequent waste management. Chemical decontamination is an important task in the decommissioning of nuclear power plants and is usually performed by circulating the chemical solution in selected systems or full systems in order to reduce dose levels. However, the decontamination of segmented metal parts is also considered to reduce the contamination to such levels that they may be disposed of at a lower classification or be unconditionally released, and it helps to achieve the goal of waste minimization and provide a more economical cost for disposal management. Chemical decontamination technology is used to remove the contaminated oxides deposited on the surface of metals by dissolving them with chemical mechanisms, such as chelation, acidic or alkaline dissolution, redox reaction and so on. Carbon steel is the major material used in systems and pipelines in the nuclear power plant, thus it is also commonly selected as the target to be decontaminated in the decommissioning process. In this study, the effectiveness of chemical decontamination is evaluated by using multiphase treatment process including the reduction and the oxidation steps. In the step of redox reaction, the oxidation state of the substance is very important. Especially metals of some oxidation states show solubility in water, which has a decisive influence on the chemical decontamination. The experiment of decontamination of metal scraps is carried out by the immersion method within a chemical solution. The relative operation parameters such as temperature, pH, and concentration of the chemical solution are recorded to demonstrate the effect of the decontamination process. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Scalable Solar Fuels Production in A Reactor Train System by Thermochemical Redox Cycling of Novel Nonstoichiometric Perovskites

Hydrogen production via two-step thermochemical water splitting redox cycles using nonstoichiometric redox-active metal oxides has the potential to dramatically increase fuel production rates. At moderate-to-low water splitting temperatures, surface reaction kinetics co-limit the process. In such cases, stable and high surface area microstructures that allow exploitation of the full thermodynamic potential of the materials are essential as is tight thermal integration of the reactor module. This project’s goals were the development of novel nonstoichiometric perovskite oxides with high stability and favorable thermodynamic and kinetic properties, to optimize their microstructure for maximizing the fuel productivity, and to build a prototype reactor train system (RTS) comprising at least one reactor to meet specific performance targets: (1) capable of an in-house solar thermochemical hydrogen (STCH) productivity ≥ 12 mL g -1 for stable continuous operation ≥ 20 cycles; and (2) demonstration of scalable solar fuels production at practical solar reactor level in an industrial-scale concentrated solar tower (CST) using developed perovskites to achieve a hydrogen production rate ≥ 1 g h -1 .

08 HYDROGEN↗

DOE OSTI2020

(Oxy)hydroxides Formed on Aluminum Fuel Materials After Irradiation and Long-Term Wet Storage - 20354

The aluminum cladding of research-reactor fuel experiences general corrosion when in contact with water during in-reactor service and post-discharge wet storage, resulting in the formation of adherent aluminum (oxy)hydroxide films. These (oxy)hydroxides contain chemically-bound water that poses challenges for extended dry storage due to the risk of thermal or radiolytic decomposition releasing free water and/or hydrogen and oxygen gases. This study describes characterization of the (oxy)hydroxides present on several aluminum materials used in reactor operation and subsequently stored wet in the L-Basin storage facility at the Savannah River Site (SRS) for an extended period. Characterization data providing insight into the loading, composition, and morphology of (oxy)hydroxides to be expected on service-exposed aluminum cladding provides valuable benchmarks for designing adequate drying and dry-storage approaches. This work is part of a broader investigation to address knowledge gaps and technical data needs for dry storage of aluminum-clad spent nuclear fuel (ASNF), which included in-lab growth of (oxy)hydroxide films on aluminum alloy substrates to investigate formation behavior, investigation of drying methods to remove existing (oxy)hydroxides from ASNF cladding, and measurement of radiolytic yield of hydrogen from (oxy)hydroxide powders and films. In this study, (oxy)hydroxide films were characterized for three aluminum-alloy materials used in reactors and subsequently stored wet for up to approximately 40 years in L-Basin at SRS: one cropping from a Missouri University Research Reactor (MURR) fuel element (Al-6061 alloy), one cropping from a Universal Sleeve Housing (USH) (Al-6063 alloy), and one Mark-16B fuel assembly (either Al-6061 or Al- 6063). The USH and Mark-16B were used in SRS production reactors. Characterization of the as-received (oxy)hydroxides included scanning electron microscopy (SEM) in both plan-view and cross-section to characterize the (oxy)hydroxide layer's morphology, thickness, and structure. X-ray diffraction (XRD) was used to identify the chemical composition and distinguish between the various aluminum (oxy)hydroxides known to form under reactor and storage conditions. XRD analysis revealed both bayerite (Al(OH)3) and boehmite (AlOOH) on the surface of the MURR and USH samples, as well as bayerite, boehmite, and gibbsite (another Al(OH)3 polymorph) on the surface of the Mark-16B sample. The aluminum trihydroxides, bayerite and gibbsite, are typically associated with corrosion in low-temperature (<80 deg. C) water, while boehmite is expected to form at higher water temperature (>80 deg. C). The presence of bayerite on the USH, which is believed to have operated close to 90 deg. C, suggests that boehmite formed during in-reactor exposure was not protective against further hydroxide growth in low-temperature wet storage. Cross-section scanning electron microscopy (SEM) showed total (oxy)hydroxide layer thicknesses of ∼5- 10 μm for the MURR and ∼5-15 μm for the Mark-16B. The thickness of the USH's (oxy)hydroxide layer was indiscernible by the current mounting and imaging method, despite plan-view SEM and XRD confirming the presence of an (oxy)hydroxide layer. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

KRUSTY Reactor Design

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a reactor design, development, and test program to demonstrate the nuclear operation of a Kilopower reactor. Kilopower systems are intended to provide between 1 and 10 kW(electric) in space, or on the surface of planets or moons, with a clear evolution to substantially higher power systems. KRUSTY was a prototype of a 1-kW(electric) highly enriched uranium–fueled Kilopower system. In March of 2018, KRUSTY successfully operated as a fission power system and was the first nuclear-powered operation of any truly new reactor concept in the United States in over 40 years. This paper discusses the design of the KRUSTY reactor along with the philosophy, goals, and engineering work that ultimately led to KRUSTY’s success.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2020

KRUSTY Reactor Design

Kilopower↗

NASA NTRS2008

Analysis of Thermal and Reaction Times for Hydrogen Reduction of Lunar Regolith

System analysis of oxygen production by hydrogen reduction of lunar regolith has shown the importance of the relative time scales for regolith heating and chemical reaction to overall performance. These values determine the sizing and power requirements of the system and also impact the number and operational phasing of reaction chambers. In this paper, a Nusselt number correlation analysis is performed to determine the heat transfer rates and regolith heat up times in a fluidized bed reactor heated by a central heating element (e.g., a resistively heated rod, or a solar concentrator heat pipe). A coupled chemical and transport model has also been developed for the chemical reduction of regolith by a continuous flow of hydrogen. The regolith conversion occurs on the surfaces of and within the regolith particles. Several important quantities are identified as a result of the above analyses. Reactor scale parameters include the void fraction (i.e., the fraction of the reactor volume not occupied by the regolith particles) and the residence time of hydrogen in the reactor. Particle scale quantities include the particle Reynolds number, the Archimedes number, and the time needed for hydrogen to diffuse into the pores of the regolith particles. The analysis is used to determine the heat up and reaction times and its application to NASA s oxygen production system modeling tool is noted.

Hegde, U.↗

NASA NTRS2009

Analysis of Thermal and Reaction Times for Hydrogen Reduction of Lunar Regolith

Hegde, U.↗

DOE OSTI2023

Design of a prototypical natural circulation water-based reactor cavity cooling system (RCCS) for a pebble-bed generic FHR

A prototypical natural circulation water-based reactor cavity cooling system (RCCS) for the UC Berkeley Mark-1 pebble-bed gFHR is designed based on one-dimensional thermal hydraulics modeling and optimization implemented in an in-house MATLAB code. The model employs a lumped core consisting of fuel pebble and graphite pebble regions, while the graphite reflector, vessel, and RCCS are represented as separate but energy-coupled regions. The model is derived based on steady state energy balance equations accounting for conductive heat transfer from the lumped core to the vessel and subsequent radiative heat transfer to the RCCS and convective heat transfer in the water. Further, mass flow rate is calculated based on momentum and thermal energy balance in the RCCS. Starting with ANL’s water NSTF as baseline, effects of RCCS design parameters such as size of the plate between pipes, pipe diameter, source-to-sink distance, surface emissivity, and pitch from the core are examined in an integral effects framework which accounts for subsequent variation of the mass flow rate, number of pipes, convection coefficient, mean region and surface temperatures, radiative view factors, and water outlet temperature. The importance of including a prototypical reactor design in RCCS design calculations is emphasized as the calculations show that temperature drops from the core to the RCCS fluid to transfer the heat tend to be the limitation not the heat removal capacity of the fluid. A closed-loop design is obtained with capability to safely remove up to 0.72% of the nominal reactor power at maximum estimated peak conditions and 0.40% at shutdown. The design is based on physics calculations and does not account for economic optimization.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Evaluation of the anisotropic grain boundaries and surfaces of α -U via molecular dynamics

Alloys based on uranium-zirconium are gaining renewed interest as fuels for the Versatile Test Reactor and a number of microreactor designs. Implementing metallic fuel in reactors creates the need for robust descriptive and predictive fuel performance modeling. Here, the current state of metallic fuel performance modeling relies on empirical equations derived from historical experiments, which may be unreliable when applied outside of their temperature, power, and composition phase space. One area where such data is lacking is the irradiation behavior of alpha -U, specifically tearing and porosity formation at the early stages of irradiation. While grain boundaries likely play a key role in this fuel behavior, relatively little is known about grain boundaries in alpha-U. Thus, we evaluate the grain boundary, surface energy, and work of adhesion of alpha -U utilizing molecular dynamics. Symmetric tilt grain boundaries (STGBs) are analyzed with the tilt plane oriented along each major crystallographic axis, for a total of eighty unique grain boundaries. The effect of temperature, tilt plane, and misorientation angle on interfacial energies are analyzed. The interfacial energies typically increase with temperature and there is significant variance as a function of misorientation angle, irrespective of the tilt plane. At 500 K, the average surface energy (1.23 J/m 2 ) is approximately 1.5 times the grain boundary energy (0.79 J/m 2 ), and the work of adhesion is approximately twice the grain boundary energy (1.68 J/m 2 ). Orientations for the likely formation of twins and likely failure planes are identified.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Continuous Flow Photoelectrochemical Reactor with Gas Permeable Photocathode: Enhanced Photocurrent and Partial Current Density for CO 2 Reduction

Photoelectrochemical (PEC) CO 2 reduction using a photocathode is an attractive method for making valuable chemical products due to its simplicity and lower overpotential requirements. However, previous PEC processes have often been diffusion-limited leading to low production rates of the CO 2 reduction reaction, due to inefficient gas diffusion through the liquid electrolyte to the catalyst surface, particularly at high current densities. In this study, a gas-permeable photocathode in a continuous flow PEC reactor is incorporated, which facilitates the direct supply of CO 2 gas to the photocathode-electrolyte interface, unlike dark reaction-based flow reactors. This concept is demonstrated using Ag-TiO 2 on carbon paper, illuminated through a quartz window and flowing liquid electrolyte. CO 2 supply is managed via pressure and flow control on the non-illuminated side of the carbon paper. The photocurrent density is significantly influenced by the flow rates and pressure of CO 2 gas, and the electrolyte flow rates. Compared to the traditional H-cell, the continuous PEC flow reactor achieves ≈10-fold increase in CO faradaic efficiency, 30-fold increase in production rate and 16-fold increase in stability without catalyst modifications. This work provides essential insights into the design and application of continuous gas-liquid flow PEC reactor systems, highlighting their potential for other PEC reactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Dynamic Probabilistic Risk Assessment Based Response Surface Approach for FLEX and Accident Tolerant Fuels for Medium Break LOCA Spectrum

After the Fukushima Daiichi Accident, the safety features such as accident tolerant fuel (ATF) and diverse and flexible coping strategies (FLEX) for existing nuclear fleets are being investigated by the US Department of Energy under the Light Water Reactor Sustainability Program. This research is being conducted to quantify the risk-benefit of these safety features. Dynamic probabilistic risk assessment (DPRA)-based response-surface approach has been presented to quantify the FLEX and ATF benefits by estimating the risk associated with each option. ATFs with multilayered silicon carbide (SiC), iron-chromium-aluminum, and chromium-coated zirconium cladding were considered in this study. While these ATF candidates perform better than the current zirconium cladding (Zr), they may introduce additional failure modes in some operating conditions. The fuel failure analysis modules (FAMs) were developed to investigate ATF performance. The dynamic risk assessments were performed using RAVEN, a DPRA tool, coupled with RELAP5 and FAMs. A cumulative distribution function-based index provided a mean of comparing the benefits of safety enhancements. For medium break loss of coolant accidents, FLEX operational timing window for each fuel type was estimated. Among these ATF candidates, SiC-type ATF was the most beneficial candidate for an increased safety margin than Zr-based fuel and was found to complement FLEX strategies in terms of risk and coping time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Multiscale Catalytic Fast Pyrolysis of Grindelia Reveals Opportunities for Generating Low Oxygen Content Bio-Oils from Drought Tolerant Biomass

Grindelia squarrosa (curlycup gumweed) biomass possesses unique biochemistry, cell wall composition, and leaf architecture tailored for prolific growth in arid and semiarid climates. Most notably, this plant has developed high levels of extractable resins that have high effective H/C eff ratios ((mol H - 2 x mol O)/mol C), which is hypothesized to lead to low coke formation during catalytic fast pyrolysis (CFP) over the ZSM-5 catalyst. In microscale experiments with high ZSM-5 loadings (biomass-to-catalyst mass ratio (B/C) ~ 0.1), in situ CFP generated high yields of aromatic hydrocarbons (30% carbon yield) while ex situ CFP favored aliphatic hydrocarbons (25% carbon yield). The difference between the two configurations was attributed to the constant catalyst temperature during ex situ CFP. Deactivation leading to partially deoxygenated vapor products occurred rapidly until B/C ≤ 0.5 by the adsorption of organic species blocking access to acid sites inside the micropores of the catalyst. This was followed by more gradual deactivation leading to primary vapor breakthrough, which we attribute to coke formation on acid sites on the external surface of ZSM-5 crystallites. Noncatalytic fast pyrolysis of Grindelia in a bench scale reactor produced oils with oxygen content (18 wt % on dry basis) and carbon yield (33%) comparable to those of CFP of woody biomass. The CFP of Grindelia further reduced the oxygen content to 7 wt % for in situ CFP and 4 wt % for ex situ CFP at B/C of 2-3. The good deoxygenation was attributed to a combination of a high H/C eff ratio and overall better quality of the pyrolysis vapors that were passed over the ZSM-5 catalyst. The high inorganic content of the Grindelia likely catalyzed pyrolysis to remove oxygenated coke precursors. This integrated CFP study demonstrated that Grindelia could be an important feedstock for generating stabilized noncatalytic and CFP oils for downstream processing into fuels and/or extraction of high-value chemicals. The preprocessing of this feedstock will be required to remove inorganics, which cause an irreversible deactivation of ZSM-5.

BIOMASS FUELS↗

DOE OSTI2023

Conference Report on the 7th International Symposium on Liquid metals Applications for fusion (ISLA-7)

Supported by the world magnetic fusion research community, a series of International Symposia on Liquid metals Applications for fusion (ISLA) have been held biannually since 2010. The 7th edition (ISLA-7) was held for the period from 12 December through 16 December 2022, at Chubu University located in Kasugai, Aichi, Japan. For the first time in the history of this series of symposia, ISLA-7 was held in a hybrid fashion, due to the COVID-19 situation. The total number of the participants was 60, 34 out of whom attended the symposium in person, and the rest participated online. As to the presentation statistics, 29 papers were presented in person, whereas 21 presentations were delivered online but real-time by the presenters in China, Spain, the UK, and the USA. Both of the presentations delivered in person and online were recorded, and the video has been shared by all participants. These participants represent 11 countries: China, Czech, Italy, Japan, Latvia, Netherlands, Russia, Thailand, the UK, and the USA. All these numbers are among the largest in this series of symposia. Covered by these presentations are; in session-2, program overviews and liquid metal research review; in session-3, liquid metal flows, and MHD issues; in session-4, liquid metal facilities; in sessions-5 and 6, liquid metal experiments and modeling; in session-7, divertor physics and heat flux mitigation; in session-8, plasma and liquid metals interactions; in session-9 liquid metal plasma-facing components, erosion, and wettability. In addition, there were an opening session whereby several opening addresses were delivered and also a closing session where all technical session summaries were presented by the respective session chairs.

divertor↗

DOE OSTI2023

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

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

01 COAL, LIGNITE, AND PEAT↗