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At least 163 records · Page 9

Task 12 PV Sustainability - Status of PV Module Recycling in Selected IEA PVPS Task 12 Countries

Photovoltaic (PV) deployment has accelerated in recent years compared to projections in the early 2010s. This means that PV end of life (EOL) waste streams will also increase at a higher pace than anticipated. To meet and optimise PV EOL management, appropriate regulatory and technological approaches must be implemented in the near term, ensuring that available options are adapted to the conditions of each country or region. This report aims to review the current regulatory and industrial landscape for selected countries belonging to the International Energy Agency's PV Power Systems technology collaboration programme, to assess status of PV EOL management, allow for comparison and cross-fertilization, and establish a foundation for future tracking of progress. Although volumes of EOL PV modules are still small, EOL PV is treated and recycled in a proper manner in the countries and regions that have EOL regulations in place. However, the current low volumes, limited available recycling technologies, logistics challenges, and undeveloped markets for recovered materials result in a high-cost, low-revenue scenario for PV module recycling globally. Nevertheless, the implementation of PV EOL regulations in more countries and R&D investment in PV recycling is expected to accelerate further improvements to meet future demand and to achieve high-value, low-cost recycling. We hope this report contributes to understanding the global status of PV recycling and to accelerating its development as a promising option for the proper EOL management of PV modules in the coming decades.

14 SOLAR ENERGY↗

Auto Recycler Report: Results from a Questionnaire about Processing Electric Vehicles and Handling High-Voltage Batteries

With the transition to clean energy the demand for electric vehicles in the United States is rapidly growing. As demand continues to rise in the next couple of decades, sourcing materials (e.g., lithium, nickel, cobalt, graphite, etc.) to put into new batteries for electric vehicles will be critical. The U.S. does not have significant reserves of most of these materials and relies heavily on foreign countries. The lithium-ion batteries in electric vehicles are large and contain substantial amounts of critical materials, therefore, they are a promising source of materials for new batteries. Recycling electric vehicle batteries when they reach their end-of-life will enable the United States to generate a domestic supply of materials needed for future batteries. [1-3] The auto recycling industry is the largest collective owner of end-of-life vehicles in the U.S. and will be the primary handlers of battery-powered vehicles (i.e., hybrid or electric) when they reach the end of their useful life. In an effort to better understand how the auto recycling industry currently handles battery-powered vehicles and their high-voltage batteries, DOE’s ReCell Center for Advanced Battery Recycling (ReCell) developed a questionnaire and distributed it to various trade organizations in the automotive recycling industry.

25 ENERGY STORAGE↗

Demonstration of Complete Recycling Processes of Reversible Epoxies Using Solar Energy Conversion

Reversible epoxies using the Diels–Alder chemistry enables recycling processes through depolymerizing the polymer at higher temperature and then repolymerizing upon cooling. Compared to conventional bulk heating, photothermal heating can save time and resource and, consequently, reduce costs to reach an elevated temperature for recycling processes of the reversible epoxies. In previous studies, self‐healing of cracks and reattachments of two broken pieces have been presented using a laser; however, recycling of a sample as a whole is not feasible by using such a point light source. Herein, complete recycling processes are demonstrated utilizing an area light source, i.e., sunlight. Reversible epoxies are incorporated with carbon black and refractory plasmonic titanium nitride nanoparticles (NPs). Under concentrated (10 times) sunlight, they can generate sufficient heat (≈140 °C) to completely liquefy, reprocess, and reshape the samples multiple times. Recycling processes are validated by evaluation of mechanical properties for each cycle. Using an integrated experimental and theoretical approach, photothermal performance is investigated in terms of the dispersion and loading of photothermal NPs in the matrix, as well as the sample thickness. In this study, an insight is provided into the design of polymer/photothermal nanomaterial composites which can be sustainably recycled using abundant solar energy.

14 SOLAR ENERGY↗

Economic assessment for recycling critical metals from hard disk drives using a comprehensive recovery process

Since the 2011 price spike of rare earth elements (REEs), research on permanent magnet recycling has blossomed globally to reduce future REE criticality. Hard disk drives (HDDs) have emerged as one feasible feedstock for recovering valuable REEs such as praseodymium, neodymium, and dysprosium. However, current processes for recycling e-waste only focus on certain metals due to feedstock and metal price uncertainties. In addition, some believe that recycling REEs is unprofitable. To shed some light on the economic viability of REE recycling from HDDs, this paper combines techno-economic information of a hydrometallurgical process with end-of-life HDD availability in a simulation model. Results showed that adding REEs to HDD recycling was profitable given current prices. As a result, recovered REEs could meet up to 5.1% rest of world (excluding China) magnet demand. Aluminum, gold, copper scrap and REEs were the primary main revenue streams from HDD recycling.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

V-ATPase-dependent luminal acidification is required for endocytic recycling of a yeast cell wall stress sensor, Wsc1p

Highlights: •A targeted genome screen identified 5 gene groups affecting Wsc1p recycling. •V-ATPase-dependent luminal acidification is required for Wsc1p recycling. •Activity of V-ATPase might be required for cargo recognition by the retromer complex. -- Abstract: Wsc1p is a major cell wall sensor protein localized at the polarized cell surface. The localization of Wsc1p is maintained by endocytosis and recycling from endosomes back to the cell surface, but changes to the vacuole when cells are subjected to heat stress. Exploiting this unique property of Wsc1p, we screened for yeast single-gene deletion mutants exhibiting defects in Wsc1p trafficking. By expressing 3GFP-tagged Wsc1p in mutants with deleted genes whose function is related to intracellular trafficking, we identified 5 gene groups affecting Wsc1p trafficking, impaired respectively in endocytic internalization, multivesicular body sorting, the GARP complex, endosomal maturation/vacuolar fusion, and V-ATPase. Interestingly, deletion of the VPH1 gene, encoding the V{sub o} subunit of vacuolar-type H{sup +}-ATPase (V-ATPase), led to mis-localization of Wsc1p from the plasma membrane to the vacuole. In addition, disruption of other V-ATPase subunits (vma mutants) also caused defects of Wsc1p trafficking and vacuolar acidification similar to those seen in the vph1Δ mutant. Moreover, we found that deletion of the VPS26 gene, encoding a subunit of the retromer complex, also caused a defect in Wsc1p recycling and mis-localization of Wsc1p to the vacuole. These findings clarified the previously unidentified Wsc1p recycling pathway and requirement of V-ATPase-dependent luminal acidification for Wsc1p recycling.

60 APPLIED LIFE SCIENCES↗

Achieving high rate performance in hybrid pristine-recycled cathodes using model-informed electrode designs

Direct recycling lithium-ion battery cathodes, a process that retains the engineered oxide structures from end-of-life materials, presents a cost-effective and energy-efficient alternative to other battery recycling methods. However, while direct-recycled cathodes have demonstrated performance comparable to that of pristine materials at low cycling rates, their high-rate performance remains uncertain. Morphology changes in cathode particles, a main mode of degradation, directly impact rate performance by limiting surface kinetics and solid-phase diffusion. If direct recycling processes do not sufficiently restore pristine-like morphologies, the recycled materials may retain structural defects that hinder high-rate performance. The present work uses a physics-based pseudo-2D model to simulate hybrid electrodes with pristine and artificially “aged/recycled” NMC materials to investigate potential impacts of incorporating performance-limited aged cathode materials into cells. The study highlights how differences in transport and kinetic properties can influence rate capabilities in mixed electrodes — particularly in high-loading cells in high-demand applications. However, model results also reveal a possible mitigation strategy via dual-layer electrode architectures with lower-performing materials positioned near the current collector. Simulations of 4.0 mAh cm −2 cells cycled at 4C using a dual-layer architecture provided approximately 5%–30% more capacity in constant-current protocols compared to homogeneously blended electrode architectures with the same loadings and mixed-material compositions. These findings highlight the importance of strategic electrode design in minimizing potential performance losses and facilitating the integration of recycled materials into high-performance batteries, advancing sustainable and cost-effective battery manufacturing.

25 ENERGY STORAGE↗

Bio-inspired interfaces for easy-to-recycle lithium-ion batteries

The recycling of spent lithium-ion batteries has significant potential to benefit our society economically and environmentally as well as preserving raw materials. Although diverse process chains have been applied or under development to recycle batteries, a common, critical issue for battery recycling is the separation of the metallic current collector from the composite film of the electrode. In this study, inspired by the amazing controllable attachment and detachment ability of geckos’ foot-hairs, microscale near-surface architecture is designed on the interface between the current collector and the composite film in lithium-ion batteries, so that it displays controllable and directional adhesion, i.e., enhanced adhesion can be obtained during its lifetime to cope with the substantial volume changes of the composite film upon intercalation and deintercalation, whereas during recycling, the composite layer of the electrode can be easily peeled off from the current collector in a certain direction. We report this study is the first application of structural adhesives for the development of easy-to-recycle lithium-ion batteries. This technology can also be extended to other electronic products to avoid an ever-growing volume of electronic waste. The fundamental understanding on the interfacial adhesion and delamination mechanisms provides a scientific footing for the realization of next-generation easy-to-recycle electronics.

25 ENERGY STORAGE↗

Opportunities for plasma separation techniques in rare earth elements recycling

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

Economic feasibility↗

Recycled graphite enabled superior performance for lithium ion batteries

Recycling graphite attracts growing attention since cumulative amount of spent Li-ion batteries and the shortage of graphite supply chain. Although various recycling methods have been reported, the recycled graphite cannot reach the strict commercial standards of purity, scalability, efficiency, and capacity, preventing it from battery manufacturing. Herein, the important roles of defects and functional groups on the graphite surface are deeply studied, and a closed-loop graphite recycling process with the surface recovery and modification for the graphite from the end-of-life batteries is demonstrated. The recovered graphite delivers a purity of over 99.9 % and an average initial coulombic efficiency of 91.5 %. Compared with commercial graphite in industrial standard battery testing parameters, full cells with recovered graphite possess enhanced rate reversibility, doubled cycle life, over 10 % higher capacity along with half anode material cost. In conclusion, these impressive results not only underscore the transformative potential of surface reconstruction and modification in graphite recycling, but also present economic feasibility and sustainable pathway for significantly improving battery performance and addressing global resource challenges via integration with the hydrometallurgical recycling process.

25 ENERGY STORAGE↗

Fuel recycling control in long pulse operation with full tungsten divertors in EAST tokamak

Fuel recycling control in long pulse discharges is studied in EAST tokamak with tungsten divertors by particle balance. Double null configuration, proper Resonant Magnetic Perturbation (RMP), divertor cryopumps and realtime lithium injection, are all very effective for recycling control. High heating power discharge leads to low recycling due to the enhancement of particle exhausting. High external gas injection is required in a low fuel recycling discharge to keep a constant density, and Dα emission is increased by external injection, therefore a higher Dα emission may indicate low fuel recycling for the same plasma density. Reproducible long pulse discharges of over 100 s with core electron temperature >10 keV, and 1056 s discharge with ~1.5 MW heating power were obtained in the EAST 2021 campaign, fuel recycling was well controlled by divertor cryopumps and realtime lithium injection. The results provide a valuable reference for the high power and long pulse operation in future fusion reactors, such as ITER and CFETR.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Exposure to hazardous substances in Cathode Ray Tube (CRT) recycling sites in France

Highlights: • Chemical risks were assessed in the nine cathode ray tube screens recycling facilities. • The main hazardous agents are dust containing lead, cadmium, barium and yttrium. • Exposure and pollutant levels are described for different operations and processes. • All the operations and processes are concerned by significant levels of pollutants. • We suggest recommendations to reduce chemical risk. - Abstract: The Waste Electrical and Electronic Equipment (WEEE) or e-waste recycling sector has grown considerably in the last fifteen years due to the ever shorter life cycles of consumables and an increasingly restrictive policy context. Cathode Ray Tubes (CRTs) from used television and computer screens represent one of the main sources of e-waste. CRTs contain toxic materials such as lead, cadmium, barium, and fluorescent powders which can be released if recycling of CRTs is not appropriate. Exposure to these harmful substances was assessed in nine workshops where CRT screens are treated. Particulate exposure levels were measured using a gravimetric method and metals were analysed by plasma emission spectrometry. The maximum levels of worker exposure were 8.8 mg/m{sup 3}, 1504.3 μg/m{sup 3}, 434.9 μg/m{sup 3}, 576.3 μg/m{sup 3} and 2894.3 μg/m{sup 3} respectively for inhalable dust, barium, cadmium, lead and yttrium. The maximum levels of airborne pollutants in static samples were 39.0 mg/m{sup 3}, 848.2 μg/m{sup 3}, 698.4 μg/m{sup 3}, 549.3 μg/m{sup 3} and 3437.9 μg/m{sup 3} for inhalable dust, barium, cadmium, lead and yttrium. The most harmful operations were identified, and preventive measures for reducing the chemical risk associated with screen recycling were proposed. Workplace measurements were used to define recommendations for reducing the chemical risks in CRT screens recycling facilities and for promoting the design and development of “clean and safe” processes in emerging recycling channels.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Acetolysis for Epoxy-Amine Carbon Fibre-Reinforced Polymer Recycling

Carbon fibre-reinforced polymers (CFRPs) are used in many applications in the global energy transition, including for lightweighting aircraft and vehicles and in wind turbine blades, shipping containers and gas storage vessels1,2,3,4. Given the high cost and energy-intensive manufacture of CFRPs5,6,7, recycling strategies are needed that recover intact carbon fibres and the epoxy-amine resin components. Here we show that acetic acid efficiently depolymerizes both aliphatic and aromatic epoxy-amine thermosets used in CFRPs to recoverable monomers, yielding pristine carbon fibres. Deconstruction of materials from multiple sectors demonstrates the broad applicability of this approach, providing clean fibres from 2 h reactions. The optimal conditions were scaled to 80.0 g of post-consumer CFRPs, and demonstrative composites were fabricated from the recycled carbon fibres, which were recycled two more times, maintaining their strength throughout. Process modelling and techno-economic analysis, with feedstock cost informed by wind turbine blade waste generation8, indicates this method is cost effective, with a minimum selling price of US$1.50 per kg for recycled carbon fibres whereas life cycle assessment shows process greenhouse gas emissions around 99% lower than virgin carbon fibre production. Overall, this approach could enable recycling of industrial CFRPs as it provides clean, mechanically viable recycled carbon fibres and recoverable resin monomers from the thermoset.

09 BIOMASS FUELS↗

Assessment of the Impact of the Single Stream Recycling on Paper Contamination in Recovery Facilities and Paper Mills

Contaminated recyclables pose one of the largest roadblocks to an effective implementation of a circular economy system. Current knowledge surrounding the effects of various recycling methods on contamination rates is limited, thus preventing effective quantification of contamination effects. This study aims to fill this knowledge gap by assessing the impact of single stream recycling on paper contamination in MRFs and their end-products based on different composition studies conducted by facilities nationwide. This project expects to provide the foundational knowledge that could catalyze significant cost savings and energy consumption at MRFs and paper mills by understanding the levels of inbound and outbound contamination rates in SSR systems. Statistical analysis conducted in this project utilizes the available nationwide inbound and outbound samples collected as part of material composition and audit studies to identify and measure the significance of various factors on the resultant contamination levels. The research results provide benefits to both the recycling industry and its customers by addressing the causes and impact of contamination in recycled products, particularly with the wide applicability of single stream recycling within the United States.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

In-Space Recycler Technology Demonstration

In 2014, a 3D printer was installed and used successfully on the International Space Station (ISS), creating the first additively manufactured part in space. While additive manufacturing is a game changing technology for exploration missions, the process still requires raw feedstock material to fabricate parts. Without a recycling capability, a large supply of feedstock would need to be stored onboard, which negates the logistical benefits of these capabilities. Tethers Unlimited, Inc. (TUI), received a Small Business Innovation Research (SBIR) award to design and build the first In-space Recycler for demonstration aboard the ISS in 2017. To fully test this technology in microgravity, parts will be 3D printed, recycled into reusable filament, and then reprinted into new parts. Recycling scrap into printer filament is quite challenging in that a recycler must be able to handle a large variety of possible scrap configurations and densities. New challenges include: dealing with inevitable contamination of the scrap material, minimizing damage to the molecular structure of the plastic during reprocessing, managing a larger volume of hot liquid plastic, and exercising greater control over the cooling/resolidification of the material. TUI has developed an architecture that addresses these challenges by combining standard, proven technologies with novel, patented processes developed through this effort. Results show that the filament diameter achieved is more consistent than commercial filament, with only minimal degradation of material properties over recycling steps. In May 2016, TUI completed fabrication of a flight prototype, which will ultimately progress to the demonstration unit for the ISS as a testbed for future exploration missions. This capability will provide significant cost savings by reducing the launch mass and volume required for printer feedstock as well as reduce waste that must be stored or disposed.

Recycling↗

The Low-Recycling Lithium Boundary and Implications for Plasma Transport

Pumping of incident hydrogen and impurity ions by lithium enables control of the particle inventory and fueling profile in magnetic-confined plasmas, and may raise the plasma temperature near the wall. As a result, the density gradient is expected to contribute substantially to the free-energy, affecting particle and thermal transport from micro-turbulence which is typically the dominant transport mechanism in high-temperature fusion experiments. Transport in gyrokinetic simulations of density-gradient-dominated profiles is characterized by a small linear critical gradient, large particle flux, and preferential diffusion of cold particles. As a result, the heat flux is below 5/2 or even 3/2 times the particle flux, usually assumed to be the minimum for convection. While surprising, this result is consistent with increasing entropy. Coupled TEM-ITG (ion-temperature- gradient) simulations using ηe = ηi find η = ∇T /∇n∼0.8 maximizes the linear critical pressure gradient, which suggests that experiments operating near marginal ITG stability with larger η would increase the linear critical pressure gradient by transferring free-energy from the temperature gradient to the density gradient. Simulations were performed with profiles predicted for the Lithium Tokamak Experiment (LTX) if ion thermal transport was neoclassical, while electron thermal transport and particle transport were a fixed ratio above the neoclassical level. A robust TEM instability was found for the outer half radius, while the ITG was found to be driven unstable as well during gas puff fueling. This suggests that TEM transport will be an important transport mechanism in high-temperature low-recycling fusion experiments, and in the absence of stabilizing mechanisms, may dominate over neoclassical transport. A diagnostic suite has been developed to measure hydrogen and impurity emission in LTX in order to determine the lower bound on recycling that can be achieved in a small tokamak using solid lithium coatings, assess its dependence on the operating condition of the lithium surface, and evaluate its impact on the discharge. Coatings on the close-fitting stainless-steel substrate produce a significant reduction in recyling, so that the effective particle confinement times are as low as 1 ms. Measurements of particle inventory in the plasma and hydrogen Lyman-α emission indicate that hydrogen recycling at the surface increases as subsequent discharges are performed; nevertheless, strong pumping of hydrogen is observed even after almost double the cumulative fueling is applied that should saturate the lithium coating to the penetration depth of hydrogen ions. Probe measurements show that when external fueling is terminated, the scrape-off-layer of discharges with fresh coatings decays to lower density and rises to higher electron temperature than for discharges with a partially-passivated surface, consistent with reduced edge cooling from recycled particles. Near the end of the discharge, higher plasma current correlates with reduced τp * and hydrogen emission, suggesting that discharges with fresh coatings achieve higher electron temperature in the core. A novel approach using neutral modeling was developed for the inverse problem of determining the distribution of recycled particle flux from PFC surfaces given a large number of emission measurements, revealing that extremely low levels of recycling (Rcore∼0.6 and Rplate∼0.8) have been achieved with solid lithium coatings. Together with impurity emission measurements, modeling suggests that during periods of particularly low electron density, influx of impurities from the walls contributes substantially to the global particle balance.

magnetic confinement↗

Environmental and Economic Implications of Emerging Plastic Recycling Technologies

Recycling will play a crucial role in mitigating plastic pollution and promoting a circular economy for polymers. Quantitative analysis can help guide the optimization and implementation of these plastic management strategies, enabling increased circularity while minimizing costs, energy use, greenhouse gas emissions, and other environmental impacts. This talk will outline the Bio-Optimized Technologies to keep Thermoplastics out of Landfills and the Environment (BOTTLE) Consortium's approach to analysis-guided plastic recycling research. Stringent process modelling, life cycle assessment, and techno-economic analysis are used to benchmark the technical feasibility, environmental impacts, and costs of chemical and biological recycling technologies in comparison to conventional fossil fuel-based plastic manufacturing. Across emerging recycling strategies, several key challenges become apparent - including plastic feedstock pretreatment requirements, high energy or chemical use, and recycled plastic yields and quality - highlighting opportunities for future innovation. Through this consistent and in-depth analysis approach, BOTTLE aims to provide the plastics community with key metrics and insights to drive plastic recycling innovation towards a more sustainable and circular economy.

circular economy↗

Delamination recycling of multilayer plastic films: Solvent-assisted separation pathways and recovery of solid polyolefins

Multilayer plastic films are excellent packaging materials due to the bound layers of multiple polymers, with each different polymer contributing to the film properties. Desirable properties lead to continuously growing demand for multilayer films. Multilayer plastic films are typically single-use and, as such, their increased production and disposal have led to waste management problems. Multilayer films are not currently recyclable primarily due to the multiple bound polymers. This work advances delamination as a recycling process to separate and sequester valuable polymers from multilayer films, facilitating the incorporation of these polymers into the circular economy. We effect delamination in a physical process that preserves targeted polymers as solid film, hence retaining their embodied energy. This work documents three different pathways of inducing delamination of multilayer films, with appropriate solvents disrupting adhesion between adjacent layers or dissolving a minor component of the film in less than an hour and at temperatures below 90°C, and where all initial polyethylene is maintained in its solid form throughout the process and is recovered at high purity. Solvent-based delamination is exemplified on commercial multilayer films with majority polyethylene (PE), and polyethylene terephthalate (PET) or ethylene vinyl alcohol copolymer (EVOH) or nylon also present. Solvent-based delamination is an energy-efficient and environmentally friendly recycling process that improves upon dissolution-precipitation recycling, since delamination involves very little dissolution and no precipitation, and is superior to pyrolysis which breaks down the polymers, while delamination keeps polymer chains intact. Furthermore, delamination recycling can contribute to the sustainable use of multilayer films as they continue to protect our food and medicine.

Chemical Recycling↗

Closed‐Loop Recycling of Poly(pentylene Adipate‐ co ‐Terephthalate) via Amine‐Catalyzed Methanolysis

Advancing circularity through effective chemical recycling strategies is essential for enabling the sustainable use of emerging biodegradable polyesters in film applications. In this context, poly(pentylene adipate-co-terephthalate) with a 40/60 adipate-to-terephthalate ratio (PPeAT60), a significantly stiffer and partially biobased copolyester recently reported by our team, offers improved mechanical performance and processability compared to commercial poly(butylene adipate-co-terephthalate), while providing a platform to evaluate advanced recycling approaches for film applications. Here, this study describes depolymerization of PPeAT60 through amine-catalyzed methanolysis, followed by the repolymerization of the recovered monomers. The resulting repolymerized material exhibited a molar mass distribution, chemical structure, and thermal stability comparable to the virgin polymer, confirming the technical feasibility of the methanolysis-based recycling route. Both polymers displayed nearly identical melting, glass transition, and decomposition temperatures, crystallinity, and modulus, demonstrating full structural and mechanical reproducibility after recycling. Variations in crystallization kinetics, elongation at break, and barrier properties likely arise from trace impurities (<1%) introduced during processing acting as nucleating and stress-inducing agents. Overall, these results demonstrate that PPeAT60 retains its key properties after chemical recycling, establishing methanolysis as a promising platform for recycling of this partially biobased polymer that may be able to replace both conventional polyolefins and PBAT in flexible packaging applications.

09 BIOMASS FUELS↗