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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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DOE OSTI2024

Deploying a New AI Software Tool for Rapid Characterization & Quantification of Unconventional Sources of Critical Minerals

Poster for the 2024 NETL Resource Sustainability Meeting. The poster presents a new project award by the Office of Technology Transitions to accelerate application and commercial utilization of an NETL-developed technology to rapidly characterize critical mineral occurrences within secondary and/or unconventional feedstocks, such as coal refuse or waste impoundments.

Creason, Christopher↗
DOE OSTI2025

Initial Design of SABRE Fueled Molten Salt Experiment Irradiation Vehicle

Molten Salt Reactors (MSRs) are emerging as promising advanced reactor technologies, utilizing molten salts for both fuel and primary cooling. These reactors may offer advantages such as passive safety, enhanced economic viability, and efficient waste reprocessing while operating at high temperatures and low pressures, which leads to increased system efficiency and reduced mechanical stress on containment structures. However, challenges arise from the complex chemistry and high corrosion rates of fueled molten salts, alongside the volatility of certain fission products during irradiation. The accumulation of these fission products can alter the fuel salt chemistry, affecting corrosion potential and radioactive source terms. Therefore, understanding these phenomena under neutron irradiation is essential for future MSR designs. The SABRE (Salt and Actinide Burnup in a Reactor Environment) experiment, currently in conceptual design at Idaho National Laboratory (INL), aims to investigate these challenges by conducting a drop-in capsule experiment in the Advanced Test Reactor (ATR). The primary objectives include achieving a minimum burnup of 2 GWd/MTU and characterizing fission products while studying corrosion behavior in molten salt systems. This innovative experiment will leverage recent advancements in ATR capabilities, allowing for the safe irradiation of molten salts, thereby advancing the understanding and qualification of MSR technology for future nuclear power generation.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Sustainable upcycling of polyethylene waste to compatibilizers and valuable chemicals

Controllable functionalization of polyethylene (PE) waste could generate new polymeric materials that are generally difficult to manufacture sustainably while also addressing the growing plastics waste problem. However, these modifications remain challenging due to the inherent stability of the PE backbone. Non-thermal atmospheric plasma enables molecular activation under mild conditions while utilizing renewable energy but is primarily employed for surface modification, as plasmas do not penetrate the bulk of materials. Herein, controllable bulk oxidative functionalization of PE wax (PEW) and low-density PE (LDPE) of varying molecular weights was achieved, with up to 6 mol% oxygen incorporation, by manipulating melt viscosity. This functionalization was accomplished either through temperature adjustment or by introducing a melt viscosity modifier, removable via simple extraction methods, to reduce LDPE viscosity, enhance diffusion and chain mobility, and enable bulk oxidation. The oxidized LDPE induces compatibilization in blends of poly(lactic acid) (PLA) and LDPE with improved interfacial adhesion and mechanical properties, such as a 70% increase in elongation-at-break values vs. the control. These findings pave the way for catalyst-free upcycling of direct plastics waste and plastics waste-derived products, enabling the creation of high-value products across various markets.

Plastic upcycling↗
DOE OSTI2020

Advanced Retrieval and Disposition Techniques for Remote Handled Mixed Low-Level Waste - 20319

Legacy waste generated by the sodium-cooled fast reactor, EBR-II, program at the Idaho National Laboratory (INL) (owned by the U.S. Department of Energy and managed and operated by Battelle Energy Alliance, LLC) is challenging to treat and disposition using conventional methods. As a result, Veolia Nuclear Solutions is under contract with the Idaho National Laboratory to demonstrate an integrated retrieval and disposition solution for Remote-Handled Mixed Low-Level Waste currently stored in underground liners at INL. Delivery of the integrated solution builds on the expertise and successes of Veolia Nuclear Solutions under its Problematic Waste Treatment Initiative with INL. This initiative focuses solely on the treatment of problematic (reactive metal containing) waste streams using the Veolia Nuclear Solutions GeoMelt{sup R} In-Container Vitrification (ICV{sup TM}) technology. Under the contract, Veolia Nuclear Solutions will provide a fully commissioned prototype remote retrieval system to semi-remotely retrieve and size-reduce problematic waste liners into a safe and consolidated package for transport. The consolidated package will be shipped to Richland, Washington for demonstration treatment using the robust GeoMelt Richland system at Perma-Fix Northwest. The treated waste will ultimately be disposed of as a vitrified Low-Level Waste glass monolith. Veolia Nuclear Solutions has delivered countless remotely operated systems globally to solve some of the industry's most challenging problems. To ensure risk is mitigated in the best possible manner, a methodical phased approach is being utilized to validate the integrated solution. This contract focuses on the delivery and deployment of the prototype retrieval system onsite and the treatment of a single liner. Following successful demonstration treatment using GeoMelt ICV, the project is planning to make prototype enhancements before retrieving and treating another liner. Establishing a new integrated approach for retrieval and disposition of waste offers many benefits to INL and the U.S. Department of Energy. It is anticipated that the integrated solution will provide significant cost and schedule savings by increasing the number of liners dispositioned per year. In addition, the complexity of the overall waste disposition process will be reduced. Remotely retrieving and size-reducing waste in the field will provide additional safety to operational personnel and allow critical resources, such as hot cells, to focus on the primary missions at hand. Vitrification (using the GeoMelt ICV technology) allows for the direct processing of metal clad waste thereby significantly reducing pretreatment steps while providing a robust waste form for long-term disposal. The results from this ongoing contract are presented in this paper. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Ion Exchange Processing of AP-105 Hanford Tank Waste through Crystalline Silicotitanate in a Staged 2- then 3-Column System (Rev.1)

The Tank Side Cesium Removal (TSCR) system, under development by Washington River Protection Solutions LLC (WRPS), will send initial low-activity Hanford waste tank supernate feeds to the Hanford Waste Treatment and Immobilization Plant (WTP) Low-Activity Waste (LAW) Facility. In addition to entrained solids removal from the supernate, the primary goal of TSCR is to remove cesium-137 ( 137 Cs) by ion exchange, allowing contact handling of the liquid effluent product at the WTP. Crystalline silicotitanate (CST) ion exchange media, manufactured by Honeywell UOP, LLC (product IONSIVTM R9140-B), was selected as the ion exchange media at TSCR. CST is a non-elutable inorganic material that has demonstrated robust chemical, physical, and radiation tolerance while maintaining functionality. However, exchange kinetics of Cs onto CST is slow, resulting in low utilization of the CST Cs load capacity before unacceptable Cs breakthrough. Two process flow designs have been tested, as follows. 1. Lead-lag column processing: The lead column was removed after the lag column effluent reached the waste acceptance criteria (WAC) limit, the lag column was moved into the lead position, and a new lag column was installed. This format used ~52% Cs load capacity on the lead column. 2. Lead-lag-polish column processing: The processing was stopped when the polish column effluent reached the WAC limit. This format resulted in 81% Cs load capacity on the lead column. Testing with diluted feed from Hanford tank AP-105 (AP-105DF) incorporated a nuanced change to the lead-lag-polish column system where the polish column was inserted when the lag column effluent reached WAC limit. A 10.9-L volume of AP-105DF (diluted to 5.6 M Na) was processed through the Direct Feed Test Platform system, established at Pacific Northwest National Laboratory to support small-scale waste qualification efforts. The columns consisted of 10-mL CST beds (CST Lot 2002009604, sieved to screen out >30-mesh particles) placed in 1.5-cm-inner-diameter columns. Feed was processed at 1.83 bed volumes (BV) per hour; the flowrate, in terms of contact time with the CST bed, matched the expected flowrate at TSCR. The <30-mesh CST sieve cut was expected to provide appropriate performance scaling to a full-height column. The installation of the polish column later in processing (after processing 523 BVs) did not appear to fundamentally change the utilization of the lead column for Cs exchange nor did it extend the total feed processing volume when compared to the previous test with AP-107 feed. Table ES.1 and Figure ES.1 summarize the measured AP-105DF Cs load performance.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Summary of Information Available and Recommendations for a Doe Complex-Wide Waste Glass Database

The purpose of this document is to summarize the existing repositories of nuclear waste glass property-composition data produced for DOE. A framework is described for consolidation of the data into a single database. Recommended attributes of the consolidated database are provided, including quality assurance, the user interface, and means for updates and maintenance. Future work will utilize the framework described herein to produce the complex-wide database and establish the user interface.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Biobased chemical recycling: aminolysis of PET using renewable reagents and monomers to synthesize new semi-aromatic polyamides

Chemical recycling of PET is a method of depolymerizing polymer chains to monomeric components enabling the synthesis of second-generation materials with virgin-like quality. Commercial chemical recycling techniques rely upon high pressure methanolysis to create precursors capable of synthesizing a second-generation PET resin. However, despite the circular approach of methanolysis, a product with a very short lifespan and similar value is created. The approach of the current study is to utilize aminolysis as an ambient pressure technique to create precursors for higher value materials with longer lifespans to address the current crisis in plastic waste. Semi-aromatic polyamides (SAP) are desired in this circumstance because of their high melting point and heat resistance combined with good melt-processability similar to aliphatic polyamides. In this study SAPs were synthesized using precursors recovered from the aminolysis of PET employing biobased diamines and dicarboxylic acids. While aminolysis has been explored in previous studies, this work investigated the use of biobased components from castor oil: decamethylene diamine during recycling and sebacic acid during polymerization. Polymer synthesis resulted in the formation of SAPs similar to polyphthalamides (PPA) with novel structures given the aromatic portion from terephthalic acid (TPA) and aliphatic portion from the diamines and diacids. The synthesized materials exhibited excellent thermal stability with high glass transition temperatures. Novel polymers were created with varying aliphatic chain length to understand fundamental parameters needed to produce a valuable polymer from post-consumer waste.

High performance Applications↗
DOE OSTI2020

Analytical Study to Use the Excess Digester Gas of Wastewater Treatment Plants

This study presents an analytical method that can be used to enhance the power production rate and the energy-saving at wastewater treatment plants. The digester used at wastewater treatment plants produces digester gas by anaerobic digestion, with which biofuel production can be achieved. Biofuels can be used to meet some of the energy requirements of the wastewater treatment facility through combined heat and power (CHP) gas engines (cogeneration). Using micro gas turbine (MGT), a CHP technology can be introduced in wastewater treatment plants (WWTPs). The combination of MGTs and absorption chillers is a promising technology as it produces electricity, heating, and cooling simultaneously. The study demonstrated how the waste heat of MGTs could be used to drive absorption chillers. In this analytical study, a detailed technical and economic analysis is provided on the trigeneration system, i.e., the integration of MGTs and absorption chillers driven by waste digester gas of the wastewater treatment plants. It can meet the heating and cooling demands of the plants, which promote the reduction of utility costs. The technology presented is also useful for other thermal energy users.

09 BIOMASS FUELS↗
DOE OSTI2022

Process and Applications Development for Recycled Mixed-Stream Composites

The goal of this IACMI Phase II Technical Collaboration Project was to establish the viability of producing affordable, recycled composite parts, which were produced from fibers with the properties in the range of those reclaimed through the controlled pyrolysis technology demonstrated in Phase I. For the purpose of this report, we use the terms “recovered carbon fiber” (rCF) and “recovered glass fiber” (rGF) as the material reclaimed from controlled pyrolysis. This fiber recycling technology utilizes the inherent energy in composites for fuel and preserves the structural value of glass fiber (GF) and carbon fiber (CF) for reuse. It can also be used for recycling other waste streams at the same facility, thus spreading capital risk and recovery across multiple industries and achieving economy of scale. A second goal to be addressed was the viability of using recycled fibers as reinforcing materials in additive manufacturing applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Sol–gel synthesis of iodosodalite precursors and subsequent consolidation with a glass binder made from oxides and sol–gel routes

Radioiodine accumulates in aqueous solutions and off-gas streams during nuclear fuel reprocessing due to its solubility in aqueous solutions and volatility, respectively. Additionally, radioiodine is highly mobile in geological environments and iodine-129 has been found to be one of the largest long-term contributors to chronic dose to humans in scenarios of radionuclide migration from geological repositories. Most of the radioiodine can be captured during fuel reprocessing in off-gas streams using solid sorbents and scrubbing solutions. Once iodine is captured, it must be stored in a durable form for eventual disposal. Iodosodalite has been investigated as a waste form for radioiodine, however these synthesis processes typically result in mixed products and iodine volatilization during consolidation. Therefore, this paper proposes a novel approach to synthesizing iodosodalite utilizing a sol-gel method. This method was chosen to lower processing temperatures and improve product yield. Preliminary experiments conducted to determine the viability of this synthetic method are presented. Additionally, consolidation of sol-gel derived iodosodalite with a glass-binder was explored using three different methods: 1) incorporating the glass-binder during gel preparation using alkoxide precursors; 2) separately preparing the glass binder using a sol-gel method; and 3) separately preparing the glass-binder using a melt-quench technique. Glass-bonded iodosodalite was successfully synthesized using these novel sol-gel approaches.

36 MATERIALS SCIENCE↗
DOE OSTI2022

West Virginia University Industrial Assessment Center (Final Progress Report)

The Industrial Assessment Center at West Virginia University has been successful in workforce development, and in generation of energy savings for manufacturing facilities during the period 2016 to 2021. Graduate and undergraduate students have benefited from energy assessment experience and most of them have found good positions as energy engineers and analysts in the industrial sector. Several peer reviewed research papers in archival journals as well as conference papers on the topic of energy engineering and assessment have been published. The implemented energy savings for manufacturing facilities have been significant in the areas of lighting, compressed air, process heating, steam, HVAC, chillers and cooling towers, and motors. In addition, water use reduction, smart manufacturing applications to save energy, cyber security evaluation, energy management, productivity improvements and waste reduction opportunities that lead to energy intensity reductions have been explored. The students have obtained an opportunity to interact with energy efficiency and productivity improvement professionals at various conferences and workshops and their research has generated important results. In summary, the West Virginia University Industrial Assessment Center (WVU-IAC) has fulfilled its mission in regard to workforce development, energy efficiency for manufacturing facilities, and laid a strong platform enhancing sustainability through reductions in carbon emissions achieved through energy efficiency and energy management initiatives and reductions in water usage and waste reduction. During the project period (2016-2021) the WVU-IAC has made numerous energy efficiency, water use reduction, waste reduction, and productivity improvement recommendations, a significant number of them having been implemented by the manufacturing facilities. The research adds significant understanding to the area of energy efficiency, water and waste reduction, and productivity improvement. The technical effectiveness and economic feasibility of the methods and techniques investigated and demonstrated through this project have been exemplary, resulting in significant recommended and implemented resource savings and reductions in carbon emissions. The project has been of significant benefit to the public owing to replication of results within the industrial sector, thus reducing operating costs for businesses that result in increase of growth and employment, as well as community benefits in terms of reductions in carbon emissions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Enabling Partnership between South Carolina and NREL for Advancing Opportunities in Plastics Recycling Research (EPSCOR for Plastics Recycling)

Proposal Objectives: 1. Utilize depolymerization/fractionation techniques to recover highly processable and reactive feedstocks for polymer synthesis from lignin. 2. Synthesize lignin‐derived non‐isocyanate polyurethane, epoxy, and polyamide using non‐ toxic, biobased route designed for chemical recycling. Characterize resulting materials. 3. Design a high‐yielding chemical recycling process for as‐synthesized materials yielding usable building blocks for many generations of polymer synthesis. 4. Optimize chemical recycling of PET waste for the synthesis of lignin‐based polymers. Compare properties to commercial materials. 5. Optimize reaction conditions and recycling steps to facilitate enhanced sustainability of the synthetic steps and final properties of materials. 6. Complete a lifecycle assessment of lignin utilization and chemical recycling to compare their environmental performance to that of materials produced from virgin material. Identify hot spots and benefits using the chemical recycling process.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Reduction of Pertechnetate by Chemical and Photochemical Approaches and Incorporation of Tc(IV) into Titanium Dioxide

Technetium-99 is a prevalent fission product from nuclear waste. The long half-life (211,000 yr) and environmental mobility of pertechnetate (TcO 4 - ) render Tc particularly challenging to isolate and stabilize. Here, in this study, we present two approaches for development of potential wasteforms using titanium dioxide, TiO 2 . Approach 1 is a low temperature chemical synthesis of TiO 2 doped with Tc(IV) from TcO 4 - intended to mimic the Tc waste stream from the UREX family of separations and removes 98.5 % of the Tc, mainly present as edge-shared Tc(IV) pairs. Approach 2 utilizes TiO 2 to photocatalytically reduce TcO 4 - to Tc(IV) stabilized on the surface of or within the TiO 2 lattice. The %Tc removed from solution and adsorbed to TiO 2 is pH dependent, with the maximum Tc(IV) adsorbed at pH 3–4 as either TcO 2 or edge-sharing Tc(IV) octahedra. The Tc(IV)-TiO 2 composites materials formed by both approaches are suitable for consolidation into a dense wasteform by Hot Isostatic Pressing (HIPing).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Molecular Level Understanding of Polyethylene Terephthalate (PET) Depolymerization in Base/Alcohol Hybrid Systems

Polyethylene terephthalate (PET) depolymerization in base/alcohol hybrid systems represents a promising low-energy approach for chemically recycling PET waste into valuable monomers. This study investigates the mechanistic pathways of PET depolymerization in NaOH/alcohol solutions, emphasizing the competing roles of hydroxide and alkoxide species. Utilizing a combination of experimental techniques, density functional theory (DFT) calculations, and molecular dynamics (MD) simulations, we explore how factors such as base concentration, alcohol chain length, and pKa values of alcohols influence PET depolymerization efficiency and pathways. Our findings indicate that alkoxide ions (RO⁻) exhibit notably higher reactivity than hydroxide ions (HO⁻), favoring an alcoholysis pathway in the base/alcohol hybrid system. Experimental results across a series of C1 to C5 alcohols show that longer-chain alcohols, particularly 1-butanol, achieve higher PET conversion, although this does not align solely with simple nucleophilicity trends of alkoxides. While DFT calculations reveal comparable activation energies for various alkoxides in PET depolymerization, MD simulations underscore the significant role of alcohol chain length, with longer-chain alcohols forming more stable or frequent interactions with PET. Additionally, the alkoxide concentration, influenced by the alcohol’s pK a , directly impacts PET conversion. These suggest that PET depolymerization is governed by a balance between alkoxide concentration and alkoxide-PET interactions, rather than activation energies or nucleophilicity alone. From a practical perspective, incorporating long-chain alcohols as cosolvents may enhance process efficiency but increases raw material costs by approximately 30%. However, long-chain alcohols present a safer and more sustainable alternative to hazardous cosolvents such as dichloromethane. This work offers a molecular-level understanding of PET depolymerization in base/alcohol systems and provides insights into optimizing these systems for more efficient and sustainable PET recycling processes.

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

Mathematical Foundations for Nonlocal Interface Problems: Multiscale Simulations of Heterogeneous Materials (Final LDRD Report)

Nonlocal models provide a much-needed predictive capability for important Sandia mission applications, ranging from fracture mechanics for nuclear components to subsurface flow for nuclear waste disposal, where traditional partial differential equations (PDEs) models fail to capture effects due to long-range forces at the microscale and mesoscale. However, utilization of this capability is seriously compromised by the lack of a rigorous nonlocal interface theory, required for both application and efficient solution of nonlocal models. To unlock the full potential of nonlocal modeling we developed a mathematically rigorous and physically consistent interface theory and demonstrate its scope in mission-relevant exemplar problems.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Mobile Hot Cell Digital Twin: End-of-life Management of Disused High Activity Radioactive Sources – 23598

Sealed radioactive sources are utilized for a wide range of applications across nuclear facilities, universities, hospitals, and industry. When these sources reach the end of serviceable life, they become waste. As waste, this radioactive material then goes through a process of recapture and then transfer to long term storage. With the advancement of technology in conjunction with better accessibility of technology, industries are exploring the use of digital automation to enhance productivity, efficiency, and safety while minimizing operation and maintenance costs, health and environmental risks, and uncertainty in the project life cycles. One area for exploration is the use of a digital twin to help design a robust, versatile, and safe solution for recapturing spent sources. We believe this avenue can also provide further advantages in the operations aspect of end-of-life management of spent radioactive sources by reducing the deployment time, increasing operator safety, and reducing operation & maintenance cost. We present a novel digital twin framework for end-of-life management of disused high activity radioactive sources. We have designed and developed a framework that houses a digital twin for visualizing and monitoring the recapture process to inform the engineering and design of a new Mobile Hot Cell. Furthermore, we demonstrate the feasibility of the proposed framework by providing a prototypical implementation, supporting the Mobile Hot Cell and human-machine interface's virtual replication.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2020

Anthropogenic Markers in Alta Irrigation District Water Supply Wells

In July 2016, LLNL produced a report for the Kings River Watershed Coalition Authority (KRWCA) entitled “Groundwater Age and Nitrate Isotopic Composition in Alta Irrigation District Water Supply Wells” (Esser et al., 2016). That report summarized groundwater age and nitrate isotopic composition data produced by LLNL for Alta Irrigation District (AID) groundwater wells sampled by KRWCA in a pilot project to test the utility of advanced isotopic methods for constraining the timing and source of nitrate in groundwater at selected sites in the Kings River service area. One section of that report made recommendations for follow-on study. The first and strongest recommendation was to measure a wider suite of source tracers including co-contaminants such as herbicides, pesticides, pharmaceuticals, personal care products, and food constituents and additives. KRWCA followed up on this recommendation in Phase II of the pilot study by re-sampling the original set of wells and submitting the samples to a commercial laboratory for analysis of a limited range of co-contaminants (including pharmaceuticals, personal care products , and food constituents and additives, but not including herbicides or pesticides). They have asked that LLNL review and interpret these data in the context of previous LLNL analyses and to evaluate the utility of such co-contaminant analyses in providing additional constraints on the source of groundwater nitrate contamination in Alta Irrigation District water supply wells. The goal of the second phase of this pilot project is to evaluate the utility of co-contaminant occurrence for constraining nitrate source in groundwater at selected sites in the Kings River service area, with special reference to the use of such data in conjunction with advanced isotopic methods such as nitrate isotopic composition and groundwater age. Nitrate isotopic composition alone cannot distinguish nitrate derived from animal manure from nitrate derived from human septic waste. The presence or absence of agricultural chemicals (herbicides, pesticides, veterinary pharmaceuticals) or chemicals associated with people (human pharmaceuticals, artificial sweeteners) can help make this distinction. Co-contaminant analyses using multi-analyte LC-MS-MS protocols are now commercially available and reasonably priced. The feasibility and utility of the using co-contaminants for nitrate source attribution can be evaluated by 1) determining the degree to which co-contaminants occur in distinct and easily attributable groupings (e.g. agricultural chemicals vs personal care products and food additives); 2) determining the degree to which co-contaminant occurrence is consistent with nitrate isotopic composition and groundwater age (e.g. no co-contaminant occurrence in very old groundwater; co-contaminants consistent with animal manure or human septic waste occurring in groundwaters having nitrate isotopic composition also consistent with animal manure or human septic waste); and 3) determining the degree to which co-contaminants provide additional constraint on nitrate source over and beyond nitrate isotopic composition and groundwater age (e.g. distinguishing between animal manure and human septic waste).

58 GEOSCIENCES↗
DOE OSTI2025

Technoeconomic Analysis of a Microwave-Assisted Novel Process That Converts Polypropylene Plastic Waste to Propylene

Propylene is an important petrochemical that is used in various industries, including the automobile and polymer sectors. Conventionally, propylene has been produced through fluid catalytic cracking, steam cracking, and propane dehydrogenation. In this project, a novel process to produce propylene from polypropylene plastic waste using a microwave reactor is introduced. Propylene production is simulated in Aspen Plus for both the conventional propane dehydrogenation process and the novel design, with heat integration applied to minimize utility demands and the conventional process serving as the base case for comparison. Finally, a tailored technoeconomic analysis is carried out for both simulated cases to estimate important economic indicators. Analysis of the results shows that the novel microwave-assisted process outperforms the conventional route for propylene production, achieving a single-pass conversion of almost 100%, compared with only 33.8% in the conventional plant. The Net Present Value of the novel plant is $\$1720.3$ MM, which is 3.5 times higher than the conventional process, while the Levelized Cost of Propylene is reduced by 40%. Capital and operating expenditure are also improved in the proposed scheme, with reductions of approximately $\$29$ MM and $\$222$ MM/yr, respectively. In addition to cost savings, this novel process also provides a convenient means to recycle waste polypropylene.

42 ENGINEERING↗