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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Infinitely Recyclable Network Polymers, Enabling Sustainable Manufacturing (CRADA Final Report)

This FLO Materials project was aimed at commercializing a new, infinitely recyclable material that can enable closed-loop lifecycles for hard-to-recycle plastics and plastic products. Four hundred million metric tons of virgin plastic is produced each year, yet less than 10% of this material is recycled. In the US alone, 2% of energy consumption is dedicated to the manufacture of virgin plastics, polymer resin, and synthetic rubbers. By keeping plastic materials in circulation longer, we can reduce waste, lower manufacturing costs, cut energy and oil consumption, and drastically reduce greenhouse gas (GHG) emissions. Specifically, FLO’s innovation overcomes the complications associated with salvaging difficult-to-recycle plastics (i.e., contaminated thermoplastic linear polymers, thermoset cross-linked network polymers), which represent at least 20% of total polymer global production, with a recycling rate of near 0%. Chemical recycling of these new polymers through depolymerization allows all additives to be easily removed at room temperature and the recovered monomers to be remanufactured into next generation materials with 100% recovery of mechanical performance and aesthetic quality.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effects of Mechanical Recycling on Carbon Fiber-Based Hybrid Composites

Carbon fiber (CF) reinforced composites are high-performing, highly utilized material systems historically used in aerospace. As the cost of CF decreases, other industries, such as automotive and energy generation, seek to adopt CF composites into their applications. A sudden increase in CF demand may create supply chain issues if the adoption happens without scaling up of the CF production. A solution for reducing the reliance on CF is to substitute some portion of the CF content with another fiber type without significantly reducing the material properties. When multiple reinforcing fillers are introduced into a composite system, the materials system is often referred to as a hybrid composite and in this case a CF-based hybrid composite. To further relieve reliance on CF and with sustainable manufacturing becoming more prominent in industry, mechanical recycling can be employed to replace all or a percentage of the virgin material content. Utilizing recycled content in place of virgin content will further aid in reducing the reliance on virgin CF and decrease overall material costs. Here, the effects of utilizing mechanically recycled feedstocks on the mechanical properties of injection molded samples are explored to understand the feasibility of re-manufacturing recycled CF-based hybrid composites. By determining the mechanical properties and mechanisms in which the properties change through varying recycled content, the assessment of how the material will perform in other manufacturing processes can be inferred. As a result, industry will gain better insight into utilizing mechanically recycled feedstocks to reduce their reliance on the CF supply chain.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The Isotopic Limit of Recycling

Despite advances in recycling technologies and practices, the world still mostly operates on a once-through materials use cycle. The once-through approach to the materials supply chain cannot work into perpetuity. The vast majority of current recycling efforts focus on mechanical or chemical separation-based techniques and are often subsequently limited on the number of times a component can be recycled or upcycled. By looking at things from a particle physics and nuclear history perspective, we propose a thought experiment to determine the physical limit of recycling and propose subsequent limits and standards to evaluate all recycling efforts. This uncommon approach to analysis demonstrates that the current limits to recycling are not physical in nature but engineering.

Lang, Eric↗
NASA NTRS1988

Isotopic constraints on crustal growth and recycling

The Sm-Nd isotopic data on clastic and chemical sediments are used with the present-day age distribution of continental crustal rocks to estimate the rates of crustal accretion, growth and recycling throughout earth's history. A new method for interpreting Nd model ages on both chemical and clastic sediments is proposed. A general relationship is derived between the mean crustal residence time of material recycled from the crust to the mantle (i.e., sediments), the mean age of the crust, and the crustal growth and recycling rates. This relationship takes into account the fact that the age distribution of material in the continental crust is generally different from the age distribution of material recycled into the mantle. The episodic nature of the present-day age distribution in crustal rocks results in similar episodicity in the accretion and recycling rates. The results suggest that by about 3.8 Ga ago, about 40 percent of the present continental volume was present. Recycling rates were extremely high 3-4 Ga ago and declined rapidly to an insignificant value of about 0.1 cu km/a during most of the Phanerozoic. The Nd model age pattern on sediments suggests a fairly high rate of growth during the Phanerozoic.

Jacobsen, Stein B.↗
NASA NTRSDate not supplied

Should Oxygen, Hydrogen, and Water on the Moon Be Provided by Earth Supply, Life Support Recycling, or Regolith Mining?

The water needed for space life support has so far been provided by either direct supply from Earth on most missions or by life support wastewater recycling on the International Space Station (ISS). With the recent large reduction in launch cost, Earth resupply has become more attractive, but recycling always costs less than resupply for a large enough crew on a long enough mission. Water is also needed to make up recycling losses and oxygen and hydrogen are needed for propulsion fuel. This paper compares the costs of oxygen, hydrogen, and water on the moon for Earth supply, lunar recycling, and lunar mining. While Earth supply is the most expensive by far, lunar recycling and mining costs are not much different. Life support wastewater provides a large but limited supply, so lunar mining will always be needed. Minor cost reductions may make mining less expensive than recycling.

Harry W Jones↗
DOE OSTI2022

Recycling Measurements for the Lithium Tokamak Experiment

The lithium tokamak experiment (LTX) is a spherical torus designed to investigate a low-recycling wall regime for magnetically confined plasmas. Traditional measurements of recycling using Dα emission are not feasible in LTX due to reflections off the plasma-facing-components: stainless-steel shell, liquid lithium layer, and molybdenum limiters. Since lithium has low VUV reflectivity, LTX will use Lyman-α emission to measure particle recycling. LTX will use 10- and 20-channel AXUV diode arrays with Lyman-α filters to view recycling off the inboard and outboard shells. A single detector views recycling off a limiter. Measurements will be used with neutral modeling to calculate recycling and neutral deposition. To investigate the performance of an AXUV diode with directly-deposited filter, measurements were obtained with this detector and a visible detector viewing a calibration plasma then compared with emission calculated using a collisional-radiative model.

Physics - Plasma physics↗
DOE OSTI2025

Impact of electric vehicle battery recycling on reducing raw material demand and battery life-cycle carbon emissions in China

The rapid growth of electric vehicles (EVs) in China challenges raw material demand. This study evaluates the impact of recycling and reusing EV batteries on reducing material demand and carbon emissions. Integrating a national-level vehicle stock turnover model with life-cycle carbon emission assessment, we found that replacing nickel-cobalt-manganese batteries with lithium iron phosphate batteries with battery recycling can reduce lithium, cobalt, and nickel demand between 2021 and 2060 by up to 7.8 million tons (Mt) (67%), 12.4 Mt (96%), and 37.2 Mt (93%), respectively, significantly decreasing reliance on import. Moreover, battery recycling coupled with reuse can reduce carbon emissions by up to 6,532-6,864 Mt (36.0-37.9%), depending on four recycling methods employed. However, this reuse strategy delays battery recycling and risks lithium supply shortage, necessitating trade-offs between carbon reduction and material supply. Future technologies, such as lithium-sulfur and all-solid-state batteries, despite their energy efficiency, might exacerbate lithium shortage, underscoring the crucial need for increased lithium supply.

25 ENERGY STORAGE↗
DOE OSTI2024

Winding Down: End of Service and Recycling for Wind Energy [Slides]

In this webinar hosted by the U.S. Department of Energy's WINDExchange initiative, experts from the National Renewable Energy Laboratory introduce attendees to key concepts in end-of-service processes for wind energy technologies and infrastructure, including decommissioning, repowering, and recycling. As wind energy projects across the United States become older, decisions about end-of-service options and component processing are of growing importance to project owners and operators, state and local decision-makers, and neighboring communities. There is also concern about the blade waste that must be processed, with a number of recycling solutions being developed to meet this need. This webinar introduces the processes and activities involved at the end of a wind energy project's lifespan; discusses the impacts these activities have on communities, landowners, the wind energy industry, and other stakeholders; explains different blade recycling methods; and discusses the future of recycling in the wind energy industry.

17 WIND ENERGY↗
DOE OSTI2025

Heterogeneity of the Dominant Causes of Performance Loss in End-of-Life Cathodes and Their Consequences for Direct Recycling

Recycling Li-ion batteries from electric vehicles is critical for reducing costs and supporting the development of a domestic battery supply chain. Direct recycling of cathodes, like LiNixMnyCozO2 (NMC), is attractive due to its low cost, energy use, and emissions compared to traditional recycling techniques. However, a comprehensive understanding of the active material properties at end-of-life is needed to guide direct recycling processes and the performance-dependent reuse applications. Here, NMC material from an end-of-life commercial pouch cell is characterized and bench-marked against pristine non-cycled counterparts with respect to capacity, impedance, crystallography, morphology, and microstructure to identify major degradation modes and understand variability in the end-of-life material. The spatial heterogeneity of each property throughout the cell is also quantified. While the degraded material demonstrated similar capacity as the pristine, its impedance and rate capability are severely diminished. Furthermore, samples from the periphery of the electrode layers showed more severe performance loss compared to samples extracted from central regions. The dominant culprit of performance loss is the material microstructure, where the magnitude of particle cracking showed the strongest correlation to the impedance components that are most unfavorably impacted. This work suggests severe cracks in cathode active materials are the primary challenge that direct recycling methods must overcome.

25 ENERGY STORAGE↗
DOE OSTI2023

Dual Recycling of Depolymerization Catalyst and Biodegradable Polyester that Markedly Outperforms Polyolefins

Chemically recyclable, circular polymers continue to attract increasing attention, but rendering both catalysts for depolymerization and high-performance polymers recyclable is a more sustainable yet challenging goal. Here we introduce a dual catalyst/polymer recycling system in that recyclable inorganic phosphomolybdic acid catalyzes selective depolymerization of high-ceiling-temperature biodegradable poly(δ-valerolactone) in bulk phase, which, upon reaching suitable molecular weight, exhibits outstanding mechanical performance with a high tensile strength of ≈66.6 MPa, fracture strain of ≈904 %, and toughness of ≈308 MJ m –3 , and thus markedly outperforms commodity polyolefins, recovering its monomer in pure state and quantitative yield at only 100 °C. In sharp contrast, the uncatalyzed depolymerization not only requires a high temperature of >310 °C but is also low yielding and non-selective. Importantly, the recovered monomer can be repolymerized as is to reproduce the same polymer, thereby closing the circular loop, and the recycled catalyst can be reused repeatedly for depolymerization runs without loss of its catalytic activity and efficiency.

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

Chemically Recyclable and Tunable Polyolefin-Like Multiblock Copolymer Adhesives

Adhesives are important in creating multilayer products, such as in packaging and construction. Most current hot-melt adhesives such as poly(ethylene-co-vinyl acetate) (EVA) and polyurethanes lack chemical recyclability and do not easily de-bond, complicating recycling. Here, we achieved tunable adhesive properties of chemically recyclable polyolefin-like multiblock copolymers through regulating the incorporation of crystalline hard blocks, amorphous soft blocks, and ester content highlighted by adhesive strengths up to 6.80 MPa. We further demonstrated applications of these adhesives in multi-layer films and showed that the adhesives can be readily de-bonded, recovered, and chemically recycled. Overall, this study into structure-property relationships, including effects of crystallinity, soft-block incorporation, and ester content of the multiblock copolymers on adhesive properties, has resulted in a modular hot-melt adhesive platform that exhibits chemical recyclability for virgin-quality adhesive re-generation, reprocessability for repeated reuse of the recovered adhesive, and tunability for designing adhesives with a wide range of low to high (up to ~80% stronger than EVA) adhesion strengths.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Simulation of the impact of particle recycling on the plasma in MPS-LD device based on the BOUT++ LPD module

A linear plasma device (LPD) module has been developed under the BOUT++ framework to simulate plasma transport in the MPS-LD. However, previously, the LPD module used a simplistic neutral particle model that only includes particle density and velocity, which prevents the full understanding of the plasma-neutrals interactions. In this work, we further optimize the neutral model by using a more complete neutral fluid model containing the continuity equation, momentum equation, and energy equation. The reactions such as charge exchange, excitation, and radiation collisions are included. Since the neutral particle source is mainly provided by particle recycling from the target, a particle recycling model is employed, which includes both fast reflection and slow thermal release. The upgraded LPD module is applied to simulate the argon (Ar) discharge experiment of MPS-LD, and the benchmark against experiment measurement and SOLPS-ITER simulation results are presented. Good agreements are obtained, showing the validation of the upgraded module. After that, the impact of particle recycling on Ar plasma is investigated. It is found that a higher recycling coefficient (R) promotes the achievement of high-density plasma at the target. In conclusion, the recycled Ar atoms change target plasma pressure as well as plasma-neutral collisions, which both contribute to plasma momentum loss, thus promoting the rollover of ion flux to the target.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Direct Recycling of Blended Cathode Materials by Froth Flotation

We report that direct Li-ion battery recycling involves separating cathode active materials in the solid phase while preserving their electrochemical performance. To reuse the recycled ones in new batteries, it is necessary to separate individual cathode components, which would typically occur prior to the rejuvenation and any compositional reformulation processes. Herein, a froth flotation process is developed to separate pristine lithium nickel-manganese-cobalt oxide (LiNi 0.333 Mn 0.333 Co 0.333 O 2 , NMC111) and lithium manganese oxide (LMO) materials. The flotation results show that with multiple stages of the separation processes, a satisfactory separation is achieved with 95% grade or above of NMC111 in the froth product and 95% grade of LMO in the tailing product. The electrochemistry results show that the flotation chemicals have negligible impact on the electrochemical performance of recycled active materials, whereas the NMC111 exhibits a minor capacity fade after being in contact with deionized water at 2% solid concentration. An improvement in both the rate and cycling performance is achieved at 10% solid concentration or higher. It is found that there is little compositional and structural change to the aqueous recycled NMC111 powders. An effective and low-cost separation method for direct recycling mixed cathode compositions is demonstrated.

25 ENERGY STORAGE↗
DOE OSTI2024

Recycling Perspectives of Electric Arc Furnace Slag in the United States: A Review

This article presents a comprehensive review of electric arc furnace (EAF) slag recycling in the United States, examining its classification and the associated challenges and opportunities of its industrial use. The study affirms EAF slag's nonhazardous status. Here, the main challenges identified in EAF slag applications include substantial variations in composition and volume instability during/after hydration. Analysis of the U.S. recycling practices reveals that EAF slag is predominantly reused, with minimal landfill disposal. However, its prevalent use as a low value-added aggregate in construction applications underscores the industry's ongoing challenge to get additional value from EAF slag recycling. Despite these challenges, the study highlights a great potential for increased value extraction from EAF slag recycling. Beyond conventional applications as a clinker material for the cement industry, the review explores modern technologies for steelmaking slag recycling, revealing options for recovering valuable metals such as Cr, V, Mo, and Fe through methods such as leaching, reduction, and oxidation.

42 ENGINEERING↗
DOE OSTI2026

Recyclability of reversible polymer networks over a Dozen reprocessing cycles

Reversible polymer networks capable of reversible reactions along their backbone provide a promising strategy for addressing waste management challenges associated with conventional thermoset products. However, reversible polymer networks cannot be recycled infinitely. Unavoidable side reactions eventually cause significant degradation of mechanical properties or loss of recyclability. This study aims to answer a simple yet critical question on reversible polymer network systems: how many reprocessing cycles can be achieved before profound mechanical degradation or a loss of recyclability? The recyclability of Diels–Alder (DA) network samples was evaluated by repeating consistent reprocessing cycles until they were no longer reprocessable. To enhance their recyclability, the chemical structure of the maleimide precursor was tailored to mitigating side reactions by maleimide homopolymerization. Remarkably, by employing a maleimide precursor with alkyl substitutions on its phenyl group, the DA network system attained 12 reprocessing cycles using injection molding at 160 °C without significant degradation of mechanical properties. However, the 13th reprocessing cycle did not succeed. Rheological analysis revealed the accumulation of non-reversible bonds within the network structure during repeated reprocessing, despite fairly consistent mechanical properties under operating conditions. This study demonstrates that the rational design of the maleimide precursor is an effective means to enhance the reprocessability of DA networks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Substitution of virgin carbon fiber with low-cost recycled fiber in automotive grade injection molding polyamide 66 for equivalent composite mechanical performance with improved sustainability

Recycled carbon fiber has historically proven challenging to integrate into composite manufacturing due in no small part to the low-density, randomly oriented, discontinuous fiber format that results from typical recycling. Discontinuous fiber requires the use of alternative technologies than those traditionally applied to continuous fiber (e.g., hand lay-up, winding). Extrusion compounding is one such applicable technology, but material transfer into the system requires alternative feeding equipment or the use of an altered procedure as trialed in this research. In this study, an injection molding compound for automotive applications was prepared with recycled carbon fiber and compared against an existing commercial compound. Input fibers and molded compound were evaluated for mechanical performance, while relevant variables such as compounded fiber alignment and aspect ratio were compared to the existing baseline material to confirm a like-for-like composite material structure. Overall, analysis indicates that recycled fiber performs similarly to virgin fiber reinforcement, demonstrating that recycled fiber may be a viable drop-in replacement for short-fiber discontinuous applications.

42 ENGINEERING↗
DOE OSTI2023

A decision support tool for e-waste recycling operations using the hen-and-chicks bio-inspired optimization metaheuristic

E-waste from end-of-life electrical and electronic devices is one of the fastest growing waste streams from households and businesses. E-waste recycling yields environmental sustainability and economic benefits. Due to continuous changes in e-waste types and compositions, recycling businesses face challenges to optimize their operational configuration to achieve better economic and environmental performance. To help e-waste recyclers mitigate this problem, we have developed a modular decision support tool called the Comprehensive Manufacturing Assessment Tool (CMAT) that can simulate both e-waste recycling operations and economics. This tool can give valuable insights regarding the profitability of the entire operation and different e-waste types. In addition, a new bio-inspired metaheuristic optimization algorithm, hen-and-chicks optimization (HACO), was developed to assign manpower to different workstations to maximize operational efficiencies. According to the results of our case study, laptops, desktops, and computer peripherals are the three electronic waste products that produce the most profit. Our examination of the sensitivity of material prices shows that the price of steel has the most significant influence on total profit, because it is the most widely used material in the majority of electronic devices. We have released the decision support tool as open-source software under a general public license. It could be customized for other recycling industries beyond e-waste to achieve business sustainability by making their operations more efficient.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Achieving low-temperature hydrothermal relithiation by redox mediation for direct recycling of spent lithium-ion battery cathodes

Lithium-ion battery (LIB) recycling is an urgent need to address the massive generation of spent LIBs from portable devices and electrical vehicles. However, the large-scale recycling is hampered by economic and safety issues associated with today's recycling processes. In this study, we demonstrate a safe and energy efficient direct regeneration process based on low-temperature hydrothermal relithiation (LTHR) at low pressure for spent LiNi x Co y Mn z O 2 (0 < x,y,z <1, x + y + z = 1, or NCM) cathode materials. A low concentration of low-cost redox mediator is employed to improve the relithiation kinetics of spent NCM materials, enabling full relithiation temperature to be reduced from 220 °C to 100 °C or below. Correspondingly, the pressure incurred in the relithiation process can be reduced from ~25 bar to 1 bar, offering significantly improved operation safety. Specifically, three NCM materials, including chemically delithiated NCM111, cycled (degraded) NCM111, and cycled NCM622, were successfully regenerated with complete recovery of composition, crystal structure, and electrochemical performance, achieving the same effectiveness as that achieved at high temperature process. Meanwhile, the total energy consumption of spent cell recycling and the greenhouse gas emission is also reduced. This work provides a facile and scalable way to more sustainable LIB recycling with high economic return, high operation safety and low cost.

25 ENERGY STORAGE↗