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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
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↗
DOE OSTI2023

Benefits and Risks of New Polymers in the Current and Future Recycling System

New plastics are increasingly being developed to address challenges around plastic pollution and end-of-life management. However, the incorporation of these new polymers into the existing plastic ecosystem raises numerous risks, as well as some benefits. This flash talk briefly discusses how new plastics could raise contamination levels and prevent mechanical recycling, how we could mitigate that risk by improving education around recycling collection, and how new plastics could potentially reduce the cost and environmental impact of certain chemical recycling technologies.

benefit-risk analysis↗
DOE OSTI2013

Evaluation of fuel cycle scenarios on MOX fuel recycling in PWRs and SFRs

Prospects on advanced fuel cycle scenario are considered for achieving a progressive integration of Sodium Fast Reactor (SFR) technology within the current French Pressurized Water Reactor (PWR) nuclear fleet, in a view to benefit from fissile material multi-recycling capability. A step by step process is envisioned, and emphasis is put on its potential implementation through the nuclear mass inventory calculations with the COSAC code. The overall time scale is not optimized. The first step, already implemented in several countries, the plutonium coming from the reprocessing of used Light Water Reactor (LWR) fuels is recycled into a small number of LWRs. The second step is the progressive introduction of the first SFRs, in parallel with the continuation of step 1. This second step lets to prepare the optimized multi recycling of MOX fuel which is considered in step 3. Step 3 is characterized by the introduction of a greater number of SFR and MOX management between EPR reactors and SFRs. In the final step 4, all the fleet is formed with SFRs. This study assesses the viability of each step of the overall scenario. The switch from one step to the other one could result from different constrains related to issues such as resources, waste, experience feedback, public acceptance, country policy, etc.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Wastes associated with recycling spent MOX fuel into fast reactor oxide fuel

A study sponsored by the DOE has been performed by AREVA to estimate the process and secondary wastes produced from an 800 MTIHM/yr (initial metric tons heavy metal a year) recycling plant proposed to be built in the U.S. utilizing the COEX process and utilized some DOE defined assumptions and constraints. In this paper, this plant has been analyzed for a recycling campaign that included 89% UO{sub x} and 11% MOX UNF to estimate process and secondary waste quantities produced while manufacturing 28 MTIHM/yr of SFR fuel. AREVA utilized operational data from its backend facilities in France (La Hague and MELOX), and from recent advances in waste treatment technology to estimate the waste quantities. A table lists the volumes and types of the different final wastes for a recycling plant. For instance concerning general fission products the form of the final wastes is vitrified glass and its volume generation rate is 135 l/MTHM, concerning Iodine 129 waste its final form is synthetic rock and its volume generation rate is 0.625 l/MTIHM.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

New developments in RTR fuel recycling

As most utilities in the world, Research and Test Reactors (RTR) operators are currently facing two challenges regarding the fuel, in order to comply with local safety and waste management requirements as well as global non-proliferation obligation: - How to manage used fuel today, and - How fuel design changes that are currently under development will influence used fuel management. AREVA-La-Hague plant has a large experience in used fuel recycling, including traditional RTR fuel (UAl). Based on that experience and deep knowledge of RTR fuel manufacturing, AREVA is currently examining possible options to cope with both challenges. This paper describes the current experience of AREVA-La-Hague in UAl used fuels recycling and its plan to propose recycling for various types of fuels such as U{sub 3}Si{sub 2} fuel or UMo fuel on an industrial scale. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

All-Polyester Multilayer Plastics (‘All-Polyester MLPs’): A Redesign for Inherently Recyclable Plastics

Multilayer plastics (MLPs) are widely used in modern packaging because they combine multiple functions such as oxygen and moisture barriers, mechanical strength, puncture resistance, and heat sealability into lightweight and cost-effective packaging solutions. These attributes are essential for food, beverage, pharmaceutical, and consumer goods packaging. However, conventional commercial MLPs typically consist of five to twelve layers made from chemically incompatible materials, including polyolefins, polyethylene terephthalate, nylon, ethylene-vinyl alcohol (EVOH), adhesives, and tie layers. This complexity makes MLPs extremely difficult to recycle. As a result, the vast majority of multilayer plastics (MLPs) are disposed of through landfilling or incineration. This disposal pathway perpetuates demand for virgin material production, thereby driving high industrial energy consumption, increasing greenhouse gas (GHG) emissions, and contributing to the long-term accumulation of plastic waste. The scope of work included: (1) Design and fabrication of all-polyester multilayer structures using commercially relevant processing methods; (2) Experimental validation of barrier, mechanical, and sealing performance; (3) Demonstration of both mechanical and chemical recycling pathways; and (4) Comprehensive techno-economic analysis (TEA) and life-cycle assessment (LCA) to quantify cost, energy, and environmental impacts.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A Study on Recycled Polymers Recovered from Multilayer Plastic Packaging Films by Solvent–Targeted Recovery and Precipitation (STRAP)

Multilayer plastic film use increased in multiple packaging applications due to its versatility and overall increased performance over monolayer structures. However, the performance gains from multiple layers also make recycling difficult because they contain multiple polymers that can be immiscible and burdensome to traditional mechanical recycling operations. A possible solution is the solvent-targeted recovery and precipitation (STRAP) process, but the effect on the retrieved polymer is still unknown. Here, the STRAP process is applied to two different multilayer films and samples of recovered polymers are evaluated for physical, molecular, and thermal properties. Changes in the molecular weight are not significant, but differences in thermal properties are reported along with the coprecipitation of different polymers. Solvent retention in the polymer matrix from STRAP reduced the glass transition temperature of samples, but enhanced drying recovered it. Heavy metals, such as Cd, Cr, and Pb are not detected, indicating regulatory compliance for different applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Chemical Recycling of Polycaprolactones via Reactive Melt Processing

Chemical recycling is a promising technology for the deconstruction of waste plastics into monomers or other chemical intermediates, which can be converted into other value-added products or repolymerized into polymers. In this work, polycaprolactone and poly(4-propylcaprolactone) were chemically recycled by exploiting ring-closing depolymerization (RCD). To demonstrate the utility of this approach, reactive distillation experiments were initially conducted in a heated round-bottom flask with a distillation head to explore the effect of temperature and catalyst loading on RCD. Inspired by industrial devolatilization equipment, analogous experiments were conducted using a twin-screw melt compounder that was modified to simultaneously heat and mix polymer in the presence of a catalyst while continuously removing the evolved monomer vapors with a vacuum system and collecting them in a cold trap. Yield and selectivity of the recovered monomer were characterized by 1 H nuclear magnetic resonance spectroscopy and gas chromatography-mass spectrometry. Importantly, the more scalable twin-screw melt compounder approach produced values of monomer selectivity (∼90%) and yield (∼80%) similar to those of the round-bottom flask experiments. The recovered monomers were also successfully repolymerized into the same neat polymer with comparable molar masses without purification steps or adding initiator. Here, the results of this study promote the use of reactive devolatilization extrusion as a scalable approach to polyester depolymerization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Tailoring the Properties of Chemically Recyclable Polyethylene‐Like Multiblock Polymers by Modulating the Branch Structure

Abstract Developing plastics that fill the need of polyolefins yet are more easily recyclable is a critical need to address the plastic waste crisis. However, most efforts in this vein have focused on high‐density polyethylene (PE), while many different types of PE exist. To create broadly sustainable PE with modular properties, we present the synthesis, characterization, and demonstration of materials applications for chemically recyclable PE‐like multiblock polymers prepared from distinct hard and soft blocks using ruthenium‐catalyzed dehydrogenative polymerization. By altering the branching pattern within the soft blocks, a series of PE‐like multiblock polymers were synthesized with tunable glass transition temperatures ( T g ) while maintaining consistent high melting temperatures ( T m ). A clear U‐shape trend between T g and mechanical properties was found, showcasing their potential as sustainable materials with tailored properties spanning commercial linear low‐density polyethylene (LLDPE) and low‐density polyethylene (LDPE). These materials offer adjustable adhesive strength to metal and demonstrate chemical recyclability and selective depolymerization in mixed plastic streams, promoting circularity and separation.

Zhao, Yucheng↗
DOE OSTI2025

Upcycling Polynorbornene Derivatives into Chemically Recyclable Multiblock Linear and Thermoset Plastics

Synthetic polymers have found widespread use, but their ineffective end-of-life treatment is causing a significant environmental and human health crisis. Here, we demonstrate the upcycling of polynorbornene derivatives (pNBEs) through their deconstruction into distinct oligomeric buildings blocks that can be repolymerized into chemically recyclable pNBEs-like multiblock polymers via dehydrogenative polymerization. The resulting materials exhibit diverse mechanical properties, while integrating high melting temperatures (T m as high as 133 °C). Notably, this method could also enable the selective deconstruction of permanently cross-linked polydicyclopentadiene (pDCPD) thermosets into telechelic-OH functionalized oligomers, overcoming the significant challenges posed by their robust network structure in recycling and degradation. The resulting pDCPD oligomers can subsequently be repolymerized with macrodiols to create multiblock thermosets with tunable mechanical properties, including Young's modulus and tensile elongation. After use, upcycled plastics could be effectively deconstructed back to the oligomers for recovery and repolymerization. Overall, this work establishes an approach that can be utilized to upcycle pNBEs into previously inaccessible multiblock thermosets and thermoplastics with full recyclability, and may be generalizable to a range of polymers to shift their end-of-life waste disposal toward sustainable recovery and reuse.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Synthesis of Recycled Poly(ethylene terephthalate)/Polyacrylonitrile/Styrene Composite Nanofibers by Electrospinning and Their Mechanical Properties Evaluation

Consumption of polyethylene terephthalate (PET) products has increased dramatically in recent decades, resulting in the generation of a large amount of PET waste. For that reason, is necessary to find a new application of recycled material. In this article, we report the synthesis and characterization of recycled poly (ethylene terephthalate) (RPET) obtained from the chemical recycling of post-consumer PET bottles by glycolysis method and the formation of composites nanofibers RPET/polyacrylonitrile (PAN)/styrene (ST). The RPET synthesis was studied through infrared spectroscopy (FT-IR) and thermogravimetric analysis (TGA). The viscosity and frequency sweep of the polymeric solutions was evaluated. The composites nanofibers were elaborated by the electrospinning technique and characterized by scanning electron microscopy (SEM), FT-IR, TGA/DSC and nanoindentation. The RPET/PAN/ST composite nanofibers present an average diameter of 456 nm and higher thermal stability compared PAN fibers. The mechanical properties such as hardness and elastic modulus were 4.5 and 7.5 times PAN fibers values, respectively.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2024

Improving the Recyclability of Polymer Composites With Cellulose Nanofibrils

Cellulose nanofibers (CNFs) have been widely studied for their reinforcing potential in high-performance composites. While there are numerous publications on CNF-reinforced composites in a variety of polymer matrices, few have considered the recyclability of such thermoplastic composites and whether the incorporation of CNFs deteriorates or improves their performance upon reprocessing. In this study, two thermoplastic resins, poly(lactic acid) (PLA), and glycol-modified polyethylene terephthalate (PETg), were prepared with CNF reinforcement and thermomechanically recycled to investigate the effect of CNF inclusion on the composite properties after reprocessing as well as their effect on the composites’ number of useful life cycles. Additionally, changes in mechanical, thermal, rheological, molecular, and microstructural properties of the composites and/or base resins were monitored as a function of cycle numbers. As is typical, the polymers’ molecular weight and mechanical performance deteriorated with continued processing. However, the addition of spray dried CNF was found to better maintain the mechanical performance of both polymers throughout multiple recycling steps as compared to neat samples. For example, the tensile strength of PETg with 20 wt% CNF after 6 processing cycles was found to exceed that of virgin neat PETg, and higher loadings of CNF were found to preserve a higher yield strength during multiple rounds of reprocessing compared to PETg composites with lower CNF loadings. Ultimately this study indicates that the addition of CNF to some thermoplastic materials can increase both their sustainability by offsetting the use of high-embodied energy resins and their circularity by enabling performance retention over more use cycles.

42 ENGINEERING↗
DOE OSTI2017

Facile Synthesis of Magnetically Recyclable Fe{sub 2}O{sub 3}–MFe{sub 2}O{sub 4} Photocatalyst from Saprolite-Limonite Laterite Leach Liquors

Photocatalyst degradation is an effective and environment-friendly method for dye pollution. Magnetically recyclable Fe{sub 2}O{sub 3}–MFe{sub 2}O{sub 4} composites were successfully synthesized from laterite leach liquors by a simple coprecipitation-calcination method. The as-prepared samples were characterized by x-ray diffraction (XRD), physical property measurement system (PPMS), and UV-Vis. The results show that the Fe{sub 2}O{sub 3}–MFe{sub 2}O{sub 4} composites can be easily recycled from the solution due to the magnetic properties. Photodegradation experiments results indicated that the degradation rate of rhodamine B (RhB) solution were found to be about 90.0% for the composites, and the degradation rate were still more than 80.0% after being reused for five times. The heterostructure between the Fe{sub 2}O{sub 3} and MFe{sub 2}O{sub 4} effectively enhanced the separation of electron hole pairs, facilitating the photocatalysis process. This paper provided a facile pathway for comprehensive utilization of laterite leach liquor to synthesize magnetically recyclable Fe{sub 2}O{sub 3}–MFe{sub 2}O{sub 4} with enhanced photocatalyst performance.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

An Economic Model and Experiments to Understand Aluminum-Cerium Alloy Recycling

We provide an economic model to understand the impact of adoption, sorting and pricing of scrap on the recycling of a new aluminum-cerium (AlCe) alloy for use in engine blocks in the automobile industry. The goal of the laboratory portion of this study is to investigate possible effects of cerium contamination on well-established aluminum recycling streams. Here, our methodology includes three components: (1) focused data gathering from industry supply chain participants, (2) experimental data through laboratory experiments to understand the impact of cerium on existing alloys and (3) an economic model to understand pricing incentives on a recycler’s separation of AlCe engine blocks.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Friction Extrusion: Solid-State Metal Synthesis and Recycling in Sustainable Manufacturing

Friction extrusion (FE) is a novel solid-state process for synthesis and recycling of metals and alloys. The novelty of FE is that it utilizes the frictional heating and extensive plastic deformation intrinsic in the process to stir, mechanically alloy, consolidate, and convert powders, chips, and other recyclable feedstock metals into a usable product form of highly engineered materials. FE represents a potentially transformational sustainable manufacturing technology. Being a solid-state process, it eliminates the energy-intensive melting and solidification steps, which are necessary in the conventional metal recycle and synthesis processes. Therefore, FE is a highly energy-efficient, practically zero-emission, and economically competitive process. Here, in this work, the concept and configuration of FE are introduced, the energy-saving advantage of FE is analyzed, the feasibility of FE is demonstrated with synthesizing Al alloys, and the results of some metallographic and mechanical properties studies are presented. A prognosis of the friction extrusion technology is outlined.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Comparative analysis of thorium and uranium fuel for transuranic recycle in a sodium cooled Fast Reactor

The present paper compares the reactor physics and transmutation performance of sodium-cooled Fast Reactors (FRs) for TRansUranic (TRU) burning with thorium (Th) or uranium (U) as fertile materials. The 1000 MWt Toshiba-Westinghouse Advanced Recycling Reactor (ARR) conceptual core has been used as benchmark for the comparison. Both burner and breakeven configurations sustained or started with a TRU supply, and assuming full actinide homogeneous recycle strategy, have been developed. State-of-the-art core physics tools have been employed to establish fuel inventory and reactor physics performances for equilibrium and transition cycles. Results show that Th fosters large improvements in the reactivity coefficients associated with coolant expansion and voiding, which enhances safety margins and, for a burner design, can be traded for maximizing the TRU burning rate. A trade-off of Th compared to U is the significantly larger fuel inventory required to achieve a breakeven design, which entails additional blankets at the detriment of core compactness as well as fuel manufacturing and separation requirements. The gamma field generated by the progeny of U-232 in the U bred from Th challenges fuel handling and manufacturing, but in case of full recycle, the high contents of Am and Cm in the transmutation fuel impose remote fuel operations regardless of the presence of U-232.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Modeling hydrodynamic and biomass pyrolysis effects of recycled product gases in a bubbling fluidized bed reactor

Fast pyrolysis of biomass in a fluidized bed reactor is typically conducted in a nitrogen gas environment. Recycling product gas can improve the economics of operating such a system by reducing reliance on pure process streams, but much less is known about how recycling pyrolysis product gas may affect fluidization behavior and pyrolysis kinetics. Therefore, gas effects in a fluidized bed biomass pyrolysis reactor were investigated using engineering correlations, low-order models, and CFD simulations for N 2 , H 2 , CO, CO 2 , and CH 4 carrier gas mixtures. Here, our findings reveal viscosity of a gas mixture can be significantly underestimated depending on the model and correlation. Furthermore, fluidization characteristics such as U mf and gas-solid convective heat transfer can be greatly affected by the gas properties. By utilizing H 2 as the fluidizing gas (instead of N 2 ), while maintaining a constant fluidization ratio (U s /U mf ), the bio-oil yields can be increased ~5%. This is due to the lower density H 2 producing similar hydrodynamics as N 2 at higher gas flow rates. These higher flow rates result in shorter gas residence times, and as a result, less secondary reactions that convert bio-oil to light gases and char. Model results also suggest that bio-oil yield is not significantly affected by the type of carrier gas used, with bio-oil yield varying by ~2% across different gas mixtures while maintaining constant flow rate. In conclusion, this indicates that recycled pyrolytic gas can be used as the carrier gas for biomass pyrolysis.

09 BIOMASS FUELS↗
DOE OSTI2018

Tensile performance of sustainable Strain-Hardening Cementitious Composites with hybrid PVA and recycled PET fibers

Highlights: • SHCCs with hybrid PVA/PET fibers are theoretically and experimentally studied. • A semi-empirical way to predict strain capacity of hybrid-fiber SHCCs is proposed. • The impacts of PET fiber surface treatment and curing time are explored. • SHCCs achieve satisfactory performance even 50% PVA fibers are replaced by PET fibers. • Using PET fibers in SHCCs effectively reduces material cost and environmental impact. - Abstract: Strain-Hardening Cementitious Composite (SHCC) is a type of advanced construction material that can enhance the resiliency and durability of structures. However, the high cost of the constituents limits the wide application of SHCCs. To reduce the material cost and improve the sustainability, this study explores the potential of replacing commonly-used polyvinyl alcohol (PVA) fibers by recycled polyethylene terephthalate (PET) fibers. The potential of fiber hybridization was first evaluated using micromechanical modeling, and the ultimate tensile strain of hybrid-fiber SHCCs was estimated using a semi-empirical method. Then the tensile performance of SHCCs after standard curing and accelerated aging was experimentally evaluated, and the crack pattern development with increasing tensile strain was recorded. Satisfactory mechanical performance can be achieved even when 50% of PVA fibers are replaced by recycled PET fibers with surface treatment. In addition, using recycled PET fibers in SHCCs can significantly reduce the material cost and environmental impact.

36 MATERIALS SCIENCE↗