Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “surface reactor”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

The TRANSCEND Consortium - In-situ Identification of Surface Corrosion Products on Spent Nuclear Fuels - 20276

The management of spent nuclear fuel is a major ongoing concern for the UK owing to the cessation of reprocessing operations at Sellafield and the large, complex inventory arising from Magnox, AGR, PWR and prototype reactors. Retrieval and relocation operations for legacy fuels are imminent and therefore, any models that enhance our understanding of fuel evolution will help mitigate the risks associated with fuel storage and disposal. The TRANSCEND Consortium on nuclear waste management comprises four work packages, within this current paper we provide a summary overview of progress to date and illustrative results from Theme 3: Spent Nuclear Fuels. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Laser Powder Bed Fusion Additive Manufacture Nb1Zr Development

Next generation fission and fusion nuclear reactors require materials that can withstand operating temperatures greater than 500 °C, neutron irradiation doses of up to 200 displacements per atom (dpa), and potentially corrosive coolants such as the alkali liquid metals sodium, lithium, and NaK (Na33K eutectic alloy). Refractory alloys, such as Nb1Zr (Nb-1wt%Zr) and Molybdenum alloy TZM (Mo-0.5wt%Ti-0.08wt%Zr) have been traditionally considered viable candidates for advanced fission and fusion reactor concepts. However, it is relatively difficult to generate complex geometries of interest from these alloys using traditional manufacturing methods. In addition, there needs to be a concentrated effort to address refractory metal challenges at elevated temperature operation. In order to generate complex geometries of interest, modern manufacturing techniques are considered to increase the technological readiness level (TRL), cost-effectiveness, and schedule savings. This work focused on the continued development of laser powder bed fusion (L-PBF) additive manufacturing (AM) to improve both design flexibility, evaluate microstructure and properties, and ultimately accelerate the TRL and qualification of these processes and alloys for components to potentially be put into service. Niobium alloy Nb1Zr was identified through a down-selection process outlined in previous reports as a candidate to develop in L-PBF AM. Historically, Nb1Zr had been explored for high temperature fast spectrum fission reactors for both terrestrial and space applications. Molybdenum alloy TZM has also been considered for these reactor concepts due to exceptional high-temperature strength, creep resistance, and stability under irradiation. L-PBF AM of TZM has previously been investigated at LANL under the Microreactor program, NASA, ORNL, and in academia. However, due to the crack prone nature of TZM, L-PBF AM of TZM resulted in significant microcracking and additional development is required to pursue viable maturation. Other AM methods have been found to be more successful in printing TZM, and those alternatives approaches are discussed in this effort. The efforts detailed in this report focused on continued development of Nb1Zr through L-PBF and development of TZM via L-PBF and electron powder bed fusion (E-PBF). The objective of this work was to further the development of these AM techniques for the chosen refractory alloys, elucidating and addressing associated challenges through characterization of several demonstration builds. At LANL, Nb1Zr builds were completed using an EOS M290 and M400 machines, and a refractory alloy-dedicated L-PBF system, the Xact Metal XM200G, was installed. The XM200G primary purpose was to do the Nb1Zr parameter development process; however, due to difficulties associated with the machine installation and qualification process, it was decided to pivot development to the larger M400 and M290 machines. Although the supply of Nb1Zr powder was limited, it was sufficient to generate sub-scale metallographic specimens for the purpose of parameter development. This was first accomplished on the EOS M400 then the M290 due to machine schedule availability. Further development of TZM has been initiated at the University of Texas El Paso (UTEP) under contract with LANL to use both a heated build envelope L-PBF machine and E-PBF machine that have been found in the literature to mitigate microcracking. UTEP was provided with TZM powder and build plates to support parallel TZM parameter development across both machines. As part of the contract, UTEP will also be conducting microstructural characterization once optimized process parameters have been identified. The optimized process parameters for each machine will be used to generate a series of metallographic, mechanical, and surface finish specimens for subsequent characterization and testing. In the next section, we provide a detailed discussion of the methodology used for investigating the feasibility of leveraging these alloys for use in advanced reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Interpretation of Ion Irradiation and Neutron Irradiation Damage in Additively Manufactured 316 Stainless Steel using Multiscale Modeling

The accelerated adoption of nuclear energy necessitates advanced manufacturing technologies, such as additive manufacturing, to meet heightened supply chain requirements and support innovative reactor technologies. Due to the unique microstructural characteristics of additively manufactured materials under distinct solidification conditions, comprehensive evaluation of their performance in reactor environments is essential. The Advanced Materials and Manufacturing Technologies program under the Department of Energy's Office of Nuclear Energy focuses on understanding the irradiation performance and damage evolution of laser powder bed fusion 316 stainless steel, with an emphasis on integrating ion and neutron irradiation data to accelerate the development and qualification of materials for advanced nuclear reactor applications. While ion irradiation is a cost- and time-effective method, modeling and simulation are required to interpret the data for the broader range of irradiation conditions encountered in advanced reactors. In fiscal year 2025, integrated multiscale modeling and simulations were conducted to assess irradiation damage in additively manufactured 316 stainless steel. Key outcomes include predictions of chromium enrichment at grain boundaries, nickel enrichment at dislocation cell walls and void surfaces, and heterogeneous void evolution under ion and neutron irradiation conditions. Cluster dynamics simulations revealed the coarsening of voids at high irradiation temperatures and the suppression of void growth by high network dislocation density, while also demonstrating significant growth and coarsening of voids and self-interstitial atom loops at low dose rates. Machine learning-accelerated atomistic simulations highlighted the impact of the local environment and chromium concentration on vacancy diffusivity, providing key insights on the influence of composition on void swelling and radiation-induced segregation. Additionally, molecular dynamics simulations demonstrated the presence of defect production bias and a significant effect of carbon content on defect cluster behavior. These combined efforts aim to predict the performance of additively manufactured materials under various reactor conditions, supporting their qualification for nuclear reactor applications by interpreting ion irradiation data. This report underscores the potential of integrated multiscale modeling to analyze ion irradiation data in the effort to accelerate the qualification of additively manufactured materials for nuclear reactor components.

316 stainless steel↗
DOE OSTI2023

Novel pyrolytic boron nitride coating to reduce graphite interactions in molten fluoride salt

Future salt reactors like the Fluoride-salt-cooled-High Temperature Reactor require varying material flavors. Graphite is required for neutron moderation and potential fuel forms, while structural metals are required for containment. Studies show graphite/metal interactions exist when both materials share a salt medium. These interactions may accelerate the corrosion of the metal and change the surface of graphite materials. A novel pyrolytic boron nitride coating on graphite is investigated for reducing graphite/metal interactions. Finally, this is the first known application of such a coating, and salt exposure tests reveal the pyrolytic boron nitride coating reduces the interactions between stainless steel and uncoated graphite.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Low-temperature oxidation of methane and methanol on iridium oxides

Iridium oxides (IrO 2 ) are of significant interest for low-temperature oxidation of small molecules such as CH 4 and CH 3 OH, although the physical origin of their high activity remains under debate. Here, we demonstrate that the enhanced activity of IrO 2 arises from the formation of coordinatively unsaturated (CUS) oxygen species. By combining ambient-pressure X-ray spectroscopy and density functional theory calculations, we present evidence for the formation of CUS oxygen during CH 4 and CH 3 OH oxidation. Such surface speciation correlates with the conversion of methane to carbon dioxide and methanol to methyl formate on rutile IrO 2 and hydrous IrO 2 powder catalysts in a plug-flow reactor at room temperature. These findings extend the understanding of the physical origin of the higher activity of iridium oxide thin-film catalysts to powder catalysts and provide insights into the tuneability of iridium-oxide-containing catalysts for low-temperature C–H and O–H bond activation.

AP-XPS↗
DOE OSTI2024

Coil optimization for quasi-helically symmetric stellarator configurations

Filament-based coil optimizations are performed for several quasi-helical stellarator configurations, beginning with the one from Landreman & Paul ( Phys. Rev. Lett. , vol. 128, 2022, 035001), demonstrating that precise quasi-helical symmetry can be achieved with realistic coils. Several constraints are placed on the shape and spacing of the coils, such as low curvature and sufficient plasma–coil distance for neutron shielding. The coils resulting from this optimization have a maximum curvature 0.8 times that of the coils of the Helically Symmetric eXperiment (HSX) and a mean squared curvature 0.4 times that of the HSX coils when scaled to the same plasma minor radius. When scaled up to reactor size and magnetic field strength, no fast particle losses were found in the free-boundary configuration when simulating 5000 alpha particles launched at $3.5\,\mathrm {MeV}$ on the flux surface with a normalized toroidal flux of $s=0.5$ . An analysis of the tolerance of the coils to manufacturing errors is performed using a Gaussian process model, and the coils are found to maintain low particle losses for smooth, large-scale errors up to amplitudes of approximately $0.15\,\mathrm {m}$ . Another coil optimization is performed for the Landreman–Paul configuration with the additional constraint that the coils are purely planar. Visual inspection of the Poincaré plot of the resulting magnetic field-lines reveal that the planar modular coils alone do a poor job of reproducing the target equilibrium. Additional non-planar coil optimizations are performed for the quasi-helical configuration with $5\,\%$ volume-averaged plasma beta from Landreman et al. ( Phys. Plasma , vol. 29, issue 8, 2022, 082501), and a similar configuration also optimized to satisfy the Mercier criterion. The finite beta configurations had larger fast-particle losses, with the free-boundary Mercier-optimized configuration performing the worst, losing approximately $5.5\,\%$ of alpha particles launched at $s=0.5$ .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Catalytic Upgrading of Ethanol to C8+ Distillate Range Ethers via Guerbet Coupling and Etherification

Guerbet coupling followed by etherification is a two step process for conversion of ethanol into distillate range molecules. This involves first alcohol oligomerization, followed by acid-catalyzed dehydration. As we will show in this presentation, ethanol can be converted to higher linear and α-branched alcohols by C-C coupling reactions (ethanol oligomerization) as well as to high molecular weight esters by C-O coupling reactions with Cu/MgxAlOy (CuHT) catalysts. Alcohols may be converted to ethers via bimolecular dehydration in a subsequent step. We have identified more than 160 number of species in the products including alcohols, esters, aldehydes, ketonces, and olefins. Alcohols range from C4 to C10. Both alcohols and esters follow a Schulz-Flory chain growth model. We show the relationship between the catalyst properties (BET surface area, acid and base site count and Cu loading and synthesis method) and the performance in the reactions. We also show that physical mixtures of CuHT and HT can have similar product selectivity of low loading CuHT catalysts. The selectivity towards diesel fuel precursor compounds (hereafter ‘DFPC’) increased with conversion until reaching a plateau at high ethanol conversion (~70%). Alcohol selectivity follows a Schultz-Flory distribution at all studied conversions, and that adsorbed ethanol-derived species may undergo surface oligomerization into 1-butanol and higher alcohols before desorbing in a chain-growth mechanism. Zeolite catalysts convert the C4+ alcohols into C8+ ethers in both batch and continuous flow reactors. Selectivities of up to 80% to C8+ ethers at around 70% conversion using a single pass continuous flow system are able to be achieved. The final product feedstocks obtained from etherification have been used in technoeconomic (TEA) and lifecycle analysis (LCA), which indicate a reduction in greenhouse gas (GHG) emissions of 50% relative to conventional diesel. These final feedstocks are undergoing engine testing to elucidate the physiochemical properties and will be compared to diesel #2 ASTM standards as a reference and will serve as a basis to improve the final bio-diesel blendstocks from etherification.

Huber, George↗
DOE OSTI2023

Catalytic upgrading of ethanol to C8+ distillate range ethers via Guerbet coupling and etherification

In this presentation we describe the catalytic approaches for conversion of ethanol into diesel fuel ethers. This involves first alcohol oligomerization, followed by acid-catalyzed dehydration. As we will show in this presentation, ethanol can be converted to higher linear and α-branched alcohols by C-C coupling reactions (ethanol oligomerization) as well as to high molecular weight esters by C-O coupling reactions with Cu/MgxAlOy (CuHT) catalysts. Alcohols may be converted to ethers via bimolecular dehydration in a subsequent step. We have identified more than 160 number of species in the products including alcohols, esters, aldehydes, ketones, and olefins. Alcohols range from C4 to C10. Both alcohols and esters follow a Schulz-Flory chain growth model. We show the relationship between the catalyst properties (BET surface area, acid and base site count and Cu loading and synthesis method) and the performance in the reactions. We also show that physical mixtures of CuHT and HT can have similar product selectivity of low loading CuHT catalysts. The selectivity towards diesel fuel precursor compounds (hereafter ‘DFPC’) increased with conversion until reaching a plateau at high ethanol conversion (~70%). Alcohol selectivity follows a Schultz-Flory distribution at all studied conversions, and that adsorbed ethanol-derived species may undergo surface oligomerization into 1-butanol and higher alcohols before desorbing in a chain-growth mechanism. Zeolite catalysts convert the C4+ alcohols into C8+ ethers in both batch and continuous flow reactors. Selectivities of up to 80% to C8+ ethers at around 70% conversion using a single pass continuous flow system are achieved. The final product feedstocks obtained from etherification have been used in technoeconomic (TEA) and lifecycle analysis (LCA), which indicate a reduction in greenhouse gas (GHG) emissions of 50% relative to conventional diesel and diesel fuel prices that are lower than biodiesel. These final feedstocks are undergoing engine testing to elucidate the physiochemical properties and compare well to diesel #2 ASTM standards.

Huber, George↗
DOE OSTI2020

Effects of cation stoichiometry on surface morphology and crystallinity of ZnGeN 2 films grown on GaN by metalorganic chemical vapor deposition

ZnGeN 2 films were grown on GaN-on-sapphire templates via metalorganic chemical vapor deposition. Energy dispersive X-ray spectroscopy was used to estimate the Zn/(Zn+Ge) composition ratio in the films. This ratio decreased with increase in growth temperature but increased with increase in total reactor pressure or Zn/Ge precursor flow rate ratio. Systematic mapping of these key growth parameters has allowed us to identify the growth window to achieve ZnGeN 2 with stoichiometric cation composition. Compositional and statistical analyses performed on data acquired from atom probe tomography provided insight into the local compositional homogeneity. The cations Zn and Ge did not demonstrate segregation or clustering at the sub-nanometer level. Based on X-ray diffraction 2θ-ω scan profiles and transmission electron microscope nano-diffraction patterns, the films with near-stoichiometric cation ratios were single crystalline with planar surfaces, whereas zinc-rich or zinc-poor films were polycrystalline with nonplanar surfaces. The growth direction of the single crystalline ZnGeN 2 films on GaN templates was along the c-axis. Room temperature Raman spectra showed features associated with the phonon density of states, indicating the presence of cation disorder in the lattice. A cathodoluminescence peak associated with transitions involving deep level defects was observed around 640 nm. The intensity of this peak increased by almost 2.5 times as the temperature was reduced to 77 K from room temperature. A similar peak was observed in photoluminescence spectra collected at 80 K.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Development of a Chlorine Cathode and Anode Basket Assembly for Production of Uranium Chloride

A chlorine cathode has been developed for in situ chlorination of metals, oxides, and oxychlorides in molten chloride electrolytes that could be used to support synthesis of chloride fuel salts for molten salt reactors. The chlorine cathode is designed to electrochemically reduce chlorine gas to generate chloride ions that, when paired with a metal anode, chlorinate that metal as it is oxidized into the salt. The designed porous carbon electrode effectively distributes Cl 2 to the electrode surface and efficiently generates Clions in the molten chloride electrolyte. This report highlights recent improvements made to the electrode assembly, with a focus on operational control of the anode basket stability. Synthesis tests demonstrated the successful chlorination of uranium metal, resulting in 3.6 wt% uranium generated in the LiCl-KCl base salt in 45 minutes, performed in a bench-scale chlorination apparatus. Higher concentrations could be achieved by applying longer chlorination times or increasing the amount of uranium loaded in the anode basket. Overall, the chlorine cathode can be used with an appropriately designed anode to chlorinate uranium in situ for synthesis of molten salt reactor fuel salts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Towards the Development of Molten Salt Reactor Multiphysics Modeling Capabilities: Depletion, Thermochemistry, Reactor Dynamics, and Species Tracking

This report documents the simulation and modeling work performed under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, utilizing the tools and codes developed under the program. The focus in this Fiscal Year (FY) is on the depletion, thermochemistry, reactor dynamics, and species transport in MSRs. The fission products travelling in the entire primary loop is unique in MSRs. There are many physical/chemical mechanisms that can significantly affect the fission products concentration in the fuel salt, e.g., diffusion into gas bubbles, diffusion in the core moderators, deposition on the surface of structures/pipes, etc. The fission product concentration in the fuel salt can potentially affect the neutronics, system dynamics, chemical potentials, etc., so accurately predicting the fission products distribution in the primary loop is important. Under the main objective, different activities are pursued to assess the NEAMS tools applicability for a variety of areas on species transport, including the depletion analyses using Griffin (fission product source), the redox potential assessment at different depletion points, the assessment of xenon transport effect on the neutronics and reactor dynamics, a survey of correlations for calculating the mass transfer coefficient of different fission products, etc.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Developing Materials for Extreme Environments and Their Use in Nuclear Waste Canisters and Reactors - 20559

The paper focuses on the development of materials which can be utilized in extreme industrial environments. The paper discusses the advancement of materials and their application in components which are utilized in extreme industrial environments as such that of the nuclear field and especially in the nuclear waste field. Nuclear power plants have become an indispensable part of the electricity generation, medical, food processing and many other industries. Though burning small amount of fuel as compared to conventional power plants, they also create waste which is not easy to handle as other types of wastes. The nuclear waste sitting at the bottom of spent fuel tanks around the globe has raised public concerns on how it will be dealt with. Europe has started to give an answer by working on geological repositories. Though till yet, waste has been cooled in spent fuel tanks and after processing, is precisely placed in nuclear waste canisters and casks and transported to sites across the country for further cooling and storage. Though in all this process there had been a great deal of advancement on the type of casks and canisters used and the processes for transporting nuclear material and waste. Often reports about radioactive material leakage, moisture content inside barrels etc. has surfaced. Be it official or unofficial report, there seems a technical failure on how the nuclear waste has been stored and placed at facilities around the globe. The other aspect of this material development is to be beneficial for nuclear reactors. As the technology gets advanced, nuclear reactors change their titles from Gen II to Gen III and so on. The new fleet of upcoming reactors will be exceptionally safer, reliable and more efficient. But these benefits will also bring drawbacks with them. As these reactors will operate at high temperature (above 800 degree Celsius) they also ask for advancement in materials used in the reactor core, fuel used, reactor control etc. The paper tries to answer such concerning questions. The work shows the study done on different material that can be better candidates for extreme environments. (authors)

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

Radiation effects in Mn+1AXn phases

M n+1 AX n phases exhibit unique laminated atomic structures that result in properties typical of both ceramics and metals. Due to their unusual characteristics, these materials have been proposed for use in a wide variety of industrial applications, including in nuclear reactors—both fission and fusion systems—where they will be exposed to extreme irradiation conditions and high temperatures. Recently, numerous studies have investigated radiation effects on the M n+1 AX n phases, revealing complex behavior—phase transformations, surface modification, and mechanical property changes—induced by ion or neutron irradiation over a range of temperatures. This review summarizes recent experimental and theoretical work on the response of the M n+1 AX n phases to irradiation and discusses the intrinsic controls on the radiation tolerance of these materials. Based on the review of the present body of work, a comprehensive understanding of the mechanisms of irradiation-induced structural modification and defect evolution in M n+1 AX n phases is developed, as well as proposed strategies for designing novel M n+1 AX n phases with enhanced performance under extreme irradiation conditions.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

High-resolution characterization of ceramic-metal interface of TiN coating on ferritic-steels for nuclear application

Advanced fuel cladding is critical for fast reactors, offering sufficient thermal conductivity, mechanical and dimensional stability and radiation tolerance of the cladding base material. Additionally, it must provide corrosion resistance and high temperature coolant compatibility on the cladding outer surface, as well as chemical stability on the cladding inner wall against fuel cladding chemical interaction (FCCI). TiN ceramic coating has been considered an effective diffusion barrier for inner and outer cladding-walls for enhanced performance. The TiN-metal interface microstructure and chemistry play a critical role in coating bond strength and integrity under harsh conditions. High-resolution transmission electron microscopy characterization of ceramic-metal interface at atomic resolution in unirradiated, irradiated and thermal cycled conditions were performed. The interface remained intact after irradiation up to 200 dpa or thermal cycling five times up to 550 °C. In conclusion, this work discusses the potential impact of these results on coating performance and design for advanced claddings.

36 - MATERIALS SCIENCE↗
DOE OSTI2022

Deformation mechanism in nanolaminate FeCrAl alloys by ,em>in situ micromechanical strain rate jump tests at elevated temperatures

FeCrAl alloys have attracted extensive attention as one of the potential cladding materials for the commercial light water reactors. Although the creep behaviors of coarse-grain FeCrAl alloys have been investigated at elevated temperatures, little is known on the deformation mechanism of fine-grain FeCrAl alloys. We performed surface mechanical grinding treatment to fabricate nanolaminated ferritic FeCrAl alloys. In situ micropillar compression tests were applied to determine the underlying deformation mechanism of nanolaminated FeCrAl alloys at elevated temperatures. The strain rate sensitivity and activation energy for the dominant deformation mechanism were estimated considering the presence of a threshold stress.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Three-chamber electrochemical reactor for selective lithium extraction from brine

Efficient lithium recovery from geothermal brines is crucial for the battery industry. Current electrochemical separation methods struggle with the simultaneous presence of Na + , K + , Mg 2+ , and Ca 2+ because these cations are similar to Li + , making it challenging to separate effectively. We address these challenges with a three-chamber reactor featuring a polymer porous solid electrolyte in the middle layer. This design improves the transference number of Li + (t Li+ ) by 2.1 times compared to the two-chamber reactor and also reduces the chlorine evolution reaction, a common side reaction in electrochemical lithium extraction, to only 6.4% in Faradaic Efficiency. Employing a lithium-ion conductive glass ceramic (LICGC) membrane, the reactor achieved high t Li+ of 97.5% in LiOH production from simulated brine, while the concentrations of Na + K + , Mg 2+ , and Ca 2+ are below the detection limit. Electrochemical experiments and surface analysis elucidated the cation transport mechanism, highlighting the impact of Na + on Li + migration at the LICGC interface.

Science & Technology - Other Topics↗
DOE OSTI2022

Catalytic resonance of ammonia synthesis by simulated dynamic ruthenium crystal strain

Ammonia affords dense storage for renewable energy as a fungible liquid fuel, provided it can be efficiently synthesized from hydrogen and nitrogen. In this work, the catalysis of ammonia synthesis was computationally explored beyond the Sabatier limit by dynamically straining a ruthenium crystal (±4%) at the resonant frequencies (10 2 to 10 5+ Hz) of N 2 surface dissociation and hydrogenation. Density functional theory calculations at different strain conditions indicated that the energies of NH x surface intermediates and transition states scale linearly, allowing the description of ammonia synthesis at a continuum of strain conditions. A microkinetic model including multiple sites and surface diffusion between step and Ru(0001) terrace sites of varying ratios for nanoparticles of differing size revealed that dynamic strain yields catalytic ammonia synthesis conversion and turnover frequency comparable to industrial reactors (400°C, 200 atm) but at lower temperature (320°C) and an order of magnitude lower pressure (20 atm).

10 SYNTHETIC FUELS↗
DOE OSTI2026

Combined Nitrogen and Phosphorous Recovery via Electrochemical Technology Integration into Municipal Wastewater Treatment Plants

This project developed electroN-P, an electrochemical technology for recovering nitrogen and phosphorus as a fertilizer product from anaerobic digester centrate, targeting an advancement from TRL 4 to 6. The reactor was scaled 220× from a 250 mL batch cell to a continuous 4-channel system treating 55 L of wastewater, recovering >80% of phosphorus. Energy consumption under constant-voltage operation was lower than the embedded energy of conventional fertilizers, while constant-current operation produced a cost-competitive product with a smaller reactor footprint. TEA and LCA outcomes were highly sensitive to the magnesium source; alternative magnesium salt configurations projected reduced costs and embedded energy compared to sacrificial rods, but at the expense of significantly longer operation times. The recovered fertilizer performed comparably to diammonium phosphate and triple superphosphate in soil and plant trials. Integrating the technology into a whole-plant model reduced aeration energy by nearly 50%, lowering the levelized cost of water treatment from $0.668/m 3 to $0.648/m 3 . Results support targeting commercialization at smaller (≤1 MGD) facilities with high-strength digester streams. Further investigation into the transport and corrosion kinetics governing sacrificial anode wear is recommended to support continuous, longer-term operation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗