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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 91 records · Page 5

Hydrogen-based ore-to-part manufacturing of near-net-shape stainless steel

Decarbonizing iron and steelmaking, combined with global disruptions to raw material supply chains, necessitates novel approaches to iron and steel production. In this work, we demonstrate a direct ore-to-part manufacturing route using a mixture of ore-derived oxide powders of Fe 2 O 3 , Cr 2 O 3 , NiO, and MoO 3 as feedstock for additive manufacturing, combined with sintering under H 2 to produce a near-net-shape austenitic stainless-steel. Complete reduction of all constituent oxides, including MoO 3 and Cr 2 O 3 , is achieved in-situ at 1300 °C, resulting in dense, crack-free bulk alloy. The fabricated part retains geometric fidelity while undergoing substantial volumetric shrinkage inherent to redox and sintering. Thermodynamic calculations elucidate the co-reduction mechanisms and alloying pathways that enable complete metallization. This work is the first demonstration of net-shaping metal parts directly from ore derived oxides, and this ore-to-part approach can minimize the emissions and lead time for manufacturing associated with downstream processing such as rolling, forging, and machining.

Yang, Mingzhang [Univ. of Waterloo, ON (Canada); F↗

A portable fiber optic sensor for the luminescent sensing of cobalt ions using carbon dots

Cobalt is critical to energy-relevant technologies, and demand for cobalt will increase significantly with growing global adoption of renewables. However, supply chain stability is threatened by economic and geopolitical factors, incentivizing domestic cobalt production from alternative resources such as coal, coal utilization byproducts (e.g., ash, acid mine drainage) and electronic waste. Rapid, inexpensive, and portable characterization techniques are needed to reduce production costs associated with cobalt prospecting and process monitoring. Here, in this research, we develop a compact, portable fiber optic luminescent probe for cobalt using phosphorus and nitrogen co-doped carbon dots as the sensing material. The carbon dot emission overlaps well with the cobalt absorption band at ~510 nm, leading to a selective decrease in emission as a function of cobalt concentration. The system responds nearly instantly to the presence of cobalt, with detection limits of 0.7 and 3.5 ppm in water and pH 1.68 buffer, respectively, providing comparable performance to a commercial spectrometer at a significantly lower cost. Moreover, the sensor is selective for cobalt in the presence of 13 of the most common metal ions encountered in coal utilization byproducts and is responsive to cobalt when spiked into an acid mine drainage leachate sample, highlighting the sensor's potential for real-world deployment in challenging matrices. In addition, integrating the carbon dots with a filter paper substrate produced ‘test strip’ sensors that exhibited a selective and sensitive visual response to cobalt using a handheld UV lamp. Taken together, the sensing system represents a significant step forward in the development of low-cost practical sensors for high-value metals in complex streams.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

American Made Challenges Battery Voucher Program Cooperative Research and Development Agreement (Cooperative Research and Development Final Report, CRADA Number CRD-21-17533)

Renewance is a Phase II winner of the U.S. Department of Energy Lithium-ion Battery Recycling Prize. The Prize is designed to incentivize American entrepreneurs to develop and demonstrate processes that, when scaled, have the potential to profitably capture 90% of all discarded or spent lithium-based batteries (LIB) in the Unites States for eventual recovery of key materials for re-introductions into the U.S. supply chain. The objective of this work is to enable a more efficient evaluation of battery sources for second life applications prior to ultimately being recycled, through evaluation of chemistry characteristics, projected battery lifetime, and application history. This work will develop the capability to identify groups of batteries that may be useful for second life and reduce the cost of end-of-life (EOL) LIB evaluation and repurposing. To meet the objective, NREL will use existing and new data to create a refined algorithm that could be used to evaluate batches of batteries for potential reuse based on manufacturing date and historical use characteristics. Based on current battery market prices and compiled literature data, a starting-point estimate of the market value of the batteries for reuse based on expected lifetime will be included in the algorithm. With the projected surge in LIB demand, battery second life is a new area ripe for development and investment from companies like Renewance. With so few large format batteries reaching EOL to date, this is a new market with a variety of areas for optimization and adding value. This work with Renewance is an example of how existing expertise in battery degradation at NREL can be used to reduce the cost of shifting a battery into a second life application. With these cost reductions, this work is also facilitating the development of a battery circular economy in the United States. A robust circular economy can maximize the utilization of critical metals demanded by battery technology such as nickel and cobalt while also reducing the costs of batteries in the marketplace for the many end-uses needed for the green energy transition. The supply of these metals is limited, and we face a supply chain shortage both domestically and globally unless we can ensure they are being used to their maximum potential. This research can improve the economics of a battery circular economy to make it a more likely path for EOL batteries with critical metals. CRADA benefit to DOE, Participant, and US Taxpayer: assists laboratory in achieving programmatic scope competencies, uses the laboratory's core competencies.

25 ENERGY STORAGE↗

Carbon Ore-Derived Critical Materials for Clean Energy Technologies

Conference presentation at American Institute of Chemical Engineers (AIChE) Annual Meeting, San Diego, California, October 27–31, 2024. Trends in the manufacture of electric vehicles that use graphite-based LIBs are rising steeply in the United States and globally, but the U.S. domestic supply chains for graphite, the largest component in an LIB by mass, is severely limited and faces complicated geopolitical dynamics with foreign sources. Consequently, the United States has designated graphite as a critical mineral to focus attention and resources to develop technologies to meet the challenge of limited domestic graphite supply chains. Results obtained so far based on the UCOP process have successfully validated the technology at the laboratory scale, with the produced graphite material showing up to 95% degree of graphitization, high carbon purity of ~99.98%, residual ash content of ≤0.02%, negligible moisture, low trace elements, and high electrochemical stability. These results suggest that the emerging UCOP technology is a promising approach to effectively synthesize high-quality graphite from abundant coal and coal waste resources in the United States to create a sustainable domestic critical graphite supply chain. A brief description of the status of UCOP process development and representative results will be presented.

01 COAL, LIGNITE, AND PEAT↗

Effective Materials Property Information Management for the 21st Century

This paper discusses key principles for the development of materials property information management software systems. There are growing needs for automated materials information management in various organizations. In part these are fueled by the demands for higher efficiency in material testing, product design and engineering analysis. But equally important, organizations are being driven by the need for consistency, quality and traceability of data, as well as control of access to sensitive information such as proprietary data. Further, the use of increasingly sophisticated nonlinear, anisotropic and multi-scale engineering analyses requires both processing of large volumes of test data for development of constitutive models and complex materials data input for Computer-Aided Engineering (CAE) software. And finally, the globalization of economy often generates great needs for sharing a single "gold source" of materials information between members of global engineering teams in extended supply chains. Fortunately, material property management systems have kept pace with the growing user demands and evolved to versatile data management systems that can be customized to specific user needs. The more sophisticated of these provide facilities for: (i) data management functions such as access, version, and quality controls; (ii) a wide range of data import, export and analysis capabilities; (iii) data "pedigree" traceability mechanisms; (iv) data searching, reporting and viewing tools; and (v) access to the information via a wide range of interfaces. In this paper the important requirements for advanced material data management systems, future challenges and opportunities such as automated error checking, data quality characterization, identification of gaps in datasets, as well as functionalities and business models to fuel database growth and maintenance are discussed.

Ren, Weiju↗

NREL Is Strengthening the Future of Hydropower, A Cornerstone of America's Energy System

The National Renewable Energy Laboratory (NREL) is a leader in advancing hydropower technologies, positioning hydropower as a pillar of an affordable, reliable, and secure energy future. Through its hydropower program, NREL is conducting innovative research that reduces energy costs, drives efficiency, and supports systems integration - unlocking economic opportunities, rebuilding supply chains, and fueling America's global competitiveness.

13 HYDRO ENERGY↗

How demand for and trade of construction materials affects greenhouse gas emissions

Construction materials generate nearly one-third of global carbon emissions, yet conventional accounting captures only a fraction of this impact. Using EXIOBASE data spanning 25 years, we tracked emissions across construction supply chains for cement, steel, metals, and plastics. While global construction demand nearly tripled, regional patterns diverged significantly. The EU reduced emissions despite increased demand through renewable energy adoption and emissions trading, while China's construction boom—driving most global growth—significantly increased domestic emissions. Manufacturing contributes most to embodied emissions compared to resource extraction and waste treatment. Increased reliance on offshore production undermines domestic emission control strategies, highlighting the need for expanded carbon border adjustment mechanisms. Without policies addressing full supply chain emissions, even aggressive climate initiatives will be compromised by carbon leakage, creating an emissions trajectory incompatible with global climate targets.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Closing the Gap: A Global Perspective [Slides]

Against the backdrop of negotiations at COP26, a group of internationally recognised research and technology organisations launched a collaboration, with the intention to identify the national and international technology-led opportunities to decarbonise fossil fuel basins globally. This study will evidence the opportunities available to players across the entire energy ecosystem. Governments and funders will be able to spread costs and investment risk, energy companies will develop a greater understanding of the global transition and possible opportunities to develop pilot projects worldwide, and there will be greater incentive to the supply chain once they are aware of the global applicability of certain technologies and technology solutions. Through the analysis and comparison of national energy systems, a number of Net Zero Deployment Strategies and Technology Priorities have been identified, that are shaping the direction of the construction of net zero integrated energy systems globally. These have been considered to design Recommendations for International Collaboration to accelerate the global energy transition.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Climate Information and Lessons Learned from the NASA Earth eXchange (NEX), Short-term Prediction Research and Transition Center (NASA SPoRT), and the NASA Regional Climate Model Evaluation System (RCMES)

Climate resilience can emerge from a combination of (1) climate projections that enable future-oriented planning and (2) contemporary observations that can be used for adaptation in the face of realized climate. NASA is uniquely positioned to provide global climate projections and satellite-based observations to users who must take a global perspective on climate risk (e.g., supply chain managers). Here, we will share the capabilities and experiences of three NASA projects. The first project, the NASA Earth eXchange (NEX) provides two downscaled climate projections, NEX-GDDP-CMIP6, a global 25 km resolution product, and NEX-DCP30-CMIP6, an 800 m resolution product covering the coterminous U.S. specifically designed for U.S. National Climate Assessment (NCA). NEX also offers land surface products that mirror the twice-daily products provided by the Moderate Resolution Imaging Spectroradiometer (MODIS) but are derived from operational geostationary weather satellite data collected at 5-10 minutes intervals. The second project, the Short-term Prediction Research and Transition Center (SPoRT), was established in 2002 to transition unique NASA satellite products and capabilities to stakeholders to improve decision-making that benefits society. SPoRT provides products and capabilities derived from NASA observations and models to end users in government, academia, and the private sector. SPoRT translates NASA Earth science into actionable solutions reaching over 400 stakeholders across 80 organizations. Finally, the Regional Climate Model Evaluation System (RCMES) is designed to facilitate regional-scale evaluations of climate models by providing standardized access to a vast and comprehensive set of observations, such as satellite, in-situ, and reanalyses, and modeling resources such as CMIP & CORDEX. These three projects form part of the core capabilities at the NASA Centers deliver climate information under the new NASA Earth Science to Action (ES2A) strategy.

NEX↗

The Circular Economy Lifecycle Assessment and Visualization Framework: A Case Study of Wind Blade Circularity in Texas

Moving the current linear economy toward circularity is expected to have environmental, economic, and social impacts. Various modeling methods, including economic input-output modeling, life cycle assessment, agent-based modeling, and system dynamics, have been used to examine circular supply chains and analyze their impacts. This work describes the newly developed Circular Economy Lifecycle Assessment and Visualization (CELAVI) framework, which is designed to model how the impacts of supply chains might change as circularity increases. We first establish the framework with a discussion of modeling capabilities that are needed to capture circularity transitions; these capabilities are based on the fact that supply chains moving toward circularity are dynamic and therefore not at steady state, may encompass multiple industrial sectors or other interdependent supply chains and occupy a large spatial area. To demonstrate the capabilities of CELAVI, we present a case study on end-of-life wind turbine blades in the U.S. state of Texas. Our findings show that depending on exact process costs and transportation distances, mechanical recycling could lead to 69% or more of end-of-life turbine blade mass being kept in circulation rather than being landfilled, with only a 7.1% increase in global warming potential over the linear supply chain. We discuss next steps for framework development.

17 WIND ENERGY↗

Structural Chokepoints Determine the Resilience of Agri-Food Supply Chains in the United States

The agricultural and food systems of the United States are critical for ensuring the stability of both domestic and global food systems. Thus, it is essential to understand the structural resilience of the country’s agri-food supply chains to a suite of threats. Here we employ complex network statistics to identify the spatially resolved structural chokepoints in the agri-food supply chains of the United States. We identify seven chokepoints at county scale: Riverside CA, San Bernardino CA, Los Angeles CA, Shelby TN, Maricopa AZ, San Diego CA and Cook IL; as well as seven chokepoints at freight analysis framework scale: Los Angeles–Long Beach CA, Chicago– Naperville IL, New York–New Jersey NJ, New York–New Jersey NY, Remainder of Texas, Remainder of Pennsylvania, and San Jose–San Francisco–Oakland CA. These structural chokepoints are generally consistent through time (2007, 2012, 2017), particularly for processed food commodities. This study improves our understanding of agri-food supply-chain security and may aid policies aimed at enhancing its resilience.

Agriculture↗

Overcoming barriers to improved decision-making for battery deployment in the clean energy transition

Decarbonization plans depend on the rapid, large-scale deployment of batteries to sufficiently decarbonize the electricity system and on-road transport. This can take many forms, shaped by technology, materials, and supply chain selection, which will have local and global environmental and social impacts. Current knowledge gaps limit the ability of decision-makers to make choices in facilitating battery deployment that minimizes or avoids unintended environmental and social consequences. These gaps include a lack of harmonized, accessible, and up-to-date data on manufacturing and supply chains and shortcomings within sustainability and social impact assessment methods, resulting in uncertainty that limits incorporation of research into policy making. These gaps can lead to unintended detrimental effects of large-scale battery deployment. To support decarbonization goals while minimizing negative environmental and social impacts, we elucidate current barriers to tracking how decision-making for large-scale battery deployment translates to environmental and social impacts and recommend steps to overcome them.

25 ENERGY STORAGE↗

2023 Critical Materials Strategy

The global effort to curb carbon emissions is accelerating demand for clean energy technologies and the materials they rely on. Demand for these materials will only continue to grow, especially as some nations aim to achieve net zero emissions by 2050. While some major materials like steel, copper, and aluminum are already powering the fossil fuel economy, others are more minor materials with potential supply risks. These risks could jeopardize the ability to reduce greenhouse gas emissions within the desirable timeframe to avoid significant climate change. In some cases, it may be necessary to take action to improve the resilience of material supply chains and mitigate supply risks. Understanding the importance of individual materials to clean energy and the supply risks associated with them is necessary to identify which materials may serve as potential roadblocks to a clean energy future. The U.S. Department of Energy (DOE) issued a series of 13 supply chain deep dive assessment reports on various energy technologies in 2022 in response to President Biden’s Executive Order on America’s Supply Chains (E.O. 14017). These reports emphasized that supply chain bottlenecks can occur at any stage of the value chain from mining and refining to component and even sub-system manufacturing. The bottlenecks are a combination of factors such as material availability, equipment availability, work force availability and quality, logistics, regulatory framework, and market conditions. These bottlenecks were worsened during the global Covid-19 pandemic. Its lingering impacts have hindered capacity expansion for material supply chains and prevented product lead-time recovery. One approach to reduce supply chain risks for the United States is to have a strong domestic manufacturing sector with a diverse set of producers. Boosting responsible domestic production would require leveraging the latest science not only in material extraction but also in developing substitutes, recycling, reuse, and remanufacturing. This report is an updated analysis of previous Critical Materials Strategy (CMS) reports published by the DOE in 2010, 2011, and 2019 based on national and global priorities, technology advancement, and technology adoption trends. Like the CMS reports, this analysis presents the results of a formal material criticality assessment to identify which materials are critical to the continued deployment of clean energy technologies globally. The analysis in this report leveraged the DOE supply chain deep dive assessments to develop the initial list of materials to evaluate. This DOE Critical Materials Assessment (CMA) is conducted independently of criticality assessments performed by other U.S. government agencies, such as that conducted by the U.S. Geological Survey (USGS). This analysis complements the USGS critical minerals determination in three aspects. First, the DOE assessment is performed from a global perspective, while the USGS analysis focusses on the importance of minerals to the U.S. economy. Second, this report focuses on the importance of materials to clean energy technologies, rather than to the economy in general. Lastly, this study is forward looking to 2035 based on clean energy deployment scenarios, whereas the USGS assessment is retrospective. Materials evaluated in this report that do not appear in the USGS Critical Minerals List include copper, uranium, electrical steel, and SiC. A draft version of this report received ~80 public comments related to supporting data and methodological improvement. Those comments have been incorporated as much as possible where appropriate. Highlights of findings from this 2023 CMA include: Rare earth materials (neodymium, praseodymium, dysprosium, and terbium) used in magnets in electric vehicle (EV) motors and wind turbine generators continue to be critical. While dysprosium (Dy) and terbium (Tb) are both heavy rare earth elements that serve the same function in magnets, the criticality of Tb is slightly lower than that for Dy in the short term due to the widespread use of Dy in high-grade magnets and Tb’s present role as a substitute. Similarly, praseodymium (Pr) is critical in the medium term but only near critical in the short term because it is more substitutable in magnets than neodymium (Nd); Materials used in batteries for EVs and stationary storage are now considered to be critical. While cobalt (Co) was found to be critical in this and previous reports, lithium (Li) becomes critical in the medium term due to its broader use in various battery chemistries and the rampant growth of the EV industry. Natural graphite is a new addition in this assessment and is also found to be critical; Platinum group metals used in hydrogen electrolyzers, such as platinum (Pr) and iridium (Ir), are critical due to an increased focus on hydrogen technologies to achieve net zero carbon emissions, while those used in catalytic converters, such as rhodium (Rh) and palladium (Pd), were screened out due to the decreased importance of catalytic converters in the medium term; Gallium (Ga) continues to be critical due to its use in light-emitting diodes (LEDs). In addition, the use of Ga has increased in magnet manufacturing and in semiconductor in forms such as gallium arsenide (GaAs) or gallium nitride (GaN); Major materials like Aluminum (Al), copper (Cu), nickel (Ni), and silicon (Si) move from noncritical in the short term to near critical in the medium term due to their importance in electrification; Electrical steel is near critical due to its use in transformers for the grid and electric motors in EVs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Process design for recovering rare-earth elements from mine tailings with low rare-earth concentrations via sequential leaching and solvent extraction

Rare earth elements (REEs) are essential for advanced technologies and yet face significant supply chain risks due to their concentrated global production and limited domestic availability. Addressing this challenge requires efficient processes capable of upgrading low-grade secondary resources such as mine tailings. In this study, we developed a novel separation flowsheet that integrates sequential leaching and 2-stage solvent extraction (SX) processes to recover high-purity heavy REEs (HREEs) and light REEs (LREEs) from a simulated mine-tailing concentrate containing 2.4 wt% total REEs (TREEs; 0.6 wt% LREEs and 1.8 wt% HREEs). Sequential leaching with controlled pH adjustment selectively precipitated REEs while retaining the large amount of impurities in the solution, producing an REE-enriched leachate by following leaching processes with roughly twice the REE concentration and half the impurity concentration compared to that of single-step leaching. The optimized SX flowsheet employed Cyanex 572 to extract HREEs and Fe over LREEs, followed by Fe removal using tributyl phosphate (TBP), while the raffinate stream was processed by SX with di(2-ethylhexyl)phosphoric acid (D2EHPA) to recover LREEs under optimized conditions balancing both extraction efficiency and purity. Although increased extractant availability in the organic phase improved LREE recovery, it also increased co-extraction of Ca, underscoring trade-offs in process optimization. Both HREE- and LREE-rich solutions were subsequently precipitated into solid products via oxalate precipitation, resulting in high-purity REE solids containing ∼92.0 wt% HREEs (∼95.7 wt% TREEs) and ∼92.8 wt% LREEs (∼94.0 wt% TREEs). In conclusion, this proof-of-concept study using simulated mine tailings demonstrates a promising approach for upgrading low-grade REE resources, while highlighting the need for future validation with real materials.

Mine tailings↗

Decadal-Scale Hydrothermal Alteration of Basalt: Implications for Long-Term Reactivity in Subsurface Technologies

Global demands to secure critical mineral supply chains and managing water resources require innovative resource management strategies. Subsurface basalt reservoirs offer a dual-purpose application, where CO2 enhanced critical metal recovery can be coupled with water remediation strategies for the extraction of economically important and environmentally relevant elements. This study utilizes static batch experiments conducted on Columbia River Basalt Group samples to evaluate long-term fluid–rock interactions relevant to coupled subsurface applications. Samples were reacted under elevated temperature and pressure conditions, for 296 and 4,061 days, providing a unique dataset to assess geochemical evolution, element partitioning, and aqueous chemistry over decadal timescales. The alteration was dominated by silicate, aluminosilicate, and oxide phases. Progressive hydrothermal alteration increased the cation exchange capacity through the formation of secondary minerals (e.g. clays and zeolites), influencing solute retention, ion exchange behavior, and aqueous chemistry. Grain-scale and bulk analyses revealed selective cation release and retention patterns, establishing a mechanistic baseline for predicting element mobility. These geochemical constraints inform the prospective use of CO2-enhanced metal recovery for critical resources (e.g. Co, Ni, Mn, Mg, Ti, Fe) and associated water-quality impacts, providing a foundation for the design and management of engineered fluid–rock systems in basalt reservoirs.

Gibson, Marie N.↗

Advanced Manufacturing and Materials for Hydropower: Challenges and Opportunities

Hydropower is a well-established industry that has been largely contributing to the global generation of clean and renewable energy for more than a century. In the United States in 2021, it accounted for 30% of all renewable energy generation and 6.1% of the total energy portfolio. Hydropower technology and designs have been optimized throughout the years, but manufacturing of hydropower components still relies heavily on traditional methods and materials. Changes in global energy production systems and international supply chain issues are inspiring the manufacturing sector to reconsider their processes. Similarly, the hydropower industry is facing manufacturing challenges stemming from well-known maintenance issues, environmental impact mitigations, and changes in operations. These challenges, along with continued innovation in new hydropower and pumped storage development and modernization of the fleet, present an opportunity for advanced manufacturing and materials (AMM) to provide immense value to the hydropower industry. In support of the US Department of Energy’s (DOE’s) Water Power Technologies Office (WPTO), this report aims to characterize the current and emerging manufacturing-related challenges in US hydropower and to identify the high-impact opportunities in AMM that could address these challenges. The results highlighted in this report were collected through literature review, individual stakeholder interviews, and an in-person workshop organized at DOE’s Oak Ridge National Laboratory Manufacturing Demonstration Facility that brought together hydropower industry stakeholders, advanced manufacturing R&D, and the government.

13 HYDRO ENERGY↗

Interconnected Risks in Electricity Systems: Understanding Research Challenges, Needs, and Partnerships

The U.S. federal government has a potential role in mitigating the most poorly addressed risks across electricity markets and interdependent systems. Electricity system risks stem from extreme acute shocks (e.g., cyberattacks, extreme weather, and supply chain disruptions) and chronic stressors (e.g., global economic competition, uncertainties surrounding emerging technologies, climate change, and related conflicts). These acute shocks and chronic stressors can result in dire consequences for society, underscoring the need for better information for decision makers in both public and private sectors. Best practices and a shared understanding of risk management and risk quantification must be rapidly developed and disseminated. Informed by a quantitative treatment of risk to electrical infrastructure and interdependent systems, decision makers can more prudently and efficiently prioritize mitigation initiatives to maximize benefits to government, businesses, and the public.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Grain export restrictions during COVID-19 risk food insecurity in many low and middle income countries

Global food security is threatened by the effects of COVID-19 on international agricultural supply chains and locusts destroying crops and livelihoods in the Horn of Africa and South Asia. We quantify the possible impacts on global supplies and prices of wheat, rice and maize. We show that local production declines have moderate impacts on global prices and supply – but trade restrictions and precautionary purchases by a few key actors could create global food price spikes and severe local food shortages.

Grain export restrictions↗