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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Novel Module Architecture for Lower CapEx and Improved Recyclability for c-Si PV Modules

Photovoltaic (PV) energy production is currently increasing at a rate at which recycling is becoming necessary. A novel module architecture has been demonstrated that has potential for high value recycling for c-Si PV. This architecture eliminates the vacuum lamination process and cross-linked en capsulants. Functioning prototypes of c-Si have been fabricated for stress testing in collaboration with NREL. These modules are being tested against traditionally manufactured modules. Based on preliminary results, this module architecture is a potentially viable solution for improving the manufacturing cost and recyclability of PV modules while retaining module performance.

computer architecture↗
DOE OSTI2017

Scale-up of high specific activity 186g Re production using graphite-encased thick 186 W targets and demonstration of an efficient target recycling process

Production of high specific activity 186g Re is of interest for development of theranostic radiopharmaceuticals. Previous studies have shown that high specific activity 186g Re can be obtained by cyclotron irradiation of enriched 186 W via the 186 W(d,2n) 186g Re reaction, but most irradiations were conducted at low beam currents and for short durations. In this paper, enriched 186 W metal targets were irradiated at high incident deuteron beam currents to demonstrate production rates and contaminants produced when using thick targets. Full-stopping thick targets, as determined using SRIM, were prepared by uniaxial pressing of powdered natural abundance W metal or 96.86% enriched 186 W metal encased between two layers of graphite flakes for target material stabilization. An assessment of structural integrity was made on each target preparation. To assess the performance of graphite-encased thick 186 W metal targets, along with the impact of encasing on the separation chemistry, targets were first irradiated using a 22 MeV deuteron beam for 10 min at 10, 20, and 27 μA, with an estimated nominal deuteron energy of 18.7 MeV on the 186 W target material (after energy degradation correction from top graphite layer). Gamma-ray spectrometry was performed post EOB on all targets to assess production yields and radionuclidic byproducts. The investigation also evaluated a method to recover and recycle enriched target material from a column isolation procedure. Material composition analyses of target materials, pass-through/wash solutions and recycling process isolates were conducted with SEM, FTIR, XRD, EDS and ICP-MS spectrometry. Finally, to demonstrate scaled-up production, a graphite-encased 186 W target made from recycled 186 W was irradiated for ~2 h with 18.7 MeV deuterons at a beam current of 27 μA to provide 0.90 GBq (24.3 mCi) of 186g Re, decay-corrected to the end of bombardment. ICP-MS analysis of the isolated 186g Re solution provided data that indicated the specific activity of 186g Re in this scaled-up production run was 2.6±0.5 GBq/μg (70±10 Ci/mg).

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2012

Efficient One-Step Electrolytic Recycling of Low-Grade and Post-Consumer Magnesium Scrap

Metal Oxygen Separation Technologies, Inc. (abbreviated MOxST, pronounced most) and Boston University (BU) have developed a new low-cost process for recycling post-consumer co-mingled and heavily-oxidized magnesium scrap, and discovered a new chemical mechanism for magnesium separations in the process. The new process, designated MagReGen TM , is very effective in laboratory experiments, and on scale-up promises to be the lowest-cost lowest-energy lowest-impact method for separating magnesium metal from aluminum while recovering oxidized magnesium. MagReGen TM uses as little as one-eighth as much energy as today's methods for recycling magnesium metal from comingled scrap. As such, this technology could play a vital role in recycling automotive non-ferrous metals, particularly as motor vehicle magnesium/aluminum ratios increase in order to reduce vehicle weight and increase efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2014

Recycling at LANL [Slides]

Recycling is a process to change waste materials into new products to prevent waste of potentially useful materials, reduce the consumption of fresh raw materials, reduce energy usage, and reduce air pollution and water pollution by reducing the need for "conventional" waste disposal. Solid waste sent to the Los Alamos landfill has recently become more costly for the Laboratory, due to increased tipping fees charged by Los Alamos County. Going forward, LANL will not only pay higher fees for rejected recycle material disposed of as solid waste, but will lose the chance to take credit for recycling within our pollution prevention reporting program.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Evaluation of chemical additives for glycolic destruction in the recycle collection tank

Savannah River National Laboratory (SRNL) has completed a work scope in support of the Savannah River Remediation (SRR) Nitric-Glycolic flowsheet. Glycolic acid will replace formic acid as a reducing agent in the pre-processing of High-Level Waste sludge performed at the Defense Waste Processing Facility (DWPF). Glycolic acid will perform the same function as formic acid, namely reduction of mercury and adjustment of feed rheology and melter oxidation/reduction potential, while significantly reducing the potential for hydrogen generation in DWPF processing. Development testing has demonstrated glycolic acid virtually eliminates hydrogen production in the pre-processing steps. The Nitric-Glycolic flowsheet significantly improves DWPF’s ability to address Savannah River Site’s key challenge - the incorporation of effluent received from the Salt Waste Processing Facility (SWPF). SWPF will deliver significant effluent volume to DWPF, resulting in a concurrent increase in DWPF effluent returned to the Concentration, Storage and Transfer Facilities (CSTF). This work scope demonstrates that glycolate can be destroyed under the Nitric-Glycolic flowsheet prior to returning the DWPF recycle stream to CSTF. To avoid potential flammability issues due to thermolysis of glycolate in CSTF, SRR tasked SRNL to quantify and mitigate glycolate returns via DWPF’s recycle stream. The development of a strategy for glycolic mitigation was initiated with a system’s engineering workshop. Various chemical and/or physical solutions for how and where to destroy glycolate were considered – consistent with DWPF’s operational capabilities and process requirements. The workshop identified chemical oxidation of glycolate within the DWPF Recycle Collection Tank (RCT) a as the most promising option with sodium permanganate and Fenton’s reagent (metallic ion catalyzed hydrogen peroxide) as the two most promising oxidants.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Recovery of High Value Anode Materials for a Closed Loop Li-ion Battery Recycling Process (Final Report)

Battery Resourcers’ goal with this Small Business Innovative Research Phase 1 project was to produce high quality and high purity graphite generated from its Li-ion battery recycling technology. Battery Resourcers’ technology recovers cathode material from a broad spectrum of Li-ion battery regardless of size, shape or chemistry. In Battery Resourcers existing model, the graphite is recovered to be used as a reductant and therefore the battery materials cost or recycling cost is not lowered by the recovery of the graphite. Currently, Battery Resourcers is piloting its lithium ion battery recycling process and the recovered LiNi 0.33 Mn 0.33 Co 0.33 O 2 (NMC111) or LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC111) cathode materials have shown that they can outperform existing commercial NMC111 cathode materials while being produced at a projected lower cost. Battery Resourcers and its subcontractor WPI have demonstrated the same success with the recovered graphite for anode materials. The success of this award will enable Battery Resourcers offer lowest cost anode materials while reducing the carbon footprint of the battery industry. This will potentially lower the cost of EV by lowering the upfront cost of the battery and the end of life disposal costs. The technical objectives of this Phase 1 research project are to purify the recovered graphite from Battery Resourcers leaching process and demonstrate it is viable to be used in new electric vehicle lithium ion batteries. This project demonstrated that Battery Resourcers can recover graphite with less than 2% impurities. To separate the graphite from other materials Battery Resourcers will employed new filtering techniques and chemical processing methods.

25 ENERGY STORAGE↗
DOE OSTI2023

Polymer Recycling Opportunities and Challenges [Slides]

Given the multitude of polymer types and emerging recycling technologies, it can be challenging to determine how to reach a circular, sustainable, and technically-viable economy for plastics. Here, we discuss some of the key opportunities (reducing environmental impacts and costs) and challenges (poor material quality and contamination issues) facing plastic recycling. We also show how leveraging multiple recycling options could enable these opportunities and challenges to work in synergy.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

AL-CRADA-2025-01 Final Report: American-Made Wind Turbine Materials Recycling Prize Accelerate! Phase 2

This report summarizes the Phase 2 achievements of the Wind Turbine Materials Recycling Prize project led by Critical Materials Recycling (CMR) in partnership with Ames National Laboratory. The team demonstrated the technical feasibility and economic viability of recovering and reusing rare-earth Nd-Fe-B magnets from end-of-life (EOL) wind turbine generators. Through mechanical disassembly, demagnetization, and precision processing, magnets were harvested and characterized to assess structural, compositional, and magnetic properties. Results showed that recovered magnets performed on par with commercial-grade counterparts, enabling their integration into actuator and motor prototypes without redesign. System-level modeling and finite-element simulations validated operational performance, while Life Cycle Cost (LCC) analysis revealed up to 20% material cost savings and 2–3% reductions in overall motor system costs. Life Cycle Assessment (LCA) further confirmed substantial environmental benefits, including a ~94% reduction in global warming potential relative to virgin magnet production. The project’s success was enabled by a tightly integrated partnership between industry and national lab experts, illustrating a viable path for domestic magnet-to-magnet recycling. These findings support a scalable, circular solution for rare-earth material recovery, reducing dependence on imported critical minerals and advancing sustainable clean energy technologies.

Lograsso, Thomas [Ames Laboratory (AMES), Ames, IA↗
DOE OSTI2024

Recycling of Lithium-Ion Batteries via Electrochemical Recovery: A Mini-Review

With the rising demand for lithium-ion batteries (LIBs), it is crucial to develop recycling methods that minimize environmental impacts and ensure resource sustainability. The focus of this short review is on the electrochemical techniques used in LIB recycling, particularly electrochemical leaching and electrodeposition. Our summary covers the latest research, highlighting the principles, progress, and challenges tied to these methods. By examining the current state of electrochemical recovery, this review intends to provide guidance for future advancements and enhance LIB recycling efficiency.

25 ENERGY STORAGE↗
DOE OSTI2018

Operational Performance Characterization of a Heat Pump System Utilizing Recycled Water as Heat Sink and Heat Source in a Cool and Dry Climate

The wastewater leaving from homes and businesses contains abundant low-grade energy, which can be utilized through heat pump technology to heat and cool buildings. Although the energy in the wastewater has been successfully utilized to condition buildings in other countries, it is barely utilized in the United States, until recently. In 2013, the Denver Museum of Nature & Science at Denver, the United States implemented a unique heat pump system that utilizes recycled wastewater from a municipal water system to cool and heat its 13,000 m 2 new addition. This recycled water heat pump (RWHP) system uses seven 105 kW (cooling capacity) modular water-to-water heat pumps (WWHPs). Each WWHP uses R-410A refrigerant, has two compressors, and can independently provide either 52 °C hot water (HW) or 7 °C chilled water (CHW) to the building. This paper presents performance characterization results of this RWHP system based on the measured data from December 2014 through August 2015. The annual energy consumption of the RWHP system was also calculated and compared with that of a baseline Heating, Ventilation, and Air Conditioning (HVAC) system which meets the minimum energy efficiencies that are allowed by American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) 90.1-2013. The performance analysis results indicate that recycled water temperatures were favorable for effective operation of heat pumps. As a result, on an annual basis, the RWHP system avoided 50% of source energy consumption (resulting from reduction in natural gas consumption although electricity consumption was increased slightly), reduced CO 2 emissions by 41%, and saved 34% in energy costs as compared with the baseline system.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Application of Ionic Liquids for the Recycling and Recovery of Technologically Critical and Valuable Metals

Population growth has led to an increased demand for raw minerals and energy resources; however, their supply cannot easily be provided in the same proportions. Modern technologies contain materials that are becoming more finely intermixed because of the broadening palette of elements used, and this outcome creates certain limitations for recycling. The recovery and separation of individual elements, critical materials and valuable metals from complex systems requires complex energy-consuming solutions with many hazardous chemicals used. Significant pressure is brought to bear on the improvement of separation and recycling approaches by the need to balance sustainability, efficiency, and environmental impacts. Due to the increase in environmental consciousness in chemical research and industry, the challenge for a sustainable environment calls for clean procedures that avoid the use of harmful organic solvents. Ionic liquids, also known as molten salts and future solvents, are endowed with unique features that have already had a promising impact on cutting-edge science and technologies. This review aims to address the current challenges associated with the energy-efficient design, recovery, recycling, and separation of valuable metals employing ionic liquids.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Embodied Energy in Pyrolysis and Solvolysis Approaches to Recycling for Carbon Fiber-Epoxy Reinforced Composite Waste Streams

Carbon fiber composites are increasingly used in aerospace, motorcycles, sporting, and high-performance vehicles, and their end of life recycling is of growing interest. This study deals with the life cycle assessment (LCA) of carbon fiber reinforced plastics (CFRP) waste streams. The embodied energy (EE) of recycling CFRP via two viable methods—i.e., pyrolysis and solvolysis—is studied. Both pyrolysis and solvolysis were studied for EE with different variants. Alongside fiber recovery from CFRP, the pyrolysis process calculations consider energy recovery from syngas and oil produced within the system. For pyrolysis, electric furnace and natural gas were primarily considered. For solvolysis, different solvent scenarios were considered, including (a) deionized water, (b) water and potassium hydroxide, (c) acetone and water, and (d) water with acetic acid and potassium hydroxide. Energy reduction from one generation to the next has also been highlighted. The EE for recycling CFRP is quantified and discussed for these scenarios in this paper.

composites↗
DOE OSTI2022

Recycling of Pretreated Polyolefin-Based Ocean-Bound Plastic Waste by Incorporating Clay and Rubber

Plastic waste found in oceans has become a major concern because of its impact on marine organisms and human health. There is significant global interest in recycling these materials, but their reclamation, sorting, cleaning, and reprocessing, along with the degradation that occurs in the natural environment, all make it difficult to achieve high quality recycled resins from ocean plastic waste. To mitigate these limitations, various additives including clay and rubber were explored. In this study, we compounded different types of ocean-bound (o-HDPE and o-PP) and virgin polymers (v-LDPE and v-PS) with various additives including a functionalized clay, styrene-multi-block-copolymer (SMB), and ethylene-propylene-based rubber (EPR). Physical observation showed that all blends containing PS were brittle due to the weak interfaces between the polyolefin regions and the PS domains within the polymer blend matrix. Blends containing clay showed rough surfaces and brittleness because of the non-uniform distribution of clay particles in the polymer matrix. To evaluate the properties and compatibility of the blends, characterizations using differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and small-amplitude oscillatory shear (SAOS) rheology were carried out. The polymer blend (v-LDPE, o-HDPE, o-PP) containing EPR showed improved elasticity. Incorporating additives such as rubber could improve the mechanical properties of polymer blends for recycling purposes.

42 ENGINEERING↗
DOE OSTI2016

RELATIVE CONTRIBUTIONS OF THE WEAK, MAIN, AND FISSION-RECYCLING r-PROCESS

There has been a persistent conundrum in attempts to model the nucleosynthesis of heavy elements by rapid neutron capture (the r-process). Although the locations of the abundance peaks near nuclear mass numbers 130 and 195 identify an environment of rapid neutron capture near closed nuclear shells, the abundances of elements just above and below those peaks are often underproduced by more than an order of magnitude in model calculations. At the same time, there is a debate in the literature as to what degree the r-process elements are produced in supernovae or the mergers of binary neutron stars. In this paper we propose a novel solution to both problems. We demonstrate that the underproduction of nuclides above and below the r-process peaks in main or weak r-process models (like magnetohydrodynamic jets or neutrino-driven winds in core-collapse supernovae) can be supplemented via fission fragment distributions from the recycling of material in a neutron-rich environment such as that encountered in neutron star mergers (NSMs). In this paradigm, the abundance peaks themselves are well reproduced by a moderately neutron-rich, main r-process environment such as that encountered in the magnetohydrodynamical jets in supernovae supplemented with a high-entropy, weakly neutron-rich environment such as that encountered in the neutrino-driven-wind model to produce the lighter r-process isotopes. Moreover, we show that the relative contributions to the r-process abundances in both the solar system and metal-poor stars from the weak, main, and fission-recycling environments required by this proposal are consistent with estimates of the relative Galactic event rates of core-collapse supernovae for the weak and main r-process and NSMs for the fission-recycling r-process.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2012

Application of Fully Ceramic Microencapsulated Fuel for Transuranic Waste Recycling in PWRs

Presented is an investigation of the utilization of Tristructural-Isotropic (TRISO) particle-based fuel designs for the recycling of transuranic (TRU) wastes in typical Westinghouse four-loop pressurized water reactors (PWRs). Though numerous studies have evaluated the recycling of TRU in light water reactors (LWRs), this work differentiates itself by employing TRU-loaded TRISO particles embedded within a SiC matrix and formed into pellets that can be loaded into standard 17 x 17 fuel element cladding. This approach provides the capability of TRU recycling and, by virtue of the TRISO particle design, will allow for greater burnup (i.e., removal of the need for UO2 mixing) and improved fuel reliability. In this study, a variety of assembly layouts and core loading patterns were analyzed to demonstrate the feasibility of TRU-loaded TRISO fuel. The assembly and core design herein reported are a work in progress, so they still require some fine-tuning to further flatten power peaks; however, the progress achieved thus far strongly supports the conclusion that with further rod/assembly/core loading and placement optimization, TRU-loaded TRISO fuel and core designs that are capable of balancing TRU production and destruction can be designed within the standard constraints for thermal and reactivity performance in PWRs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2012

Ames Lab 101: Rare-Earth Recycling

Recycling keeps paper, plastics, and even jeans out of landfills. Could recycling rare-earth magnets do the same? Perhaps, if the recycling process can be improved. Scientists at the U.S. Department of Energy's Ames Laboratory are working to more effectively remove the neodymium, a rare earth, from the mix of other materials in a magnet.

36 MATERIALS SCIENCE↗
DOE OSTI2016

MICROBIALLY MEDIATED LEACHING OF RARE EARTH ELEMENTS FROM RECYCLABLE MATERIALS

Bioleaching offers a potential approach for recovery of rare earth elements (REE) from recyclable materials, such as fluorescent lamp phosphors or degraded industrial catalysts. Microorganisms were enriched from REE-containing ores and recyclable materials with the goal of identifying strains capable of extracting REE from solid materials. Over 100 heterotrophic microorganisms were isolated and screened for their ability to produce organic acids capable of leaching REE. The ten most promising isolates were most closely related to Pseudomonas, Acinetobacter and Talaromyces. Of the acids produced, gluconic acid appeared to be the most effective at leaching REE (yttrium, lanthanum, cerium, europium, and terbium) from retorted phosphor powders (RPP), fluidized cracking catalyst (FCC), and europium-doped yttrium oxide (YOEu). We found that an Acinetobacter isolates, BH1, was the most capable strain and able to leach 33% of the total REE content from the FCC material. These results support the continuing evaluation of gluconic acid-producing microbes for large-scale REE recovery from recyclable materials.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2019

Impact of Li-Ion Battery Recycling on the Supply Chain

With the increasing demand of the lithium ion batteries (LIB), it is expected that supply of some critical metals used in Li-ion batteries such as cobalt and lithium will fall short in the near-term, or their prices could increase significantly in response to the high demand. Besides increasing mining and production activities, we believe that a closed-loop system with recycling at the end-of-life provides a pathway to lower environmental impacts and a source of high value materials that can be used in producing new batteries. This presentation reviews the current state of the LIB manufacturing supply chain, discuses evolution and supply chain issues for cathode and anode materials, addresses some issues associated with battery end-of-life, and sheds light on the importance of LIB recycling from the environmental and value chain perspectives. This presentation also discusses the expected benefits of recycling on the global LIB supply chain.

25 ENERGY STORAGE↗