Critical Materials Recovery – Electrochemical Recovery
Critical Materials Recovery - Electrochemical Recovery research at Idaho National Laboratory.
36 MATERIALS SCIENCE↗
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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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Critical Materials Recovery – Solvent Extraction
Critical Materials Recovery - Solvent Extraction research at Idaho National Laboratory.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Critical Materials Recovery – Supercritical Fluids
Critical Materials Recovery - Supercritical Fluids research at Idaho National Laboratory.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Evaluation of performance indicators applied to a material recovery facility fed by mixed packaging waste
Highlights: • Material Flows assessment of a Material Recovery Facility has been realized. • Performance Indicators for a generic MRF have been proposed. • A Dashboard has been utilized to measure the facility performance. • Experimental values of incoming waste and output products composition are reported. - Abstract: Most of the integrated systems for municipal solid waste management aim to increase the recycling of secondary materials by means of physical processes including sorting, shredding and reprocessing. Several restrictions prevent from reaching a very high material recycling efficiency: the variability of the composition of new-marketed materials used for packaging production and its shape and complexity are critical issues. The packaging goods are in fact made of different materials (aluminium, polymers, paper, etc.), possibly assembled, having different shape (flat, cylindrical, one-dimensional, etc.), density, colours, optical properties and so on. These aspects limit the effectiveness and efficiency of the sorting and reprocessing plants. The scope of this study was to evaluate the performance of a large scale Material Recovery Facility (MRF) by utilizing data collected during a long period of monitoring. The database resulted from the measured data has been organized in four sections: (1) data related to the amount and type of inlet waste; (2) amount and composition of output products and waste; (3) operating data (such as worked hours for shift, planned and unscheduled maintenance time, setting parameters of the equipment, and energy consumption for shift); (4) economic data (value of each product, disposal price for the produced waste, penalty for non-compliance of products and waste, etc.). A part of this database has been utilized to build an executive dashboard composed by a set of performance indicators suitable to measure the effectiveness and the efficiency of the MRF operations. The dashboard revealed itself as a powerful tool to support managers and engineers in their decisions in respect to the market demand or compliance regulation variation as well as in the designing of the lay-out improvements. The results indicated that the 40% of the input waste was recovered as valuable products and that a large part of these (88%) complied with the standards of the recycling companies. The evaluation of the indicators led to the decision to modify the layout to improve the interception of some polymers for which the performance indicators were poor. In particular, two additional optical sorters have to be inserted to increase the yield indicator and to the overall performance of the facility. Definitely, the results of the work allowed to: increase the yield and purity of products’ flows; ensure the compliance of waste flows; increase the workability.
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Techno-Economic and life cycle assessment of standalone Single-Stream material recovery facilities in the United states
Material Recovery Facilities (MRFs) are crucial players in achieving a circular economy. MRFs receive complex waste streams and separate valuable recyclables from these mixtures. This study conducts techno-economic analysis (TEA) to estimate the net present value (NPV) and life cycle assessment (LCA) to estimate different environmental impacts of a commercial scale standalone, single-stream MRF to assess the economic feasibility and environmental impacts of recovering valuable recyclables from an MRF processing 120,000 tonnes per year (t/y). The TEA employs a discounted cash flow rate of return (DCFROR) analysis over a 20-year facility lifetime, along with a sensitivity analysis on the impact of different operating and economic parameters. Results show that the total fixed cost of building the MRF facility is $\$ $23 MM, and the operating cost is $\$ $45.48/tonne. Further the NPV of the MRF can vary from $\$ $3.57 MM to $\$ $60 MM, while 100-year global warming potential can range from 5.98 to 8.53 kg carbon dioxide equivalents (CO2-eq) per tonne of MSW. We have also found that MSW composition (arising from regional effects) significantly impacts costs, 100-year global warming potential, and other impact categories such as acidification potential, eutrophication potential, ecotoxicity, ozone depletion, photochemical oxidation, carcinogenic effects, and non-carcinogenic effects. Sensitivity and uncertainty analysis indicate that waste composition and market prices significantly impact the profitability of the MRF, and the waste composition mostly impacts global warming potential. Our analysis also indicates that facility capacity, fixed capital cost, and waste tipping fees are vital parameters that affect the economic viability of MRF operations.
36 MATERIALS SCIENCE↗
Critical Materials Recovery – Metal Oxide Reduction
Critical Materials Recovery - Metal Oxide Reduction research at Idaho National Laboratory.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Analysis of material recovery facilities for use in life-cycle assessment
Highlights: • Life-cycle assessment of solid waste management relies on accurate process models. • Material recovery facility (MRF) processes were modeled with new primary data. • Single stream, dual stream, pre-sorted, and mixed waste MRFs were considered. • MRF electricity consumption ranges from 4.7 to 7.8 kW h per Mg input. • Total cost ranges from $19.8 to $24.9 per Mg input. - Abstract: Insights derived from life-cycle assessment of solid waste management strategies depend critically on assumptions, data, and modeling at the unit process level. Based on new primary data, a process model was developed to estimate the cost and energy use associated with material recovery facilities (MRFs), which are responsible for sorting recyclables into saleable streams and as such represent a key piece of recycling infrastructure. The model includes four modules, each with a different process flow, for separation of single-stream, dual-stream, pre-sorted recyclables, and mixed-waste. Each MRF type has a distinct combination of equipment and default input waste composition. Model results for total amortized costs from each MRF type ranged from $19.8 to $24.9 per Mg (1 Mg = 1 metric ton) of waste input. Electricity use ranged from 4.7 to 7.8 kW h per Mg of waste input. In a single-stream MRF, equipment required for glass separation consumes 28% of total facility electricity consumption, while all other pieces of material recovery equipment consume less than 10% of total electricity. The dual-stream and mixed-waste MRFs have similar electricity consumption to a single-stream MRF. Glass separation contributes a much larger fraction of electricity consumption in a pre-sorted MRF, due to lower overall facility electricity consumption. Parametric analysis revealed that reducing separation efficiency for each piece of equipment by 25% altered total facility electricity consumption by less than 4% in each case. When model results were compared with actual data for an existing single-stream MRF, the model estimated the facility’s electricity consumption within 2%. The results from this study can be integrated into LCAs of solid waste management with system boundaries that extend from the curb through final disposal.
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Material Recovery and Waste Form Development FY 2015 Accomplishments Report
The Material Recovery and Waste Form Development (MRWFD) Campaign under the U.S. Department of Energy (DOE) Fuel Cycle Technologies (FCT) Program is responsible for developing advanced separation and waste form technologies to support the various fuel cycle options defined in the DOE Nuclear Energy Research and Development Roadmap, Report to Congress, April 2010. The FY 2015 Accomplishments Report provides a highlight of the results of the research and development (R&D) efforts performed within the MRWFD Campaign in FY-14. Each section contains a high-level overview of the activities, results, technical point of contact, applicable references, and documents produced during the fiscal year. This report briefly outlines campaign management and integration activities, but primarily focuses on the many technical accomplishments made during FY-15. The campaign continued to utilize an engineering driven-science-based approach to maintain relevance and focus. There was increased emphasis on development of technologies that support near-term applications that are relevant to the current once-through fuel cycle.
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Techno-economics of hydrocarbon fuel production and recyclables recovery from landfill-destined municipal solid waste: AI-enhanced materials recovery facility design
Sustainable aviation fuels (SAF) production from cellulosic paper fractions of municipal solid waste (MSW) destined for landfills has strong potential to advance environmental, social, and economic sustainability across the aviation and waste sectors. This study proposes an artificial intelligence-enabled material recovery facility (AI-MRF) design to efficiently characterize, separate, process, and convert recovered paper waste from MSW into intermediate chemicals and SAF. The AI-MRF, designed to process 233,091 metric tons of MSW annually, integrates smart manufacturing technologies including AI, visual and hyperspectral imaging, multi-sensor data, and traditional sorting systems. Well-characterized and sorted cellulosic paper waste was utilized for chemical and fuel production scenarios, while clean plastics, metals, and glass were considered for recycling. Conversion of paper waste into intermediate sugars achieved a net present value (NPV) of up to $\$67$ million. For sugar-to-SAF production scenarios, the minimum fuel selling price (MFSP) was calculated at $\$6.11$ per gasoline gallon equivalent (GGE) when excluding recyclable revenue, and $\$4.03$ per GGE when halving recyclable revenue. The MFSP was further reduced to $\$1.96$ per GGE when accounting for SAF sales and recyclables. Nationally, this approach could yield about 2 billion GGE of hydrocarbon fuel annually from available MSW in the United States.
09 BIOMASS FUELS↗
Preliminary Mark-18A (Mk-18A) Target Material Recovery Program Product Acceptance Criteria
The Mk-18A Target Material Recovery Program (MTMRP) was established in 2015 to preserve the unique materials, e.g. 244 Pu, in 65 previously irradiated Mk-18A targets for future use. This program utilizes existing capabilities at SRS and Savannah River National Laboratory (SRNL) to process targets, recover materials from them, and to package the recovered materials for shipping to ORNL. It also utilizes existing capabilities at ORNL to receive and store the recovered materials, and to provide any additional processing of the recovered materials or residuals required to prepare them for future beneficial use. The MTMRP is presently preparing for the processing of these valuable targets which is expected to begin in ~2019. As part of the preparations for operations, this report documents the preliminary acceptance criteria for the plutonium and heavy curium materials to be recovered from the Mk-18A targets at SRNL for transport and storage at ORNL. These acceptance criteria were developed based on preliminary concepts developed for processing, transporting, and storing the recovered Mk-18A materials. They will need to be refined as these concepts are developed in more detail.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Prioritizing material recovery for end-of-life printed circuit boards
Highlights: Black-Right-Pointing-Pointer Material recovery driven by composition, choice of ranking, and weighting. Black-Right-Pointing-Pointer Economic potential for new recycling technologies quantified for several metrics. Black-Right-Pointing-Pointer Indicators developed for materials incurring high eco-toxicity costs. Black-Right-Pointing-Pointer Methodology useful for a variety of stakeholders, particularly policy-makers. - Abstract: The increasing growth in generation of electronic waste (e-waste) motivates a variety of waste reduction research. Printed circuit boards (PCBs) are an important sub-set of the overall e-waste stream due to the high value of the materials contained within them and potential toxicity. This work explores several environmental and economic metrics for prioritizing the recovery of materials from end-of-life PCBs. A weighted sum model is used to investigate the trade-offs among economic value, energy saving potentials, and eco-toxicity. Results show that given equal weights for these three sustainability criteria gold has the highest recovery priority, followed by copper, palladium, aluminum, tin, lead, platinum, nickel, zinc, and silver. However, recovery priority will change significantly due to variation in the composition of PCBs, choice of ranking metrics, and weighting factors when scoring multiple metrics. These results can be used by waste management decision-makers to quantify the value and environmental savings potential for recycling technology development and infrastructure. They can also be extended by policy-makers to inform possible penalties for land-filling PCBs or exporting to the informal recycling sector. The importance of weighting factors when examining recovery trade-offs, particularly for policies regarding PCB collection and recycling are explored further.
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Material Recovery and Waste Form Development Strategic Plan
The Material Recovery and Waste Form Development Strategic Plan describes the strategy for the MRWFD Campaign in DOE NE-43.
Arm, Stuart T.↗
Material Recovery Facilities (MRFs) in the United States: Operations, revenue, and the impact of scale
An analysis was conducted using nationwide survey data to evaluate how material recovery facilities (MRFs) operations vary regionally and with scale. The survey characterized materials, processes, and energy use involved with operations, and revenue for recyclables. This is the first nationwide analysis of MRFs in the US that accounts for mass processed, energy consumed, and revenue. Of a population of 521 MRFs, 48 responses representing MRFs from five US regions were received and analyzed (9.2 % response rate). Responses were analyzed by size according to yearly mass of inbound materials (small: <1,000 Mg/year, medium: 1,000–10,000 Mg/year, and large: >10,000 Mg/year). Most MRFs identify as single-stream; source from residences; utilize tipping floors, picking lines, baling and warehousing; and are powered by electricity. Most revenue and inbound mass (>50%) came from fiber (cardboard and paper). Glass had little revenue, and plastics were difficult to transition to market. Percent residue ranged from 1-39%, averaged <20%, and increased as the mass of inbound material increased. Large MRFs reported more sources of material, employed advanced sorting technology, had greater plastics revenue (33% versus 5% for small MRFs), and had more market access for plastics compared to small MRFs. Large MRFs had two orders of magnitude less annual electricity consumption per Mg recyclables than small MRFs (5–90 kWh/Mg versus ∼300–550 kWh/Mg). Results demonstrate environmental and economic benefits of larger-scale MRFs, which could be implemented more broadly in the US through regional hub-and-spoke arrangements for collecting and processing recyclables, lowering energy consumption and increasing revenue for recyclables.
Hub-and-Spoke↗
Experiments for Satellite and Material Recovery from Orbit. Volume III - Experiment Missions Final Report
Experiment missions for OSO satellite rendezvous, capture, material recovery, refurbishment, and extravehicular operation work
SATELLITE RENDEZVOUS↗
Environmental performances of different configurations of a material recovery facility in a life cycle perspective
Highlights: • An attributional LCA assessed the environmental performances of an integrated MRF. • Different configurations of the MRF technological evolution have been analysed. • Reliable data provide a large LCI table for all the configurations and each sub-units. • A biological treatment in-situ improves the potentials of land occupation and global warming. • The inclusion of a small-scale gasifier could improve almost all the environmental potentials. - Abstract: The study evaluated the environmental performances of an integrated material recovery facility (MRF) able to treat 32 kt/y of unsorted mixed waste, made of residuals from household source separation and separate collection. The facility includes a mechanical sorting platform for the production of a solid recovered fuel (SRF) utilized in an external waste-to-energy plant, bio-cells for tunnel composting of organic fraction, and a sanitary landfill for the safe disposal of ultimate waste. All the MRF sub-units have been analysed in depth in order to acquire reliable data for a life cycle assessment study, focused on the environmental performances of different configurations of the facility. The study investigated a “past” configuration, including just mechanical sorting, landfilling and biogas combustion in a gas engine, and the “present” one, which includes also a composting unit. Two possible “future” configurations, having a gasifier inside the MRF battery limits, have been also analysed, assessing the performances of two fluidized bed reactors of different size, able to gasify only the residues generated by the sorting platform or the whole amount of produced SRF, respectively. The analysis evaluated the contributions of each unit in the different configurations and allowed a reliable assessment of the technological evolution of the facility. The results quantified the positive effect of the inclusion of an aerobic treatment of the waste organic fraction. The SRF gasification in situ appears to improve the MRF environmental performances in all the impact categories, with the exclusion of that of global warming.
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Downhole fluid injection systems, CO 2 sequestration methods, and hydrocarbon material recovery methods
Downhole fluid injection systems are provided that can include a first well extending into a geological formation, and a fluid injector assembly located within the well. The fluid injector assembly can be configured to inject a liquid CO 2 /H 2 O-emulsion into the surrounding geological formation. CO 2 sequestration methods are provided that can include exposing a geological formation to a liquid CO 2 /H 2 O-emulsion to sequester at least a portion of the CO 2 from the emulsion within the formation. Hydrocarbon material recovery methods are provided that can include exposing a liquid CO 2 /H 2 O-emulsion to a geological formation having the hydrocarbon material therein. The methods can include recovering at least a portion of the hydrocarbon material from the formation.
54 ENVIRONMENTAL SCIENCES↗
Life cycle cost assessment of material recovery from perovskite solar cells
Perovskite photovoltaic (PV) cells have created a significant interest over the last few years due to their low-cost and high-power conversion efficiencies. While perovskite PVs are still under development, we analyze cost of alternative sustainable end-of-life management for perovskite PV cells; this allows to reuse economically valuable materials and prevent environmental contamination. Here, we studied the life cycle cost assessment of recovering metals such as lead, aluminum, gold, nickel, and silver and other valuable materials such as glass from waste perovskite PVs. We also developed a recycling scheme to optimize the material recovery and determine the economically feasible ways to separate the cells layer-by-layer. Further, we assessed the cost and the net cost of the perovskite PV recycling processes. We found that the most feasible recycling technique’ cost is $\$$10.70 and its net cost is $\$$– 2.95 per 1 m 2 module. These values could be further improved by optimizing and reusing chemicals involved in process. These results indicate that the cost of perovskite PV recycling is economically feasible and there is potentional to gain benefit from sustainable end-of-life management of perovskite PVs.
14 SOLAR ENERGY↗
Evaluation of mixed #3–7 plastic waste from material recovery facilities (MRFs) in the United States
Plastic recycling rates are still low in the United States (U.S.), with less than 10% of municipal solid waste (MSW) plastic being recycled. Most unrecycled plastics are identified by Resin Identification Codes (RIC) from #3–7, which are commonly destined for landfill or waste-to-energy facilities (WTE). Therefore, the composition and quality of outbound bales containing #3–7 plastics were assessed to understand the potential to increase recycling rates. Three bales were sourced from three different Material Recovery Facilities (MRFs) located in the United States. Each bale was manually sorted and characterized for quality and performance via multiple plastic characterization techniques. Considerable differences in bale composition were observed between MRFs, which correlated with the technology used by each MRF in the sorting process. The differences were substantial in the residual levels of poly(ethylene terephthalate) (PET) and high-density polyethylene (HDPE), which are highly desired for mechanical recycling processes and not expected in #3–7 plastics bales. Traditional recycling processes including washing, extrusion, and injection molding of the sorted material were employed prior to the physical, thermal, and molecular characterization. Despite differences in bale composition by plastic type, some polymer properties were similar across MRFs. Here, this research suggests that landfill-diverted mixed plastic waste can be utilized in the mechanical recycling of currently unrecycled materials, as processes can be designed to work with consistent polymer properties. It also highlights the need to upgrade the sorting systems to prevent waste feedstocks, which can be recycled with current technologies, from contaminating other plastic streams or reach landfills.
36 MATERIALS SCIENCE↗