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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 OSTI2023

Assessing and Improving Biooxidation for Acid Generation and Rare Earth Element Extraction

Microorganisms (Acidithiobacillus ferrooxidanns) are effective in oxidizing ferrous ions that can be used to oxidize pyrite and produce sulfuric acid. Many coal waste resources contain significant concentrations of rare earth elements (REE) and critical materials (CM) that can be extracted using sulfuric acid. These coal waste resources often contain significant concentrations of pyrite, which if not utilized or removed present a future environmental liability for potential acid mine drainage. Thus, the combination of pyrite and REE/CM in coal waste provides a significant resource opportunity for sulfuric acid generation that can be utilized using biooxidation. In addition, the pyrite concentrate used for acid generation also contains REE/CM content that is released during biooxidation of the pyrite concentrate that augments the REE/CM release from the main ore being leached with the acid generated from the pyrite. Thus, this approach provides a very significant environmental advantage as well as augmented REE/CM recovery. Although there are many studies associated with biooxidation in relation to mineral oxidation, there is a lack of information regarding the effects of operating parameters on biooxidation performance and optimization for practical applications. In this study, findings from research in assessing and improving biooxidation for acid generation for REE/CM extraction are presented. Results show that bacteria can very effectively and efficiently oxidize ferrous ions to ferric ions, which oxidize pyrite to produce acid for REE/CM extraction. The factors that showed significant impact on biooxidation performance include air flow rate, stirring speed, residence time, solids concentration, and temperature. The dominance of Leptospirillum ferriphilum species was noted in the bioreactor after a prolonged period of operation, although Acidithiobacillus ferrooxidanns was used in the beginning.

Free, Michael L.↗

DOE OSTI2026

Recycling of Printed Circuit Boards to Recover Critical Materials

The printed circuit board (PCB), a central component of most electronic devices, represents a significant fraction of the electronic product waste stream. The complex composition of PCBs, consisting of metals, polymers, and fiberglass, requires specialized recovery steps to reclaim valuable and critical materials and the safe disposal of brominated compounds. In this review paper, we describe the current state of critical material recovery and traditional recycling technologies and identify key obstacles to large-scale implementation. Metals present at high concentrations, such as copper, lead, and iron, are conventionally recovered from PCBs using hydrometallurgical, pyrometallurgical, or electrometallurgical processes. Hydrometallurgical methods achieve high selectivity through chemical leaching but pose significant challenges for effluent and reagent recovery. Pyrometallurgical methods facilitate rapid metal separation through smelting but require substantial energy and may release harmful gases. Electrometallurgical techniques produce high-purity metals but are constrained by pretreatment requirements and the consumption of energy. The non-metallic fraction of PCB waste is recycled using thermochemical conversion, microwave-aided heating, and direct recycling of epoxy–fiberglass composites, enabling material or energy recovery. The recovered polymer from direct recycling may have reduced mechanical strength and poor compatibility with new polymer matrices, and the resulting products from the thermal conversion suffer from incomplete conversion, degradation of quality, and residual contamination, as compared to synthetic polymers. Recent process developments have focused on extracting rare earth and supply-critical materials present at lower concentrations in the waste stream. The literature on existing and emerging approaches for recycling PCB wastes is reviewed to identify sustainable, economically viable, and environmentally responsible strategies for the recovery and reuse of critical materials from waste streams.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Soil Carbon Change Due to Land Conversion to Grassland in a Semi-Arid Environment

A 5-year study evaluated the change in the quantity of soil total C (STC), soil organic C (SOC), and soil inorganic C (SIC) stored in the surface 60 cm of the soil profile on two adjacent blocks of land with a long-term history of cropping (CH) or undisturbed grassland (NH) on similar soil types between 1999 and 2004. The NH area was tilled and a grass-legume species mix was seeded into plots on both the NH and the CH areas. Selected plots of restored grass were established so they could be grazed (GG) by livestock while other plots were left ungrazed (UG). Original undisturbed (and ungrazed) grassland plots within the NH area were used as a control treatment. Initially, STC and SOC in CH were lower than NH when compared under the semi-arid environmental conditions found in southwestern North Dakota. Over the study period, the undisturbed grass control plots had increases in STC and SOC levels in the soil profile of 3.90 kg·m−2 and 3.34 kg·m−2, respectively. Restored grass on the NH area with grazing showed increases in STC and SOC values of 2.11 and 1.26 kg·m−2, respectively, while without grazing, profile STC and SOC had values of 3.80 and 3.28 kg·m−2, respectively. Restored grass on the CH area showed increases in profile STC and SOC values of 0.55 and 1.96 kg·m−2, respectively, for the grazed plots and 0.78 and 2.11 kg·m−2, respectively, when left ungrazed. Soil inorganic C, though present in the soils, did not significantly change during the study. The lower C accumulation in the CH plots may be due to a lag time in the establishment of mycorrhizal associations with the seeded species, the inoculums of which were already present in the NH soils. Changes in STC were likely due to changes in water relationships in the soil profile where management changes affected water infiltration and its movement causing leaching of SIC below the 60 cm depth evaluated. Soils under undisturbed grassland continue to accumulate carbon while soils of the disturbed grassland or cropped prior to re-establishing grass showed losses that occurred due to either accumulating C at a lower rate or perhaps to C loss during the initial establishment period (1–2 years).

Yellajosula, Gayatri↗

DOE OSTI2024

Technoeconomic Assessment of Phosphoric Acid and Rare Earth Element Recovery from Phosphoric Acid Sludge

Sustainability faces many challenges, including the availability of materials necessary for technological advancement. Rare earth elements (REEs), for example, are key materials for several manufacturing industries that can unlock renewable energy and sustainable development. In this study, a decanter centrifuge has been employed to successfully separated phosphoric acid and REE-containing particles from phosphoric acid sludge with concentrations ranging from 1000 to 2200 ppm REEs. Operating efficiently with up to 35 wt.% solids, the centrifuge was demonstrated to achieve approximately 95% phosphoric acid recovery and 90% REE recovery in a single pass, eliminating the need for additional processing steps. This breakthrough supports a proposed rare earth oxide (REO) recovery process integrating phosphoric acid (PA), elemental phosphorus (P4), and REO into two potential pathways: PA-REO and PA-P4-REO. These processes aim to reintroduce recovered phosphoric acid into the main product to significantly increase output and revenue. Post-separation, phosphorus-rich particles can be converted to P4, while REE-containing solids undergo further treatment including acid leaching, extraction/stripping, precipitation, and calcination to produce a marketable REO material. Technoeconomic analysis indicates promising profitability, with the PA-REO process showing a delta net present value (ΔNPV) of USD 441.8 million over a 12-year period and expected return within a year of construction, while the PA-P4-REO process yields a ΔNPV of USD 178.7 million over a 12-year return period. Both pathways offer robust financial prospects and demonstrate the feasibility of commercial-scale REO recovery from phosphoric acid sludge, offering an economically feasible approach to produce REEs for future sustainable development challenges related to sustainability.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Data from: Soil phosphorus drawdown by perennial bioenergy cropping systems in the Midwestern US

We analyzed phosphorus (P) inputs (fertilization and atmospheric deposition) and outputs (harvest and leaching losses) over seven years in three representative biomass crops—switchgrass ( Panicum virgatum L.), miscanthus ( Miscanthus X giganteus ) and hybrid poplar trees ( Populus nigra X P . maximowiczii ) – as well as in no-till corn (maize; Zea mays L.) for comparison, all planted on former cropland in SW Michigan, USA.

corn↗

DOE OSTI2023

Assessing carbon storage capacity and saturation across six central US grasslands using data–model integration

Abstract. Future global changes will impact carbon (C) fluxes and pools in most terrestrial ecosystems and the feedback of terrestrial carbon cycling to atmospheric CO2. Determining the vulnerability of C in ecosystems to future environmental change is thus vital for targeted land management and policy. The C capacity of an ecosystem is a function of its C inputs (e.g., net primary productivity – NPP) and how long C remains in the system before being respired back to the atmosphere. The proportion of C capacity currently stored by an ecosystem (i.e., its C saturation) provides information about the potential for long-term C pools to be altered by environmental and land management regimes. We estimated C capacity, C saturation, NPP, and ecosystem C residence time in six US grasslands spanning temperature and precipitation gradients by integrating high temporal resolution C pool and flux data with a process-based C model. As expected, NPP across grasslands was strongly correlated with mean annual precipitation (MAP), yet C residence time was not related to MAP or mean annual temperature (MAT). We link soil temperature, soil moisture, and inherent C turnover rates (potentially due to microbial function and tissue quality) as determinants of carbon residence time. Overall, we found that intermediates between extremes in moisture and temperature had low C saturation, indicating that C in these grasslands may trend upwards and be buffered against global change impacts. Hot and dry grasslands had greatest C saturation due to both small C inputs through NPP and high C turnover rates during soil moisture conditions favorable for microbial activity. Additionally, leaching of soil C during monsoon events may lead to C loss. C saturation was also high in tallgrass prairie due to frequent fire that reduced inputs of aboveground plant material. Accordingly, we suggest that both hot, dry ecosystems and those frequently disturbed should be subject to careful land management and policy decisions to prevent losses of C stored in these systems.

58 GEOSCIENCES↗

DOE OSTI2025

Burn severity and vegetation type control phosphorus concentration, molecular composition, and mobilization

Shifting phosphorus (P) dynamics after wildfires can have cascading impacts from terrestrial to aquatic environments. However, it is unclear whether shifts in P composition or P concentration are responsible for changes in P dynamics post-fire. We used laboratory leaching experiments of Douglas fir forest and sagebrush shrubland chars to examine how the potential mobility of P compounds is influenced by different burn severities. Burning produced a 6.9- and 29-fold increase in particulate P mobilization but a 3.8- and 30.5-fold decrease in aqueous P released for Douglas fir forest and sagebrush shrubland, respectively. The mechanisms driving particulate- and dissolved-phase P compound mobilization were contrasting. Phosphorus compound mobilization in the particulate phase was controlled by solid char total P concentrations, while the aqueous phase was driven by solubility changes of molecular species. Nuclear magnetic resonance (NMR) and X-ray absorption near-edge structure (XANES) on the solid chars indicated that organic orthophosphate monoester and diester species were thermally mineralized to inorganic P moieties with burning in both vegetation types, which decreases P solubility. This coincided with the production of calcium- and magnesium-bound inorganic P compounds. With increasing burn severity there were systematic shifts in P concentration and composition – higher-severity chars mobilized P compounds in the particulate phase, although the magnitude of change was vegetation-specific. Our results indicate a post-fire transformation to both the composition of the solid charred material and how P compounds are mobilized, which may influence its environmental cycling and fate.

31P solution-state NMR↗

DOE OSTI2023

Cosmogenic 10 Be in pyroxene: laboratory progress, production rate systematics, and application of the 10 Be– 3 He nuclide pair in the Antarctic Dry Valleys

Here, we present cosmogenic- 10 Be and cosmogenic- 3 He data from Ferrar dolerite pyroxenes in surficial rock samples and a bedrock core from the McMurdo Dry Valleys, Antarctica, with the goal of refining the laboratory methods for extracting beryllium from pyroxene, further estimating the 10 Be production rate in pyroxene and demonstrating the applicability of 10 Be– 3 He in mafic rock. The ability to routinely measure cosmogenic 10 Be in pyroxene will open new opportunities for quantifying exposure durations and Earth surface processes in mafic rocks. We describe scalable laboratory methods for isolating beryllium from pyroxene, which include a simple hydrofluoric acid leaching procedure for removing meteoric 10 Be and the addition of a pH 8 precipitation step to reduce the cation load prior to ion exchange chromatography. 10 Be measurements in pyroxene from the surface samples have apparent 3 He exposure ages of 1–6 Myr. We estimate a spallation production rate for 10 Be in pyroxene, referenced to 3 He, of 3.6 ± 0.2 atoms g –1 yr –1 . 10 Be and 3 He measurements in the bedrock core yield initial estimates for parameters associated with 10 Be and 3 He production by negative-muon capture ($f_{10}^{*}$ = 0.00183 and $f_{3}^{*}f_{C}f_{D}$ = 0.00337). Next, we demonstrate that the 10 Be– 3 He pair in pyroxene can be used to simultaneously resolve erosion rates and exposure ages, finding that the measured cosmogenic-nuclide concentrations in our surface samples are best explained by 2–8 Myr of exposure at erosion rates of 0–35 cm Myr –1 . Finally, given the low 10 Be in our laboratory blanks (average of 5.7 × 10 3 atoms), the reported measurement precision, and our estimated production rate, it should be possible to measure 2 g samples with 10 Be concentrations of 6 × 10 4 and 1.5 × 10 4 atoms g –1 with 5 % and 15 % uncertainty, respectively. With this level of precision, Last Glacial Maximum to Late Holocene surfaces can now be dated with 10 Be in pyroxene. Application of 10 Be in pyroxene, alone or in combination with 3 He, will expand possibilities for investigating glacial histories and landscape change in mafic rock.

58 GEOSCIENCES↗

DOE OSTI2026

Modeling supercritical CO 2 flow and mineralization in reactive host rocks with PFLOTRAN v7.0

Understanding the flow and reactivity of CO 2 injected into geological reservoirs is important for many subsurface applications including secure geologic carbon storage (GCS), critical mineral extraction, enhanced geothermal systems (EGS), and enhanced oil recovery (EOR). Traditionally, subsurface CO 2 injection for GCS applications has focused on geologic formations with favorable subsurface configurations for CO 2 migration and trapping through non-reactive mechanisms such as structural, solubility, and petrophysical trapping. Recently, CO 2 -reactive rocks such as mafic and ultramafic basalts have been investigated for their potential to react with injected CO 2 in situ to simultaneously dissolve host rock minerals and mineralize CO 2 as carbonates. Engineering rapid CO 2 mineralization in the subsurface is attractive because of the increased density of stored CO 2 , the additional safety factors associated with solidification, and the potential to extract valuable critical minerals. Here we present recent developments in the parallel flow and reactive transport simulator PFLOTRAN to model coupled CO 2 -brine flow and reactive transport for a wide range of injection and production applications involving reactive CO 2 -brine systems. These developments are based on the well established and trusted CO 2 flow capabilities in the STOMP-CO 2 simulator. New capabilities added to PFLOTRAN include new CO 2 -brine equations of state with optional thermal coupling, several new constitutive relationships like capillary pressure smoothing and scanning path hysteresis, a fully implicit well model, and native linkage with PFLOTRAN's well-established reactive transport libraries. A series of benchmarks between PFLOTRAN and STOMP-CO 2 verify the newly developed CO 2 -brine flow capabilities. Demonstrations of coupled CO 2 -brine flow modeling and reactive transport show how CO 2 mineralization can be engineered in reactive host rocks. Finally, an example use case involving copper leaching by CO 2 and critical mineral extraction is presented to showcase the strengths of this new implementation. Several limitations still remain, including limited availability of field data to parameterize models. Future work should constrain the evolution of mineral surface area during mineralization and the temperature and/or pH dependence of geochemical reactions for specific systems of interest.

Critical Minerals↗

DOE OSTI2025

Soil oxygen dynamics: a key mediator of tile drainage impacts on coupled hydrological, biogeochemical, and crop systems

Tile drainage removes excess water and is an essential, widely adopted management practice to enhance crop productivity in the US Midwest and throughout the world. Tile drainage has been shown to significantly change hydrological and biogeochemical cycles by lowering the water table and reducing the residence time of soil water, although examining the complex interactions and feedbacks in an integrated hydrology–biogeochemistry–crop system remains elusive. Oxygen dynamics are critical to unraveling these interactions and have been ignored or oversimplified in existing models. Understanding these impacts is essential, particularly so because tile drainage has been highlighted as an adaptation under projected wetter springs and drier summers in the changing climate in the US Midwest. We used the ecosys model that uniquely incorporates first-principle soil oxygen dynamics and crop oxygen uptake mechanisms to quantify the impacts of tile drainage on hydrological and biogeochemical cycles and crop growth in corn–soybean rotation fields. The model was validated with data from a multi-treatment, multi-year experiment in Washington, IA. The relative root mean square error (rRMSE) for the corn and soybean yield in validation is 5.66 % and 12.57 %, respectively. The Pearson coefficient (r) of the monthly tile flow during the growing season is 0.78. Plant oxygen stress turns out as an emergent property of the equilibrium between the soil oxygen supply and biological demand. The impact of tile drainage on the system is achieved through a series of coupled feedback mechanisms. The model results show that tile drainage reduces the soil water content and enhances soil oxygenation. It additionally increases the subsurface discharge and elevates inorganic nitrogen leaching, with seasonal variations influenced by climate and crop phenology. The improved aerobic condition alleviates crop oxygen stress during wet springs, thereby promoting crop root growth during the early growth stage. The development of greater root density, in turn, mitigates water stress during dry summers, leading to an overall increase in the crop yield by ∼6 %. These functions indicate the potential of tile drainage in bolstering crop resilience to climate change and the use of this modeling tool for large-scale assessments of tile drainage. The model reveals the underlying causal mechanisms that drive the agroecosystem response to drainage on the coupled hydrology, biogeochemistry, and crop system dynamics.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2023

Baltimore Ecosystem Study: Soil atmosphere fluxes of carbon dioxide, nitrous oxide and methane, 1998 - ongoing

The Baltimore Ecosystem Study (BES) established a network of long-term permanent biogeochemical study plots in 1998. These plots provide long-term data on vegetation, soil and hydrologic processes in the key ecosystem types within the urban ecosystem. The network of study plots includes forest plots (upland and riparian), chosen to represent the range of forest conditions in the area and grass plots (to represent home lawns). Plots are instrumented with lysimeters (drainage and tension) to sample soil solution chemistry, time domain reflectometry probes to measure soil moisture, dataloggers to measure and record soil temperature, and trace gas flux chambers to measure the flux of carbon dioxide, nitrous oxide and methane from soil to the atmosphere. Measurements of in situ nitrogen mineralization, nitrification and denitrification were made at approximately monthly intervals from Fall 1998 - Fall 2000. Detailed vegetation characterization (all layers) was done in summer 1998 and 2015. Data from these plots has been published in Groffman et al. (2006, 2009), Groffman and Pouyat (2009), Savva et al. (2010), Costa and Groffman (2013), Duncan et al. (2013), Waters et al. (2014), Ni and Groffman (2018), Templeton et al. (2019). Literature Cited Costa, K.H. and P.M. Groffman. 2013. Factors regulating net methane flux in urban forests and grasslands. Soil Science Society of America Journal 77:850 - 855. Duncan, J. M., L. E. Band, and P. M. Groffman. 2013. Towards closing the watershed nitrogen budget: Spatial and temporal scaling of denitrification. Journal of Geophysical Research Biogeosciences 118:1-5; DOI: 10.1002/jgrg.20090 Groffman PM, Pouyat RV, Cadenasso ML, Zipperer WC, Szlavecz K, Yesilonis IC,. Band LE and Brush GS. 2006. Land use context and natural soil controls on plant community composition and soil nitrogen and carbon dynamics in urban and rural forests. Forest Ecology and Management 236:177-192. Groffman, P.M., C.O. Williams, R.V. Pouyat, L.E. Band and I.C. Yesilonis. 2009. Nitrate leaching and nitrous oxide flux in urban forests and grasslands. Journal of Environmental Quality 38:1848-1860. Groffman, P.M. and R.V. Pouyat. 2009. Methane uptake in urban forests and lawns. Environmental Science and Technology 43:5229-5235. DOI: 10.1021/es803720h. Ni, X. and P.M. Groffman. 2018. Declines in methane uptake in forest soils. Proceedings of the National Academies of Science of the United States of America 115:8587-8590. Savva, Y., K. Szlavecz, R. V. Pouyat, P. M. Groffman, and G. Heisler. 2010. Effects of land use and vegetation cover on soil temperature in an urban ecosystem. Soil Science Society of America Journal 74:469-480. Templeton, L., M.L. Cadenasso, J. Sullivan, M. Neel and P.M. Groffman. 2019. Changes in vegetation structure and composition of urban and rural forest patches in Baltimore from 1998 to 2015. Forest Ecology and Management. In press. Waters, E.R., J.L. Morse, N.D. Bettez and P.M. Groffman. 2014. Differential carbon and nitrogen controls of denitrification in riparian zones and streams along an urban to exurban gradient. Journal of Environmental Quality 43:955–963.

Groffman, Peter M↗

DOE OSTI2020

Atomic Layer Deposition for Enhanced Reactivity, Stability, and Sulfur Tolerance of Hydrogenation Catalysts

Heterogeneous catalysts are an essential tool in the transition towards a sustainable, bio-based economy for fuels and chemicals. However, many key biomass conversion processes utilize harsh conditions that lead to nanoparticle sintering, support collapse, and metal leaching in conventional PGM catalysts. Active site poisoning resulting from the relatively high sulfur content of most biomass feedstocks further compounds these durability problems. Next-generation catalysts must be developed to address these stability challenges. In this work, we have used atomic layer deposition (ALD), to modify a conventional Pd/Al2O3 hydrogenation catalyst and generate improvements in its stability and sulfur tolerance, as well as overall catalyst activity. Ten cycles of TiO2ALD were applied to Pd/Al2O3 using a proprietary coating process developed by industry partners. The coated catalyst (10cTiO2), alongside uncoated Pd/TiO2 and Pd/Al2O3 controls, was characterized in-depth and naphthalene hydrogenation was used as a probe reaction to assess activity. The 10cTiO2 catalyst was observed to be significantly more active towards hydrogenation than uncoated Pd/Al2O3, despite evidence that the ALD coating suppressed chemisorption uptake through coverage of Pd. In order to reconcile these seemingly contradictory findings, interactions between the Pd nanoparticles and TiO2ALD coating were investigated via XAS and computational modeling. The catalysts were also assessed for their sulfur tolerance, thermal stability, and hydrothermal stability. Each of these catalyst stability parameters was enhanced by application of the TiO2ALD layer; the mechanisms by which the layer may have mitigated these degradation processes will be discussed. ALD technology holds great potential in the development of next-generation catalysts for biofuels and bioproducts and this work constitutes an important examination of the expected and unexpected benefits of applying TiO2ALD coatings to supported Pd hydrogenation catalysts.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Reactive Grinding of Coal Ash For Enhanced Rare Earth Extraction

Monazite and coal ash contain varying trace amounts of Rare Earth Elements (REE). Rare earth elements are considered to be the elements in the lanthanide series. These elements be categorized into two separate groups, light and heavy rare earth groups. Rare Earth Elements play an essential role to society and industry and can be found in a spectrum of applications such as Capacitors, Power Generation, and Catalysts for Petroleum Refining. Due to the abundance of Coal Ash and ongoing production, there is an increasing interest from the scientific community to develop renewable source of energy by extracting rare earth elements from within its contents. Commercial and experimental reactive grinding and leaching procedures have been created to help to maximize the recovery of Rare Earth Elements from Coal Ash.

Keller, Murphy↗

DOE OSTI2021

Systems and processes for recovery of high-grade rare earth concentrate from acid mine drainage

In one aspect, the disclosure relates to a continuous process for treating acid mine drainage while simultaneously recovering a high-grade rare earth preconcentrate suitable for extraction of commercially valuable rare earth oxides. In a further aspect, the preconcentrate is from about 0.1% to 5% rare earth elements on a dry weight basis. In another aspect, the disclosure relates to a method for processing the preconcentrate to generate a pregnant leach solution that does not form gels or emulsions and is suitable for processing via solvent extraction. In another aspect, the disclosure relates to a system and plant for carrying out the disclosed process. In still another aspect, the disclosure relates to a composition containing rare earth elements produced by the process disclosed herein. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

Ziemkiewicz, Peter F.↗

DOE OSTI2021

Atomic Layer Deposition for Improved Biomass Conversion Catalysts

Heterogeneous catalysts are a key enabler of the transition towards a sustainable, bio-based economy for fuels and chemicals. However, the harsh conditions in many biomass conversion processes lead to nanoparticle sintering, support collapse, and metal leaching in conventional PGM catalysts. Next-generation catalysts must be developed to address these stability challenges. This presentation will discuss ongoing work between the Catalytic Carbon Transformation and Scale-Up Center at NREL and various industrial partners to develop scalable and cost-effective atomic layer deposition (ALD) coatings for improving the performance of biomass conversion catalysts. The substantial focus will be devoted to the benefits of TiO2 ALD coatings on supported Pd hydrogenation catalysts. Ten cycles of TiO2 ALD were found to dramatically improve the activity of a conventional Pd/Al2O3 catalyst towards aromatic hydrogenation, despite partial coverage of the Pd sites by the ALD layer. Subsequent advanced characterization and atomic-scale computational modeling revealed that the ALD coating weakened the adsorption strength of hydrogenation surface intermediates, leading to higher reaction rates. Reaction testing after exposure to sulfur impurities, high temperature oxidation, and hydrothermal treatment demonstrated the improved stability of the ALD-coated catalyst. Additionally, the ALD synthesis process was found to be scalable over two orders of magnitude with minimal deviation in synthesized catalyst properties. These results were contextualized with cost models of industrial ALD coating and aromatic hydrogenation processes to further refine the value proposition of ALD coatings. Given the demonstrated improvements in hydrogenation, TiO2 ALD coatings have also been applied to supported Pt catalysts for use in other biomass conversion reactions, such as hydrodeoxygenation for the production of sustainable aviation fuel (SAF) and the oxidation of glucose to bio-derived gluconic acid.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

CLOSURE REPORT FOR CORRECTIVE ACTION UNIT 577 AREA 5 CHROMIUM CONTAINING WASTE DISPOSAL CELLS

Report will be submitted to the state of Nevada Corrective Action Unit (CAU) 577, “Area 5 Chromium Containing Waste Disposal Cells,” includes five low-level waste cells at the Nevada National Security Site (NNSS) Area 5 Radioactive Waste Management Site (RWMS) where buried waste received from Nuclear Fuel Services, Inc. (NFS), was subsequently determined to contain chromium that exceeded the Toxicity Characteristic Leaching Procedure regulatory limit, which would require the waste to carry hazardous waste code D007. CAU 577 was created to satisfy the requirements of the Settlement Agreement (SA) executed between the Nevada Division of Environmental Protection (NDEP) and the U.S. Department of Energy, National Nuclear Security Administration Nevada Field Office on April 25, 2019. The SA required that the chromium-containing waste received from NFS would be addressed following the closure process laid out in the Federal Facility Agreement and Consent Order (FFACO). The FFACO process ensures proper closure of the chromium-containing waste cells and documentation of that closure through FFACO-type documents (NDEP 2019). As stipulated in Paragraph 5C of the SA, a Corrective Action Decision Document/Corrective Action Plan (CADD/CAP) was prepared that identified and evaluated risks and corrective action alternatives (CAAs) for CAU 577, provided the plan for implementing the recommended CAA, and presented the post-closure plan (U.S. Department of Energy [DOE] Environmental Management [EM] Nevada Program 2021).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Atomic Layer Deposition for Improved Biomass Conversion Catalysts

Heterogeneous catalysts are a key enabler of the transition towards a sustainable, bio-based economy for fuels and chemicals. However, the harsh conditions in many biomass conversion processes lead to nanoparticle sintering, support collapse, and metal leaching in conventional PGM catalysts. Next-generation catalysts must be developed to address these stability challenges. This presentation will discuss ongoing work between the Catalytic Carbon Transformation & Scale-Up Center at NREL and various industrial partners to develop scalable, cost-effective atomic layer deposition (ALD) coatings for improving the performance of biomass conversion catalysts. Substantial focus will be devoted to the benefits of TiO2 ALD coatings on supported Pd hydrogenation catalysts. Ten cycles of TiO2 ALD were found to dramatically improve the activity of a conventional Pd/Al2O3 catalyst towards aromatic hydrogenation, despite partial coverage of the Pd sites by the ALD layer. Subsequent advanced characterization and atomic-scale computational modeling revealed that the ALD coating influenced the adsorption strength of hydrogenation surface intermediates in unexpected ways, leading to higher reaction rates. Reaction testing after exposure to sulfur impurities, high temperature oxidation, and hydrothermal treatment demonstrated the improved stability of the ALD-coated catalyst. Additionally, the ALD synthesis process was found to be scalable over two orders of magnitude with minimal deviation in synthesized catalyst properties. These results were contextualized with cost models of industrial ALD coating and aromatic hydrogenation processes to further refine the value proposition of ALD coatings. Given the demonstrated improvements in hydrogenation, TiO2 ALD coatings have also been applied to supported Pt catalysts for use in other biomass conversion reactions, such as hydrodeoxygenation for production of sustainable aviation fuel (SAF) and the oxidation of glucose for bio-derived gluconic acid. Recent findings from these experimental campaigns will also be shared. ALD technology holds great potential in the development of next-generation catalysts for biofuels and bioproducts and this work constitutes an important examination of the impact of ALD coatings in a variety of reaction environments.

bioenergy↗