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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Cobalt Dissolution from Metal Oxides and Battery Cathode Materials with Acetic Acid-Based Deep Eutectic Solvents

Recovery of critical metals with alternative solvents beyond those in traditional pyrometallurgy and hydrometallurgy is needed in consideration of environmental challenges and the growing demand for metals in energy technologies. Deep eutectic solvents (DESs) have emerged as sustainable alternatives for solvometallurgy in metal separation and recovery. In this study, DESs based on hydrogen bond acceptors (HBAs) including choline chloride (ChCl), acetylcholine chloride (AChCl), and betaine (Bet) were investigated for their effectiveness when paired with acetic acid (AA) as the hydrogen bond donor (HBD) for the dissolution of cobalt from cobalt oxide (CoO), lithium cobalt oxide (LiCoO 2 ), and lithium nickel manganese cobalt oxide (LNMC). Based on the spectroscopic analysis of the metal dissolution and coordination, Bet:AA was found to provide the highest solubility for CoO (0.33 M) in the form of an octahedral complex. On the other hand, ChCl:AA solvent was more effective at dissolving LiCoO 2 with 0.04 M Co 2+ corresponding to 17% dissolution efficiency and LNMC with 0.06 M Co 2+ corresponding to 72% dissolution efficiency at 50 °C, compared to Bet:AA (9% for LiCoO 2 and 31% for LNMC). Although the solubilities of LiCoO 2 and LNMC have not significantly improved in ChCl:AA, this difference in effectiveness between the solvents clearly reveals the role of the HBA in solubilization. The coordination synergy between the chloride and the –OH moiety facilitates the breakdown of the LiCoO 2 driven by the alteration of the solvent polarity. Cobalt in these solutions was found dominantly as a tetrahedral [CoCl 4 ] 2– complex. A chemical separation of cobalt oxalate from a mixed-metal oxide system based on Co, Fe, and Ni was also demonstrated, confirming the potential of these solvents for practical metal recovery.

Cobalt separation↗
DOE OSTI2022

Promising Method of Sm–Co Magnet Reprocessing in Alkali Chloride Melts

Developing new, efficient methods for samarium and cobalt recovery from scraps/rejects and swarf at Sm–Co magnet manufacturing sites during shaping and finishing is an important task in terms of meeting their growing demand. In this work, the reaction of oxygen with a solution of samarium and cobalt chlorides in a LiCl–KCl eutectic melt was studied at 400–600 °C to explore possible methods for the separation and recovery of samarium and cobalt from these waste products. The pyrochemical reaction resulted in the formation and precipitation of samarium oxychloride, while the cobalt remained in the melt in a soluble chloride form. The effect of temperature and the amount of oxygen passed through the melt (oxygen-to-samarium molar ratio) on the course of the reaction were studied. Kinetic parameters of the oxygen with samarium chloride reaction were determined.

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

Direct Recycling of Blended Cathode Materials by Froth Flotation

We report that direct Li-ion battery recycling involves separating cathode active materials in the solid phase while preserving their electrochemical performance. To reuse the recycled ones in new batteries, it is necessary to separate individual cathode components, which would typically occur prior to the rejuvenation and any compositional reformulation processes. Herein, a froth flotation process is developed to separate pristine lithium nickel-manganese-cobalt oxide (LiNi 0.333 Mn 0.333 Co 0.333 O 2 , NMC111) and lithium manganese oxide (LMO) materials. The flotation results show that with multiple stages of the separation processes, a satisfactory separation is achieved with 95% grade or above of NMC111 in the froth product and 95% grade of LMO in the tailing product. The electrochemistry results show that the flotation chemicals have negligible impact on the electrochemical performance of recycled active materials, whereas the NMC111 exhibits a minor capacity fade after being in contact with deionized water at 2% solid concentration. An improvement in both the rate and cycling performance is achieved at 10% solid concentration or higher. It is found that there is little compositional and structural change to the aqueous recycled NMC111 powders. An effective and low-cost separation method for direct recycling mixed cathode compositions is demonstrated.

25 ENERGY STORAGE↗
NASA NTRS1981

High resolution determination of elemental abundances for Z equals 8-28 at 1.2-2.4 GeV/n

Results are reported from a series of high-altitude balloon flights of a combination scintillator-double Cerenkov counter telescope to obtain abundances for the nuclei oxygen through nickel corrected to the top of the atmosphere. Over this charge range unambiguous element separation, including the rare element cobalt, has been achieved. Final results are presented of an analysis giving relative abundances over this charge and energy range and compared with other recent experiments.

Dwyer, R.↗
DOE OSTI2022

Development of Porous Crystalline Materials for Selective Binding of O 2 from Air

Porous materials that take advantage of different chemisorptive behaviors of O 2 and N 2 could be an effective alternative to approaches based on physisorption for this important separation. Recently, the tetra-nuclear cobalt complex [(Co(III) 2 (bpbp)O 2 ) 2 bdc](PF 6 ) 4 (CSD code: GAMVIB; bpbp – = 2,6-bis(N,N-bis(2-pyridylmethyl)aminomethyl)-4-tert-butylphenolato; bdc 2– = 1,4-benzenedicarboxylato) was shown to have potential for O 2 /N 2 separations based on this concept. This observation raises the question of what other known materials have similar properties. Here, we combine structure screening with a high-throughput periodic density functional theory (DFT) workflow to investigate O 2 and N 2 adsorption in materials from validated crystal structure databases (e.g., CoRE-MOF database and CSD database). These calculations identify multiple materials that have similar di-Co clusters to GAMVIB that are predicted to selectively bind O 2 over N 2 , and suggest design rules that can be used to tune the O 2 and N 2 affinities in materials of this kind.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Comprehensive Study of the Potential of Extracting and Processing Critical Minerals from Coal-Based Resources - Phase I

The Phase I report prepared for the Department of Energy addresses U.S. Executive Order 13817 titled A Federal Strategy to Ensure Secure and Reliable Supplies of Critical Minerals, issued on December 20, 2017, that lists 35 critical minerals that are vulnerable to supply disruption. A comprehensive review of each of the minerals was conducted to determine the criticality based primarily on extractability from coal-based resources. Several other factors were also considered such as gaps in supply and demand, use in current technology, and the existence of viable substitutes. It was determined that the critical minerals that show highest potential for extraction from coal-based resources are lithium, rare earth elements (REEs), cobalt, and manganese. All four of the critical minerals listed serve an important role in the technology industry, have few substitutes, and have a heavy import reliance. Most notably are lithium, which is widely used in the electric vehicle industry, and the REEs which can be found in virtually all electronic devices. The research of critical mineral extraction from coal-based resources was completed using a combination of literature review from public sources as well as cooperation from coal mines and power plants across the United States. Samples collected from six different geographical locations across the U.S. were subjected to sample preparation (i.e., pH measurement, moisture content, particle size analysis) and characterization studies using Inductively Coupled Plasma-Mass Spectroscopy (ICP-MS) and Scanning Electron Microscopy, Energy Dispersive X-Ray Spectroscopy (SEM-EDX) instruments. 27 samples of coal waste materials such as refuse, sludge, and fly ash were tested to characterize the rare earth element concentration by total rare earth elements (TREEs), heavy rare earth elements (HREEs), and light rare earth elements (LREEs). Of the 27 samples tested, 22 contained a TREE concentration higher than the threshold of 300 ppm, which is considered a viable feedstock material. 3 samples contained less than 300 ppm of TREEs; however, they were within 20 ppm of the threshold, and could potentially be considered viable sources in the future pending the advancement of more efficient extraction technologies. 2 of the 27 samples had significantly low TREE concentrations, which does not imply any potential for being a source for REEs. For the minerals identified as most critical in the literature review, a conceptual process flow diagram (PFD) was developed for their extraction from different coal-based feedstocks. The process targets selective recovery of one commodity (i.e., rare earths, lithium, cobalt, and manganese) via several hydrometallurgical separation methods. By identifying potentially extractable coal-based critical mineral resources, a study of the current and future market environments for each critical mineral, and a review of current processing methodologies for critical mineral extraction from coal-based resources, the foundation has been laid to further characterize and explore new resources and extraction techniques. As reliance on technologies in industries such as the production of electronic devices, batteries, and alloys containing critical minerals utilizing critical minerals continues to increase, a sound understanding of our nation’s dependence on and even the global criticality of certain critical minerals, will serve as a catalyst for innovation in virtually all fields of science.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Optimal Membrane Cascade Design for Critical Mineral Recovery Through Logic-based Superstructure Optimization

Critical minerals and rare earth elements play an important role in our climate change initiatives, particularly in applications related with energy storage. Here, we use discrete optimization approaches to design a process for the recovery of Lithium and Cobalt from battery recycling, through membrane separation. Our contribution involves proposing a Generalized Disjunctive Programming (GDP) model for the optimal design of a multistage diafiltration cascade for Li-Co separation. By solving the resulting nonconvex mixed-integer nonlinear program model to global optimality, we investigated scalability and solution quality variations with changes in the number of stages and elements per stage. Results demonstrate the computational tractability of the nonlinear GDP formulation for design of membrane separation processes while opening the door for decom-position strategies for multicomponent separation cascades. Future work aims to extend the GDP formulation to account for stage installation and explore various decomposition techniques to enhance solution efficiency.

Ovalle, Daniel↗
NASA NTRS1984

Design and test of a four channel motor for electromechanical flight control actuation

To provide a suitable electromagnetic torque summing approach to flight control system redundancy, a four channel motor capable of sustaining full performance after any two credible failures was designed, fabricated, and tested. The design consists of a single samarium cobalt permanent magnet rotor with four separate three phase windings arrayed in individual stator quadrants around the periphery. Trade studies established the sensitivities of weight and performance to such parameters as design speed, winding pattern, number of poles, magnet configuration, and strength. The motor electromagnetically sums the torque of the individual channels on a single rotor and eliminate complex mechanical gearing arrangements.

Source record↗
DOE OSTI2026

Chemical beneficiation of cobaltiferous pyrite: a thermodynamic and parametric study

Despite ongoing efforts to identify substitute materials, cobalt remains indispensable for the production of rechargeable batteries essential to the global energy transition. Currently, most cobalt is sourced as a by-product of nickel and copper extraction from politically and ethically unstable regions. To address this vulnerability, certain primary cobalt deposits—where cobalt occurs within the crystal lattice of pyrite (FeS 2 )—have been identified as potential alternatives. Nonetheless, conventional beneficiation methods have proven largely ineffective for the potential processing of these minerals. This study investigated the thermal decomposition of cobaltiferous pyrite contained in flotation concentrates as a subsequent chemical beneficiation stage aimed at (i) selectively removing sulfur to further increase cobalt grades and (ii) producing a ferromagnetic product suitable for downstream magnetic separation. A thermodynamic analysis was first conducted to evaluate the feasibility of the decomposition reactions and the temperature-dependent evolution of sulfur species. A parametric experimental study then assessed the influence of temperature, residence time, and gas flow rate under N 2 and CO 2 atmospheres. Under the most favorable experimental conditions tested (650 °C, 15 min), cobalt grades increased by up to 15% with negligible cobalt losses and the co-production of high-purity sulfur (>95%). Magnetic separation of the resulting calcine yielded a final concentrate containing 2.09% cobalt at 82.5% recovery, representing a 16–74% improvement over previous baseline studies on similar feedstocks.

Beneficiation↗
DOE OSTI2022

Fast charging of Li-ion cells: Effect of separator membranes and mapping of “safe lines” to avoid Li plating

An experimental method is introduced that uses microprobe Li/Cu reference electrodes to map "safe" charging regimes to avoid Li metal plating on graphite anodes at rates to 8C. With this method, a Li-ion cell closely approaches the Li plating condition but avoids descending into this regime. This "safe" approach is used to demonstrate effects of the microporous separator on Li plating in cells consisting of a layered nickel-manganese -cobalt oxide cathode and graphite anode. We argue that most of the difference in behaviors for different separators arises from time delayed Li + ion percolation through the membrane. In conclusion, our study suggests that explicitly treating kinetics of phase transitions in the lithiated graphite anode is essential for electrochemical models predicting "safe" lines for fast charging cells.

25 ENERGY STORAGE↗
DOE OSTI2025

Reciprocal Ternary Molten Salts Enable the Direct Upcycling of Spent Lithium‐Nickel‐Manganese‐Cobalt Oxide (NMC) Mixtures to Make NMC 622

Cathode active material is the most valuable component of spent lithium‐ion batteries, accounting for ≈30% of their overall value. Direct recycling of cathode materials involves recovering, regenerating, and reusing them without breaking down their chemical structure. This approach maximizes the added value of the cathode compound and reduces manufacturing costs by avoiding the need for virgin material production. However, one key challenge in scaling direct recycling from lab to industry is the requirement for highly purified cathode materials, contrasting with the low purity of black mass generated from battery shredding. No efficient separation process currently exists to isolate different lithium‐nickel‐manganese‐cobalt oxides (NMCs) from each other. Thus, direct recycling technologies that can operate with mixtures of multiple NMC stoichiometries will be best‐suited for industrial adoption. This study explores the direct recycling of NMC mixtures into NMC 622 using a “reciprocal ternary molten salts (RTMS)” system. Ionothermal relithiation and upcycling within the RTMS system successfully restore the layered structure, lithium content, and electrochemical performance of degraded NMCs, yielding results comparable to pristine NMC 622 (P‐NMC 622).

25 ENERGY STORAGE↗
DOE OSTI2022

Cobalt-free layered oxide cathodes

A cathode and a battery providing the cathode is provided. The cathode comprises a lithium metal oxide. The lithium metal oxide comprises nickel, aluminum, and iron. The lithium metal oxide is substantially free of cobalt. The battery comprises an anode, the cathode, a separator, and an electrolyte.

Belharouak, Ilias↗
DOE OSTI2021

Selective cobalt and nickel electrodeposition for lithium-ion battery recycling through integrated electrolyte and interface control

Abstract Molecularly-selective metal separations are key to sustainable recycling of Li-ion battery electrodes. However, metals with close reduction potentials present a fundamental challenge for selective electrodeposition, especially for critical elements such as cobalt and nickel. Here, we demonstrate the synergistic combination of electrolyte control and interfacial design to achieve molecular selectivity for cobalt and nickel during potential-dependent electrodeposition. Concentrated chloride allows for the speciation control via distinct formation of anionic cobalt chloride complex (CoCl 4 2- ), while maintaining nickel in the cationic form ([Ni(H 2 O) 5 Cl] + ). Furthermore, functionalizing electrodes with a positively charged polyelectrolyte (i.e., poly(diallyldimethylammonium) chloride) changes the mobility of CoCl 4 2- by electrostatic stabilization, which tunes cobalt selectivity depending on the polyelectrolyte loading. This strategy is applied for the multicomponent metal recovery from commercially-sourced lithium nickel manganese cobalt oxide electrodes. We report a final purity of 96.4 ± 3.1% and 94.1 ± 2.3% for cobalt and nickel, respectively. Based on a technoeconomic analysis, we identify the limiting costs arising from the background electrolyte, and provide a promising outlook of selective electrodeposition as an efficient separation approach for battery recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modeling Electrokinetics of Oxygen Electrodes in Solid Oxide Electrolyzer Cells

A microscale model is presented in this study to simulate electrode kinetics of the oxygen electrode in a solid oxide electrolyzer cell (SOEC). Two mixed ionic/electronic conducting structures are examined for the oxygen producing electrode in this work: single layer porous lanthanum strontium cobalt ferrite (LSCF), and bilayer LSCF/SCT (strontium cobalt tantalum oxide) structures. A yttrium-stabilized zirconia (YSZ) electrolyte separates the hydrogen and oxygen electrodes, as well as a gadolinium doped-ceria (GDC) buffer layer on the oxygen electrode side. Electrochemical reactions occurring at the two-phase boundaries (2PBs) and three-phase boundaries (3PBs) of single-layer LSCF and bilayer LSCF/SCT oxygen electrodes are modeled under various SOEC voltages with lattice oxygen stoichiometry as the key output. The results reveal that there exists a competition in electrode kinetics between 2PBs and 3PBs, but 3PBs are the primary reactive sites for single-layer LSCF oxygen electrode under high voltages. These locations experience the greatest oxygen stoichiometry variations and are therefore the most likely locations for dimensional changes. By applying an active SCT layer over LSCF, the 2PBs become activated to compete with the 3PBs, thus alleviating oxygen stoichiometry variations and reducing the likelihood of dimensional change. This strategy could reduce lattice structural expansion, proving to be valuable for electrode-electrolyte delamination prevention and will be the focus of future work.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS1985

Design consideration for magnetically suspended flywheel systems

Consideration is given to the design, fabrication, and testing of a magnetically suspended flywheel system for energy storage applications in space. The device is the prototype of a system combining passive suspension of the flywheel plate by samarium cobalt magnets and active control in the radial direction using eight separate magnetic coils. The bearing assembly was machined from a nickel-iron alloy, and the machine parts are all hydrogen annealed. Slots in the magnetic plate allow four independent quadrants for control. The motor/generator component of the system is a brushless dc-permanent magnetic/ironless engine using electronic communication. The system has been tested at over 2500 rpm with satisfactory results. The system characteristics of the flywheel for application in low earth orbit (LEO) are given in a table.

Anand, D.↗
DOE OSTI2024

Multi-functional Sorbent Development for Separation of Critical Minerals and Pollutants

Critical Metals (CMs), including Rare Earth Elements (REEs), aluminum, manganese, cobalt, and others outlined by the U.S. Department of the Interior’s Geological Survey are essential to the national and economic security of the US, and whose supply chain is susceptible to disruption. Because of the negative environmental impacts inherent with the conventional mining and processing of solid ores for CMs, adsorption-based recovery of naturally dissolved species from coal wastewaters is appealing. Acid mine drainage (AMD) remains a relatively untapped source that can be rich in REEs, and especially in Al, Mn, and other CMs. NETL’s Multi-functional Sorbent Technology (MUST) has been developed originally from the functionalized silica sorbents for carbon capture. Ongoing work aims to find AMD sites enriched with either REEs or other CM, and to perform additional field tests at these sites. Overall, our work shows the viability of recovering CMs from AMD and other coal waste streams, using a fixed-bed adsorption system that can also employ a selective elution technique to achieve highly purified metal resources.

Shi, Fan↗