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DOE OSTI2026

Novel Zwitterionic Chromatography to Separate Lithium from Unconventional Resources

Since lithium (Li) is a key element for clean energy technologies, the global lithium demand is anticipated to increase rapidly. As a result, efficient lithium extraction technologies that allow the exploitation of unconventional lithium resources, such as geothermal brines and inland brine streams, are essentially needed to meet the Li demand and keep supply chains stable. However, because of low Li concentration, low ratio of Li/Mg or Li/Ca, and complex feed compositions in these feedstocks, using conventional hydrometallurgy or current Direct Lithium Extraction (DLE) processes are often chemical-intensive, requiring substantial amounts of reagent chemicals to recover Li at scale, resulting in large chemical footprints. Therefore, we developed a novel Zwitterionic Chromatography (ZIC) process to separate Li from these resources. Because Li can be partitioned from divalent salts on ZIC under water elution without using chemicals, exploiting the unconventional resources via a ZIC approach can be environmentally benign and sustainable. In this work, we will present the development of the ZIC process for DLE applications. Simulation studies for the Li separation mechanism in ZIC and the demonstration of a continuous ZIC process to separate Li from domestic inland brine and mining wastewater will be presented. Finally, the chemical and energy footprints of ZIC in comparison to other DLE processes will be discussed.

09 BIOMASS FUELS↗

NASA NTRS2000

Synchronized target subsystem for automated docking systems

A synchronized target subsystem for use in an automated docking or station keeping system for docking a chase vehicle with a target vehicle wherein the chase vehicle is provided with a video camera which provides adjacent frames each having a predetermined time duration. A light source mounted on the target vehicle flashes at a frequency which has a time duration which is a multiple of the duration time of the frames, the light being on for at least one frame duration and being off for the remainder of the cycle. An image processing unit is connected to the camera for receiving signals from the camera and subtracting one of the adjacent frames from the other to detect whether the light appears in one frame, both frames or neither frame. If the target light appears in both frames or neither frame, the image processing unit feeds a signal to a timing circuit to advance the video camera one frame. This process is continued until the target light appears in one frame and not in the other, at which time the process of advancing the video camera is stopped.

Howard, Richard T.↗

NASA NTRS2009

Development of Life on Early Mars

Exploration of Mars has begun to unveil the history of the planet. Combinations of remote sensing, in situ compositional measurements and photographic observations have shown Mars had a dynamic and active geologic evolution. Mars geologic evolution encompassed conditions that were suitable for supporting life. A habitable planet must have water, carbon and energy sources along with a dynamic geologic past. Mars meets all of these requirements. The first 600 My of Martian history were ripe for life to develop because of the abundance of (i) Water- as shown by carved canyons and oceans or lakes with the early presence of near surface water shown by precipitated carbonates in ALH84001, well-dated at ~3.9 Gy, (ii) Energy from the original accretional processes, a molten core which generated a strong magnetic field leaving a permanent record in the early crust, active volcanism continuing throughout Martian history, and continuing impact processes, (iii) Carbon, water and a likely thicker atmosphere from extensive volcanic outgassing (i.e. H20, CO2, CH4, CO, O2, N2, H2S, SO2, etc.) and (iv) crustal tectonics as revealed by faulting and possible plate movement reflected by the magnetic pattern in the crust [1]. The question arises: "Why would life not develop from these favorable conditions on Mars in its first 600 My?" During this period, environmental near-surface conditions on Mars were more favorable to life than at any later time. Standing bodies of water, precipitation and flowing surface water, and possibly abundant hydrothermal energy would favor the formation of early life. (Even if life developed elsewhere on Earth, Venus, or on other bodies-it was transported to Mars where surface conditions were suitable for life to evolve). The commonly stated requirement that life would need hundreds of millions of year to get started is only an assumption; we know of no evidence that requires such a long interval for the development of life, if the proper habitable conditions are meet. Perhaps it could start in a very short interval during the first tens of millions of years after crustal formation. Even with impact-driven extinction events, such a short start-up time would allow life to restart multiple times until it persevered. If panspermia is considered, life could be introduced as soon as liquid surface water was present and could instantly thrive and spread.

Gibson, Everett K.↗

NASA NTRS2010

Early Mars: A Warm Wet Niche for Life

Exploration of Mars has begun to unveil the history of the planet. Combinations of remote sensing, in situ compositional measurements and photographic observations have shown Mars had a dynamic and active geologic evolution. Mars geologic evolution had conditions that were suitable for supporting life. A habitable planet must have water, carbon and energy sources along with a dynamic geologic past. Mars meets all of these requirements. The first 600 Ma of Martian history were ripe for life to develop because of the abundance of: (i) Water-as shown by carved canyons and oceans or lakes with the early presence of near surface water shown by precipitated carbonates in ALH84001, well-dated at approx.3.9 Ga, (ii) Energy from the original accretional processes, a molten core which generated a strong magnetic field leaving a permanent record in the early crust, active volcanism continuing throughout Martian history, and continuing impact processes, (iii) Carbon, water and a likely thicker atmosphere from extensive volcanic outgassing (i.e. H2O, CO2, CH4, CO, O2, N2, H2S, SO2, etc.) and (iv) crustal tectonics as revealed by faulting and possible plate movement reflected by the magnetic patterns in the crust [1]. The question arises: "Why would life not develop from these favorable conditions on Mars in its first 600 Ma?" During this period, environmental near-surface conditions on Mars were more favorable to life than at any later time. Standing bodies of water, precipitation and flowing surface water, and possibly abundant hydrothermal energy would favor the formation of early life. (Even if life developed elsewhere on Earth, Venus, or on other bodies-it was transported to Mars where surface conditions were suitable for life to evolve)

Gibson, Everett K.↗

NASA NTRS2018

Analysis and Review of NASA Earth Science Metadata: How Automation Plays a Role

The Analysis and Review of the Common Metadata Repository (CMR ARC) Team reviews all EOSDIS metadata. The team’s objective is to achieve consistency, correctness, and completeness for all metadata records in the CMR, as well as improve the discoverability of NASA's Earth Science data within the CMR framework. This work is currently being completed at Marshall Space Flight Center. CMR makes a single discovery point possible for NASA's Earth Science data users. The CMR team, in collaboration with three other core metadata teams, contributes to the stewardship of NASA's Earth Science data through a process of continual curation and the ongoing development of the Unified Metadata Model (UMM). A key tool now used in the curation process, referred to as the NASA CMR Dashboard, is an online curation dashboard developed in collaboration with software development company, Element 84. This tool facilitates the review of Earth Science metadata records and subsequent stakeholder collaboration on the resolution of identified issues. A key capability of the new tool is a suite of automated compliance checks written in Python 3.6 that verify the integrity of various metadata elements across multiple standards.

Staton, Patrick↗

DOE OSTI2025

Integrating Cyber-Informed Engineering into Process Automation

As organizations increasingly automate their core missions and essential functions to address business risks and enhance efficiency, process automation becomes pivotal. This shift, involving minimal or no manual intervention, significantly impacts an organization's cyber-risk landscape. While automation drives efficiencies, it also introduces new cyber risks if not properly managed. Cyber-Informed Engineering (CIE) provides a proactive framework for managing these digital risks, enhancing cyber-resilience in process automation. This document supports organizations in applying CIE principles to mitigate the cyber risks associated with automation. The outlined approach can be independently implemented to improve any organization’s cyber-resilience, ensuring that the advantages of automation do not result in unaddressed or unmanaged digital risks. It serves as a starting point, offering considerations for integrating CIE principles and practices into organizational processes. CIE is presented as an iterative process, fostering continuous improvement and reinforcing the engineering and operational cultures to manage digital risks effectively. The document is structured as follows: Section 1 provides background on CIE and process automation, and their integration. Section 2 explores the twelve CIE principles in the context of process automation, highlighting key questions, engineering considerations, and implications for digital risk management. Section 3 synthesizes the findings and offers recommendations to advance resilience by design.

42 - ENGINEERING↗

DOE OSTI2024

Production of Biomass–Derived p –Hydroxybenzamide: Synthesis of p –Aminophenol and Paracetamol

As we work to transition the modern society that is based on non-renewable chemical feedstocks to a post-modern society built around renewable sources of energy, fuels, and chemicals, there is a need to identify the renewable resources and processes for converting them to platform chemicals. Herein, we explore a strategy for utilizing the p-hydroxybenzoate in biomass feedstocks (e.g., poplar and palm trees) and converting it into a portfolio of commodity chemicals. The targeted bio-derived product in the first processing stage is p-hydroxybenzamide produced from p-hydroxybenzoate esters found in the plant. In the second stage a continuous reaction process converts the p-hydroxybenzamide to p-aminophenol via the Hofmann rearrangement and recovers the unreacted p-hydroxybenzamide. In the third stage the p-aminophenol can be acetylated to form paracetamol, which is readily isolated by liquid/liquid extraction at >95 % purity and an overall p-hydroxybenzamide-to-paracetamol process yield of ~90 %. We explore how utilization of protecting groups alters the challenges in this process and expands the portfolio of possible products to include p-(methoxymethoxy)aniline and N-acetyl-p-(methoxymethoxy)aniline. These target compounds could become value-added renewably-sourced platform chemicals that could be used to produce biodegradable plastics, pigments, and pharmaceuticals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1985

Oxygen extraction from lunar materials - An experimental test of an ilmenite reduction process

The reaction of ilmenite with hydrogen to produce water has been studied experimentally in order to evaluate the effectiveness of using a cold trap to improve yields in a continuous flow process. Yields were enhanced, but not to the degree observed in batch processing systems. The terrestrial simulant used in these studies contained traces of iron sulfide, which released H2S during processing with a deleterious effect on several components of the test system. More sophisticated testing should be undertaken to obtain kinetic data and attention given to the removal of sulfides in the pre-process beneficiation.

Williams, R. J.↗

NASA NTRS2007

Conditions on Early Mars Might Have Fostered Rapid and Early Development of Life

The exploration of Mars during the past decades has begun to unveil the history of the planet. The combinations of remote sensing, in situ geochemical compositional measurements and photographic observations from both above and on the surface have shown Mars to have a dynamic and active geologic evolution. Mars geologic evolution clearly had conditions that were suitable for supporting life. For a planet to be able to be habitable, it must have water, carbon sources, energy sources and a dynamic geologic past. Mars meets all of these requirements. The first 600 My of Martian history were ripe for life to develop because of the abundance of (i) Water-carved canyons and oceans or lakes with the early presence of near surface water shown by precipitated carbonates in ALH84001 well-dated at approx.3.9 Gy., (ii) Energy from the original accretional processes, a molten core which generated a strong magnetic field leaving a permanent record in the early crust, early active volcanism continuing throughout Martian history, and, and continuing impact processes, (iii) Carbon and water from possibly extensive volcanic outgassing (i.e. H2O, CO2, CH4, CO, O2, N2, H2S, SO2, etc.) and (iv) some crustal tectonics as revealed by faulting and possible plate movement reflected by the magnetic pattern in the crust. The question arises: "Why would life not evolve from these favorable conditions on early Mars in its first 600 My?" During this period, it seems likely that environmental near-surface conditions on Mars were more favorable to life than at any later time. Standing bodies of water, precipitation and flowing surface water, and possibly abundant hydrothermal energy would all favor the formation of early life. Even if life developed elsewhere (on Earth, Venus, or on other solar systems) and was transported to Mars, the surface conditions were likely very hospitable for that introduced life to multiply and evolve.

Gibson, Everett K.↗

NASA NTRS1979

Process Feasibility Study in Support of Silicon Material, Task 1

During this reporting period, major activies were devoted to process system properties, chemical engineering and economic analyses. Analyses of process system properties was continued for materials involved in the alternate processes under consideration for solar cell grade silicon. The following property data are reported for silicon tetrafluoride: critical constants, vapor pressure, heat of varporization, heat capacity, density, surface tension, viscosity, thermal conductivity, heat of formation and Gibb's free energy of formation. Chemical engineering analysis of the BCL process was continued with primary efforts being devoted to the preliminary process design. Status and progress are reported for base case conditions; process flow diagram; reaction chemistry; material and energy balances; and major process equipment design.

Li, K. Y.↗

NASA NTRS2003

Fragmentation under the Scaling Symmetry and Turbulent Cascade with Intermittency

Fragmentation plays an important role in a variety of physical, chemical, and geological processes. Examples include atomization in sprays, crushing of rocks, explosion and impact of solids, polymer degradation, etc. Although each individual action of fragmentation is a complex process, the number of these elementary actions is large. It is natural to abstract a simple 'effective' scenario of fragmentation and to represent its essential features. One of the models is the fragmentation under the scaling symmetry: each breakup action reduces the typical length of fragments, r (right arrow) alpha r, by an independent random multiplier alpha (0 < alpha < 1), which is governed by the fragmentation intensity spectrum q(alpha), integral(sup 1)(sub 0) q(alpha)d alpha = 1. This scenario has been proposed by Kolmogorov (1941), when he considered the breakup of solid carbon particle. Describing the breakup as a random discrete process, Kolmogorov stated that at latest times, such a process leads to the log-normal distribution. In Gorokhovski & Saveliev, the fragmentation under the scaling symmetry has been reviewed as a continuous evolution process with new features established. The objective of this paper is twofold. First, the paper synthesizes and completes theoretical part of Gorokhovski & Saveliev. Second, the paper shows a new application of the fragmentation theory under the scale invariance. This application concerns the turbulent cascade with intermittency. We formulate here a model describing the evolution of the velocity increment distribution along the progressively decreasing length scale. The model shows that when the turbulent length scale gets smaller, the velocity increment distribution has central growing peak and develops stretched tails. The intermittency in turbulence is manifested in the same way: large fluctuations of velocity provoke highest strain in narrow (dissipative) regions of flow.

Gorokhovski, M.↗

NASA NTRS1992

NASA Johnson Space Center: Total quality partnership

The development of and benefits realized from a joint NASA, support contractor continuous improvement process at the Johnson Space Center (JSC) is traced. The joint effort described is the Safety, Reliability, and Quality Assurance Directorate relationship with its three support contractors which began in early 1990. The Continuous Improvement effort started in early 1990 with an initiative to document and simplify numerous engineering change evaluation processes. This effort quickly grew in scope and intensity to include process improvement teams, improvement methodologies, awareness, and training. By early 1991, the support contractor had teams in place and functioning, program goals established and a cultural change effort underway. In mid-l991 it became apparent that a major redirection was needed to counter a growing sense of frustration and dissatisfaction from teams and managers. Sources of frustration were isolated to insufficient joint participation on teams, and to a poorly defined vision. Over the next year, the effort was transformed to a truly joint process. The presentation covers the steps taken to define vision, values, goals, and priorities and to form a joint Steering Committee and joint process improvement teams. The most recent assessment against the President's award criteria is presented as a summary of progress. Small, but important improvement results have already demonstrated the value of the joint effort.

Harlan, Charlie↗

NASA NTRS1984

A review of the silicon material task

The Silicon Material Task of the Flat-Plate Solar Array Project was assigned the objective of developing the technology for low-cost processes for producing polysilicon suitable for terrestrial solar-cell applications. The Task program comprised sections for process developments for semiconductor-grade and solar-cell-grade products. To provide information for deciding upon process designs, extensive investigations of the effects of impurities on material properties and the performance of cells were conducted. The silane process of the Union Carbide Corporation was carried through several stages of technical and engineering development; a pilot plant was the culmination of this effort. The work to establish silane fluidized-bed technology for a low-cost process is continuing. The advantages of the use of dichlorosilane is a siemens-type were shown by Hemlock Semiconductor Corporation. The development of other processes is described.

Lutwack, R.↗

NASA NTRS1987

Launch Processing System operations with a future look to Operations Analyst (OPERA)

The Launch Processing System architecture and the ground support operations required to provide Shuttle System engineers with the capability to safely process and launch an Orbiter are described. The described ground operations are the culmination of eleven years of experience and redesign. Some of the 'lessons learned' are examined, and problem areas which ground support operations have identified over the years as the Shuttle and Launch Processing Systems continue to grow in complexity are discussed. The Operational Analyst for Distributed Systems (OPERA), a proposed set of expert systems for the Launch Processing System Operational assistance, is discussed along with its extensions to prospective future configurations and components for the Launch Processing System.

Heard, Astrid E.↗

NASA NTRS2004

Manufacturing High-Quality Carbon Nanotubes at Lower Cost

A modified electric-arc welding process has been developed for manufacturing high-quality batches of carbon nanotubes at relatively low cost. Unlike in some other processes for making carbon nanotubes, metal catalysts are not used and, consequently, it is not necessary to perform extensive cleaning and purification. Also, unlike some other processes, this process is carried out at atmospheric pressure under a hood instead of in a closed, pressurized chamber; as a result, the present process can be implemented more easily. Although the present welding-based process includes an electric arc, it differs from a prior electric-arc nanotube-production process. The welding equipment used in this process includes an AC/DC welding power source with an integral helium-gas delivery system and circulating water for cooling an assembly that holds one of the welding electrodes (in this case, the anode). The cathode is a hollow carbon (optionally, graphite) rod having an outside diameter of 2 in. (approximately equal to 5.1 cm) and an inside diameter of 5/8 in. (approximately equal to 1.6 cm). The cathode is partly immersed in a water bath, such that it protrudes about 2 in. (about 5.1 cm) above the surface of the water. The bottom end of the cathode is held underwater by a clamp, to which is connected the grounding cable of the welding power source. The anode is a carbon rod 1/8 in. (approximately equal to 0.3 cm) in diameter. The assembly that holds the anode includes a thumbknob- driven mechanism for controlling the height of the anode. A small hood is placed over the anode to direct a flow of helium downward from the anode to the cathode during the welding process. A bell-shaped exhaust hood collects the helium and other gases from the process. During the process, as the anode is consumed, the height of the anode is adjusted to maintain an anode-to-cathode gap of 1 mm. The arc-welding process is continued until the upper end of the anode has been lowered to a specified height above the surface of the water bath. The process causes carbon nanotubes to form in the lowest 2.5 cm of the anode. It also causes a deposit reminiscent of a sandcastle to form on the cathode. The nanotube-containing material is harvested. The cathode and anode can then be cleaned (or the anode is replaced, if necessary) and the process repeated to produce more nanotubes. Tests have shown that the process results in approximately equal to 50-percent yield of carbon nanotubes (mostly of the single-wall type) of various sizes. Whereas the unit cost of purified single-wall carbon nanotubes produced by other process is about $1,000/g in the year 2000, it has been estimated that for the present process, the corresponding cost would be about $10/g.

Benavides, Jeanette M.↗

DOE OSTI2025

A Novel Continuous Ultrasound-Assisted Leaching Process for Rare Earth Element Extraction: Environmental and Economic Assessment

Rare earth elements (REEs) make up integral components in personal electronics, healthcare instrumentation, and modern energy technologies. REE leaching with organic acids is an environmentally friendly alternative to traditional extraction methods. Our previous study demonstrated that batch ultrasound-assisted organic acid leaching of REEs can significantly decrease environmental impacts compared to traditional bioleaching. The batch method is limited to small volumes and is unsuitable for industrial implementation. This study proposes a novel approach to increase reaction volume using a continuous ultrasound-assisted organic acid leaching method. Laboratory experiments showed that continuous ultrasound-assisted leaching increased the leaching rate (µg/h) 11.3–24.5 times compared to our previously reported batch method. Techno-economic analysis estimates the cost of the continuous approach using commercially purchased organic acids is $\$$9465/kg of extracted REEs and $\$$4325/kg of extracted REEs, using gluconic acid and citric acid, respectively. The sensitivity analysis reveals that substituting commercially purchased organic acids with microbially produced biolixiviant can reduce the process cost by approximately 99% while minimally increasing energy consumption. Environmental assessment shows that most of the emissions stemmed from the energy required to power the ultrasound reactor. We concluded that increased leaching capacity using a continuous ultrasound-assisted approach is feasible, but process modifications are needed to reduce the environmental impact.

54 - ENVIRONMENTAL SCIENCES/GLOBAL CLIMATE CHANGE ↗

NASA NTRS1969

Miniaturization of magnetic logic circuitry

Magnetic logic circuit design features two ferrite materials, with different formulation and magnetic characteristics, which are bonded into a continuous structure by preparing the materials as a slurry and using the doctor blade method to form flexible ferrite sheets. After firing, the sintering process was continuous across the bond.

Baba, P. D.↗

NASA NTRS2003

Self-Reacting Friction Stir Welding for Aluminum Alloy Circumferential Weld Applications

Friction stir welding is an innovative weld process that continues to grow in use, in the commercial, defense, and space sectors. It produces high quality and high strength welds in aluminum alloys. The process consists of a rotating weld pin tool that plasticizes material through friction. The plasticized material is welded by applying a high weld forge force through the weld pin tool against the material during pin tool rotation. The high weld forge force is reacted against an anvil and a stout tool structure. A variation of friction stir welding currently being evaluated is self-reacting friction stir welding. Self-reacting friction stir welding incorporates two opposing shoulders on the crown and root sides of the weld joint. In self-reacting friction stir welding, the weld forge force is reacted against the crown shoulder portion of the weld pin tool by the root shoulder. This eliminates the need for a stout tooling structure to react the high weld forge force required in the typical friction stir weld process. Therefore, the self-reacting feature reduces tooling requirements and, therefore, process implementation costs. This makes the process attractive for aluminum alloy circumferential weld applications. To evaluate the application of self-reacting friction stir welding for aluminum alloy circumferential welding, a feasibility study was performed. The study consisted of performing a fourteen-foot diameter aluminum alloy circumferential demonstration weld using typical fusion weld tooling. To accomplish the demonstration weld, weld and tack weld development were performed and fourteen-foot diameter rings were fabricated. Weld development consisted of weld pin tool selection and the generation of a process map and envelope. Tack weld development evaluated gas tungsten arc welding and friction stir welding for tack welding rings together for circumferential welding. As a result of the study, a successful circumferential demonstration weld was produced leading the way for future circumferential weld implementation.

Bjorkman, Gerry↗