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DOE OSTI2026

A Reverse Logistics Tool For Ev Battery Recycling And Repurposing,

The demand for electric vehicles (EVs) in the United States is projected to rise significantly, with sales expected to reach approximately 4.1 million units by 2030. However, the U.S. remains heavily reliant on imports for the batteries and critical raw materials—such as lithium, cobalt, and nickel—that power these vehicles. As of 2024, around 70% of these imports originate from China. This dependency has become even more precarious following China’s imposition of export restrictions in April 2025, a retaliatory move against U.S. tariffs. These developments highlight the strategic vulnerabilities posed by China’s dominant position in the critical materials market. Compounding the issue, decades of intensive extraction have severely depleted global reserves of critical materials, widening the gap between supply and growing demand. This situation underscores the urgent need for the U.S. and other nations to diversify their sources of critical materials and enhance domestic capabilities to secure these resources—an essential step toward ensuring long-term energy security. At the end of their lifecycle—whether due to the battery’s degradation or the retirement of the vehicle—EV batteries are often improperly disposed of or sent to landfills. However, many of these batteries still retain usable capacity and can follow one of three alternative pathways: (a) Re-used: deployed in another vehicle with a shorter driving range, (b) Re-purposed: utilized act as a backup storage/power for data centers, solar panels, and e-scotters or (c) Recycled: broken down to recover the critical materials. To that end, the proposed tool (REBORN) is designed to optimize the reverse logistics network for battery repurposing and recycling. Its goal is to minimize associated costs while identifying optimal locations for battery collection and processing. Ultimately, REBORN ensures that each battery is used to its fullest potential.

Srinivas, SrikarV. [Idaho National Laboratory (INL↗

DOE OSTI2025

Single-Bunch Instabilities at the Fermilab Recycler Ring

Understanding and characterizing collective instabilities is critical for high-intensity operation at the Fermilab Recycler Ring. This work presents an application of the the Nested Head-Tail (NHT) formalism for modeling single-bunch transverse instabilities, incorporating analytical solutions to the resistive wall impedances in the absence of space charge. Predicted growth rates and mode structures are benchmarked against PyHEADTAIL simulations and ongoing experimental measurements. The experimental program includes studies of bare-machine instabilities at different machine parameters. These results support the understanding of naturally-occurring instabilities in the Recycler and contribute to the development of predictive tools for beam stability in future high-intensity configurations.

Gonzalez-Ortiz, C. [Fermilab]↗

DOE OSTI2025

Single-Bunch Instabilities at the Fermilab Recycler Ring

Gonzalez-Ortiz, Cristhian [Fermilab]↗

DOE OSTI2025

Economic Analysis of the NIF Optics Recycle Loop Systems Investment Options: SAE 560 - Economic Considerations for Systems Engineering at University of Southern California

The National Ignition Facility (NIF) relies on large-scale precision optics to deliver high-energy laser pulses for fusion and high-energy-density physics research; however, the NIF routinely operates above the damage threshold for those optics, decreasing their effectiveness with every experiment. A production line composed of several dozen highly specialized processing systems, collectively referred to as the ‘optics recycle loop’, was established to support refurbishment and re-use of these critical components to reduce reliance on high-cost and high-risk optic replacement strategies. This analysis aims to identify the most cost-effective investment options for improving recycle loop throughput by maximizing availability and production flexibility while minimizing the engineering and infrastructure efforts and cost.

42 ENGINEERING↗

DOE OSTI2025

Total Recycling of Copper Cable Scrap and Production of Carbon Using Fast Microwave Technology

The recycling of cable scrap, particularly from discarded electrical wiring, is gaining significant attention due to the rising demand for copper and the need for sustainable management of electronic waste. Traditionally, mechanical and thermal processings have been used to recover copper and plastic from cables. However, these approaches are often energy-intensive, time-consuming, and costly in terms of equipment and labor. In this study, we present a simple and effective method for recovering materials from cable scrap using a domestic microwave oven. Cable pieces (2–2.5 cm long) were exposed to 700 W of microwave irradiation under rotation for 30 s, enabling the rapid and efficient separation of high-quality copper metal from the core wire, and activated carbon from the carbonized plastic sheath. Microwaves facilitate this process through Ohmic heating, which induces electrical resistance in the metal, generating heat that mechanically loosens the metal and carbonized plastic components. The process demonstrates high efficiency, achieving an 80% reduction in energy consumption compared to conventional processings. This fast and energy-efficient method shows strong potential for scaling up to industrial recycling, offering a cost-effective and environmentally friendly way to recover high-quality materials for further use or repurposing.

Bourlinos, Athanasios B. (ORCID:0000000256165993)↗

DOE OSTI2026

New Enzymes for Plastics Recycling from Biosensor-Guided Evolution and Machine Learning: Cooperative Research and Development Final Report, CRADA Number CRD-23-24335

The Agile BioFoundry (ABF) is a consortium of national laboratories dedicated to accelerating biomanufacturing and enabling the bioeconomy. The ABF operates a flexible biotechnology platform that can adjust to the needs of numerous government, academic, and industrial partners, thus enabling them to rapidly develop and optimize the production of a wide range of bioproducts. In this project, the ABF partnered with Birch Biosciences, Inc. to use ABF technology to assist in the development of high-performance enzymes that enable circular, sustainable recycling of poly(ethylene terephthalate) (PET) plastics. A primary goal of this project is to enable cost-effective, high yield, sustainable recycling of PET plastic packaging products.

09 BIOMASS FUELS↗

NASA NTRS1973

Complex permittivity measurements during high temperature recycling of space shuttle antenna window and dielectric heat shield materials

The research performed and the data obtained on candidate space shuttle antenna window and heat shield materials are presented. The measurement technique employs a free-space focused beam microwave bridge for obtaining RF transmission data, and a device which rotates a sample holder which is heated on one side by natural gas-air flames. The surface temperature of each sample is monitored by IR pyrometry; embedded and rear surface thermocouples are also used in obtaining temperature data. The surface of the sample undergoing test is subjected to approximately the same temperature/time profile that occurs at a proposed antenna position on the space shuttle as it re-enters. The samples are cycled through ten of these temperature profiles to determine the recycling effects. Very little change was noted in the materials due to the recycling.

Bassett, H. L.↗

NASA NTRS1981

Ion-exchange chromatography separation applied to mineral recycle in closed systems

As part of the controlled ecological life support system (CELSS) program, a study is being made of mineral separation on ion-exchange columns. The purpose of the mineral separation step is to allow minerals to be recycled from the oxidized waste products of plants, man, and animals for hydroponic food production. In the CELSS application, relatively large quantities of minerals in a broad concentration range must be recovered by the desired system, rather than the trace quantities and very low concentrations treated in analytical applications of ion-exchange chromatography. Experiments have been carried out to assess the parameters pertinent to the scale-up of ion-exchange chromatography and to determine feasibility. Preliminary conclusions are that the column scale-up is in a reasonable size range for the CELSS application. The recycling of a suitable eluent, however, remains a major challenge to the suitability of using ion exchange chromatography in closed systems.

Ballou, E.↗

NASA NTRS1982

Plant growth and mineral recycle trade-offs in different scenarios for a CELSS

Data for hydroponic plant growth in a manned system test is combined with nutritional recommendations to suport trade-off calculations for closed and partially closed life support system scenarios. Published data are used as guidelines for the masses of mineral nutrients needed for higher plant production. The results of calculations based on various scenarios are presented for various combinations of plant growth chamber utilization and fraction of mineral recycle. Estimates are made of the masses of material needed to meet human nutritional requirements in the various scenarios. It appears that food production from a plant growth chamber with mineral recycle is favorable to reduction of the total launch weight in missions exceeding 3 years.

Ballou, E. V.↗

NASA NTRS1988

Recycling of lower continental crust through foundering of cumulates from contaminated mafic intrusions

A mechanism is presented for recycling of lower continental material back into the mantle. Picritic magmas, possible parental to volumious continental volcanics such as the Karoo and Deccan, became trapped at the Moho, where they interacted with and become contaminated by lower crustal materials. Upon crystallization, the magmas differentiated into lower ultramafic cumulate zones and upper gabbroic-anorthositic zones. The ultramafic cumulates are denser than underlying mantle and sink, carrying lower crustal components as trapped liquid, as xenoliths or rafts, and as constituents of cumulate minerals. This model provides a potentially significant crust-mantle differentiation mechanism, and may also represent a contributing factor in crustal recycling, possibly important in producing some OIB reservoirs.

Arndt, Nicholas T.↗

NASA NTRS1991

Atmospheric water vapor transport: Estimation of continental precipitation recycling and parameterization of a simple climate model

The advective transport of atmospheric water vapor and its role in global hydrology and the water balance of continental regions are discussed and explored. The data set consists of ten years of global wind and humidity observations interpolated onto a regular grid by objective analysis. Atmospheric water vapor fluxes across the boundaries of selected continental regions are displayed graphically. The water vapor flux data are used to investigate the sources of continental precipitation. The total amount of water that precipitates on large continental regions is supplied by two mechanisms: (1) advection from surrounding areas external to the region; and (2) evaporation and transpiration from the land surface recycling of precipitation over the continental area. The degree to which regional precipitation is supplied by recycled moisture is a potentially significant climate feedback mechanism and land surface-atmosphere interaction, which may contribute to the persistence and intensification of droughts. A simplified model of the atmospheric moisture over continents and simultaneous estimates of regional precipitation are employed to estimate, for several large continental regions, the fraction of precipitation that is locally derived. In a separate, but related, study estimates of ocean to land water vapor transport are used to parameterize an existing simple climate model, containing both land and ocean surfaces, that is intended to mimic the dynamics of continental climates.

Brubaker, Kaye L.↗

NASA NTRS1992

Coupling plant growth and waste recycling systems in a controlled life support system (CELSS)

The development of bioregenerative systems as part of the Controlled Ecological Life Support System (CELSS) program depends, in large part, on the ability to recycle inorganic nutrients, contained in waste material, into plant growth systems. One significant waste (resource) stream is inedible plant material. This research compared wheat growth in hydroponic solutions based on inorganic salts (modified Hoagland's) with solutions based on the soluble fraction of inedible wheat biomass (leachate). Recycled nutrients in leachate solutions provided the majority of mineral nutrients for plant growth, although additions of inorganic nutrients to leachate solutions were necessary. Results indicate that plant growth and waste recyling systems can be effectively coupled within CELSS based on equivalent wheat yield in leachate and Hoagland solutions, and the rapid mineralization of waste organic material in the hydroponic systems. Selective enrichment for microbial communities able to mineralize organic material within the leachate was necessary to prevent accumulation of dissolved organic matter in leachate-based solutions. Extensive analysis of microbial abundance, growth, and activity in the hydroponic systems indicated that addition of soluble organic material from plants does not cause excessive microbial growth or 'biofouling', and helped define the microbially-mediated flux of carbon in hydroponic solutions.

Garland, Jay L.↗

NASA NTRS1993

Microbiological test results of the environmental control and life support systems vapors compression distillation subsystem recycle tank components following various pretreatment protocols

Microbiological samples were collected from the recycle tank of the vapor compression distillation (VCD) subsystem of the water recovery test at NASA MSFC following a 68-day run. The recycle tank collects rejected urine brine that was pretreated with a commercially available oxidant (Oxone) and sulfuric acid and pumps it back to the processing component of the VCD. Samples collected included a water sample and two swab samples, one from the particulate filter surface and a second from material floating on the surface of the water. No bacteria were recovered from the water sample. Both swab samples contained a spore-forming bacterium, Bacillus insolitus. A filamentous fungus was isolated from the floating material. Approximately 1 month after the pretreatment chemicals were changed to sodium hypochlorite and sulfuric acid, a swab of the particulate filter was again analyzed for microbial content. One fungus was isolated, and spore-forming bacteria were observed. These results indicate the inability of these pretreatments to inhibit surface attachment. The implications of the presence of these organisms are discussed.

Huff, Tim↗

NASA NTRS1992

Recycling and source reduction for long duration space habitation

A direct mathematical approach has been established for characterizing the performance of closed-loop life support systems. The understanding that this approach gives clearly illustrates the options available for increasing the performance of a life support system by changing various parameters. New terms are defined and utilized, such as Segregation Factor, Resource Recovery Efficiency, Overall Reclamation Efficiency, Resupply Reduction Factor, and Life Support Extension Factor. The effects of increases in expendable system supplies required due to increases in life support system complexity are shown. Minimizing resupply through increased recycling and source reduction is illustrated. The effects of recycling upon resupply launch cost is also shown. Finally, material balance analyses have been performed based on quantity and composition data for both supplies and wastes, to illustrate the use of this approach by comparing ten different closed-loop life support system cases.

Hightower, T. M.↗

NASA NTRS1993

Estimation of continental precipitation recycling

The total amount of water that precipitates on large continental regions is supplied by two mechanisms: 1) advection from the surrounding areas external to the region and 2) evaporation and transpiration from the land surface within the region. The latter supply mechanism is tantamount to the recycling of precipitation over the continental area. The degree to which regional precipitation is supplied by recycled moisture is a potentially significant climate feedback mechanism and land surface-atmosphere interaction, which may contribute to the persistence and intensification of droughts. Gridded data on observed wind and humidity in the global atmosphere are used to determine the convergence of atmospheric water vapor over continental regions. A simplified model of the atmospheric moisture over continents and simultaneous estimates of regional precipitation are employed to estimate, for several large continental regions, the fraction of precipitation that is locally derived. The results indicate that the contribution of regional evaporation to regional precipitation varies substantially with location and season. For the regions studied, the ratio of locally contributed to total monthly precipitation generally lies between 0. 10 and 0.30 but is as high as 0.40 in several cases.

Brubaker, Kaye L.↗

NASA NTRS1994

Subduction and volatile recycling in Earth's mantle

The subduction of water and other volatiles into the mantle from oceanic sediments and altered oceanic crust is the major source of volatile recycling in the mantle. Until now, the geotherms that have been used to estimate the amount of volatiles that are recycled at subduction zones have been produced using the hypothesis that the slab is rigid and undergoes no internal deformation. On the other hand, most fluid dynamical mantle flow calculations assume that the slab has no greater strength than the surrounding mantle. Both of these views are inconsistent with laboratory work on the deformation of mantle minerals at high pressures. We consider the effects of the strength of the slab using two-dimensional calculations of a slab-like thermal downwelling with an endothermic phase change. Because the rheology and composition of subducting slabs are uncertain, we consider a range of Clapeyron slopes which bound current laboratory estimates of the spinel to perovskite plus magnesiowustite phase transition and simple temperature-dependent rheologies based on an Arrhenius law diffusion mechanism. In uniform viscosity convection models, subducted material piles up above the phase change until the pile becomes gravitationally unstable and sinks into the lower mantle (the avalanche). Strong slabs moderate the 'catastrophic' effects of the instabilities seen in many constant-viscosity convection calculations; however, even in the strongest slabs we consider, there is some retardation of the slab descent due to the presence of the phase change.

King, S. D.↗

NASA NTRS1993

Performance of high-recovery recycling reverse osmosis with wash water

Inclusion of a recycling loop for partially-desalted water from second-stage reverse-osmosis permeate has been shown useful for achieving high-recovery at moderate applied pressures. This approach has now been applied to simulated wash waters, to obtain data on retention by the membranes of solutes in a mixture comparable to anticipated spacecraft hygiene wastewaters, and to generate an estimate of the maximum concentration that can be expected without causing membrane fouling. A first experiment set provides selectivity information from a single membrane and an Igepon detergent, as a function of final concentration. A reject concentration of 3.1% Total Organic Carbon has been reached, at a pressure of 1.4 Mega Pascals, without membrane fouling. Further experiments have generated selectivity values for the recycle configuration from two washwater simulations, as a function of applied pump pressure. Reverse osmosis removal has also been tested for washwater containing detergent formulated for plant growth compatibility (containing nitrogen, phosphorous and potassium functional groups.)

Herrmann, Cal C.↗

NASA NTRS1996

Plastic Recycling Experiments in Materials Education

The objective of this project was to introduce a series of plastic recycling experiments to students in materials-related courses such as materials science, material technology and materials testing. With the plastic recycling experiments, students not only can learn the fundamentals of plastic processing and properties as in conventional materials courses, but also can be exposed to the issue of materials life cycle and the impact on society and environment.

Liu, Ping↗