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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
NASA NTRS2017

Urban Biomining Meets Printable Electronics: End-To-End at Destination Biological Recycling and Reprinting

Space missions rely utterly on metallic components, from the spacecraft to electronics. Yet, metals add mass, and electronics have the additional problem of a limited lifespan. Thus, current mission architectures must compensate for replacement. In space, spent electronics are discarded; on earth, there is some recycling but current processes are toxic and environmentally hazardous. Imagine instead an end-to-end recycling of spent electronics at low mass, low cost, room temperature, and in a non-toxic manner. Here, we propose a solution that will not only enhance mission success by decreasing upmass and providing a fresh supply of electronics, but in addition has immediate applications to a serious environmental issue on the Earth. Spent electronics will be used as feedstock to make fresh electronic components, a process we will accomplish with so-called 'urban biomining' using synthetically enhanced microbes to bind metals with elemental specificity. To create new electronics, the microbes will be used as 'bioink' to print a new IC chip, using plasma jet electronics printing. The plasma jet electronics printing technology will have the potential to use martian atmospheric gas to print and to tailor the electronic and chemical properties of the materials. Our preliminary results have suggested that this process also serves as a purification step to enhance the proportion of metals in the 'bioink'. The presence of electric field and plasma can ensure printing in microgravity environment while also providing material morphology and electronic structure tunabiity and thus optimization. Here we propose to increase the TRL level of the concept by engineering microbes to dissolve the siliceous matrix in the IC, extract copper from a mixture of metals, and use the microbes as feedstock to print interconnects using mars gas simulant. To assess the ability of this concept to influence mission architecture, we will do an analysis of the infrastructure required to execute this concept on Mars, and additional opportunities it could offer mission design from the biological and printing technologies. In addition, we will do an analysis of the impact of this technology for terrestrial applications addressing in particular environmental concerns and availability of metals.

Space mission↗
NASA NTRS2018

Recycling and Sustainable Acquisition Workshop

Recycling Program: Overview; C & D Solid Waste Diversion: Concrete; Composting Process; Composting Program; Program Performance; Recycling Program Initiatives; SSC Landfill Life Expectancy; Outreach: Earth Day 2018; Sustainable Acquisition.

Boone, Chelsea↗
DOE OSTI2020

Actinide and rare earth drawdown system for molten salt recycle

A method for recycling molten salt from electrorefining processes, the method having the steps of collecting actinide metal using a first plurality of cathodes from an electrolyte bath, collecting rare earths metal using a second plurality of cathodes from the electrolyte bath, inserting the collected actinide metal and uranium into the bath, and chlorinating the inserted actinide metal and uranium. Also provided is a system for recycling molten salt, the system having a vessel adapted to receive and heat electrolyte salt, a first plurality of cathodes adapted to be removably inserted into the vessel, a second plurality of cathodes adapted to be removably inserted into the vessel, an anode positioned within the vessel so as to be coaxially aligned with the vessel, and a vehicle for inserting uranium into the salt.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Electron Cloud Simulations In The Fermilab Recycler

We present a simulation study to characterize the stability region of the Fermilab (FNAL) Recycler in the context of secondary emission yield (SEY). Interactions between electrons and beam pipe material can produce electron clouds that jeopardize beam stability in certain focusing configurations. Such an instability was documented in the Recycler, and the work presented here reflects improvements to better understand that finding. We incorporated the Furman-Pivi Model into a PyECLOUD analysis, and we determined the instability threshold given various bunch lengths, intensities, SEY magnitudes, and model parameters.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Actinide and rare earth drawdown system for molten salt recycle

A method for recycling molten salt from electrorefining processes, the method having the steps of collecting actinide metal using a first plurality of cathodes from an electrolyte bath, collecting rare earths metal using a second plurality of cathodes from the electrolyte bath, inserting the collected actinide metal and uranium into the bath, and chlorinating the inserted actinide metal and uranium. Also provided is a system for recycling molten salt, the system having a vessel adapted to receive and heat electrolyte salt, a first plurality of cathodes adapted to be removably inserted into the vessel, a second plurality of cathodes adapted to be removably inserted into the vessel, an anode positioned within the vessel so as to be coaxially aligned with the vessel, and a vehicle for inserting uranium into the salt.

Willit, James L.↗
DOE OSTI2023

Fermilab Main Injector and Recycler Operations in the Megawatt Era

Significant upgrades to Fermilab's accelerator complex have accompanied the development of LBNF (the Long Baseline Neutrino Facility) and DUNE (Deep Underground Neutrino Experiment). These improvements will facilitate 1-MW operation of the NuMI (Neutrinos at the Main Injector) beam for the first time this year through changes to the Recycler slip-stacking procedure and shortening of the Main Injector ramp time. The modifications to the Recycler slip-stacking and efforts to reduce the duration of the Main Injector ramp will be discussed. Additionally, details regarding further shortening of the ramp time and the subsequent impacts on future accelerator operations are presented.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Linear Modelling from Betatron Phase Measurements at the Fermilab Recycler NOvA ring

Utilizing the measurement of coherent betatron oscillation phase has emerged as fast and precise approach for identifying and rectifying errors in implementing a desired lattice in CESR (Cornell Electron Storage Ring). One key advantage of betatron phase measurement over β measurement is its sensitivity to phase variations between widely separated points. This methodology has been successfully implemented for the Recycler NOvA Ring at Fermilab, with the adoption of TAO (Tool for Accelerator Optics) developed by Cornell University. By employing this technique, a linear model of the Recycler NOvA ring is established, enabling the correction of quadrupole errors.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Wind Turbine Blade Repurposing and Recycling: Coupling Repurposing Methods with 3D Printing Technology

Fiber-reinforced thermoplastic composites continue to be implemented in several marketsbecause of their strength capacity and light weight. Especially in the wind industry, wind bladesare made of this material which makes them ideal for wind energy generation, but bladesbecome a problem at end-of-life. Because recycling thermoplastic composites technologiesare still not cost and environmentally effective, research in this space is needed. This paperpresents a case study for coupling repurposed wind turbine blades and 3D printing technology.The purpose is to remanufacture decommissioned wind blades into bus stop roof and seatingsections to then use recycled glass fiber from a decommissioned wind turbine blade to 3Dprint structural and/or fixtures needed in the assembly. We provide an overview of the designprocess, and the development process steps in repurposing and 3D printing the material,delving into key parameters required for a successful implementation.

Henao, Yulizza↗
DOE OSTI2024

Materials Research for Battery Recycling

This presentation for the summer 2024 class of Energy Execs offers a summary of materials research work for battery recycling conducted at NREL.

battery recycling↗
DOE OSTI2025

Upconversion of non-recycled MSW paper fractions into biochar via slow pyrolysis and life cycle analysis: Pathways to net negative GHG emission

This study presents an integrated and sustainable approach to valorizing non-recycled municipal solid waste (MSW), a heterogeneous and underutilized waste stream destined for landfilling, by converting it into valuable biochar resources. Specifically, we investigated the upcycling of nonrecycled paper waste based on compositional analysis into four major fractions: high cellulose, high lignin, high contamination, and high ash content papers. These fractions were then homogenized and subjected to slow pyrolysis. The high cellulose fraction (36.1 %) was the most abundant, and contained 66.7 % cellulose, while the high lignin fraction showed the highest lignin (12.1 %) and carbon content (44 %), resulting in highest energy value of 17.4 MJ kg −1 . Biochar yields ranged from 25.6 % to 35.6 %, with the high ash fraction producing the highest yield and alkalinity (pH ≈ 11.2) due to its higher mineral content. Elemental analysis revealed enhanced carbon content up to 76.9 % and reduced oxygen and hydrogen, confirming effective carbonization. The high lignin-derived biochar showed the highest aromatic carbon content (82.8 %) and greater structural stability, while contaminated and ash-rich fractions exhibited dense, low-porosity surfaces due to the presence of contaminants and minerals. Spectroscopic analysis revealed degradation of carbohydrates, disappearance of cellulose peaks and formation of aromatic and mineral derived phases. The scaled life cycle process yielded a global warming potential (GWP) of 119.3 kg CO 2 -eq per ton of dry paper waste, offset by soil carbon sequestration of − 556.41 kg CO 2 -eq, resulting in a net impact of − 427.36 kg CO 2 -eq. This represents a net carbon removal exceeding by ~186 % the emissions associated with landfilling paper waste with electricity generation.

09 BIOMASS FUELS↗
DOE OSTI2021

Li-ion Identification For the Next Generation of Cathode Recycling

OnTo’s end-to-end solution will demonstrate (in partnership/collaboration with relevant industries) collection of lithium-ion batteries through recycling of cathode material. The DISCC project will prototype 1) deactivation of batteries 2) identification 3) sorting using automated techniques, 4) cutting with waterjet technology and 5) Cathode-Healing™ to produce valuable cathodes from scrap batteries.

25 ENERGY STORAGE↗
DOE OSTI2022

DEVELOPMENT OF OIL FREE CENTRIFUGAL BLOWER AS ENABLING TECHNOLOGY FOR SOLID OXIDE FUEL CELL ANODE GAS RECYCLING

Broad commercialization of solid oxide fuel cells (SOFCs), requires anode offgas recycle blowers (AORB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This work presents details of the development and testing of an oil-free, low cost centrifugal AORB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. The advantages of this novel technology are discussed, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology.

03 NATURAL GAS↗
DOE OSTI2025

Lightweight, Flexible Electromagnetic Shielding Composite Films Reinforced with Recycled Carbon Fibers and Carbon Nanofillers

Lightweight, flexible polymer composites are widely adopted in modern electronic devices and systems for high-efficiency electromagnetic interference (EMI) shielding. Reinforcing polymer composites with conductive fillers offers a promising alternative to conventional metal-based shielding material thanks to their low density, tunable properties, and flexibility. Herein, lightweight, flexible ultra-high molecular weight polyethylene composite films reinforced with recycled carbon fibers (rCFs) and carbon-based nanofillers, including graphene nanoplatelets (GNPs) and carbon nanotubes, are reported for EMI shielding applications. The incorporation of these nanofillers significantly reduces the required content of rCFs and improves processability while maintaining comparable shielding effectiveness. The addition of these nanofillers with rCFs enhances the EMI shielding effectiveness by up to 15 dB. Incorporating 1 wt% GNPs can replace 5 wt% rCFs and achieve comparable EMI shielding performance, while 5 wt% of either nanofillers can substitute for 10 wt% rCFs. Numerical modeling of electromagnetic wave transmission reveals that increasing nanofiller concentrations enhances both reflection and absorption losses, with absorption consistently dominating across all levels. Furthermore, this study not only provides insight into the synergistic contributions of rCFs and carbon nanofillers to shielding effectiveness but also paves the way for the design of sustainable, lightweight EMI shielding composite films for applications in electric vehicles, medical equipment, and portable electronics.

carbon nanofiller↗
DOE OSTI2025

Cathode Upcycling for Direct Recycling of Lithium‐Ion Batteries Using a Precipitation Approach

With the increased production of electric vehicles to reduce carbon emissions, the lithium-ion battery market to supply those vehicles has grown dramatically. To enhance battery sustainability and circularity, direct recycling methods aim to recover intact cathode materials. However, end-of-life cathode materials are typically 15–20 years old and often have lower energy density compared to current cathode materials. To address this challenge, a rapid precipitation process is developed to boost energy density by converting low Ni-compositions, LiNi 0.33 Co 0.33 Mn 0.33 O 2 (NMC111), into higher Ni-compositions (NMC622). This process forms a Ni-rich coating on cathode particles that diffuses into the core upon high-temperature relithiation, increasing compositional homogeneity. The upcycling process leverages existing infrastructure, offering low capital cost and minimal additional chemical input. Through ex situ tomographic transmission X-ray microscopy (TXM), 3D Ni:Co elemental mixing is quantified, confirming that elemental content evens at the secondary particle level with a mean NMC622 composition upon relithiation. However, elemental gradients remain in the single crystalline primary particles. Ex situ high-resolution and in situ wide-angle X-ray diffraction reveals concurrent structural changes during the relithiation process. These findings provide key insights into the structural and chemical mechanisms of elemental diffusion to obtain further improvements of increased capacity and retention through compositional conversion of cathode materials.

Cathode Upcycling↗
DOE OSTI2024

Redesigned Nylon 6 Variants with Enhanced Recyclability, Ductility, and Transparency

Geminal (gem−) disubstitution in heterocyclic monomers is an effective strategy to enhance polymer chemical recyclability by lowering their ceiling temperatures. However, the effects of specific substitution patterns on the monomer's reactivity and the resulting polymer's properties are largely unexplored. Here we show that, by systematically installing gem-dimethyl groups onto ϵ-caprolactam (monomer of nylon 6) from the α to ϵ positions, both the redesigned lactam monomer's reactivity and the resulting gem-nylon 6’s properties are highly sensitive to the substitution position, with the monomers ranging from non-polymerizable to polymerizable and the gem-nylon properties ranging from inferior to far superior to the parent nylon 6. Remarkably, the nylon 6 with the gem-dimethyls substituted at the γ position is amorphous and optically transparent, with a higher T g (by 30 °C), yield stress (by 1.5 MPa), ductility (by 3×), and lower depolymerization temperature (by 60 °C) than conventional nylon 6.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

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

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

INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMI↗