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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 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Post-Closure Report for Closed Resource Conservation and Recovery Act Corrective Action Units, Nevada National Security Site, Nevada For Calendar Year 2022

This report serves as the combined annual report for post-closure activities in compliance with the requirements listed in Resource Conservation and Recovery Act (RCRA) Permit Number NEV HW0101 (Rev. 6) associated with the following closed corrective action units (CAUs): CAU 90, Area 2 Bitcutter Containment; CAU 91, Area 3 U-3fi Injection Well; CAU 92, Area 6 Decon Pond Facility; CAU 110, Area 3 WMD U-3ax/bl Crater; CAU 111, Area 5 WMD Retired Mixed Waste Pits; CAU 112, Area 23 Hazardous Waste Trenches. All post-closure inspections and evaluations were performed in accordance with requirements set out in RCRA Permit NEV HW0101, Rev. 6.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Recovery of Enriched Mo-100 from Low Specific Activity Mo-99/Tc-99m Generator Waste Streams

This study assessed two potential techniques for the extraction of pure Mo-100 target material from Mo-99/Tc-99m waste streams: 1) an established solvent-extraction method tailored for Mo-99 spent solution recycling, and 2) a low-temperature molten salt electrochemical process. By making minor modifications to the conventional solvent extraction method, particularly to accommodate the altered solubility limits arising from elevated Na+ concentrations in the waste, we achieved quantitative Mo recoveries. Although the electrochemical technique offers advantages in scalability and processing simplicity, it proved ineffective in recovering Mo from a NaOH-KOH salt melt.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2024

Optimal Membrane Cascade Design for Critical Mineral Recovery through Logic-based Superstructure Optimization

In this work, we extend the superstructure model proposed by Wamble et al. (2022) that considers feed input locations, recycling strategies, split fractions, stage numbers, and membrane area. We include the total number of stages as a decision variable, which might be particularly useful when there is cost as- sociated with adding additional stages. We propose a Generalized Disjunctive Programming (GDP) superstructure model that integrates all the design variables of the system. We also investigate the scalability of the model by varying the number of stages and the number of finite elements per stage to determine the impact on recovery and solution time.

Tran, Norman↗
DOE OSTI2024

Characterization of Oil and Gas Drill Cuttings for Critical Mineral Recovery and Reuse Potential as Soil Supplements

Expansion of unconventional oil and natural gas production over the last decade in the United States has resulted in record production of natural gas and oil in 2024. Millions of tons of drill cuttings generated from shale gas development are currently disposed of in landfills. Converting these cuttings into value product(s) such as critical minerals (CMs) and soil supplements, has the potential of reducing environmental impact of fossil fuel exploration. In this study we characterize the CM distribution and extractability from collected drill cuttings and core samples from major U.S. shale formations. A four-step sequential extraction, consisting of a sonicated soap step, sonicated EDTA step , mildly reducing agent, and a oxidizing agent, was developed to simultaneously extract CMs and convert the drill cuttings into soil supplements. Viability of converted drill cuttings as soil supplement was determined with a seedling growth experiment. Results show high concentrations of vanadium (V) (up to 1575 ppm, barite (up to 5 wt. %), and rare earth elements (REE) concentrations (up to 253 ppm). High extractability of selected critical minerals such as REE (19-50%) and Ba (10-58%) show promising results. Preliminary results show seedling growth in a mixture of converted drill cuttings with soil. These results show the potential for recovery of CMs from drill cuttings as an alternative domestic and the reduction of the environmental impact of fossil fuel production.

Barczok, Maximilian↗
DOE OSTI2024

Identifying Critical Mineral Binding Mechanisms and Distribution in Acid Mine Drainage Treatment Solids to Inform Targeted Recovery Methods

In this study, micro-X-ray Fluorescence and micro/bulk X-ray Adsorption Near Edge Spectroscopy were collected at Stanford Synchrotron Radiation Lightsource and the Advanced Photon Source to: (1) gain a detailed characterization of critical minerals in Fe/Mn (hydr)oxide host phases; and (2) investigate the Co/Ni coordination and redox speciation associated with Fe/Mn (hydr)oxides phases in AMD solids with diverse composition (e.g., Al-rich, Mn-rich, Al/Mn/Fe-rich). Preliminary results show co-location of Co/Ni within Mn-rich hotspots, while Fe-rich hotspots were associated with heavy REEs. In Al-rich solids, Mn speciation was mostly comprised of Mn+3/+4 oxides, while the Mn-rich solids contain predominately Mn+4. These results suggest the AMD matrix plays an important role in how Co/Ni are coordinated, which aids in evaluating the efficacy to utilize AMD solids as a resource, and informs other novel sorbent and recovery technologies.

Hoffman, Colleen↗
DOE OSTI2024

Solidification of SRPPF Aqueous Recovery Liquid: Process Disruptions

Savannah River National Laboratory has identified a magnesium oxysulfate grout formulation to solidify the liquid effluent from the Savannah River Plutonium Processing Facility (SRPPF) Aqueous Recovery System (ARS). The formulation uses reactive, light burnt MgO, anhydrous MgSO 4 , and dead burnt MgO and provides good mixability, similar density to the original Portland Cement-based mix, and a leachate pH of 9.39, within the assumed Waste Isolation Pilot Plant (WIPP) brine pH range. The formulation will solidify the effluent using a solid first, lost paddle design, within a 55-gallon drum. A series of seven different process disruptions, or irregular processing during the expected ARS liquid effluent solidification process, were completed to assess the severity of the impact of the process disruption and how the formulation behaves under these conditions. Seven process disruptions were investigated including: No Mixing, Partial Mixing, Compacted/Stratified, Sealed, Overfilled, Underfilled, and Undermixed. The impact on solidification, leachate pH, Er (a Pu/Am surrogate) distribution, and density of the resulting grout were established. Overall, four of the process disruptions, No Mixing, Partial Mixing, Compacted/Stratified, and Overfilled, resulted in basic, unabsorbed liquid that would require additional solidification to be acceptable for WIPP. Most solids generated in this testing met the expected WIPP leachate pH requirements. Solids from the Compacted/Stratified process disruption test, however, produced a leachate pH slightly above the assumed range in the WIPP performance assessment. The distribution of Er for most of the tests was relatively consistent. The No Mixing process disruption test, however, resulted in non-homogeneous Er distribution, indicating that radioactive material would not be evenly distributed throughout this solid’s matrix. The Overfilled test is the only mix with a density slightly below the acceptable value. The Sealed and Overmixed tests produced a solid closest to the standard mix with no unabsorbed liquid, expected leachate pH levels, consistent Er concentrations, and expected density, indicating these process disruptions do not have a negative impact on the final grout form. Based on the other process disruptions, it is critical to have premixed dry materials and a well-defined mixing process to produce a solid, homogeneous magnesium oxysulfate cement, with no unabsorbed liquid. These process disruption tests show that the lack of adequate mixing is fundamental to creating an improperly solidified material that may require remediation.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Treatment and Mineral Recovery from Combustion Residual Leachate and Produced Water

This talk presents the design of operationally flexible diafiltration membrane systems for Li/Co recovery, and applies robust optimization methodologies using these flexible systems to generate optimal designs immune to membrane manufacturing variability and uncertain process inlet conditions. The results highlight the use of robust optimization to find design strategies and insights that may reduce technical risks arising from model uncertainties.

Able, Chad↗
DOE OSTI2024

Surrogate modeling of the leaching process in a rare earth elements recovery plant

The data are summarized in the slides for a poster as presented at the 2024 AIChE annual meeting in San Diego, California, USA. The slides summarize our work on the PrOMMiS project over the past year. The slides describe the systematic design and optimization of a flowsheet for the recovery of critical minerals and rare earth elements. Then, it summarizes the results of our benchmarking of surrogate modeling methodologies for the optimization of these flowsheets.

Fardis, Dimitrios↗
DOE OSTI2024

TCF - Sustainable Well Cement for Geothermal, Thermal Recovery, and Carbon Storage wells

Primary cementing is the most important operation performed on a subterranean well. Cement, placed in the annulus between the casing and the formations, serves as a hydraulic seal preventing fluids and gas migrations, protecting steel casing from corrosion, and supporting the well structure. Poor cementing jobs can be directly responsible for wells not reaching their full capacity, casing corrosion, compromised well integrity and, in the worst-case scenarios, well collapse. Geothermal, thermal recovery, and carbon storage wells offer environments that are especially difficult for cements to survive while the required lifespan of these wells can be years. In these wells currently used cements cannot provide durable well integrity, and new solutions are necessary. The necessity of stabilizing the electric grid, increasing its flexibility, and providing energy on demand will further expand the market of durable cement solutions for applications in high-temperature underground reservoir thermal energy storage wells (HT RTES). The design challenges of special cement systems for such wells originate from chemistry limitations of currently used well cements, aggressive environments, temperature and repeated shock conditions associated with them, and very weak formations that are not uncommon in these wells. During the last 70 years the most common systems for thermal-well construction have been Ordinary Portland Cement (OPC) (absolute majority of the wells), silica-lime system, and high aluminum cement-containing formulations. The major issues of calcium-silicate hydrates, that form during the hydration of OPC resulting in hardened material, are their poor chemical resistance to acids due to the calcium interactions with acid anions followed by its eventual dissolution, even in mild acids, such as carbonic acid from CO 2 dissolution, and inadequate bonding to the steel causing serious casing corrosion problems (Sugama & Pyatina, 2019). Performance of OPC-based cement may be significantly improved with organic additives; however, those are limited by their temperature stability. An alternative to calcium-silicate cement was developed by BNL and commercialized by Halliburton as ThermaLock TM cement. Calcium-aluminate-phosphate-based chemistry of the material allowed overcoming acid-resistance problems of OPC, especially in CO 2 -rich geothermal environments. In 2012-2015, building upon this experience, BNL developed Thermal Shock Resistant Cement (TSRC) with the support of Geothermal Technology Office (GTO) of DOE. TSRC has high-temperature stable chemistry, superior properties of cement-metal casing bond and corrosion protection (4-times better than currently used OPC-based formulation), significantly outperforms common well-cements in thermal-shock tests, has self-healing properties, and like ThermaLock TM is CO 2 resistant incorporating carbonate ions into stable hydrates (Gill et al., 2012).

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Findings on subtask 3.3 – applicability of automated brine chemistry determinations for treatment and recovery processes through facility automation/modularization: engineering design study

Under the Energy & Environmental Research Center’s (EERC’s) ~$\$$22 million Phase II Brine Extraction and Storage Test (BEST) Program, a multimillion-dollar brine treatment technology test bed facility was established in western North Dakota to provide a platform for evaluating developing technologies and approaches for brine treatment and volume reduction. The initial facility, and associated research effort, was funded by the U.S. Department of Energy (DOE), with in-kind contributions provided by several industry participants and the state of North Dakota. Since its opening, the Brine Technology Test Facility (BTTF) has supported performance evaluations of desalination technologies capable of treating high-salinity produced water (PW) and enabled data collection for multiple approaches of PW management and critical material recovery. As part of the decommissioning process for the original project, facility ownership and liability were transferred to Select Water, which is providing the EERC with a continuing site access option for state or federal research and/or commercial technology development. This report documents the findings from a design study conducted by the EERC and the engineering firm that was originally contracted to design and construct the facility (Advanced Engineering and Environmental Services, LLC [AE2S]) that evaluated the current status of BTTF and its systems and developed a retrofit design to increase the facility’s capabilities through automation and modularization of its PW treatment infrastructure. The proposed retrofit will provide DOE and industry with an expanded range of conditioned PW that can be produced at the facility for evaluating fit-for-purpose water treatment technologies, online instrumentation for brine chemistry determination, and systems that recover critical materials like lithium and magnesium. The current facility consists of an 9600-square-foot facility that includes a 40-foot by 65-foot Class 1, Division 2-rated demonstration area and associated control rooms and lab-ready space capable of sourcing oil and gas PW and wastewater from industrial sources or tailoring brine compositions up to 300,000 mg/L total dissolved solids (TDS) and supplying them at rates up to 25 gpm for extended-duration technology demonstrations. The colocation of the facility with Select Water’s water management facilities allows for access and unloading of more than 10,000 bbl/day of trucked water delivered to site and associated access to on-site Class I and Class II brine disposal wells and nearby hazardous waste landfills operated and/or contracted by Select Water to dispose of concentrate and/or effluents associated with the testing.

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

Process Systems Engineering-Informed Design and Scale-Up of Multi-stage Diafiltration Cascades for Lithium and Cobalt Recovery from Spent Lithium-Ion Batteries

These slides present work jointly completed by Tasks in PrOMMiS. The first half of the presentation motivates the importance of critical materials for national security and how the recovery of critical minerals via membrane separations can be more cost effective than currently used technology. The second half of the presentation presents cost-optimal results for the custom cost model for diafiltration using the superstructure flowsheet developed by CMU. These results highlight how PSE can inform process targets (i.e., product purity targets) and suitable design strategies for scaled-up membrane cascades.

critical materials↗
DOE OSTI2025

Helium recovery system at IB3a

The increasing need for optimal and sustainable use of cryogenic resources to support Fermilab’s scientific mission has highlighted the necessity of improving the Laboratory’s helium management practices. An assessment of cryogenic test facilities identified the Technical Division’s Industrial Building 3a (IB3A) as a key site requiring upgrades to integrate a helium recovery system. The IB3A facility is essential for characterizing and testing superconductors, cables, and coils for various R&D projects, including the US High-Luminosity LHC Accelerator Upgrade Project (AUP), Mu2e, and other external collaborations. Currently, the facility relies on 500 L helium Dewars and vents the vaporized helium directly into the atmosphere, leading to significant helium loss. Given the non-renewable nature of helium, recovering and reusing this resource is critical for the sustainability of Fermilab’s operations. To address this challenge, a project has been initiated to connect IB3A to an existing helium purification station and refrigeration system located in another building via a dedicated pipeline pass over the roof of several buildings. This solution will enable the efficient capture of vented helium, its transfer to the purification station, and subsequent liquefaction for reuse in future operations. The project includes a detailed design phase, specifying the pipeline route, flow control mechanisms, and integration with the existing cryogenic infrastructure, followed by phased implementation and commissioning. By implementing this pipeline connection and upgrading IB3A, Fermilab aims to significantly reduce helium waste, lower operational costs, and align with its commitment to sustainability. This initiative provides a model for resource-efficient cryogenic operations and reinforces the Laboratory’s capacity to support its science mission for the long term.

Porwisiak, D. [Fermilab]↗
DOE OSTI2025

Reservoir Dynamics in Proposed Operational Scenarios Where CO 2 -EOR Fields are Transitioned From CO 2 -Flood Enhanced Oil Recovery to Dedicated Carbon Storage: A Field Case Study

This study models the transition of CO 2 -enhanced oil recovery (CO 2 -EOR) fields to dedicated carbon storage using a generalized reservoir model informed by real field data, SACROC. Through scenario-based simulations, the work evaluates how reservoir depletion levels, boundary conditions, fluid properties, and domain size affect pressure buildup, CO 2 plume migration, and long-term containment performance. The results inform practices for repurposing oil fields into reliable CO 2 storage sites.

02 PETROLEUM↗
DOE OSTI2025

Control Selection for the Neutralization Tank in the Aqueous Recovery System at SRPPF

• Neutralization and solidification is the last step in the Aqueous Recovery Process • All waste streams are acidic and must be neutralized before being combined with grout in a solidification drum • The neutralization tank is a 250 L, 24” diameter, 45” high tank • The batch tank is a 125 L tank • The solidification drum is a 55-gallon drum, pre-filled with grout & a sacrificial mixing paddle • Normal mass in neutralization tank: 50 g Pu • Normal mass in batch tank or drum: 25 g Pu

Dressman, Phillip M. [Savannah River Nuclear Solut↗
DOE OSTI2025

Microbial Biomining for the Release and Recovery of Rare Earth Elements in Abandoned Coal Mine Drainage

Microbes can be used for biomining rare earth elements (REEs) from abandoned coal-mine drainage (AMD) solids. Domestically Pennsylvania has ~11,000 abandoned mines, with ~500 AMD passive remediation systems (PRSs) that precipitate REE rich solids. In passive systems, REEs, co-precipitate with manganese (Mn), accumulating as a valuable leachate when resolubilized. REEs like lanthanum (La) are used in battery technology. Microbial metabolism that co-resolubilize Mn and REEs could result in an affordable release process that does not require the addition of hazardous chemical additives. Microbial sequestering of La can be used for selective purification from a mixed REE composition. Currently, the microbial mechanisms that contribute to mass REE resolubilization and selective sequestration are poorly understood. We have isolated bacteria (Bacillus mycoides JR07 and Bacillus pseudomycoides KB7) that solubilize Mn oxide, La oxide, and AMD solids by acidogenesis. Preliminary results show methylotrophic bacterial isolate B3 can take up soluble La, which may have a potential application in the purification of La from a mixed REE leachate. Determining the microbial metabolism and genes involved in the REE resolubilization and selective biomining of La is crucial to optimize the biomining of AMD solids. Our work addresses the growing need to develop novel REE recovery methods from domestic sources.

microbiology↗