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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A critical review and meta-analysis of energy demand, carbon footprint, and other environmental impacts from carbon fiber manufacturing

The demand for carbon fibers and carbon fiber-reinforced polymers (CFRPs) is rapidly growing due to their outstanding mechanical properties and potential to enhance sustainability, particularly for lightweighting applications. However, carbon fibers are typically produced from fossil-based feedstocks, involve energy-intensive processes, and have limited options for sustainable end-of-life management or circularity. Despite these challenges, the energy demand and lifecycle environmental implications of their production remain poorly understood. Here, we conduct a critical literature review and meta-analysis of carbon fiber manufacturing, revealing significant variations in reported energy demand, carbon footprint, and lifecycle inventory data. Our analysis makes two novel contributions. First, we identify key underlying factors driving these variations. Second, we highlight that carbon fiber, far from being a homogeneous product, has grades varying substantially in mechanical properties, end-use markets, energy intensity of manufacturing processes, and therefore environmental impacts—an aspect often underrepresented in life cycle assessments. We assert that current data are insufficient for reliably evaluating environmental impacts, posing a risk of misleading decision-making. Addressing this gap requires new lifecycle inventory datasets clearly incorporating carbon fiber heterogeneity and key influencing factors identified in this study. Additionally, we propose actionable recommendations, including a checklist, to advance sustainability in the carbon fiber sector.

CED↗
DOE OSTI2022

Gamma Driven Catalysis of Ammonia

Experiments were conducted to investigate a passive production mechanism for the world’s most energy intensive commodity, ammonia. A novel method, gamma catalyzed ammonia production at ambient conditions, was investigated. Ammonia is currently produced through the highly energy intensive Haber-Fritz process, which requires an operation pressure of 400 atmosphere and 600 degrees Celsius. Due to the high demand and need for ammonia, the Haber-Bosch process consumes 25% all energy produced globally. Reported herein was an attempt to produce ammonia at ambient temperature (20 C) and ambient pressure (1 atm), through a novel process developed at PNNL, gamma driven catalysis of ammonia. Although the measurements of the ammonia production suggest wild success, reports in the literature by Gao et.al. suggest an experimental positive bias in the results. To rule out the potential positive bias, multiple additional production campaigns would be needed to with an alternate analysis technique such as ion chromatography, as suggested by Gao et.al. Unfortunately, due to this late determination of potential positive bias, the results of this study remain inconclusive to the feasibility of gamma driven catalysis of ammonia and more work is needed to describe the chemical evolution with time. The results are a first step and demonstrate that gamma-catalyst mediated reactions are possible. This represents a key opportunity to explore the fundamental chemistry of high band gap catalysts that can change the paradigm of radiation, transforming it from a waste to a valuable energy source.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2023

Count Every Trip: Finding the Uncertainty in Energy Estimates Made from Inferred Travel Modes

To properly inform transport policy and infrastructure changes, transportation related metrics need both measured values and uncertainties of those values. Travel monitoring smartphone apps can record people's travel behavior, but trip data quality is limited by sensor errors, user labeling rates and the accuracy of inference algorithms used for travel diary creation. We discuss the use of phone app recorded travel diary data to estimate energy consumption, and propose the use of propagation of variance to find error bars for such estimates. We define energy consumption for one trip as trip length times the energy intensity per distance unit of the travel mode used. We characterize trip length errors with relative error and inferred trip mode errors with confusion matrix columns. The resulting variances of each measurement are then propagated to the final calculated energy consumption. We tested our uncertainty methods on a dataset that used phone app data combined with prompted recall, consisting of 92,234 labeled trips for over 500,000 miles. Accounting for uncertainty using expected energy intensities and variance propagation gives a dataset-wide aggregate energy consumption percent error of about 9%, within one standard deviation from the truth. Future work could involve applying similar methods to other travel diary based metrics.

ADVANCED PROPULSION SYSTEMS,MATHEMATICS AND COMPUT↗
DOE OSTI2023

Count Every Trip: Finding the Uncertainty in Energy Estimates Made from Inferred Travel Modes

To properly inform transport policy and infrastructure changes, transportation related metrics need both measured values and uncertainties of those values. Travel monitoring smartphone apps can record people's travel behavior, but trip data quality is limited by sensor errors, user labeling rates and the accuracy of inference algorithms used for travel diary creation. We discuss the use of phone app recorded travel diary data to estimate energy consumption, and propose the use of propagation of variance to find error bars for such estimates. We define energy consumption for one trip as trip length times the energy intensity per distance unit of the travel mode used. We characterize trip length errors with relative error and inferred trip mode errors with confusion matrix columns. The resulting variances of each measurement are then propagated to the final calculated energy consumption. We tested our uncertainty methods on a dataset that used phone app data combined with prompted recall, consisting of 92,234 labeled trips for over 500,000 miles. Accounting for uncertainty using expected energy intensities and variance propagation gives a dataset-wide aggregate energy consumption percent error of about 9%, within one standard deviation from the truth. Future work could involve applying similar methods to other travel diary based metrics.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Estimating Travel Energy Consumption Uncertainty Based on Inferred Travel Mode and Sensed Travel Length

To properly inform transport policy and infrastructure changes, transportation related metrics need both measured values and uncertainties of those values. Travel monitoring smartphone apps can record people's travel behavior, but trip data quality is limited by sensor errors, user labeling rates and the accuracy of inference algorithms used for travel diary creation. We discuss the use of phone app recorded travel diary data to estimate energy consumption, and propose the use of propagation of variance to find error bars for such estimates. We define energy consumption for one trip as trip length times the energy intensity per distance unit of the travel mode used. We characterize trip length errors with relative error and inferred trip mode errors with confusion matrix columns. The resulting variances of each measurement are then propagated to the final calculated energy consumption. We tested our uncertainty methods on a dataset that used phone app data combined with prompted recall, consisting of 92,234 labeled trips for over 500,000 miles. Accounting for uncertainty using expected energy intensities and variance propagation gives a dataset-wide aggregate energy consumption percent error of about 8%, within one standard deviation from the truth. Future work could involve applying similar methods to other travel diary based metrics.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2024

Field Validation of a Pilot-scale Black Liquor Membrane for Water Removal at Ahlstrom-Munksjö Paper Mill in Mosinee, WI

Project Background: The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized technologies in the industrial sector to help inform decisions towards accelerating commercialization and deployment. Pulp and paper is considered one of the most energy-intensive industries in the manufacturing sector. There are several methodologies for converting wood into pulp in the paper-making industry. The kraft process is a chemical method for producing wood pulp. The kraft process generates black liquor as a byproduct of pulp production. Traditionally, water is evaporated from the liquor by a set of multi-effect evaporators (MEEs), which concentrate weak black liquor (WBL) into strong black liquor (SBL) to support efficient combustion in a recovery boiler. Concentrating black liquor is an energy-intensive step in recovering pulping chemicals and generating high-pressure steam from dissolved wood solids. About 7% of pulp and paper energy usage, or nearly 164 trillion Btu, is used to remove water from black liquor in U.S. kraft pulp mills per year. The U.S. DOE’s IEDO is interested in the black liquor membrane technology evaluated in this report because it offers the potential for a more energy-efficient and less carbon-intensive kraft pulping process across 99 kraft pulp mills in 24 states (Agenda 2020 Technology Alliance 2016). This ITV project validates an innovative black liquor membrane technology for kraft pulp mills to understand its impact and benefits. Via Separations is a technology vendor that developed a graphene oxide membrane system to remove water from WBL before entering the evaporator set. High-pressure positive displacement (HPR) pumps move the black liquor through membranes that separate water and create a more concentrated black liquor. The vendor claims their pre-commercial technology reduces evaporator steam consumption by dewatering WBL before entering the evaporators. They also claim their technology has non-energy benefits such as enhanced soap collection and improved pulp throughput. This evaluation focuses on validating the energy and carbon dioxide (CO 2 e) emissions benefits associated with the membrane system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Microporous metal–organic frameworks for the purification of propylene

Separation of propylene from its analogous hydrocarbons such as propane is of great importance in the petrochemical industry to produce valuable chemical feedstocks with desired purity. However, the well-established method currently used for industrial propane/propylene separation is energy intensive. It involves repeated cycling in the cryogenic and high-pressure distillation process and requires multiple columns and high reflux ratios because of the very similar physical properties of the two species. Thus, it is identified as one of the most capital- and energy-intensive processes. Adsorptive separation based on porous adsorbents is regarded as an alternative energy-efficient technology to replace or supplement the traditional heat-driven cryogenic distillation processes. In this context, metal–organic frameworks (MOFs) have emerged as the most promising candidates for propane/propylene separation, taking into consideration their unique tunability with respect to pore geometry and pore functionality. In this highlight, we summarize the latest advancement in developing MOFs as physisorbents for the separation and purification of propylene from propane, with a focus on those that demonstrate selective molecular exclusion and propane-selective adsorption. We discuss the adsorption preferences related to the material design and separation mechanisms, and review the existing challenges. Lastly, we offer our perspectives on various strategies for the future design of MOFs that hold true potential for propylene purification under industrial settings.

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

Reinventing wastewater treatment plants: energy neutral treatment and enhanced fertilizer production through a novel resource recovery center

Wastewater treatment plants (WWTPs) are typically energy intensive, mainly due to the secondary treatment processes such as activated sludge (AS) for treatment of organics as well as nutrients like nitrogen. Nitrogen removal presents a big problem for WWTPs. The main form of nitrogen in wastewater is ammonium, and an AS process uses oxygen to convert ammonium into nitrite and nitrate which is then converted to nitrogen through denitrification process. During anaerobic digestion (AD), organic nitrogen gets degraded, resulting in an effluent stream (centrate) with a high nitrogen content, mostly in the form of ammonium. This contributes 15-30% of total nitrogen to the wastewater influent which further increases energy consumption for aeration. The project aims to transform this conventional municipal WWTPs into energy-neutral, resource-recovering facilities by integrating three core technologies: • Cloth Media Filtration (CMF) to replace conventional primary sedimentation (CPS) and increase the diversion of organics from the energy intensive secondary treatment to AD. This results in reduced energy demand for aeration in the secondary process while simultaneously increasing the biogas production in the anaerobic digesters. • Anerobic Digester to increase biogas and ammonia production. • Membrane Evaporation (ME) to recover ammonia from AD centrate and produce marketable fertilizer. The benefits of proposed WWTP process modifications were evaluated using techno economic analysis (TEA) and life cycle assessment (LCA). For CMF portion of the research a statistical analysis was employed to develop data-driven tools that could be used to enhance and optimize its performance in terms of energy savings and effluent quality. The main objective of this project is to reduce the energy demand for secondary treatment at municipal WWTPs by at least 50%, increase anaerobic digester (AD) biogas and ammonia production by 100% and 120%, respectively, and recover 90% of ammonia from the AD. Integrated CMF, AD, and ME was shown to work synergistically toward achieving these decarbonization targets through energy-positive treatment and fertilizer recovery techniques.

42 ENGINEERING↗
NASA NTRS1979

Electron calibration of instrumentation for low energy, high intensity particle measurements at Mercury

Unique identification of the high intensity, impulsively accelerated charged particle fluxes discovered during Mariner 10's first encounter with Mercury (March 1974) requires a detailed knowledge of the responses of the two University of Chicago charged particle telescopes to low energy fluxes over a wide dynamic range of flux levels. The results of detailed analyses show that these telescopes can separate and identify unambiguously the presence of electron and proton fluxes for a wide range of electron spectra and intensities in the relevant overall range of about 30 keV to 2 MeV.

Christon, S. P.↗
DOE OSTI2024

Electrochemical reduction of per- and polyfluorinated alkyl substances (PFAS): is it possible? Applying experimental and quantum mechanical insights from the reductive defluorination literature

Remediation of per- and polyfluorinated alkyl substances (PFAS) in global water systems is a critical human and environmental health challenge facing society. PFAS consumption is associated with a litany of adverse health effects, and our knowledge of these dangers is still evolving. Current techniques to remove PFAS from water include adsorption to media (e.g. granular activated carbon, ion-exchange resin), nanofiltration, and reverse osmosis. However, these processes create a concentrated PFAS residual that requires further management. Destructive techniques are therefore needed to detoxify these residuals. Oxidative techniques have garnered the most attention (e.g. supercritical water oxidation, electrochemical oxidation) but are energy intensive and potentially form toxic by-products. As an alternative, several groups have researched advanced reduction processes that form aqueous electrons, but these processes are still chemical and energy intensive (e.g. ultraviolet/SO 3 2− , electron beam). This concise review therefore focuses on whether electrochemical reduction — a chemical-free, modular process — could be technically feasible for PFAS destruction.

King, Jacob F.↗
NASA NTRS2001

Variable Iron K(alpha) Lines in Seyfert 1 Galaxies

We find that variability of the iron K alpha line is common in Seyfert 1 galaxies. Using data from the ASCA archive for objects that have been observed more than once during the mission, we study the time-averaged spectra from individual observations, thereby probing variability on timescales that range from days to years. Since the statistics of the data do not warrant searches for line variability in terms of a complex physical model, we use a simple Gaussian to model the gross shape of the line and then use the centroid energy, intensity, and equivalent width as robust indicators of changes in the line profile. We find that approximately 70% of Seyfert 1 galaxies (10 out of 15) show variability in at least one of these parameters: the centroid energy, intensity, and equivalent width vary in six, four, and eight sources, respectively. Because of the low signal-to-noise ratio, limited sampling, and time averaging, we consider these results to represent lower limits to the rate of incidence of variability. In most cases changes in the line do not appear to track changes in the continuum. In particular, we find no evidence for variability of the line intensity in NGC 4151, suggesting an origin in a region larger than the putative accretion disk, where most of the iron line has been thought to originate. Mrk 279 is investigated on short timescales. The time-averaged effective line energy (as measured by the Gaussian center energy, which is weighted by emission in the entire line profile) is 6.5 keV in the galaxy rest frame. As the continuum flux increases by 20% in a few hours, the Fe K line responds within approximately 10,000 seconds with the effective line energy increasing by 0.22 keV (approximately 10,500 kilometers per second). We also examine the ROSAT PSPC spectrum of Mrk 279 but find inconsistencies with ASCA. Problems with the ASCA and ROSAT calibration that affect simultaneous spectral fits at low energies are discussed in an appendix.

Weaver, K. A.↗
DOE OSTI2024

Turbulence spreading effects on the ELM size and SOL width

BOUT++ turbulence simulations were performed to investigate the impact of turbulence spreading on the edge localized mode (ELM) size and divertor heat flux width (λ q ) broadening in small ELM regimes. Here, this study is motivated by EAST experiments. BOUT++ linear simulations of a pedestal radial electric field (E r ) scan show that the dominant toroidal number mode (n) shifts from high-n to low-n, with a narrow mode spectrum, and the maximum linear growth rate increases as the pedestal E r well deepens. The nonlinear simulations show that as the net E × B pedestal flow increases, the pressure fluctuation level and its inward penetration beyond the top of the pedestal both increase. This leads to a transition from small ELMs to large ELMs. Both inward and outward turbulence spreading are sensitive to the scrape-off-layer (SOL) plasma profiles. The inward turbulence spreading increases for the steep SOL profiles, leading to increasing pedestal energy loss in the small ELM regime. The SOL width (λ q ) is significantly broadened progressing from the ELM-free to small ELM regime, due to the onset of strong radial turbulent transport. The extent of the SOL width (λ q ) broadening depends strongly on outward turbulence spreading. The fluctuation energy intensity flux Γ ε at the separatrix can be enhanced by increasing either pedestal E r flow shear or local SOL pressure gradient. The λ q is broadened as the fluctuation energy intensity flux Γ ε at the last close flux surface (LCFS) increases. Local SOL E × B flow shear will restrain outward turbulence spreading and the associated heat flux width broadening. Operating in H-mode with small ELMs has the potential to solve two critical problems: reducing the ELM size and broadening the SOL width.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Evaluating cross-sectoral impacts of climate change and adaptations on the energy-water nexus: a framework and California case study

Abstract Electricity and water systems are inextricably linked through water demands for energy generation, and through energy demands for using, moving, and treating water and wastewater. Climate change may stress these interdependencies, together referred to as the energy-water nexus, by reducing water availability for hydropower generation and by increasing irrigation and electricity demand for groundwater pumping, among other feedbacks. Further, many climate adaptation measures to augment water supplies—such as water recycling and desalination—are energy-intensive. However, water and electricity system climate vulnerabilities and adaptations are often studied in isolation, without considering how multiple interactive risks may compound. This paper reviews the fragmented literature and develops a generalized framework for understanding these implications of climate change on the energy-water nexus. We apply this framework in a case study to quantify end-century direct climate impacts on California’s water and electricity resources and estimate the magnitude of the indirect cross-sectoral feedback of electricity demand from various water adaptation strategies. Our results show that increased space cooling demand and decreased hydropower generation are the most significant direct climate change impacts on California’s electricity sector by end-century. In California’s water sector, climate change impacts directly on surface water availability exceed demand changes, but have considerable uncertainty, both in direction and magnitude. Additionally, we find that the energy demands of water sector climate adaptations could significantly affect California’s future electricity system needs. If the worst-case water shortage occurs under climate change, water-conserving adaptation measures can provide large energy savings co-benefits, but other energy-intensive water adaptations may double the direct impacts of climate change on the state’s electricity resource requirement. These results highlight the value of coordinated adaptation planning between the energy and water sectors to achieve mutually beneficial solutions for climate resilience.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Atmospheric Cold Plasma Jet Coating and Surface Treatment for Improved Adhesive Bonding Performance of Dissimilar Material Joints Subject to Harsh Environmental Exposure

The program goal was the development and demonstration of a novel material coating system using an innovative atmospheric cold microwave plasma jet to enable surface functionalization for corrosion protection, wear resistance and improved bonding strength. The technical approach was directed towards proof-of-concept demonstration of advanced point-of-manufacturing material bonding to improve adhesive joint performance subject to harsh environmental exposure. The assembled team, consisting of the researchers at the University of Illinois, end-users at General Motors and small business manufacturer Starfire Industries, successfully demonstrated a single, cost-effective, high-volume production process that meets the requirements of multi-material combinations relevant to the energy-intensive transportation industry (e.g. Al-steel, Mg-steel, Al-Mg and Al-CFRP joints for body-in-white structures) while eliminating offline pretreatment for Al and Mg alloy substrates that are energy intensive, have chemical waste disposal issues, and add cost. Technical demonstration of dissimilar material joining while maintaining bonding strength and cohesion after long-duration environmental exposure was accomplished for all materials of interest. This novel approach has broad applicability for manufacturing in automotive, aerospace, marine, railcar, and specialty consumer goods, etc.

36 MATERIALS SCIENCE↗
NASA NTRS1974

Intensity and energy spectrum of electrons accelerated in the earth's bow shock

Shock waves accelerate charged particles in the solar atmosphere, in interplanetary space and around the earth's magnetosphere. Acceleration of both electrons and protons occurs in the earth's bow-shock. The acceleration of protons up to 100 keV appears to be a steady state process and may even occur upstream from the bow shock due to waves generated by reflected solar wind protons. The electrons, on the other hand, are known to be accelerated in or near the shock. The intensity of these electrons ranges from about 100 to 2,000 per sr-sq cm-sec-keV at 14 keV. The energy spectrum is not a simple power low and is highly variable. If segments of the spectra are fitted to a power low, slopes ranging from -2 to -4.5 result over the energy range 0.5 to 100 keV.

Anderson, K. A.↗
DOE OSTI2020

Evaluating Energy Efficiency Opportunities from Connected and Automated Vehicle Deployments Coupled with Shared Mobility in California

Connected and Automated Vehicles (CAVs) can be considered to be a disruptive transportation technology, with the potential to significantly improve overall transportation system efficiency; however, CAVs may increase induce vehicle miles traveled (VMT) and bring on greater energy consumption. Further, shared mobility is another disruptive transportation event that is reshaping our travel patterns. The primary goal of this project was to extensively collect data from vehicles and associated infrastructure equipped with CAV technologies from both real-world experiments and simulation studies mainly deployed in California, and develop a comprehensive framework for evaluating energy efficiency opportunities from large-scale (e.g., statewide) introduction of CAVs and a wide deployment of shared mobility systems in a variety of scenarios. To quantify the combined impact of CAV and shared mobility on travel behavior, traffic performance, and energy efficiency, a unique mesoscopic simulation-based model was developed for mobility and energy efficiency evaluation considering these disruptive transportation technologies. As a complement to existing studies on nationwide evaluation of CAVs’ energy impacts, this project was focused on data collection efforts and CAV applications under congested traffic environments that are frequently experienced on a massive scale across the major metropolitan areas in California. Extensive real-world data collection supplemented with simulation studies were conducted to cover a variety of CAV and shared mobility scenarios, particularly on scenarios less-explored in the existing research. Another key component of this project was to consider the interaction between different CAV technologies and shared mobility models, and the compound effect on energy efficiency. A comprehensive modeling suite was developed to quantify the impact of new mobility technologies on travel behavior and traffic performance. The developed modeling framework includes an energy intensity module, mode choice module and activity generation module that are integrated into an agent-based BEAM simulation platform to perform impact analysis based on a variety of scenarios. In addition, the RouteE model has been upgraded to incorporate the impact of CAVs on traffic flow, VMT and energy intensity, using micro-simulation data collected from both freeways and urban arterials. A novel fundamental influencing factor (FIF) mode choice model was developed to link CAV and shared mobility components with travel behaviors, and adapted into the BEAM-centered model framework. A statewide energy inventory was constructed under various CAV technology deployment scenarios by incorporating datasets and models for predicting vehicle market share and vehicle usage, which are tightly associated with the penetration of shared mobility systems. Based applying this modeling suite to a calibrated network in Riverside California, it was found that cooperative automated driving in general will improve mobility, but automated vehicles, even when deployed in a shared autonomous fleet, will likely bring an increase of VMT (up to 36%) due to mode shifts and deadheading. Ride-hailing vehicles typically have better energy efficiency and a higher share of electric vehicles, which helps offset the negative impact from VMT increases when estimating the system-level energy consumption. In general, simulation results show a 6% increase in energy consumption for the scenarios with an increasing shift to ride-hailing modes. The statewide analysis based on the National Household Travel Survey (NHTS) sample data is consistent with the findings from the Riverside network and validate the developed clustering-prediction modeling methodology. The outcomes from this project will help close the knowledge gap on recognizing the potential performance and energy impacts of a broad deployment of CAV and shared mobility technologies across a wide range of roadway infrastructure with varying levels of congestion. Results from this project: 1) will support policymakers in steering CAV development and deployment towards an energy favorable direction; 2) reduce uncertainties in estimating energy saving opportunities from new mobility technologies and services; 3) increase the confidence of CAV technology investors both on the infrastructure side (i.e., transportation agencies) and on the vehicle side (i.e., OEMs); and 4) expedite the deployment of energy-efficient CAV and shared mobility applications.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Staying Competitive in Clean Manufacturing: Insights on Barriers from Industry Interviews

While industrial emissions research has historically focused on energy-intensive sectors like steel, cement, and chemicals, this study addresses a critical gap by examining barriers across all the manufacturing industry in the U.S. Sectors like food processing, retail, plastics, and transportation face unique challenges distinct from heavy industry, operating on thin margins with limited bargaining power while experiencing heightened consumer and stakeholder pressure for improved environmental responsibility. Through structured interview data collection process and using quantitative ratings and qualitative analysis, this research identifies and categorizes emission reduction barriers across four key themes: financial, technical, organizational, and regulatory. Unlike energy-intensive industries that may pursue hydrogen or carbon capture technologies, discrete manufacturing industry like automotive, electrical and electronics, and machine manufacturers typically focus on energy efficiency, electrification of thermal processes, and alternate fuel switching, solutions better aligned with their lower-temperature processes and distributed facility profiles. The study’s primary contribution lies in documenting specific barrier manifestations within organizations and identifying proven mitigation strategies that companies have successfully implemented or observed among peers.

business competitiveness↗
DOE OSTI2021

Continuous Liquid–Liquid Extraction and in-Situ Membrane Separation of Miscible Liquid Mixtures

Separation operations are critical across a wide variety of manufacturing industries and account for about one quarter of all in-plant energy consumption in the United States. Conventional liquid-liquid separation operations require either thermal or chemical treatment, both of which have a large environmental impact and carbon footprint. Consequently, there is a great need to develop sustainable, clean methodologies for separation of miscible liquid mixtures. The greatest opportunities to achieve this lie in replacing high-energy separation operations (e.g., distillation) with low-energy alternatives such as liquid-liquid extraction. One of the primary design challenges in liquid-liquid extraction is to maximize the interfacial area between two immiscible (e.g., polar and non-polar) liquids for efficient mass transfer. However, this often involves energy-intensive methods including ultrasonication, pumping the feed and the extractant through packed columns with high tortuosity, or using a supercritical fluid as an extractant. Emulsifying the feed and the extractant, especially with a surfactant, offers a large interfacial area, but subsequent separation of emulsions can be energy-intensive and expensive. Thus, emulsions are typically avoided in conventional extraction operations. Herein, we discuss a novel, easily scalable, platform separation methodology termed CLEANS (Continuous Liquid-liquid Extraction And iN-situ membrane Separation). CLEANS integrates emulsion-enhanced extraction with continuous, gravity-driven, membrane-based separation of emulsions into a single unit operation. Furthermore, our results demonstrate that the addition of a surfactant and emulsification significantly enhance extraction (by > 250% in certain cases), even for systems where the best extractants for miscible liquid mixtures are known. Utilizing the CLEANS methodology, we demonstrate continuous separation of a wide range of miscible liquid mixtures, including soluble organic molecules from oils, alcohols from esters, and even azeotropes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗