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DOE OSTI2018

Opportunities for plasma separation techniques in rare earth elements recycling

Rare earth elements recycling has been proposed to alleviate supply risks and market volatility. In this context, the potential of a new recycling pathway, namely plasma mass separation, is uncovered through the example of nedodymium - iron - boron magnets recycling. Plasma mass separation is shown to address some of the shortcomings of existing rare earth elements recycling pathways, in particular detrimental environmental effects. Here, a simplifed mass separation model suggests that plasma separation performances could compare favourably with existing recycling options. In addition, simple energetic considerations of plasma processing suggest that the cost of these techniques may not be prohibitive, particularly considering that energy costs from solar may become significantly cheaper. Further investigation and experimental demonstration of plasma separation techniques should permit asserting the potential of these techniques against other recycling techniques currently under development.

Economic feasibility↗

DOE OSTI2011

Electrostatic interaction effect for human DNA separation with functionalized mesoporous silicas

This work describes the development of highly efficient human DNA separation with functionalized mesoporous silica (FMS) materials. To demonstrate the electrostatic interaction effect between the target DNA molecules and FMS, three aminofunctionality types comprised of a mono-, a di-, and a tri-amine functional group were introduced on the inner surfaces of mesoporous silica particles. Systematic characterization of the synthesized materials was achieved by solid-state {sup 29}Si and {sup 13}C-NMR techniques, BET, FT-IR, and XPS. The DNA separation efficiency was explored via the function of the amino-group number, the amount used, and the added NaCl concentration. The DNA adsorption yields were high in terms of the use of triaminofunctionalized FMS at the 10 ng/L level, and the DNA desorption efficiency showed the optimum level at over 3.0 M NaCl concentration. The use of FMS in a DNA separation process provides numerous advantages over the conventional silica-based process. -- Graphical abstract: Control of electrostatic interaction for DNA biding by aminofunctionalized modification: mono-amine (MA), di-amine (DA), and tri-amine (TA). The red-ball means the amine groups of FMS. Display Omitted Highlights: {yields} Highly efficient and direct DNA separation was demonstrated with aminofunctionalized FMS. {yields} Systematic characterization of the synthesized materials was achieved by solid-state {sup 29}Si and {sup 13}C-NMR techniques, BET, FT-IR, and XPS. {yields} The DNA separation efficiency was explored via the function of the amino-group number, particles size, amount of FMS used, and the NaCl concentration. {yields} The electrostatic interaction between the target DNA labeled by cyanine (Cy-5) and aminofunctionalized FMS were achieved via confocal microscopy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Enhanced, continuous, liquid-liquid extraction and in-situ separation of volatile fatty acids from fermentation broth

In 2018 alone, the US landfilled 35.3 million tons of food waste, about 24% of the total landfilled mass. In addition to the negative impacts landfills have demonstrated on the environment and human health, some states have begun to outlaw or dissuade the disposal of food waste and sewage sludge into landfills altogether. An urgent need has thus been created for the development of digestion processes like anaerobic digestion (AD) and arrested methanogenesis (AM) to convert food waste into valuable chemical products. Unfortunately, the buildup of volatile fatty acids (VFAs) during these processes eventually halts the reaction, and energy efficient methodologies for VFA removal are critical for the operation of fermenters. Additionally, VFAs themselves can serve as valuable chemical precursors, and recently AD processes have been modified to increase VFA production during fermentation. However, even with significant research over the past three decades, the separation of VFAs from the fermenter broth has remained expensive. Moreover, the separation of these VFAs from the fermenter broth may cost up to 50% of the entire process budget, hindering the widespread commercial adoption of AD and AM. Here we present a novel liquid-liquid extraction process termed CLEANS (Continuous Liquid-liquid Extraction And iN-situ Separation) as a highly efficient method for continuously separating VFAs from a real fermentation broth solely under gravity. Our optimized process (using an aqueous broth feed pH of 2.5, tri-noctylamine as an extractant, and a 10:1 ratio of aqueous broth to organic extractant), achieved a VFA distribution constant K D = 44.5 ± 7.9, a single-pass recovery = 81.3 ± 2.5%, and an extraction factor = 8.1 ± 0.3. These KD values are over an order of magnitude higher than what has been previously reported for comparable processes. A high aqueous-to-organic flowrate ratio, enabled for the first time by CLEANS, was found to be particularly crucial for achieving optimal extraction. Our separation process demonstrates excellent reproducibility and potential for scalability. The economic and environmental implications of this work are briefly discussed.

42 ENGINEERING↗

DOE OSTI2025

A Novel Zwitterionic Chromatography Approach to Separate Lithium from Unconventional Resources

Lithium (Li) is a key element for clean energy technologies, and, accordingly, the global lithium demand has been increasing rapidly. Therefore, to meet the Li demand and maintain supply chain stability, it is critical to develop efficient lithium extraction technologies that allow exploitation of unconventional lithium resources, such as geothermal brines and inland brine streams. However, the recovery of Li from these resources is challenging due to low Li concentration, low ratios of Li/Na, Li/Mg, or Li/Ca, and complex feed compositions. To address this, we introduced a new Direct Lithium Extraction (DLE) process using Zwitterionic Chromatography (ZIC) to separate Li from other salts. Since salts are partitioned on ZIC under water elution, no reagent chemicals are needed, and the Li separation is not limited by the adsorption capacity. We prepared 13 different zwitterionic (ZI) resins to investigate the salt retention on various ZI groups and then screened out promising sorbents for efficient Li separation. It was found that salt retention was synergistically affected by the pore size and ZI configurations. Using carboxybetaine (QAC3CA) sorbents, multicomponent separations showed that Li can be partitioned from divalent salts or Na with selectivities of 1.8 or 1.9, respectively. Although the selectivity is relatively low, in real brine tests, Li was separated from Ca and Mg with 79.2 % yield, showing the potential for a continuous process to achieve high productivity and high yield. Simulation studies suggest the salt elution mechanism is related to the hydration reaction energy and the effective hydrated radius of cations.

critical minerals↗

DOE OSTI2024

Potential for light-induced separation of critical rare-earth elements

Current methods for separations of critical rare earth elements (REEs) require multi-step, waste-generating procedures that lack the ability to selectively separate similarly sized ions, despite such an onerous process. REEs possess unique optoelectronic properties that are often exploited for photomagnetic or photoluminescent applications but could be harnessed to drive element selective separations. Here, recent work exploring photochemical reactions of REE complexes points to promise for investigating alternative separations using photoactive molecules and macromolecular frameworks, highlighting a possible pathway towards realizing practical REE separations to increase the sustainability and longevity of mining and recycling these elements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2017

Effect of the medium’s density on the hydrocyclonic separation of waste plastics with different densities

Highlights: • The density of medium is the key parameter to separate plastic particles. • The paper shows the theoretical analysis is in good agreement with test. • The optimum value of the medium’s density was obtained. • The optimum value of the medium’s density lies near that of denser particles. - Abstract: Hydrocyclones can be applied to recycle waste plastics with different densities through separating plastics based on their differences in densities. In the process, the medium density is one of key parameters and the value of the medium’s density is not just the average of the density of two kinds of plastics separated. Based on the force analysis and establishing the equation of motion of particles in the hydrocyclone, a formula to calculate the optimum separation medium density has been deduced. This value of the medium’s density is a function of various parameters including the diameter, density, radial position and tangential velocity of particles, and viscosity of the medium. Tests on the separation performance of the hydrocyclone has been conducted with PET and PVC particles. The theoretical result appeared to be in good agreement with experimental results.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Electrospun Separator Based on Sulfonated Polyoxadiazole with Outstanding Thermal Stability and Electrochemical Properties for Lithium-Ion Batteries

Traditional polyolefin separators used in lithium-ion batteries (LIBs) are seriously limited by the issues of inferior security and poor electrolyte wettability. Most of the very promising candidate separators based on heat-resistant polymers are, however, inherently difficult to process. Herein, a unique sulfonated aromatic heterocyclic polymer, lithiated poly(diphenyl ether oxadiazole) sulfonate (Li-SPEOD), was synthesized through a simple one-pot method and further electrospun to act as a novel separator (es-Li-SPEOD) for LIBs. In this work, the prepared Li-SPEOD possesses a high degree of sulfonation with a high molecular weight (M w = 4.31 × 10 5 ). The es-Li-SPEOD separator exhibits excellent mechanical and fire-resistance properties and is able to maintain dimensional stability at a temperature of even up to 400 °C in air. The ionic conductivity (3.57 mS cm –1 ) and lithium-ion transference number (0.37) of the es-Li-SPEOD with an electrochemical stability window of 4.5 V vs Li + /Li can be improved by 382.4 and 32.1%, respectively, compared to those of Celgard-2500 in the LiPF 6 electrolyte. The enhanced rate capability and cycle performance of the LiFePO 4 –Li half-cell are therefore obtained. Moreover, the es-Li-SPEOD displays an outstanding dendrite-suppressing effect for the lithium metal anode. This research proves that the Li-SPEOD-based separator has a broad application perspective in next-generation lithium batteries.

25 ENERGY STORAGE↗

DOE OSTI2026

Interfacial Chemistry Involved in Selective Separation of NMC/LMO and LCO/LMO Binary Cathode Materials by Froth Flotation Using Oleic Acid

The variability in cathode compositions within recycled lithium-ion battery (LIB) feedstocks poses a significant challenge to efficient downstream refining processes. This study demonstrates the feasibility of using froth flotation with oleic acid as a collector to selectively separate lithium nickel-manganese-cobalt oxide (NMC) and lithium cobalt oxide (LCO) from lithium manganese oxide (LMO) materials. Laboratory-scale flotation tests achieved an 80% separation efficiency in a single stage, producing a froth product with >90% purity of NMC/LCO at approximately 90% yield. Concurrently, the LMO materials were enriched in the sink product with ∼90% purity and ∼90% yield. This approach was further validated using recycled cathode materials, confirming its applicability to realistic feedstocks. The underlying mechanism governing the selective separation of NMC/LCO from LMO was investigated using ζ-potential measurements, contact angle measurements, bubble-particle attachment experiments, and X-ray photoelectron spectroscopy (XPS) analysis. Both contact angle and bubble-particle attachment results confirmed that oleic acid adsorption rendered NMC and LCO surfaces hydrophobic, thereby enhancing flotation recovery. At pH 5, oleic acid adsorbed preferentially onto NMC and LCO surfaces via electrostatic interactions, while exhibiting minimal adsorption on LMO surfaces. However, separation efficiency deteriorated at higher pH, which was attributed to the co-flotation of LMO materials caused by oleate chemisorption on MnOH + species. This work establishes froth flotation as a viable cathode/cathode separation strategy, providing a low-cost, scalable pathway to preconcentrate and enrich nickel-rich and cobalt-rich cathode active materials from incompatible cathode chemistries for direct recycling or hydrometallurgical processing. Furthermore, this study reveals, for the first time, the mechanism of oleate adsorption on the surface of different cathode materials.

PH↗

DOE OSTI2011

Rationally tuned micropores within enantiopure metal-organic frameworks for highly selective separation of acetylene and ethylene

Separation of acetylene and ethylene is an important industrial process because both compounds are essential reagents for a range of chemical products and materials. Current separation approaches include the partial hydrogenation of acetylene into ethylene over a supported Pd catalyst, and the extraction of cracked olefins using an organic solvent; both routes are costly and energy consuming. Adsorption technologies may allow separation, but microporous materials exhibiting highly selective adsorption of C{sub 2}H{sub 2}/C{sub 2}H{sub 4} have not been realized to date. Here, we report the development of tunable microporous enantiopure mixed-metal-organic framework (M'MOF) materials for highly selective separation of C{sub 2}H{sub 2} and C{sub 2}H{sub 4}. The high selectivities achieved suggest the potential application of microporous M'MOFs for practical adsorption-based separation of C{sub 2}H{sub 2}/C{sub 2}H{sub 4}.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

An approach to separating Pu, U, and Ti from high-purity graphite for isotopic analysis by MC-ICP-MS

Information about elemental and isotopic systematics of ultra-trace level actinides (e.g. U and Pu) and main group elements (e.g. Ti) present within nuclear grade graphite is vital to the nuclear community for improved reactor operation and security. In support of this, extensive effort has been placed on improving analysis methods (i.e., inductively coupled plasma-mass spectrometry). However, significantly less effort has been devoted to the optimization of chemical separation methods. Within the separation community, commercially available Eichrom™ resins are often employed, as their elution characteristics for various elements have been well studied, but the direct optimization of actinides and trace metal separations from a single sample have not been widely investigated. Here, methods using various Eichrom pre-packed cartridges were explored to achieve separation of ultra-trace levels of U, Pu, and Ti from a variety of graphite samples. Once the validity of the combined separation scheme was established using certified reference materials, the method was applied to historic, unirradiated and irradiated, graphite samples. For all samples investigated, precise isotope ratio measurements for the titanium isotope systems were made.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Solid–liquid separation of lignocellulosic sugars from biomass by rotating ceramic disc filtration

In many biomass conversion processes, the separation of cellulosic sugars from residual, lignin-rich solids is a critical step, and achieving high recovery yields of sugars by conventional tangential crossflow and vacuum filtration is challenged by the presence of biomass solids, which rapidly foul filters, resulting in decreased throughput. Considering the performance limitations of traditional filtration methods, dynamic filtration, which generates high shear at the membrane surface to decrease fouling, is emerging as a viable alternative for demanding solid–liquid separations. For high solids separations, there is little available information regarding the performance, limitations, and energy consumption of dynamic filtration. To that end, here we characterized the performance of a dynamic filtration module, specifically a rotating ceramic disc (RCD) filter, for the aseptic recovery of cellulosic sugars from biomass solids following pretreatment and enzymatic hydrolysis. We show how RCD rotational velocity and percent biomass solids impact the filter throughput. Additionally, we used computational fluid dynamics (CFD) simulations to estimate the shear rate at the membrane surface and to visualize hydrodynamic profiles within the module. With the combined CFD simulations and experimental results, we estimated the energy demand and operating expenses for a viable dynamic filtration system operating with a lignocellulosic feed slurry. Our results indicate that an RCD filter can achieve ≥95% recovery of sugars and produce a retentate slurry containing 12 wt% insoluble solids with low energy consumption (a 2.2-fold improvement over cross-flow filtration) and low operating costs ($\$$0.06 per kg sugars). These results show a viable path towards operationally reliable, energy efficient, and cost-effective separations of sterilized cellulosic sugars from biomass solids and highlight the potential of dynamic filtration systems for challenging solid–liquid separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2014

Material review of Li ion battery separators

Separators for Li Ion batteries have a strong impact on cell production, cell performance, life, as well as reliability and safety. The separator market volume is about 500 million m{sup 2} mainly based on consumer applications. It is expected to grow strongly over the next decade for mobile and stationary applications using large cells. At present, the market is essentially served by polyolefine membranes. Such membranes have some technological limitations, such as wettability, porosity, penetration resistance, shrinkage and meltdown. The development of a cell failure due to internal short circuit is potentially closely related to separator material properties. Consequently, advanced separators became an intense area of worldwide research and development activity in academia and industry. New separator technologies are being developed especially to address safety and reliability related property improvements.

25 ENERGY STORAGE↗

DOE OSTI2021

Pentiptycene-based ladder polymers with configurational free volume for enhanced gas separation performance and physical aging resistance

Significance Gas separation membranes are an emerging energy-efficient alternative toward conventional, energy-intensive separation technologies such as cryogenic distillation. Ladder polymers with intrinsic microporosity show exceptional promise toward redefining state-of-the-art gas separation membranes due to their high permeability (throughput) and selectivity (separation efficiency). However, they are typically inhibited by major reductions in permeability over time due to collapsing membrane free volume (open space between polymer chains), forfeiting their greatest asset. This work explores a route toward enhanced aging resistance and overall separation performance by incorporating pentiptycene (an H-shaped scaffold containing five fused arene rings) into ladder-like polymers to incorporate natural, more permanent “micropores” that aren’t susceptible to densification of polymer chains that occurs over time in traditional microporous polymers.

36 MATERIALS SCIENCE↗

DOE OSTI2023

HP1-driven phase separation recapitulates the thermodynamics and kinetics of heterochromatin condensate formation

The spatial segregation of pericentromeric heterochromatin (PCH) into distinct, membrane-less nuclear compartments involves the binding of Heterochromatin Protein 1 (HP1) to H3K9me2/3-rich genomic regions. While HP1 exhibits liquid–liquid phase separation properties in vitro, its mechanistic impact on the structure and dynamics of PCH condensate formation in vivo remains largely unresolved. Here, using a minimal theoretical framework, we systematically investigate the mutual coupling between self-interacting HP1-like molecules and the chromatin polymer. We reveal that the specific affinity of HP1 for H3K9me2/3 loci facilitates coacervation in nucleo and promotes the formation of stable PCH condensates at HP1 levels far below the concentration required to observe phase separation in purified protein assays in vitro. These heterotypic HP1–chromatin interactions give rise to a strong dependence of the nucleoplasmic HP1 density on HP1-H3K9me2/3 stoichiometry, consistent with the thermodynamics of multicomponent phase separation. The dynamical cross talk between HP1 and the viscoelastic chromatin scaffold also leads to anomalously slow equilibration kinetics, which strongly depend on the genomic distribution of H3K9me2/3 domains and result in the coexistence of multiple long-lived, microphase-separated PCH compartments. The morphology of these complex coacervates is further found to be governed by the dynamic establishment of the underlying H3K9me2/3 landscape, which may drive their increasingly abnormal, aspherical shapes during cell development. These findings compare favorably to 4D microscopy measurements of HP1 condensate formation in live Drosophila embryos and suggest a general quantitative model of PCH formation based on the interplay between HP1-based phase separation and chromatin polymer mechanics.

3D genomics↗

DOE OSTI2016

Superhydrophobic and superhydrophilic surface-enhanced separation performance of porous inorganic membranes for biomass-to-biofuel conversion applications

A new class of inorganic-based membranes, i.e., High-Performance Architectured Surface Selective (HiPAS) membranes, is introduced to provide high perm-selective flux by exploiting unique separation mechanisms induced by superhydrophobic or superhydrophilic surface interactions and confined capillary condensation in enlarged membrane pores (~8 nm). The super-hydro-tunable HiPAS membranes were originally developed for the purpose of bio-oil/biofuel processing to achieve selective separations at higher flux relative to size selective porous membranes (e.g., inorganic zeolite-based membranes) and better high-temperature tolerance than polymer membranes (>250 C) for hot vapor processing. Due to surface-enhanced separation selectivity, HiPAS membranes can thus possibly enable larger pores to facilitate large-flux separations by increasing from sub-nanometer pores to mesopores (2-50 nm) for vapor phase or micron-scale pores for liquid phase separations. In this paper, we describe an innovative membrane concept and a materials synthesis strategy to fabricate HiPAS membranes, and demonstrate selective permeation in both vapor- and liquid-phase applications. High permeability and selectivity were demonstrated using surrogate mixtures, such as ethanol-water, toluene-water, and toluene-phenol-water. The overall membrane evaluation results show promise for the future processing of biomass pyrolysis and upgraded product vapors and condensed liquid bio-oil intermediates.

09 BIOMASS FUELS↗

DOE OSTI2014

Trivalent Lanthanide/Actinide Separation Using Aqueous-Modified TALSPEAK Chemistry

TALSPEAK is a liquid/liquid extraction process designed to separate trivalent lanthanides (Ln3+) from minor actinides (MAs) Am3+ and Cm3+. Traditional TALSPEAK organic phase is comprised of a monoacidic dialkyl bis(2-ethylhexyl)phosphoric acid extractant (HDEHP) in diisopropyl benzene (DIPB). The aqueous phase contains a soluble aminopolycarboxylate diethylenetriamine-N,N,N’,N”,N”-pentaacetic acid (DTPA) in a concentrated (1.0-2.0 M) lactic acid (HL) buffer with the aqueous acidity typically adjusted to pH 3.0. TALSPEAK balances the selective complexation of the actinides by DTPA against the electrostatic attraction of the lanthanides by the HDEHP extractant to achieve the desired trivalent lanthanide/actinide group separation. Although TALSPEAK is considered a successful separations scheme, recent fundamental studies have highlighted complex chemical interactions occurring in the aqueous and organic phases during the extraction process. Previous attempts to model the system have shown thermodynamic models do not accurately predict the observed extraction trends in the p[H+] range 2.5-4.8. In this study, the aqueous phase is modified by replacing the lactic acid buffer with a variety of simple and longer-chain amino acid buffers. The results show successful trivalent lanthanide/actinide group separation with the aqueous-modified TALSPEAK process at pH 2. The amino acid buffer concentrations were reduced to 0.5 M (at pH 2) and separations were performed without any effect on phase transfer kinetics. Successful modeling of the aqueous-modified TALSPEAK process (p[H+] 1.6-3.1) using a simplified thermodynamic model and an internally consistent set of thermodynamic data is presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

An atom probe perspective on phase separation and precipitation in duplex stainless steels

Here, three-dimensional chemical imaging of Fe–Cr alloys showing Fe-rich (α)/Cr-rich (α') phase separation is reported using atom probe tomography techniques. The extent of phase separation, i.e., amplitude and wavelength, has been quantitatively assessed using the Langer-Bar-on-Miller, proximity histogram, and autocorrelation function methods for two separate Fe–Cr alloys, designated 2101 and 2205. Although the 2101 alloy possesses a larger wavelength and amplitude after annealing at 427 °C for 100–10 000 h, it exhibits a lower hardness than the 2205 alloy. In addition to this phase separation, ultra-fine Ni–Mn–Si–Cu-rich G-phase precipitates form at the α/α' interfaces in both alloys. For the 2101 alloy, Cu clusters act to form a nucleus, around which a Ni–Mn–Si shell develops during the precipitation process. For the 2205 alloy, the Ni and Cu atoms enrich simultaneously and no core–shell chemical distribution was found. This segregation phenomenon may arise from the exact Ni/Cu ratio inside the ferrite. After annealing for 10 000 h, the number density of the G-phase within the 2205 alloy was found to be roughly one order of magnitude higher than in the 2101 alloy. The G-phase precipitates have an additional deleterious effect on the thermal embrittlement, as evaluated by the Ashby–Orowan equation, which explains the discrepancy between the hardness and the rate of phase separation with respect to annealing time (Gladman T 1999 Mater. Sci. Tech. Ser. 15 30–36).

36 MATERIALS SCIENCE↗

DOE OSTI2017

Harnessing mass differential confinement effects in magnetized rotating plasmas to address new separation needs

The ability to separate large volumes of mixed species based on atomic mass appears desirable for a variety of emerging applications with high societal impact. One possibility to meet this objective consists in leveraging mass differential effects in rotating plasmas. Beyond conventional centrifugation, rotating plasmas offer in principle additional ways to separate elements based on mass. Single ion orbits show that ion radial mass separation in a uniform magnetized plasma column can be achieved by applying a tailored electric potential profile across the column, or by driving a rotating magnetic field within the column. Furthermore, magnetic pressure and centrifugal effects can be combined in a non-uniform geometry to separate ions based on mass along the field lines. In conclusion, practical application of these separation schemes hinges on the ability to produce the desirable electric and magnetic field configuration within the plasma column.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗