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DOE OSTI2026

Strategies for using membrane-based separations to extract critical metals from waste streams

Critical metals are currently extracted by mining followed by their purification. These processes are costly and not environmentally very desirable. In this perspective paper we discuss the potential of extracting these critical metals from a range waste-streams available in abundance globally. These waste streams include brine from desalination plants, effluents from oil drilling and hydraulic fracturing, as well as discharges from various industrial processes such as metal finishing, electroplating, mining, and chemical manufacturing. We show that with a range of new separation processes being developed their separation is showing potential of being both technologically and economically feasible. We also show how high performance computing can be combined with computational models to screen and accelerate the development of new technologies for extracting critical metals from waste streams.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Streaming Compression of Scientific Data via Weak-SINDy

Here, in this paper, a streaming weak-SINDy algorithm is developed specifically for compressing streaming scientific data. The production of scientific data, either via simulation or experiments, is undergoing a stage of exponential growth, which makes data compression important and often necessary for storing and utilizing large scientific data sets. As opposed to classical “offline” compression algorithms that perform compression on a readily available data set, streaming compression algorithms compress data “online” while the data generated from simulation or experiments is still flowing through the system. This feature makes streaming compression algorithms well suited for scientific data compression, where storing the full data set offline is often infeasible. This work proposes a new streaming compression algorithm, streaming weak-SINDy, which takes advantage of the underlying data characteristics during compression. The streaming weak-SINDy algorithm constructs feature matrices and target vectors in the online stage via a streaming integration method in a memory efficient manner. The feature matrices and target vectors are then used in the offline stage to build a model through a regression process that aims to recover equations that govern the evolution of the data. For compressing high-dimensional streaming data, we adopt a streaming proper orthogonal decomposition (POD) process to reduce the data dimension and then use the streaming weak-SINDy algorithm to compress the temporal data of the POD expansion. We propose modifications to the streaming weak-SINDy algorithm to accommodate the dynamically updated POD basis. By combining the built model from the streaming weak-SINDy algorithm and a small amount of data samples, the full data flow could be reconstructed accurately at a low memory cost, as shown in the numerical tests.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Electrochemical Nutrient Recovery for the Food–Energy–Water Nexus at Municipal Wastewater Facilities: Multivariate Analyses of Seasonal Sampling and Reactor Performance

Digester-equipped municipal wastewater facilities generate recycle streams with high nutrient loads that increase energy consumption and can cause environmental pollution. The reduction of these loads through electrochemical nutrient recovery (ENR) could enhance the food–energy–water nexus by producing fertilizer (struvite). This study investigated the recovery process through a 1 year sampling of recycle streams and the implementation of nutrient recovery. Time series analyses showed that P (as orthophosphate) concentration was time-variant in digester effluent streams, while N (as ammonia) concentration was time-variant in only the aerobic system. Furthermore, these two nutrient concentrations did not correlate in any of the recycle streams. Subsequent multivariate screening analyses identified anode type, NH 4 + concentration, cathodic potential, P concentration, and temperature as most significant for ENR. Finally, the optimum conditions of cathodic potential, anode area-to-volume ratio, and temperature applied to a real recycle stream resulted in 95% P recovery with 0.03 kWh/kg P. This energy consumption is significantly lower than process energy for conventional P fertilizers (1.1 kWh/kg P) and chemical recovery processes at scale (1.7–12.9 kWh/kg P). Overall, this study recommended specific process controls for nutrient recovery, expanded the variables evaluated for ENR, and demonstrated the ability to significantly impact energy demand associated with P-based fertilizers.

36 MATERIALS SCIENCE↗

NASA NTRS2007

Digital Multicasting of Multiple Audio Streams

The Mission Control Center Voice Over Internet Protocol (MCC VOIP) system (see figure) comprises hardware and software that effect simultaneous, nearly real-time transmission of as many as 14 different audio streams to authorized listeners via the MCC intranet and/or the Internet. The original version of the MCC VOIP system was conceived to enable flight-support personnel located in offices outside a spacecraft mission control center to monitor audio loops within the mission control center. Different versions of the MCC VOIP system could be used for a variety of public and commercial purposes - for example, to enable members of the general public to monitor one or more NASA audio streams through their home computers, to enable air-traffic supervisors to monitor communication between airline pilots and air-traffic controllers in training, and to monitor conferences among brokers in a stock exchange. At the transmitting end, the audio-distribution process begins with feeding the audio signals to analog-to-digital converters. The resulting digital streams are sent through the MCC intranet, using a user datagram protocol (UDP), to a server that converts them to encrypted data packets. The encrypted data packets are then routed to the personal computers of authorized users by use of multicasting techniques. The total data-processing load on the portion of the system upstream of and including the encryption server is the total load imposed by all of the audio streams being encoded, regardless of the number of the listeners or the number of streams being monitored concurrently by the listeners. The personal computer of a user authorized to listen is equipped with special- purpose MCC audio-player software. When the user launches the program, the user is prompted to provide identification and a password. In one of two access- control provisions, the program is hard-coded to validate the user s identity and password against a list maintained on a domain-controller computer at the MCC. In the other access-control provision, the program verifies that the user is authorized to have access to the audio streams. Once both access-control checks are completed, the audio software presents a graphical display that includes audiostream-selection buttons and volume-control sliders. The user can select all or any subset of the available audio streams and can adjust the volume of each stream independently of that of the other streams. The audio-player program spawns a "read" process for the selected stream(s). The spawned process sends, to the router(s), a "multicast-join" request for the selected streams. The router(s) responds to the request by sending the encrypted multicast packets to the spawned process. The spawned process receives the encrypted multicast packets and sends a decryption packet to audio-driver software. As the volume or muting features are changed by the user, interrupts are sent to the spawned process to change the corresponding attributes sent to the audio-driver software. The total latency of this system - that is, the total time from the origination of the audio signals to generation of sound at a listener s computer - lies between four and six seconds.

Macha, Mitchell↗

NASA NTRS1980

Telemetry Computer System at Wallops Flight Center

This paper describes the Telemetry Computer System in operation at NASA's Wallops Flight Center for real-time or off-line processing, storage, and display of telemetry data from rockets and aircraft. The system accepts one or two PCM data streams and one FM multiplex, converting each type of data into computer format and merging time-of-day information. A data compressor merges the active streams, and removes redundant data if desired. Dual minicomputers process data for display, while storing information on computer tape for further processing. Real-time displays are located at the station, at the rocket launch control center, and in the aircraft control tower. The system is set up and run by standard telemetry software under control of engineers and technicians. Expansion capability is built into the system to take care of possible future requirements.

Bell, H.↗

NASA NTRS2017

Planetesimals Born Big by Clustering Instability?

Roughly 100km diameter primitive bodies (today's asteroids and TNOs; [1]) are thought to be the end product of so-called "primary accretion". They dominated the initial mass function of planetesimals, and precipitated the onset of a subsequent stage, characterized by runaway gravitational effects, which proceeded onwards to planetary mass objects, some of which accreted massive gas envelopes. Asteroids are the parents of primitive meteorites; meteorite data suggest that asteroids initially formed directly from freelyfloating nebula particles in the mm-size range. Unfortunately, the process by which these primary 100km diameter planetesimals formed remains problematic. We review the most diagnostic primitive parent body observations, highlight critical aspects of the nebula context, and describe the issues facing various primary accretion models. We suggest a path forward that combines current scenarios of "turbulent concentration" (TC) and "streaming instabilities" (SI) into a triggered formation process we call clustering instability (CI). Under expected conditions of nebula turbulence, the success of these processes at forming terrestrial region (mostly silicate) planetesimals requires growth by sticking into aggregates in the several cm size range, at least, which is orders of magnitude more massive than allowed by current growth-by-sticking models using current experimental sticking parameters [2-4]. The situation is not as dire in the ice-rich outer solar system; however, growth outside of the snowline has important effects on growth inside of it [4] and at least one aspect of outer solar system planetesimals (high binary fraction) supports some kind of clustering instability.

Cuzzi, Jeffrey N.↗

NASA NTRS2017

Planetesimals Born Big by Clustering Instability?

Asteroids↗

DOE OSTI2026

Advancing Industry 4.0: Multimodal Sensor Fusion for AI-Based Fault Detection in 3D Printing

Additive manufacturing, particularly fused deposition modeling, is transforming modern production by enabling rapid prototyping and complex part fabrication. However, its layer-by-layer process remains vulnerable to faults such as nozzle clogging, filament runout, and layer misalignment, which compromise print quality and reliability. Traditional inspection methods are costly, time-intensive, and often limited to post-process analysis, making them unsuitable for real-time intervention. In this current study, the authors developed a novel, low-cost, and portable faultdetection system that leverages multimodal sensor fusion and artificial intelligence for real-time monitoring in FDM-based 3D printing. The system integrates acoustic, vibration, and thermal sensing into a non-intrusive architecture, capturing complementary data streams that reflect both mechanical and process-related anomalies. Acoustic and thermal sensors operate in a fully contactless manner, while the vibration sensor requires minimal attachment such that it will not interfere with printer hardware, thereby preserving portability and ease of deployment. The multimodal signals are processed into spectrograms and time-frequency features, which are classified using convolutional neural networks for intelligent fault detection. The proposed system advances Industry 4.0 objectives by offering an affordable, scalable, and practical monitoring solution that improves faultdetection accuracy, reduces waste, and supports sustainable, adaptive manufacturing.

42 ENGINEERING↗

DOE OSTI2026

NREL's 1MW Water Electrolysis Stack Performance Validation to Pilot-Scale Renewable Natural Gas Production [Slides]

NREL has designed, built, and operates a 1MW water electrolyzer balance-of-plant to support industrial partners and the U.S. Department of Energy in developing next-generation PEM stacks to reduce the cost of hydrogen production. With that hydrogen, we are developing, innovating and de-risking a biomethanation process capable of megawatt-scale deployment that upgrades biogas waste streams to produce pipeline quality renewable natural gas (RNG). Biomethanation is a two-step process using a methanogenic microorganism to convert renewable hydrogen (H 2 ) and waste carbon dioxide (CO 2 ) to renewable methane (CH 4 ) - the primary component in natural gas. Using biogenic CO 2 from biogas sources like dairies, wastewater treatment plants, and landfills allows production of this drop-in direct replacement fuel. Research projects and future R&D topics are also discussed during the presentation.

08 HYDROGEN↗

DOE OSTI2025

Catalytic Oxygen Reduction for Deep O 2 Removal from CO 2 Streams

Streams of CO 2 from various capture processes may contain several impurities of which O 2 is often overlooked as a problematic impurity. Because of its reactivity, the National Energy Technology Laboratory has recommended a stringent limit, less than 10 ppm, for the O 2 level in treated CO 2 products for safe transport, storage, and utilization. Here, in this study, a variety of catalytic oxygen reduction approaches using commercial automotive exhaust emission catalysts are evaluated for O 2 removal from CO 2 streams using different reducing agents, including H 2 , CO, CH 3 OH, and CH 4 . When the amount of reductant added into the feed is carefully controlled, H 2 , CO, or CH 3 OH can effectively remove O 2 from 1.5% to below 10 ppm with a single-reactor design (>99.93% removal efficiency), while simultaneously meeting the impurity limits for other species. With CH 4 as a reductant, it is challenging to simultaneously meet the the O 2 and CO specifications in a single-reactor design because CH 4 also reacts with CO 2 to produce high levels of CO in the stream (at several hundred ppm). A dual-reactor design is developed to enable the use of CH 4 , a readily available and low-cost reductant, for the purification of CO 2 streams to meet the specifications for O 2 and other impurities.

CO2 purification↗

DOE OSTI2024

Exploring DAOS as a Burst Buffer for a 100 Gbps DAQ Real-Time Streaming System

We present an experimental evaluation of a burst buffer for a real-time DAQ streaming system designed to transmit instrument data to remote data centers. The system is based on EJ-FAT, a load balancing system capable of Nx 100Gbps streams, distributing data from event sources to processing nodes. We explore applying the DAOS system as a burst buffer to serve a number of purposes: improve resiliency, elasticity and add new functions into the processing pipeline. In the evaluation a sender transmits events over a 100Gbps network to a receiver integrated with DAOS to store the reassembled events using DAOS APIs. We evaluate the system for possible bottlenecks and provide end-to-end evaluation with a burst buffer using DAOS storage abstractions. We show that a receiver node can support 38.1 Gbps. This proves the viability of our approach and allows us to extend this work to investigate scale-out properties and new streaming optimizations.

Mei, Xinxin↗

NASA NTRS2012

Gigabit Ethernet Asynchronous Clock Compensation FIFO

Clock compensation for Gigabit Ethernet is necessary because the clock recovered from the 1.25 Gb/s serial data stream has the potential to be 200 ppm slower or faster than the system clock. The serial data is converted to 10-bit parallel data at a 125 MHz rate on a clock recovered from the serial data stream. This recovered data needs to be processed by a system clock that is also running at a nominal rate of 125 MHz, but not synchronous to the recovered clock. To cross clock domains, an asynchronous FIFO (first-in-first-out) is used, with the write pointer (wprt) in the recovered clock domain and the read pointer (rptr) in the system clock domain. Because the clocks are generated from separate sources, there is potential for FIFO overflow or underflow. Clock compensation in Gigabit Ethernet is possible by taking advantage of the protocol data stream features. There are two distinct data streams that occur in Gigabit Ethernet where identical data is transmitted for a period of time. The first is configuration, which happens during auto-negotiation. The second is idle, which occurs at the end of auto-negotiation and between every packet. The identical data in the FIFO can be repeated by decrementing the read pointer, thus compensating for a FIFO that is draining too fast. The identical data in the FIFO can also be skipped by incrementing the read pointer, which compensates for a FIFO draining too slowly. The unique and novel features of this FIFO are that it works in both the idle stream and the configuration streams. The increment or decrement of the read pointer is different in the idle and compensation streams to preserve disparity. Another unique feature is that the read pointer to write pointer difference range changes between compensation and idle to minimize FIFO latency during packet transmission.

Duhachek, Jeff↗

NASA NTRS2014

Evaluating the Adsorptive Capabilites of Chemsorb 1000 and Chemsorb 1425

The removal of trace contaminants from spacecraft cabin air is necessary for crew health and comfort during long duration space exploration missions. The air revitalization technologies used in these future exploration missions will evolve from current ISS ISS State-of-Art (SOA) and is being designed and tested by the Advanced Exploration Systems (AES) Program's Atmosphere Resource Recovery and Environmental Monitoring (ARREM) project. The ARREM project is working to mature optimum atmosphere revitalization and environmental monitoring system architectures to enable exploration beyond Lower Earth Orbit (LEO). The Air Revitalization Lab at KSC is one of six NASA field centers participating in the ARREM that specializes in adsorbent and catalyst characterization with simulated spacecraft gas streams using combinations of pressure, O2 partial pressure, CO2 partial pressure, and humidity that are representative of a range of anticipated cabin atmospheric conditions and loads. On board ISS, the Trace Contaminant Control Subassembly (TCCS) provides active control of trace contaminants from the cabin atmosphere utilizing physical adsorption, thermal catalytic oxidation, and chemical adsorption processes. High molecular weight contaminants and ammonia (NH3) are removed a granular activated carbon treated with approx. 10% by weight phosphoric acid (H3PO4) (B-S Type 3032 4×6 mesh), which is expendable and is periodically refurbished. The Type 3032 granular activated carbon bed is no longer commercially available and therefore it is important to characterize the efficiency and capacity of commercially available NH3 sorbents. This paper describes the characterization of two Molecular Products LTD activated carbons: Chemsorb 1000 and Chemsorb 1425. Untreated activated carbons (e.g. Chemsorb 1000) remove contaminants by physisorption, which concentrates the contaminant within the pores of the carbon while letting air to pass through the sorbent4. Low molecular weight or polar gases (e.g. HCl, SO2, formaldehyde, and NH3) are not removed by physisorption and typically require chemisorption for removal. Treated activated carbons (e.g. Chemsorb 1425) are impregnated with a a chemical agent (e.g. phosphoric acid) that reacts with those gases, converting them to solids or salts within the carbon and removes them from the air stream. This process occurs via neutralization or catalysis reactions and adsorption capacity is exhaustedwhen the available impregnated chemicals are consumed. Moisture affects removal performance since adsorption sites within the pores are filled with water. The performance of impregnated carbons may be enhanced by moisture content because the mechanisms of contaminant removal are chemical reactions that occur in reagents contained within the pores. The adsorptive capacity data (mol/kg) of Chemsorb 1000 and 1425 for gas mixtures (ethanol, acetone, toluene, acetaldehyde, dichloromethane, and xylene) was measured with 40% relative humidity at 23 deg C air temperature. The adsorptive capacity data (mol/kg) of Chemsorb 1425 was measured using NH3 gas streams.

adsorptive capacities↗

NASA NTRS2008

Carbothermal Processing of Lunar Regolith Using Methane

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans currently being developed by NASA. Among various candidate processes, the modeling of oxygen production by hydrogen reduction, molten salt electrolysis, and carbothermal processing are presently being pursued. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source such as a laser beam or a concentrated solar heat flux, so that a small zone of molten regolith is established. The molten zone is surrounded by solid regolith particles that are poor conductors of heat. A continuous flow of methane is maintained over the molten regolith zone. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. Oxygen is produced subsequently by (catalytically) processing the carbon monoxide downstream. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide.

Balasubramaniam, R.↗

NASA NTRS2009

Carbothermal Processing of Lunar Regolith Using Methane

Balasubramaniam, R.↗

DOE OSTI2026

Upgrading Biogas through in situ Conversion of Carbon Dioxide to Biomethane in Anaerobic Digesters

Organic waste streams generated by wastewater treatment plants, agricultural operations, and food processing industries represent an important yet underutilized opportunity for renewable energy production in the United States. Through anaerobic digestion, these waste streams can produce biogas, a mixture primarily composed of methane (CH4) and carbon dioxide (CO2), that can be upgraded to pipeline-quality natural gas. However, most existing upgrading technologies remove CO2 from biogas rather than utilizing it, leaving a significant portion of the potential energy unused. This project investigates a novel biological upgrading approach that converts CO2 into additional CH4 by supplying hydrogen (H2) to specialized microorganisms capable of performing hydrogenotrophic methanation. The main challenges associated with biological biogas upgrading are related to hydrogen supply, gas-liquid mass transfer, and process stability. First, due to the high cost of hydrogen gas, it is preferable that H2 be produced on-site using renewable energy sources such as wind or solar power. Second, hydrogen has low solubility in liquids, which limits its availability to microorganisms and requires strategies to improve gas dissolution and transfer within the reactor. Third, process inhibition may occur as a result of increased pH caused by CO2 consumption or elevated H2 partial pressure, both of which can negatively affect methanogenic activity. Although research in these areas has advanced during the course of this project, these challenges have not yet been fully resolved. To date, the biological systems that have achieved the highest methane concentrations are typically ex-situ reactors, where operational conditions can be more easily controlled. For this reason, the findings of the present project remain highly relevant. The project goal was to develop an innovative system that can accomplish biogas upgrading via biological conversion of CO2 to CH4, in a novel hybrid approach that combines the advantages of both in-situ and ex-situ systems. The proposed system employs a three-phase upflow anaerobic bioreactor with H2 delivery through a gas-permeable membrane, enabling efficient hydrogen transfer and microbial conversion. Under optimized operating conditions, the system achieved 99% H2 consumption and 90% CO2 conversion. A subsequent gas cleaning stage was implemented to further improve gas quality and meet target purity standards. The upgraded gas composition reached 97.7% CH4, 2.2% CO2, and 0.97% O2, while H2S concentrations remained below detection limits. In addition, a flue gas-driven inorganic thermoelectric generator (TEG) system was designed and experimentally validated as a potential source of electricity for H2 production. The system consisted of six TEG modules connected in series and achieved an open-circuit voltage of 4.5 V and a maximum power output of 224 mW at a temperature difference of approximately 53.5 °C, demonstrating effective conversion of waste heat into electrical power under simulated flue gas conditions. Finally, a comprehensive techno-economic analysis was completed to evaluate the capital and operating costs associated with the proposed system. The results provide important insights to guide future scale-up, optimization, and potential deployment of integrated biological biogas upgrading technologies.

09 BIOMASS FUELS↗

NASA NTRSDate not supplied

Wastewater Brine Purification and Recovery through Electrodialysis Ion Exchange

Reutilizing resources onboard the International Space Station (ISS) and for future deep space missions are critical for mission longevity and sustainability. Wastewater brine produced from water recovery systems contain chemical species that could be processed into a potential fertilizer for future plant systems. This can be achieved through a process called electrodialysis ion exchange. Wastewater containing inorganic salt components are fed through a series of ion exchange membranes to produce fertilizer (a phosphate rich stream), electrolysis-grade water, and other useful commodities. Electrodialysis cells consisting of anion and cation exchange membranes, monovalent anion exchange membranes, and bipolar membranes were utilized to achieve selective ion exchange. The use of the electrodialysis cells were effective for both water extraction and ion separation. Ions successfully diffused across their respective membranes into the concentrate, acid, and base streams. This resulted in pure water, a phosphate rich stream, and a separate anion/hydrogen and cation/hydroxide stream. However, sulfate and some phosphate ions were able to diffuse through the monovalent anion exchange membrane into the acid stream. This resulted in predominantly phosphate ions remaining in the concentrate. Optimization of the process was accomplished by altering flowrates of each stream and initial volumes, adjusting the power input and resulting current through each cell, and varying the starting parameters by splitting the inorganic waste input into the diluate and the concentrate. As expected, increasing the flowrate and the power input to each cell reduced the overall time of the process. However, mission constraints may require a longer duration process in order to reduce the power consumption. Further analysis will be required to determine the power input necessary to achieve ion diffusion effectively and in a timely manner.

Ion Exchange Membranes↗

NASA NTRS1991

Free-stream turbulence and concave curvature effects on heated, transitional boundary layers

An experimental investigation of the transition process on flat-plate and concave curved-wall boundary layers for various free-stream turbulence levels was performed. Results show that for transition of a flat-plate, the two forms of boundary layer behavior, identified as laminar-like and turbulent-like, cannot be thought of as separate Blasius and fully-turbulent profiles, respectively. Thus, simple transition models in which the desired quantity is assumed to be an average, weighted on intermittency, of the theoretical laminar and fully turbulent values is not expected to be successful. Deviation of the flow identified as laminar-like from theoretical laminar behavior is shown to be due to recovery after the passage of a turbulent spot, while deviation of the flow identified as turbulent-like from the full-turbulent values is thought to be due to incomplete establishment of the fully-turbulent power spectral distribution. Turbulent Prandtl numbers for the transitional flow, computed from measured shear stress, turbulent heat flux and mean velocity and temperature profiles, were less than unity. For the curved-wall case with low free-stream turbulence intensity, the existence of Gortler vortices on the concave wall within both laminar and turbulent flows was established using liquid crystal visualization and spanwise velocity and temperature traverses. Transition was found to occur via a vortex breakdown mode. The vortex wavelength was quite irregular in both the laminar and turbulent flows, but the vortices were stable in time and space. The upwash was found to be more unstable, with higher levels of u' and u'v', and lower skin friction coefficients and shape factors. Turbulent Prandtl numbers, measured using a triple-wire probe, were found to be near unity for all post-transitional profiles, indicating no gross violation of Reynolds analogy. No evidence of streamwise vortices was seen in the high turbulence intensity case.

Kim, J.↗