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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

Reversibly Assembled Microparticles for Sustained Applications on the Moon and Mars

A sustained presence in any extra-terrestrial environment will require the capability to generate materials, goods, and ultimately vehicles, construction supplies and habitats to be tenable. As an example, NASA, in collaboration with Made In Space, Inc., recently reported the results of extensive research toward enabling3D printing in space. The extensive characterization and comparison of 3D printed articles suggested that, overall, articles generated in the International Space Station microgravity environment were comparable to those generated on Earth. The benefit of in-space manufacturing can be increased through utilization of recyclable materials. A recent analysis of a hypothetical 1,100 day round trip mission to Mars determined that significant mass savings and increase in mission probability of success could be achieved through in-space manufacturing with recyclable materials. NASA’s project ESPUR (Enabling Sustained Presence Using Recyclables), through support from NASA Langley’s Innovative Research and Development Fund, is investigating novel, polymer-coated, epoxy microparticle systems as an enabling technology to realize in-space manufacturing using recyclable feedstocks. Building from previously reported results, further progress toward synthesis of the polymer coating containing click chemical functionalities will be described here. Finite elemental analysis (FEA) has been utilized, in light of scale-free/small world considerations in an effort to identify compositions most likely to yield robust macroscopic geometries. Initial results will be described here. Finally, potential mass savings and life cycle of this recyclable materials technology will be discussed.

Click Chemistry↗

An overview of Japanese CELSS research activities

Development of Controlled Ecological Life Support System (CELSS) technology is inevitable for future long duration stays of human beings in space, for lunar base construction and for manned Mars flight programs. CELSS functions can be divided into 2 categories, Environmental Control and Material Recycling. Temperature, humidity, total atmospheric pressure and partial pressure of oxygen and carbon dioxide, necessary for all living things, are to be controlled by the environment control function. This function can be performed by technologies already developed and used as the Environment Control Life Support System (ECLSS) of Space Shuttle and Space Station. As for material recycling, matured technologies have not yet been established for fully satisfying the specific metabolic requirements of each living thing including human beings. Therefore, research activities for establishing CELSS technology should be focused on material recycling technologies using biological systems such as plants and animals and physico-chemical systems, for example, a gas recycling system, a water purifying and recycling system and a waste management system. Japanese research activities were conducted and will be continued accordingly.

Nitta, Keiji↗

Characterization of Volume F Trash from Four Recent STS Missions: Weights, Categorization, Water Content

The fate of space-generated solid wastes, including trash, for future missions is under consideration by NASA. Several potential treatment options are under consideration and active technology development. Potential fates for space-generated solid wastes are: Storage without treatment; storage after treatment(s) including volume reduction, water recovery, sterilization, and recovery plus recycling of waste materials. Recycling might be important for partial or full closure scenarios because of the prohibitive costs associated with resupply of consumable materials. For this study, we determined the composition of trash returned from four recent STS missions. The trash material was 'Volume F' trash and other trash, in large zip-lock bags, that accompanied the Volume F trash. This is the first of two submitted papers on these wastes. This one will cover trash content, weight and water content. The other will report on the microbial Characterization of this trash. STS trash was usually made available within 2 days of landing at KSC. The Volume F bag was weighed, opened and the contents were catalogued and placed into one of the following categories: food waste (and containers), drink containers, personal hygiene items - including EVA maximum absorbent garments (MAGs)and Elbow packs (daily toilet wipes, etc), paper, and packaging materials - plastic firm and duct tape. Trash generation rates for the four STS missions: Total wet trash was 0.602 plus or minus 0.089 kg(sub wet) crew(sup -1) d(sup -1) containing about 25% water at 0.154 plus or minus 0.030 kg(sub water) crew(sup -1) d(sup -1) (avg plus or minus stdev). Cataloguing by category: personal hygiene wastes accounted for 50% of the total trash and 69% of the total water for the four missions; drink items were 16% of total weight and 16% water; food wastes were 22% of total weight and 15% of the water; office waste and plastic film were 2% and 11% of the total waste and did not contain any water. The results can be used by NASA to determine requirements and criteria for Waste Management Systems on future missions.

Strayer, Richard F.↗

Isotopic constraints on crustal growth and recycling

The Sm-Nd isotopic data on clastic and chemical sediments are used with the present-day age distribution of continental crustal rocks to estimate the rates of crustal accretion, growth and recycling throughout earth's history. A new method for interpreting Nd model ages on both chemical and clastic sediments is proposed. A general relationship is derived between the mean crustal residence time of material recycled from the crust to the mantle (i.e., sediments), the mean age of the crust, and the crustal growth and recycling rates. This relationship takes into account the fact that the age distribution of material in the continental crust is generally different from the age distribution of material recycled into the mantle. The episodic nature of the present-day age distribution in crustal rocks results in similar episodicity in the accretion and recycling rates. The results suggest that by about 3.8 Ga ago, about 40 percent of the present continental volume was present. Recycling rates were extremely high 3-4 Ga ago and declined rapidly to an insignificant value of about 0.1 cu km/a during most of the Phanerozoic. The Nd model age pattern on sediments suggests a fairly high rate of growth during the Phanerozoic.

Jacobsen, Stein B.↗

Development of Process Flowsheets for the Recovery of Metals by Solvent Extraction to Recycle Battery Materials: Evaluation of Application of AMUSE Code. Final CRADA Report

RSR Technologies (RSRT) wished to investigate the use of the AMUSE solvent extraction code, housed at Argonne National Laboratory (ANL) to evaluate the recycling of battery cells for the reclamation of metal values. The modeling studies were undertaken by the group at ANL to evaluate several separation schemes for battery metals using solvent extraction. These studies would develop a framework to be experimentally validated at RSRT at its facility in Dallas, TX. The AMUSE code modeling work would speed the development of recovery flowsheets for spent batteries.

25 ENERGY STORAGE↗

Calculation of Glycolate Concentration Factors Across the 242-25H (3H) Evaporator System

Two models were developed to predict glycolate concentration factors across the 242-25H (3H) Evaporator system. The first model, identified as the Unrestricted Evaporation Model, was designed to evaluate concentration of typical 3H feed material to relatively high densities in order to calculate the concentration factor of glycolate in a given feed stream. This model may be used to understand the potential of glycolate to concentrate from a generic feed material through the 3H system. The second model, identified as the Holistic Evaporation Model, was designed to evaluate the evaporation of dilute, glycolate-containing Defense Waste Processing Facility (DWPF) waste with the requirement that high silicon concentrations typical of recycle material require dilution to adhere to current technical safety requirements. This model may be used to understand the potential of glycolate from DWPF recycle material to concentrate as a result of feeding through the 3H system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Circular economy framework for automobiles: Closing energy and material loops

Abstract Corporations, including automotive manufacturers, are increasingly exploring extended circular economy strategies as a means to enhance the sustainability of their products. The circular economy paradigm focuses on reducing nonrenewable materials and energy, promoting renewable feedstocks and energy, and keeping products/materials in use across the life cycle of a system. As such, life cycle environmental burdens associated with vehicle manufacturing, use, and disposal could potentially be reduced through circular economy strategies; however, no such comprehensive circular economy framework currently exists for the automotive industry. We develop the first circular economy schematic of automobiles, derived from the Ellen MacArthur Foundation's framework. Further, we characterize the current automotive circular economy using metrics of renewable energy and recycled materials. Specifically, for current U.S. average sedans, we find that internal combustion engine vehicles (ICEVs) use ∼6% renewable life cycle primary energy and 27% recycled materials; for battery electric vehicles (BEVs), these measures are ∼8% and 21%, respectively. On a vehicle‐miles‐traveled basis, BEVs use ∼47% less nonrenewable life cycle primary energy than ICEVs, highlighting the importance of electrification as a strategy for automotive manufacturers to reduce environmental burdens. Our proposed circular economy framework is then applied to Ford Motor Company's sustainability programs and initiatives as an example. This schematic aims to provide a starting point for the automotive industry to operationalize circular economy strategies, the application of which could advance its overall sustainability performance.

Aguilar Esteva, Laura C.↗

Carbon recycling in materially closed ecological life support systems

Results of studies are presented of materially closed energetically open microbial ecosystems or 'closed ecosystems'. These are natural marine ecosystems that have been sealed in glass containers to prevent material exchange with the environment but allow energy to pass freely through them. They represent model life support systems for the future human habitation of space. The results are discussed analytically and indicate that these ecosystems, when subjected to a constant energy flux, seem to be reliable and self-sufficient systems for recycling of biologically produced carbon compounds.

Obenhuber, D. C.↗

Information Technology Support in the 8000 Directorate

My summer internship was spent supporting various projects within the Environmental Management Office and Glenn Safety Office. Mentored by Eli Abumeri, I was trained in areas of Information Technology such as: Servers, printers, scanners, CAD systems, Web, Programming, and Database Management, ODIN (networking, computers, and phones). I worked closely with the Chemical Sampling and Analysis Team (CSAT) to redesign a database to more efficiently manage and maintain data collected for the Drinking Water Program. This Program has been established for over fifteen years here at the Glenn Research Center. It involves the continued testing and retesting of all drinking water dispensers. The quality of the drinking water is of great importance and is determined by comparing the concentration of contaminants in the water with specifications set forth by the Environmental Protection Agency (EPA) in the Safe Drinking Water Act (SDWA) and its 1986 and 1991 amendments. The Drinking Water Program consists of periodic testing of all drinking water fountains and sinks. Each is tested at least once every 2 years for contaminants and naturally occurring species. The EPA's protocol is to collect an initial and a 5 minute draw from each dispenser. The 5 minute draw is what is used for the maximum contaminant level. However, the CS&AT has added a 30 second draw since most individuals do not run the water 5 minutes prior to drinking. This data is then entered into a relational Microsoft Access database. The database allows for the quick retrieval of any test@) done on any dispenser. The data can be queried by building number, date or test type, and test results are documented in an analytical report for employees to read. To aid with the tracking of recycled materials within the lab, my help was enlisted to create a database that could make this process less cumbersome and more efficient. The date of pickup, type of material, weight received, and unit cost per recyclable. This information could then calculate the dollar amount generated by the recycling of certain materials. This database will ultimately prove useful in determining the amounts of materials consumed by the lab and will help serve as an indicator potential overuse.

FROM↗

The Role of Innovation in the Circularity of EV Lithium-Ion Batteries

This case study analysis highlights the role of innovations in EV battery design (cells, modules, and packs), reverse supply chain, and recycling processes in yielding value for the economics of recycling (and have the largest impact on the circularity of LIBs). Part of the assessment of value will be a semi-quantitative evaluation of the value of resilience in the rapidly evolving LIB market – i.e., there are a variety of risks that recyclers would face in making a financial commitment to a recycling facility including; the possibility that batteries would not be collected in sufficient quantities, the market for key constituents (e.g., cobalt) might decrease because of changes in battery chemistry, battery manufacturers may not be willing to pay as much for recycled material, etc. The analysis would be semi-quantitative in that two simple models would be used to assess 1. material flows using a previously developed excel-based reverse supply chain flows model, and 2. A LIB recycling process material and energy balance cost model that will be used to qualitatively assess the cost impacts of process innovations and changes in feed streams. Both sets of models are highly speculative in that they rely on a multitude of assumptions and input values (e.g., EV adoption rates) that vary widely in the literature. Additionally, the initial process flow diagrams and equipment lists for the recycling cost model are based on the Argonne EverBatt model, which is still under development. However, in combination with a critical review of the literature, economic modeling can yield valuable insights into the role of innovation in the circularity of LIBs and high-technology (“energy relevant”) products in general.

28 EE - Advanced Manufacturing Office (EE-5A)↗

Spectroscopic Online Monitoring: Using a Multi-Track Visible Spectrometer to Facilitate a Mass Balance Study in a Simulated TALSPEAK Process

Nuclear energy is a promising low-carbon energy candidate to meet the increased demand for green energy, where the integration of fuel recycling can have significant benefits for material usage and waste reduction. Utilizing in situ monitoring tools can provide ample opportunities to better control and safeguard nuclear material recycle processes while also offering knowledge and insight into real-time solution properties. The simultaneous measurement of analytical targets in multiple process locations can enable real-time mass balance and material accountancy calculations. This is demonstrated here with a mass balance study of Nd 3+ on countercurrent aqueous/organic metal extraction within a single centrifugal contactor. The Nd 3+ concentration was simultaneously monitored at the inlets and outlets of both aqueous and organic phases using a visible absorbance detector that allowed for the simultaneous measurement of up to six locations. The Nd 3+ concentration was calculated by using chemical data science algorithms, where model training sets were collected on a single track of the detector. The discussion includes addressing the challenges of using a model collected on a single track and applying it as a model across the other tracks on the detector. Each track of the detector corresponds to one measurement location on the contactor. The difference in the integrated moles of Nd 3+ between the inlet and outlet at the end of the experiment was near zero, indicating that the mass balance of this experiment was maintained. Overall, the online spectroscopic monitoring was able to follow changing solution conditions and accurately measure the concentration of Nd 3+ in different locations within the contactor system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Multiscale investigation of the microstructural mechanisms driving ratchet growth in PBX 9502

The high explosive PBX 9502 undergoes irreversible expansion during thermal cycling (“ratchet growth”). Recent innovations in thermomechanical modeling via homogenization strategies are beginning to incorporate mesoscale information such as grain size, total porosity, and spatial distribution of voids and cracks. To generate a complete experimental data set to challenge and inform these models, PBX 9502 pellets were thermally cycled, cross-sectioned using ion polishing, and imaged in high resolution with scanning electron microscopy. Ratchet growth was found to drive expansion through microcracking. Microcracks were affected by agglomeration of crystals within the PBX. Virgin material showed greater ratchet growth than recycled material.

36 MATERIALS SCIENCE↗

Machine Learning-Based Process Control for Injection Molding of Recycled Polypropylene

The increased interest in artificial intelligence in manufacturing has driven the adoption of machine learning to optimize processes and improve efficiency. A key challenge in injection molding is the variability of recycled materials, which affects part quality and processing stability. This study presents a novel closed-loop process control approach for injection molding, leveraging machine learning to adaptively predict processing inputs and quality outcomes. The methodology was tested on five blends of recycled polypropylene (rPP), using artificial neural networks (ANNs), linear regression, and polynomial regression to model the relationships between material properties and process parameters. The dataset was split 80/20 into training and testing sets. The ANN model was implemented using TensorFlow and Keras, with six hidden layers of 32 neurons per layer, ReLU activation, and an Adam optimizer. Empirical tuning and early stopping were used to optimize performance and prevent overfitting. Predictions were evaluated based on mean absolute error (MAE), mean squared error (MSE), and percentage error. The results showed that yield stress, ultimate elongation, and part weight were accurately predicted within a 5% error for linear and polynomial regression models and within a 10% error for the ANN. However, modulus predictions were less reliable, with errors of ~11% for ANN and linear regression and ~40% for polynomial regression, reflecting the inherent variability of this property in rPP blends. Predictions of processing inputs had errors ranging from 3% to 25%, depending on the model and response variable. No single modeling approach was consistently superior across all responses, highlighting the complexity of the relationship between material properties, process parameters, and quality metrics. Overall, the work demonstrates that closed-loop process control, powered by machine learning, can effectively predict key quality parameters in injection molding of recycled materials. The proposed approach can improve process stability and material utilization, facilitating increased adoption of sustainable materials.

Krantz, Joshua↗

Marshall Space Flight Center solid waste characterization and recycling improvement study: General office and laboratory waste, scrap metal, office and flight surplus

The primary objectives of the study were to characterize the solid waste stream for MSFC facilities in Huntsville, Alabama, and to evaluate their present recycling program. The purpose of the study was to determine if improvements could be made in terms of increasing quantities of the present commodities collected, adding more recyclables to the program, and streamlining or improving operational efficiency. In conducting the study, various elements were implemented. These included sampling and sorting representative samples of the waste stream; visually inspecting each refuse bin, recycle bin, and roll-off; interviewing employees and recycling coordinators of other companies; touring local material recycling facilities; contacting experts in the field; and performing a literature search.

Eley, Michael H.↗

Energy and Power Evolution Over the Lifetime of a Battery

Li-ion batteries currently are dominant energy storage devices for electric vehicles. Rechargeable batteries with lower cost, longer lifetime, and higher safety are desired in support of building of a green grid infrastructure. The continued investment in new battery materials, novel battery structures, advanced manufacturing processes, and accelerated testing/validation of battery performance has led to significant progress in battery development and deployment. Battery safety/reliability, which is essential to the success of a battery technology in the real world, naturally becomes the next big topic in battery research. Recently, the increasing interest in long-duration storage, fast charging, battery secondary use, and material recycling to build a circular industry and sustainable material supply chain has compelled further attention to understand the energy/power evolution and safety over the lifetime of a battery. Here, in this short Viewpoint, we discuss some high-level analyses on the energy/power evolution of rechargeable batteries over their life cycles aiming to inspire more discussion on the safety and sustainability of some representative and emerging battery technologies.

25 ENERGY STORAGE↗