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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Recyclable CFRPs with extremely high T g : hydrothermal recyclability in pure water and upcycling of the recyclates for new composite preparation

In recent years researchers have introduced different malleable and/or degradable thermosetting polymers to address the recyclability of traditional thermoset materials. Nonetheless, the mechanical properties and glass transition temperature (T g ) of these polymers are often compromised to achieve the desired depolymerization rate. In this work, a hydrothermally recyclable epoxy/anhydride thermosetting system with superior mechanical performance and high T g (>200 °C) was developed for carbon fiber reinforced plastic (CFRP) applications, using triethanolamine as the co-curing agent and tetraglycidyl methylenedianiline (TGDDM) as the epoxy matrix. The hydrothermal recycling of such cured systems is achieved at relatively low temperature (200 °C) without the addition of a catalyst. This mild recycling process decomposes the recyclable polymer matrix into an oligomer and imparts little damage to the valuable carbon fiber. The recycled carbon fiber and the decomposed polymer resin are reused to prepare a new CFRP. Here, this study has introduced a simple and practical approach for the preparation of recyclable CFRPs with high T g and a pathway for highly efficient closed-loop recycling, which sets up a framework for the future design of sustainable polymer composites.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Mild chemical recycling of carbon fiber-reinforced epoxy composites in aqueous buffers and development of hydrothermally recyclable vitrimer composites from recyclates

Carbon fiber-reinforced polymer (CFRP) composites have gained widespread adoption across diverse industries. However, their inherent stability, stemming from the crosslinked structure of the matrix resin, poses a significant challenge in managing the growing volume of CFRP waste. Consequently, there is a pressing need for an eco-friendly upcycling method that effectively recovers and reuses both the valuable carbon fibers and the polymer matrix from CFRP waste. This study presents a novel approach for upcycling CFRP waste under environmentally friendly conditions. Firstly, CFRP waste with an amine-cured epoxy matrix was completely decomposed in aqueous buffer solutions under mild conditions (≤ 220 °C, pH = 4.8). Further, decomposed matrix polymer (DMP) was employed to transform conventional epoxy resins into recyclable vitrimers. Lastly, new composites that can be hydrothermally recycled were fabricated using both DMP and recovered carbon fibers. As a result, this work proposes a novel strategy for achieving a circular economy within the CFRP industry.

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

Life Cycle Assessment of Recycling High-Density Polyethylene Plastic Waste

Increasing production and use of various novel plastics products, a low recycling rate, and lack of effective recycling/disposal methods have resulted in an exponential growth in plastic waste accumulation in landfills and in the environment. To better understand the effects of plastic waste, Life Cycle Analysis (LCA) was done to compare the effects of various production and disposal methods. LCA shows the specific effects of the cradle-to-grave or cradle-to-cradle scenarios for landfill, incineration, and mechanical recycling. The analysis clearly indicates that increasing recycling of plastics can significantly save energy and eliminate harmful emissions of various carcinogens and GHGs into the environment. As recycling increases, the need for virgin-plastic production can be greatly reduced. Furthermore, the results of this study may help improve current mechanical recycling processes as well as potential future recycling methods, such as chemical recycling. Concerns about the current recycling/disposal methods for plastics have brought increasing attention to the waste accumulation problem. However, with the current COVID-19 pandemic, plastic accumulation is expected to increase significantly in the near future. A better understanding of the quantitative effects of the various disposal methods can help guide policies and future research toward effective solutions of the plastic waste problem.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Hygrothermal aging and recycling effects on mechanical and thermal properties of recyclable thermoplastic glass fiber composites

Abstract Glass fiber‐reinforced polymer composites are widely used in marine applications, including renewable energy devices and submarines, due to their strength‐to‐weight ratios and corrosion resistance. As sustainability becomes more important, recyclable thermoplastic composites are gaining attention in marine energy applications. These materials face harsh conditions such as high chloride water, UV radiation, pressurization, and thermal cycling, which can affect their durability and recyclability. This study examines the impact of hygrothermal aging on the recyclability of an Elium glass fiber (GF) composite. Samples were mechanically ground for recycling, and mechanical and thermal properties were compared between aged and unaged samples. After seawater aging, the tensile strength and modulus of the unaged composite dropped by 25% and 13% respectively, due to water ingress along the fiber‐matrix interface. The recycled composite showed reduced flexural strength as the long fiber composite was converted into short fibers during the process. Differential scanning calorimetry (DSC) revealed no change in glass transition temperature after aging. Weight loss (25%) was attributed to the thermal stability of the glass fibers. Dynamic mechanical analysis (DMA) showed that the storage modulus increased with aging, and fracture analysis confirmed a mixed mode of failure for aged composites. Highlights Hygrothermal aging lowers mechanical performance of Elium® GF composites. Failure mechanism tends to be matrix cracking and interface bonding. Glass transition temperature is not reduced by hygrothermal aging. Fractured composite was successfully recycled via thermoforming. Flexural strength of the recycled composite is lower.

17 WIND ENERGY↗
DOE OSTI2019

Recycling of Dilute Deacetylation Black Liquor to Enable Efficient Recovery and Reuse of Spent Chemicals and Biomass Pretreatment Waste

Previous publications showed deacetylation/dilute alkaline pretreatment followed by mechanical refining (DMR) is an effective process for overcoming biomass recalcitrance. To successfully commercialize alkaline-based pretreatments, we pioneered a new process modification and strategy to recycle and reuse the weak black liquor (WBL) to reduce water, chemical, and energy usage while increasing the solids, sodium, acetate, sugars, and lignin contents in the weak black liquor. Our results suggest that the accumulation of both chemicals and organic matter did not reduce acetyl and lignin removal in alkaline pretreatment, resulting in comparable sugar yields in enzymatic hydrolysis. Sodium and potassium were found to be the two most important inorganic substances in the recycled weak black liquor. Moreover, the accumulated sodium and phenolic compounds did not inhibit the downstream fermentation and ethanol fermentation processes. Finally, techno-economic analysis (TEA) showed the recycling of weak black liquor could decrease the minimum ethanol selling price (MESP) by approximately 5 to 15 cents per gallon of ethanol when compared to a conventional non-recycling process. solids, sodium, acetate, sugars, and lignin contents in the weak black liquor. Our results suggest that the accumulation of both chemicals and organic matter did not reduce acetyl and lignin removal in alkaline pretreatment, resulting in comparable sugar yields in enzymatic hydrolysis. Sodium and potassium were found to be the two most important inorganic substances in the recycled weak black liquor. Moreover, the accumulated sodium and phenolic compounds did not inhibit the downstream fermentation and ethanol fermentation processes. Finally, techno-economic analysis (TEA) showed the recycling of weak black liquor could decrease the minimum ethanol selling price (MESP) by approximately 5 to 15 cents per gallon of ethanol when compared to a conventional non-recycling process.

09 BIOMASS FUELS↗
DOE OSTI2017

Fed-batch hydrolysate addition and cell separation by settling in high cell density lignocellulosic ethanol fermentations on AFEX™ corn stover in the Rapid Bioconversion with Integrated recycling Technology process

Abstract The Rapid Bioconversion with Integrated recycling Technology (RaBIT) process uses enzyme and yeast recycling to improve cellulosic ethanol production economics. The previous versions of the RaBIT process exhibited decreased xylose consumption using cell recycle for a variety of different micro-organisms. Process changes were tested in an attempt to eliminate the xylose consumption decrease. Three different RaBIT process changes were evaluated in this work including (1) shortening the fermentation time, (2) fed-batch hydrolysate addition, and (3) selective cell recycling using a settling method. Shorting the RaBIT fermentation process to 11 h and introducing fed-batch hydrolysate addition eliminated any xylose consumption decrease over ten fermentation cycles; otherwise, decreased xylose consumption was apparent by the third cell recycle event. However, partial removal of yeast cells during recycle was not economical when compared to recycling all yeast cells.

Sarks, Cory↗
DOE OSTI2020

Fast Determination of Lithium Content in Spent Cathodes for Direct Battery Recycling

Determination of the lithium ion content in cathode materials, which is currently performed by inductively coupled plasma mass spectrometry (ICP-MS), involves tedious procedures and error-prone preparation. This work introduces a new methodology to quickly determine the lithium content in spent cathode materials (LiNix Mny Coz O2, x + y + z = 1, NMC) using a thermalgravimetric analysis, which bypasses the use of ICP-MS and significantly reduces the cost and time required for determining the lithium content. Based on this new method, a new approach is developed to identify spent cathode materials suitable for direct relithiation recycling. Finally, these new methods have been applied to investigate the effectiveness of direct electrochemical-relithiation on recycling the spent cathodes, and provide insights for future development of direct battery materials recycling.

cathode recycling↗
DOE OSTI2018

Benzimidazoles as Metal-Free and Recyclable Hydrides for CO 2 Reduction to Formate

We report a novel metal-free chemical reduction of CO 2 by a recyclable benzimidazole-based organo-hydride, whose choice was guided by quantum chemical calculations. Notably, benzimidazole-based hydride donors rival the hydride-donating abilities of noble-metal-based hydrides such as [Ru(tpy)(bpy)H] + and [Pt(depe) 2 H] + . Chemical CO 2 reduction to the formate anion (HCOO–) was carried out in the absence of biological enzymes, a sacrificial Lewis acid, or a base to activate the substrate or reductant. 13 CO 2 experiments confirmed the formation of H 13 COO – by CO 2 reduction with the formate product characterized by 1H NMR and 13C NMR spectroscopy and ESI-MS. The highest formate yield of 66% was obtained in the presence of potassium tetrafluoroborate under mild conditions. The likely role of exogenous salt additives in this reaction is to stabilize and shift the equilibrium toward the ionic products. After CO 2 reduction, the benzimidazole-based hydride donor was quantitatively oxidized to its aromatic benzimidazolium cation, establishing its recyclability. In addition, we electrochemically reduced the benzimidazolium cation to its organo-hydride form in quantitative yield, demonstrating its potential for electrocatalytic CO 2 reduction. These results serve as a proof of concept for the electrocatalytic reduction of CO 2 by sustainable, recyclable, and metal-free organo-hydrides.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

On a burning plasma low recycling regime with P DT = 23–26 MW, Q DT = 5–7 in a JET-like tokamak

The recent invention of a continuously flowing liquid lithium system, called 24/7-FLiLi, opens the opportunity to design a plasma pumping divertor which can significantly suppress plasma edge cooling by recycling. The paper describes the expected performance of deuterium–tritium burning plasma with low recycling using a tokamak of JET size, magnetic field and plasma current as an example. So far, only the technological aspects of flowing lithium have been tested on the HT-7 and EAST tokamaks (ASIPP, Hefei, China) with no attempts to create the low recycling regime. The compatibility of 24/7-FLiLi with tokamak plasma was confirmed and some mistakes in the design were revealed, thus, requiring another fabrication approach. Now, with the proper design of the Li system, recycling as low as 0.5 seems to be achievable. The suppression of plasma cooling by recycling in combination with neutral beam injection (NBI) for core plasma fueling by energetic particles automatically leads to ‘the best possible confinement regime’, uniquely compatible with burning plasma. This paper outlines the conceptual details of the 24/7-FLiLi divertor for a JET size tokamak. The main focus is in regard to the physics of the low recycling regime as well as to the expected performance of the burning plasma. In comparison with the results of 1994 on TFTR and 1997 on JET, the projected performance is astonishing: fusion power P DT = 23–26 MW, fusion efficiency Q DT = 5.7 – 6.4, tritium burn up 7.8%–8.7% with modest NBI power P NBI = 4 MW, and energy E NBI = 120 keV. Furthermore, this new regime could resolve the outstanding plasma physics issues related to burning plasma that are unsolvable with the currently dominant approach.

24/7-FLiLi↗
DOE OSTI2025

Enabling Partnership between South Carolina and NREL for Advancing Opportunities in Plastics Recycling Research (EPSCOR for Plastics Recycling)

Proposal Objectives: 1. Utilize depolymerization/fractionation techniques to recover highly processable and reactive feedstocks for polymer synthesis from lignin. 2. Synthesize lignin‐derived non‐isocyanate polyurethane, epoxy, and polyamide using non‐ toxic, biobased route designed for chemical recycling. Characterize resulting materials. 3. Design a high‐yielding chemical recycling process for as‐synthesized materials yielding usable building blocks for many generations of polymer synthesis. 4. Optimize chemical recycling of PET waste for the synthesis of lignin‐based polymers. Compare properties to commercial materials. 5. Optimize reaction conditions and recycling steps to facilitate enhanced sustainability of the synthetic steps and final properties of materials. 6. Complete a lifecycle assessment of lignin utilization and chemical recycling to compare their environmental performance to that of materials produced from virgin material. Identify hot spots and benefits using the chemical recycling process.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A direct recycling case study from a lithium-ion battery recall

Direct recycling of lithium-ion is a promising method for manufacturing sustainability. It is more efficient than classical methods because it recovers the functional cathode particle without decomposition into substituent elements or dissolution and precipitation of the whole particle. This case study of cathode-healing™ applied to a battery recall demonstrates an industrial model for recycling of lithium-ion, be it consumer electronic or electric vehicle (EV) batteries. The comprehensive process includes extraction of electrolyte with carbon dioxide, industrial shredding, electrode harvesting, froth flotation, cathode-healing™ and finally, building new cells with recycled cathode and anode. The final products demonstrated useful capability in the first full cells made from direct recycled cathodes and anodes from an industrial source. The lessons learned on recycling the prototypical chemistry are preliminarily applied to EV relevant chemistries.

Sloop, Steve↗
DOE OSTI2022

A New Recycled Al–Si–Mg Alloy for Sustainable Structural Die Casting Applications

The use of secondary aluminum for structural components in the automotive industry is limited by the high Fe contents in recycled alloys which often result in the formation of brittle β-Al 5 FeSi phase which reduces the ductility of aluminum castings. In this study, a new secondary Al-Si-Mg alloy with high Fe content (about 0.44 wt.%) was developed for die casting applications. Based on thermodynamic modeling, manganese was added to obtain a designed Fe-to-Mn ratio of 2 which successfully suppressed the formation of β-Al 5 FeSi phase, by forming α-Al 15 (Fe,Mn) 3 Si 2 phase with rounded or hexagonal morphology. Additionally, a fine needle-like π-Al 8 FeMg 3 Si 2 phase was also formed within the eutectic regions. The new recycled alloy showed comparable mechanical properties in as-cast and heat treated (T5 and T6) conditions to three major primary die cast alloys (≤ 0.2 wt.% Fe) with similar composition. Ductility up to 7.4% from tensile elongation was achieved in as-cast recycled alloy due to the modification and refinement of α-Al 15 (Fe,Mn) 3 Si 2 by Mn and Sr additions. Tensile elongation was further improved to 9.1% after T6 treatment as a result of dissolution of π-Al 8 FeMg 3 Si 2 phase, defragmentation of α-Al 15 (Fe,Mn) 3 Si 2 and the spheroidization of Si phase. This new alloy provides a promising path for increasing usage of recycled aluminum with high Fe content in structural die castings for automotive and other applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Contribution of Tibetan Plateau ecosystems to local and remote precipitation through moisture recycling

The ecosystems of the Tibetan Plateau (TP) provide multiple important ecosystem services that benefit both local populations and those beyond, such as through climate regulation services on precipitation for East Asia and China. However, the precipitation regulation service of the TP ecosystems for supplying moisture and maintaining precipitation is yet to be evaluated. In this study, we used the moisture recycling framework and a moisture tracking model to quantify the precipitation regulation services of TP ecosystems for their contribution to precipitation. We found TP ecosystems contributed substantially to local and downwind precipitation, with a declined contribution from 221 mm/year for the TP and neighboring areas, to <10 mm/year for eastern China and other surrounding countries. Among ecosystem types, grassland contributed most to precipitation, followed by barren and snow lands, forests, and shrublands. In terms of seasonality, precipitation contribution from TP ecosystems was greater in summer months than in non-summer months for western China, while the opposite was true for eastern China – though the magnitude was much smaller. Over the past two decades, the significant evapotranspiration increases in TP translated to a widespread increase in precipitation contribution for TP and downwind beneficiary regions from 2000 to 2020. Our study provides a quantitative way to understand the precipitation regulation services of TP ecosystems through moisture recycling, substantiating their key role to safeguard precipitation and the water cycle for downwind regions– effectively acting as an ecological security shelter that could be perceived by the public.

Li, Yan↗