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All sources NASA NTRS DOE OSTI

DOE OSTI2022

Process Scale-Up of an Energy-Efficient Membrane Solvent Extraction Process for Rare Earth Recycling from Electronic Wastes

This study reports the process scale-up and long-term performance of an energy-efficient and cost-effective membrane solvent extraction (MSX) process for separation and recovery of high purity rare earth oxides (REOs) from scrap permanent magnets (SPMs). Here, the rare earth elements (REEs), including dysprosium, neodymium, and praseodymium, are recovered from SPMs using a neutral extractant, tetraoctyl diglycolamide (TODGA) embedded in a microporous polypropylene hollow fiber membrane module. The MSX process performance is demonstrated with bench scale module with membrane surface area of 1.4 m 2 to industrial scale modules with membrane surface area of up to 20 m2 to enable the processing of up to 1 ton month –1 of SPMs. The purity and the yield of the recovered REOs are >99.5 wt% and >95%, respectively. The average extraction rate of REOs is >10 g m –2 hr –1 . A skid of MSX system is assembled with a membrane area of 40 m 2 . The MSX skid successfully recovers REOs with a capacity of 300 kg REOs/month. Finally, it is determined that the organic phase containing the extractant maintains its performance up to 250 h. The results suggest that the MSX process is an economically viable and environmentally friendly process for separation and recovery of REOs from electronic wastes.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Recovery of precious metals from space

The overall objective is to develop efficient and economical separation and recovery methods for the platinum group and other precious metals. The separation of Pd(II) from Pt(II), Ir(III), and Rh(III) with trioctylphosphine oxide (TOPO) in heptane using centrifugal partition chromatography (CPC) was investigated. Activities to achieve this objective focussed on selection and evaluation of extraction systems for the PGM and modification of selected systems for multistage operation with a view to scaling up to desired macro levels. On the basis of preliminary evaluation of a series of simple metal complexing agents and chelating agents, the TOPO in heptane was selected as a likely system for isolating of Pd(II) and Pt(II) from the other PGM. A multistage apparatus capable of configuration as a simple rugged device, a centrifugal partition chromatograph (CPC), was shown to be effective. The extraction of Pd(II) was studied by CPC and batch solvent extraction. The distribution ratios for Pd(II) determined by both methods agree well. In low HCl concentrations (less than 0.1 M), the extracted species was PdCl2.(TOPO)2, irrespective of the chloride concentration, while at acid concentrations above 0.1 M, the Pd was extracted as the ion pair, 2(TOPO.H+).(PdCl4)2-. Base line separation of Pd(II) and Pt(II) in CPC was obtained under a variety of chloride and HCl concentration. It was demonstrated that the efficiency of CPC for metal separation was limited by chemical kinetic factors rather than instrumental factors, strongly suggesting that dramatic improvements can be achieved by studying reaction kinetics of formation and dissociation of the extractable metal complex.

Freiser, Henry↗

DOE OSTI2023

Adsorptive recovery of volatile fatty acids from wastewater fermentation broth

This work developed an adsorptive separation and recovery process for anaerobically generated volatile fatty acids (VFAs) from swine wastewater fermentation. Batch adsorption studies were conducted using several weak anion exchange resins and synthetic adsorbent resins to identify a suitable candidate. Relite RAM2 with a tertiary amine functional group showed the highest adsorption (over 98%) of hexanoic acid. Under the different pH values (1.8–7.5) and extraction temperatures (30–50 ↑C), the highest adsorption was observed at a pH of 3.2, which is below the pKa of hexanoic acid, at all the evaluated temperatures. A full factorial design was used to optimize the resin and VFA concentrations, wherein over 99% adsorption could be achieved when the ratio of VFA to resin was below 0.23 (g/g) for model solution (VFAs in water). The adsorption equilibrium could be achieved within 30 min of contact time and 0.5% w/v NaOH was identified as a suitable desorption agent. Under the optimal conditions, 65–72% of VFAs present in fermentation broth was adsorbed, which was increased to 72–76% by using fresh resins. The VFAs adsorption and recovery efficiency were maintained for 9 successive cycles without requiring extensive resin washing and regeneration for both model solution and fermentation broth. Altogether, the work presents a comprehensive study for resin adsorption to recover VFAs and provides a potential industrial-relevant process to recover VFAs from fermentation broth.

09 BIOMASS FUELS↗

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

Separation of rare earth elements using supported membrane solvent extraction

A system and method for the recovery and separation of rare earth elements (REEs) are provided. The system and method include the supported membrane solvent extraction of REEs and the separation of light and heavy REEs that have been recovered from scrap permanent magnets and other electronic waste. In supported membrane solvent extraction, an organic phase consisting of an extractant and an organic solvent is immobilized in the pores of hollow fibers. An aqueous feed solution and a strip solution flow along the shell side and lumen side of the hollow fibers, respectively. The extractant functions as a carrier to selectively transport certain rare earth metal ions from the feed side to the strip side. The rare earth metals are concurrently back extracted in the strip solution, allowing processing to proceed continuously without equilibrium limitations.

Bhave, Ramesh R.↗

NASA NTRS1972

Booster recovery following premature space shuttle stage separation

Abort criteria necessary to satisfy space shuttle program requirements to include intact vehicle abort capability are discussed. Intact abort implies the ability of the booster and orbiter to separate and both continue flight to a safe landing, with a full payload aboard the orbiter. Obviously, the requirement to separate early along the ascent trajectory presupposes critical operational problems that are probably booster problems and may preclude booster recovery. On the other hand, some critical problems while mated can become manageable when separated and should result in full booster recovery. All critical orbiter problems fall into this category; since stage separation without orbiter thrust is a capability of some separation system concepts, booster stage recovery following separation is a requirement.

Hurley, M. J.↗

NASA NTRS2017

Method and Device for Extraction of Liquids from a Solid Particle Material

A method, system, and device for separating oil from oil sands or oil shale is disclosed. The method includes heating the oil sands, spinning the heated oil sands, confining the sand particles mechanically, and recovering the oil substantially free of the sand. The method can be used without the addition of chemical extraction agents. The system includes a source of centrifugal force, a heat source, a separation device, and a recovery device. The separation device includes a method of confining the sands while allowing the oil to escape, such as through an aperture.

deMayo, Benjamin↗

NASA NTRS2021

Using Electrostatic Principles to Separate Out Nutrients from ECLSS Wastewater Brines

This project will study the use electrostatics to perform electrostatic separation and recovery of Environmental Control and Life Support Systems (ECLSS) waste brines. Currently we have no way to perform nutrient recovery on ECLSS waste brines. This process can give us a competing way to separate sodium from potassium to allow tandem production of acids, bases, and plant fertilizers to run upstream operations and hydroponic systems respectively (when combined with electrodialysis). If we can recover valuable chemicals from brine, then this will decrease resupply from earth, which will allow tremendous (multiple kilograms a day up-mass reduction) cost savings. In addition, using electrostatics for regolith enrichment allow much reduced mining costs for metal production on celestial bodies and allow a smaller mining footprint.

Michael D. Hogue↗

DOE OSTI2023

Editorial: Separations for Energy and Environmental Applications

Climate change and global environmental impacts are challenging humanity as a whole, and particularly the scientific community, to rethink our approaches towards energy harvesting, storage, and utilization, and to formulate processes geared to restoring compromised environments. A large task in these efforts involves developing technologies that have low or no carbon footprint, enable the use of renewable energy sources, and minimize or eliminate contamination of water resources and generation of untreatable waste.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

A Fundamental Economic Assessment of Recovering Rare Earth Elements and Critical Minerals from Acid Mine Drainage Using a Network Sourcing Strategy

In recent years, acid mine drainage (AMD) has emerged as a promising unconventional source of rare earth elements (REEs) and other critical minerals (CMs) such as cobalt and manganese. In this regard, AMD provides a natural heap leaching effect that extracts and concentrates REE/CM from the host strata creating a partially enriched feedstock suitable for downstream extraction, separation, and recovery. While several prior studies have described processes and approaches for the valorization of AMD, very few have described the supply chain and infrastructure requirements as well as the associated economic assessment. To that end, this paper provides a fundamental economic assessment of REE/CM recovery from AMD using a network sourcing strategy in addition to a robust, flexible feedstock separations and refining facility. The methodology of this paper follows that of a typical techno-economic analysis with capital and operating costs estimated using AACE Class IV (FEL-2) guidelines. To demonstrate the range of possible outcomes, four pricing scenarios were modeled including contemporary prices (September, 2021) as well as the minimum and maximum prices over the last decade. In addition, five production scenarios were considered reflecting variations in the product suite, ranging from full elemental separation to magnet REE and CM production only (i.e., Pr, Nd, Tb, Dy, Y, Sc, Co, and Mn). The results of this analysis show that, with the exception of the minimum price scenario, all operational configurations have positive economic indicators with rates of return varying from 25% to 32% for the contemporary price scenario. The optimal configuration was determined to be production of Co, Mn, and all REEs except for mischmetal, which is not recovered. Sensitivity analysis and Monte Carlo simulation show that capital cost and HCl consumption are the two major factors influencing rate of return, thus indicating opportunities for future technology development and cost optimization. Implications of the study and a cooperative profit-sharing model for sourcing are also described.

42 ENGINEERING↗

DOE OSTI2020

Sustainable Direct Recycling of Lithium-Ion Batteries via Solvent Recovery of Electrode Materials

Separation of electrode materials from their current collectors is an enabling step toward recovering critical materials from spent lithium-ion batteries. In this study, a highly efficient, cost-effective, and environmentally sustainable separation process was developed for that purpose. Ethylene glycol, a vital commodity chemical as an antifreeze and polymer precursor, is used to delaminate electrode materials at low temperatures in seconds without altering the crystalline structure and morphology of active electrode materials. The recovered current collectors were intact without any corrosion. The authors also found that the solvent could be continuously reused, leading to the development of a closed-loop ecosystem and lithium-ion battery circular economy. The ultrafast delamination was driven by the competitive inhibition of binding through the weakening of hydrogen bonding. The ethylene glycol-based separation is a sustainable electrode recovery process that paves the way for battery recycling.

25 ENERGY STORAGE↗

DOE OSTI2023

Sequential Recovery of Critical Metals from Leached Liquor of Processed Spent Lithium-Ion Batteries

The processing and extraction of critical metals from black mass is important to battery recycling. Separation and recovery of critical metals (Co, Ni, Li, and Mn) from other metal impurities must yield purified metal salts, while avoiding substantial losses of critical metals. Solvent extraction in batch experiments were conducted using mixed metal sulphates obtained from the leach liquor obtained from spent and shredded lithium-ion batteries. Selective extraction of Mn 2+ , Fe 3+ , Al 3+ and Cu 2+ from simulated and real leached mixed metals solution was carried out using di-2-ethylhexylphophoric acid (D2EPHA) and Cyanex-272 at varying pH. Further experiments with the preferred extractant (D2EPHA) were performed under different conditions: changing the concentration of extractant, organic to aqueous ratio, and varying the diluents. At optimum conditions (40% v/v D2EPHA in kerosene, pH 2.5, O:A = 1:1, 25 °C, and 20 min), 85% Mn 2+ , 98% Al 3+ , 100% Fe 3+ , and 43% Cu 2+ were extracted with losses of only trace amounts (<5.0%) of Co 2+ , Ni 2+ , and Li + . The order of extraction efficiency for the diluents was found to be kerosene > Exxal-10 >>> dichloromethane (CH 2 Cl 2 ) > toluene. Four stages of stripping of metals loaded on D2EPHA were performed as co-extracted metal impurities were selectively stripped, and a purified MnSO 4 solution was produced. Spent extractant was regenerated after Fe 3+ and Al 3+ were completely stripped using 1.0 M oxalic acid (C 2 H 2 O 4 ).

25 ENERGY STORAGE↗

DOE OSTI2021

Understanding the Adsorption of Rare-Earth Elements in Oligo-Grafted Mesoporous Carbon

Rare-earth elements (REEs) are 17 elements of the periodic table primarily consisting of lanthanides. In modern society, the usage of REEs is ubiquitous in almost all modern gadgets and therefore efficient recovery and separation of REEs are of high importance. Selective adsorption and chelation of REEs in solid sorbents is a unique and sustainable process for their recovery. In this work, single-stranded oligos with 100 units of thymine were grafted onto carboxylated mesoporous carbon to synthesize a sorbent with phosphorus and oxygen functionalities. Additionally, the sorbent was characterized by X-ray photoelectron spectroscopy, Fourier-transform infrared spectroscopy, and scanning electron microscopy-energy-dispersive X-ray spectroscopy. Three different REEs with varying atomic radii and densities, Lu, Dy, and La, were adsorbed onto the carbon from aqueous solutions. It was observed that the adsorbed amounts increased with the increase in the atomic radius or decrease in the atomic density. Calculation of the distribution coefficients for all the equilibrium adsorption amounts suggested that adsorption is more effective in the lower concentration region. The L 3 -edge X-ray absorption near-edge structure confirmed a 3+ oxidation state of REEs in the adsorbed phase. Extended X-ray absorption fine structure (EXAFS) confirmed the binding of REEs with oxygen functionalities in the adsorbed phase. The radial distribution functions calculated from the EXAFS data suggest a longer RE–O distance for La compared to those for Lu and Dy. The coordination numbers and Debye–Waller factors have typical values of about 8–9 atoms and 0.01–0.02 Å 2 , respectively.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Quantitative Separation of Unknown Organic–Metal Complexes by Liquid Chromatography–Inductively Coupled Plasma-Mass Spectrometry

Dissolved organic matter (DOM) is widely recognized to control the solubility and reactivity of trace metals in the environment. However, the mechanisms that govern metal-DOM complexation remain elusive, primarily due to the analytical challenge of fractionating and quantifying metal–organic species within the complex mixture of organic compounds that comprise DOM. Here, we describe a quantitative method for fractionation and element-specific detection of organic–metal complexes using liquid chromatography with online inductively coupled plasma mass spectrometry (LC–ICP-MS). The method implements a post-column compensation gradient to stabilize ICP–MS elemental response across the LC solvent gradient, thereby overcoming a major barrier to achieving quantitative accuracy with LC–ICP-MS. With external calibration and internal standard correction, the method yields concentrations of organic–metal complexes that were consistently within 6% of their true values, regardless of the complex’s elution time. We used the method to evaluate the effects of four stationary phases (C18, phenyl, amide, and pentafluoroylphenyl propyl) on the recovery and separation of environmentally relevant trace metals (Mn, Fe, Co, Ni, Cu, Zn, Cd, and Pb) in Suwannee River Fulvic Acid and Suwannee River Natural Organic Matter. The C18, amide, and phenyl phases generally yielded optimal metal recoveries (>75% for all metals except Pb), with the phenyl phase separating polar species to a greater extent than C18 or amide. We also fractionated organic-bound Fe, Cu, and Ni in oxidized and reduced soils, revealing divergent metal-DOM speciation across soil redox environments. Finally, by enabling quantitative fractionation of DOM-bound metals, our method offers a means for advancing a mechanistic understanding of metal–organic complexation throughout the environment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Photoinduced structural recovery dynamics of rare-earth nickelate thin films

Photoinduced structural dynamics of rare-earth nickelate thin films, NdNiO 3 and SmNiO 3 , grown on (001) oriented SrTiO 3 were studied using time-resolved x-ray diffraction. The evolution of the (002) Bragg peak was tracked following laser excitation. The recovery pathways were found to be strongly dependent on laser fluence for NdNiO 3 and distinct for the two rare-earth nickelates. The recovery of the (002) peak shifts was modeled using a one-dimensional thermal diffusion model which showed that the recovery processes are non-thermal at high fluences. For NdNiO 3 , the timescales for the recovery of the (002) peak shift were found to be closely related to Ni magnetism recovery, potentially indicating magneto-structural coupling. Moreover, the evolution of integrated intensity and full-width-half-maximum points towards the presence of a structural phase separation during recovery. In conclusion, our studies highlight structural recovery pathways in nickelates by comparing the distinct responses of the photoinduced metal-insulator transition in NdNiO 3 and SmNiO 3 .

36 MATERIALS SCIENCE↗

DOE OSTI2026

Cobalt Dissolution from Metal Oxides and Battery Cathode Materials with Acetic Acid-Based Deep Eutectic Solvents

Recovery of critical metals with alternative solvents beyond those in traditional pyrometallurgy and hydrometallurgy is needed in consideration of environmental challenges and the growing demand for metals in energy technologies. Deep eutectic solvents (DESs) have emerged as sustainable alternatives for solvometallurgy in metal separation and recovery. In this study, DESs based on hydrogen bond acceptors (HBAs) including choline chloride (ChCl), acetylcholine chloride (AChCl), and betaine (Bet) were investigated for their effectiveness when paired with acetic acid (AA) as the hydrogen bond donor (HBD) for the dissolution of cobalt from cobalt oxide (CoO), lithium cobalt oxide (LiCoO 2 ), and lithium nickel manganese cobalt oxide (LNMC). Based on the spectroscopic analysis of the metal dissolution and coordination, Bet:AA was found to provide the highest solubility for CoO (0.33 M) in the form of an octahedral complex. On the other hand, ChCl:AA solvent was more effective at dissolving LiCoO 2 with 0.04 M Co 2+ corresponding to 17% dissolution efficiency and LNMC with 0.06 M Co 2+ corresponding to 72% dissolution efficiency at 50 °C, compared to Bet:AA (9% for LiCoO 2 and 31% for LNMC). Although the solubilities of LiCoO 2 and LNMC have not significantly improved in ChCl:AA, this difference in effectiveness between the solvents clearly reveals the role of the HBA in solubilization. The coordination synergy between the chloride and the –OH moiety facilitates the breakdown of the LiCoO 2 driven by the alteration of the solvent polarity. Cobalt in these solutions was found dominantly as a tetrahedral [CoCl 4 ] 2– complex. A chemical separation of cobalt oxalate from a mixed-metal oxide system based on Co, Fe, and Ni was also demonstrated, confirming the potential of these solvents for practical metal recovery.

Cobalt separation↗

NASA NTRS2023

Numerical Study on the Aerodynamics of an Iced Airfoil With Scale-Resolving Simulations

Scale-resolving simulations of the NACA 23012 airfoil with horn ice accretion on the leading edge are conducted using the hybrid Reynolds-averaged Navier–Stokes/large-eddy simulation (hybrid RANS/LES) and wall-modeled large-eddy simulation (WMLES) approaches implemented in the Launch, Ascent, and Vehicle Aerodynamics (LAVA) framework. Aerodynamic results at the Reynolds number of 1.8 million show good comparison with the experimental measurements at different angles of attack from pre-stall to post-stall regimes. The pressure plateaus caused by the flow separation and the recovery of pressure inside the separation bubble around the iced leading edge are well predicted with the scale-resolving simulations when sufficient grid resolution is used around the accreted ice. The unsteadiness of the turbulent flows around the iced airfoil is also examined through the turbulent kinetic energy with the Reynolds normal stress anisotropy. Kelvin–Helmholtz instability (KHI) arises at the shear layer triggered by the upper ice horn and leads to rapid laminar-to-turbulent transition over a large range of angle of attack. With the increase of the angle of attack, the region with high turbulence intensity induced by the unstable shear layer spreads quickly over the entire upper surface of the airfoil. The coherent KHI modes from the upper and lower ice horns are extracted using the spectral proper orthogonal decomposition (SPOD) technique. The SPOD modes extracted from the upper shear layer have large-scale variations in the spanwise direction and low-rank behavior where the energy of the leading SPOD mode at each Strouhal number of the KHI largely represents the total energy when the mode number in the spanwise direction is small.

ARMD↗

NASA NTRS2023

Numerical Study on the Aerodynamics of an Iced Airfoil With Scale-Resolving Simulations

ARMD↗