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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

A university team approach to regenerative concepts

An interdisciplinary team of university-affiliated scientists and engineers has undertaken the design of a controlled ecological life support system that employs physical, chemical, and biological components to supply and efficiently recycle food, atmospheric gases, water, and waste products. An Integrated Waste and Water Management System furnishes the basic capabilities for waste product preprocessing and for the establishment of baseline comparisons with proven physical and chemical systems. Attention is given to the relationships between food and oxygen supply and the mass fraction of algae in food, as well as to the potential for O2 production.

Nicks, Oran W.↗
NASA NTRS1989

Production of sodium vapor from exposed regolith in the inner solar system

The likely supply of sodium to the lunar exosphere by impact vaporization, by charged particle sputtering, and by photon stimulated desorption has been calculated. These were each compared to the supply of sodium needed to maintain the observed sodium exosphere about the Moon. The two processes already known to act on the lunar regolith, impact vaporization and charged particle sputtering, appear to be sufficient to explain the observed column density of sodium in the lunar atmosphere. Photon-stimulated desorption, given the estimates for the yield of sodium due to this process available in the literature, would produce 100 to 1000 times more sodium than is observed. If impact vaporization is the main source of sodium to the atmosphere of Mercury, then sodium photo-ions in the exosphere of Mercury are efficiently recycled to the planet.

Morgan, T. H.↗
NASA NTRS2009

Starship Life Support

The design and mass cost of a starship and its life support system are investigated. The mission plan for a multi generational interstellar voyage to colonize a new planet is used to describe the starship design, including the crew habitat, accommodations, and life support. Only current technology is assumed. Highly reliable life support systems can be provided with reasonably small additional mass, suggesting that they can support long duration missions. Bioregenerative life support, growing crop plants that provide food, water, and oxygen, has been thought to need less mass than providing stored food for long duration missions. The large initial mass of hydroponics systems is paid for over time by saving the mass of stored food. However, the yearly logistics mass required to support a bioregenerative system exceeds the mass of food solids it produces, so that supplying stored dehydrated food always requires less mass than bioregenerative food production. A mixed system that grows about half the food and supplies the other half dehydrated has advantages that allow it to breakeven with stored dehydrated food in about 66 years. However, moderate increases in the hydroponics system mass to achieve high reliability, such as adding spares that double the system mass and replacing the initial system every 100 years, increase the mass cost of bioregenerative life support. In this case, the high reliability half food growing, half food supplying system does not breakeven for 389 years. An even higher reliability half and half system, with three times original system mass and replacing the system every 50 years, never breaks even. Growing food for starship life support requires more mass than providing dehydrated food, even for multigeneration voyages of hundreds of years. The benefits of growing some food may justify the added mass cost. Much more efficient recycling food production is wanted but may not be possible. A single multigenerational interstellar voyage to colonize a new planet would have cost similar to that of the Apollo program. Cost is reduced if a small crew travels slowly and lands with minimal equipment. We can go to the stars!

Jones, Harry W.↗
DOE OSTI2025

Impacts of Ionizing Radiation on Sulfur Chloride Compounds for Advanced Fuel Cladding Decontamination Processes

Tripling the nation’s nuclear energy capacity is a critical component for significantly increasing energy production and reducing energy costs for American families and businesses. Achieving this vision requires fuel cycle technologies that maximize resource utilization while minimizing radioactive waste generation. Advanced sulfur chloride–based chlorination technologies are being developed to enable efficient recycling of fuel cladding materials, which account for a significant fraction of used nuclear fuel. However, the impacts of ionizing radiation on the longevity and performance of these sulfur chloride compounds are not well established. Here, we will explore the effects of gamma and electron-beam irradiation on the chemical composition of select sulfur chloride reagents, specifically sulfur monochloride (S2Cl2) and thionyl chloride (SOCl2), and the impacts of pre-irradiation on the chlorination yield/chemical dissolution of surrogate aluminum alloy 6061 (AA6061-T6) materials.

38 - RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCL↗
DOE OSTI2025

Gas-solid reaction-based selective lithium leaching strategy for efficient LiFePO 4 recycling

As the electric-vehicle market continues to expand, LiFePO 4 (LFP) batteries, valued for their intrinsic safety and cost-effectiveness, are being increasingly utilized. However, this widespread adoption highlights the urgent need for innovative and environmentally friendly recycling methods for spent LFP batteries due to their relatively low material value and the environmental challenges associated with traditional recycling processes. Here, in this study, we present a novel selective lithium leaching technique that involves a gas–solid reaction with chlorine gas. This method achieves a remarkable leaching efficiency of 99.8 % and a selectivity of 98.8 % at 200 °C within just 10 min, without generating acidic wastewater. The resulting LiCl solution was successfully converted into Li 2 CO 3 with an excellent purity of 99.5 %, while producing NaCl solution as the only byproduct. Notably, the olivine structure of the LFP was preserved as FePO 4 after lithium leaching. The regenerated LFP demonstrated excellent performance, retaining 94.1 % of its capacity after 150 cycles, while the lithium-leached FePO 4 delivered a reversible capacity exceeding 150 mAh/g. This approach not only enhances the efficiency of LFP recycling but also paves the way for more sustainable battery technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Achieving order of magnitude increases in CO 2 reduction reaction efficiency by product separations and recycling

CO 2 reduction reaction (CO 2 RR) systems are the heart of many proposed e-refinery schemes. There have been few studies on the separation systems that will be needed to complement CO 2 RR reactors. Here, we show that by strategic use of downstream separations and recycling of unreacted CO 2 , the efficiency of CO 2 RR can be significantly improved without changes in the electrochemical reactor.

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

Solventless Dual‐Cure Liquid Resins Via Circular Use of Phthalic Anhydride for Recyclable Composite Applications

Abstract Fiber‐reinforced composites (FRCs) possess a remarkable strength‐to‐weight ratio, making them ideal light‐weighing alternative materials of metals used in automotive, aerospace, and outdoor equipment applications, but their recycling is challenging. Chemically recyclable thermoset polymers can enable fiber recovery and reuse; however, challenges remain in the separation and purification of depolymerized small molecules for efficient polymer recycling. To this end, a series of liquid resins for chemically recyclable polymer networks is designed based on phthalic anhydride, a widely produced and inexpensive chemical. The straightforward sublimation of phthalic anhydride is leveraged to enable a simple and efficient separation process for polymer recycling. To liquefy phthalic anhydride, five mono‐acryloyl‐phthalates are synthesized to obtain stable liquid resins together with phthalic diglycidyl ester. These liquid resins undergo dual‐cure reactions that comprise photopolymerization of acrylate and, subsequently, heat‐mediated epoxy‐acid polymerization reactions. These liquid resins exhibit moderate viscosities (2600–6400 cP @ 22 °C), fast curing, and robust thermomechanical properties (T g s from 71 to 116 °C). It is demonstrated that hydrolysis of the dual‐cured polymers completes within 2 h at 80 °C, and direct sublimation produces phthalic anhydride with 82% yield. This resin system is expected to provide a cost‐competitive, highly efficient platform for recyclable FRCs.

Polymer Science↗
DOE OSTI2022

Current Challenges in Efficient Lithium‐Ion Batteries’ Recycling: A Perspective

Abstract Li‐ion battery (LIB) recycling has become an urgent need with rapid prospering of the electric vehicle (EV) industry, which has caused a shortage of material resources and led to an increasing amount of retired batteries. However, the global LIB recycling effort is hampered by various factors such as insufficient logistics, regulation, and technology readiness. Here, the challenges associated with LIB recycling and their possible solutions are summarized. Different aspects such as recycling/upcycling techniques, worldwide government policies, and the economic and environmental impacts are discussed, along with some practical suggestions to overcome these challenges for a promising circular economy for LIB materials. Some potential strategies are proposed to convert such challenges into opportunities to maintain the global expansion of the EV and other LIB‐dependent industries.

25 ENERGY STORAGE↗
DOE OSTI2023

Low temperature hydrogen plasma permeation in palladium and its alloys for fuel recycling in fusion systems

Superpermeation of hydrogen isotopes through metal foils is a critical component for efficient fuel recycling in fusion power systems. In that context hydrogen permeation through foils of palladium and its alloys with silver and copper was studied at low temperature (60 - 200°C) under plasma exposure. These alloys differ significantly in both bulk and surface properties, and comparisons can provide mechanistic insights. Here, permeation was observed only during plasma operation, confirming the negligible contribution of molecular hydrogen to the observed flux. As-received foils required surface treatment to achieve top performance. For Pd and Pd75Ag25 an oxidation treatment increased permeation an order of magnitude, but proved unstable as this desirable surface was reduced under hydrogen plasma exposure. In contrast, an Ar plasma cleaning step provided both high and stable flux. As-received FCC phase Pd60Cu40 foils required annealing to transform it into the high permeability BCC phase that delivered top performance. All foils displayed similar temperature dependence with flux declining with temperature, suggesting that the primary rate-limiting step is absorption of superthermal hydrogen. Among these foils the hydrogen flux through PdCu was 3 - 5X greater than that of Pd or PdAg, which were similar. The superiority of BCC PdCu is attributed to its superior hydrogen desorption kinetics. Using PdCu 100% permeation of supplied hydrogen was achieved, and the flux saturated with increasing plasma power at values >10 –2 mol H•m –2 •s– 1 , and under these conditions permeation rates are equivalent with or without the membrane present. The fluxes achieved are the highest reported to date at these conditions, and the results highlight the important roles of both surface and bulk properties.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Effects of Copolymer Structure on Enzyme-Catalyzed Polyester Recycling

Polyesters are an omnipresent material used for a variety of applications (e.g., bottles, packaging, textile, windshield), roughly comprising 8% of plastics produced worldwide. Enzymatic recycling is an emerging solution to deal with the increasingly diverse polyesters that are not suitable for mechanical recycling. However, enzyme activity and efficiency are still the limiting factors impeding enzymatic recycling for different plastic waste forms. The effects of thermal and structural properties (e.g., glass transition temperature, crystallinity, specific surface area), which are determined by chemical composition and preprocessing, directly influence enzyme recycling efficiency. This work investigates two extrusion methods (single screw and twin-screw extrusion) to pretreat a range of copolyesters (RPET, PETG, Ecozen, Tritan and PBT) and modify their properties (i.e., glass transition temperature (T g ), crystallinity (%), and molecular weight (M n )). A PET-specific enzyme, leaf-branch compost cutinase (LCC ICCG ), produced from a fed-batch fermentation of Escherichia coli BL21(DE3), was used for the enzymatic depolymerization of different polyesters. Several copolyesters showed improved depolymerization after pretreatment, as measured by rate and amount of monomers produced. Furthermore, those that did not depolymerize were found to have exceptionally high glass transition temperature or percent crystallinity, highlighting the importance of these physical parameters on conversion efficiency.

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

Low temperature polyolefin deconstruction via tandem cracking-hydrogenation

The use of aluminum chloride in dichloromethane to crack polyolefin chains in tandem with alkylation of the resulting products has been previously reported as an efficient polyolefin recycling route. Building off this work, we report that a tandem cracking-hydrogenation system also efficiently converts polyolefins into gasoline-range light alkanes at mild temperatures without needing a hydrocarbon co-reactant. This Lewis acid and hydrogenation bifunctional system uses anhydrous aluminum chloride as the acid catalyst and Pd/C as a hydrogenation catalyst to achieve nearly 80 % conversion of low-density polyethylene (LDPE) at 70 °C in three hours, with 90+% selectivity towards gasoline-range (C 4 -C 12 ) branched alkanes. By combining the endothermic cracking reaction with the exothermic hydrogenation reaction, the thermodynamic limitations to low-temperature polyolefin deconstruction can be overcome. In using hydrogenation instead of alkylation, the system’s carbon efficiency is greatly improved, the cost of the reactants is reduced and the overall mass of both reactants and products reduced as well.

Alkylation↗
NASA NTRSDate not supplied

Harnessing Synthetic Communities and Microbial Recycling of Space Waste Streams for Biomanufacturing Applications

The long-term habitation of extraterrestrial environments such as the Moon or Mars presents significant challenges including supplying materials to sustain life. Off-world recycling of waste materials into biomanufacturer products may ameliorate this. Current literature highlights the need for efficient waste recycling systems to support the bioproduction of essential materials including foods, pharmaceuticals, and biomaterials. The study herein concerns itself with the investigation of three key aspects: 1) formulating an optimal wastewater media on which to grow recombinant microbes for bioproduction in space, 2) examining the potential for constructing stable and metabolically synergistic synthetic microbial communities for largescale and multi-tiered biomanufacturing, and 3) testing the efficacy of one such bioengineered enzyme, cutinase, on the degradation of PET plastics characteristic of those found in ISS waste as a model for recombinant recycling-based biomanufacturing of mission-critical substrates. Formulation of an optimal wastewater media involved growing several microorganisms on mixtures of synthetic planetary wastes representative of those found in space waste systems, combined with simple carbon sources derived from a physio-chemical CO conversion system to determine their growth potential. Potential synthetic microbial communities were conceptually designed, and their stability and metabolic synergism was evaluated within the context of co-cultures. Cutinase activity assays were utilized to determine the efficacy of bioengineered cutinase on PET plastic degradation. Findings will contribute to optimization of wastewater-based media formulations, data on stable synthetic microbial communities for bioproduction, and effective methods for measuring cutinase-based PET plastic degradation. These outcomes support the development of sustainable waste recycling systems for space habitation and aim to fill gaps in the current literature and proposing innovative solutions for waste recycling in space environments. By leveraging synthetic biology this study seeks to enhance the feasibility of long-term extraterrestrial habitation through sustainable resource management.

Bioprocessing↗
NASA NTRS2019

Planetary Water Recycling Systems Trade Study

Long-term planetary space missions present new and unique challenges in life-support systems. Water constitutes the majority of the mass required to sustain human life in space and it follows that efficient water recycling has the potential to lower mission costs. The effect of partial gravity in planetary missions mean that terrestrial systems could be applicable. This trade study evaluates terrestrial and NASA developed water recycling technologies on the basis of applicability as a planetary base water recycling systems. Various bioreactors, membrane reactors, filtration, and district water reclamation systems are investigated and rated based on several standardized parameters. A customer-oriented Quality Function Deployment (QFD) is utilized to analyze the ratings of the technologies for the tasks required. The trade study aims to rank the various systems based on their Equivalent System Mass (ESM), Technology Readiness Level (TRL), scalability, crew time, and overall logistics requirements, among others. The results of the study can serve as a basis for future inquiries and studies by NASA and other interested parties. The results of this study provide a down selection from 24 systems to 5 systems that trade very close to each other. The results provide a context and justification for a future comparative hardware test program to determine which of these systems offer the best solution.

Flynn, Michael↗
DOE OSTI2021

An industrial policy framework for transforming energy and emissions intensive industries towards zero emissions

The target of zero emissions sets a new standard for industry and industrial policy. Industrial policy in the twenty-first century must aim to achieve zero emissions in the energy and emissions intensive industries. Sectors such as steel, cement, and chemicals have so far largely been sheltered from the effects of climate policy. A major shift is needed, from contemporary industrial policy that mainly protects industry to policy strategies that transform the industry. For this purpose, we draw on a wide range of literatures including engineering, economics, policy, governance, and innovation studies to propose a comprehensive industrial policy framework. The policy framework relies on six pillars: directionality, knowledge creation and innovation, creating and reshaping markets, building capacity for governance and change, international coherence, and sensitivity to socio-economic implications of phase-outs. Complementary solutions relying on technological, organizational, and behavioural change must be pursued in parallel and throughout whole value chains. Current policy is limited to supporting mainly some options, e.g. energy efficiency and recycling, with some regions also adopting carbon pricing, although most often exempting the energy and emissions intensive industries. An extended range of options, such as demand management, materials efficiency, and electrification, must also be pursued to reach zero emissions. New policy research and evaluation approaches are needed to support and assess progress as these industries have hitherto largely been overlooked in domestic climate policy as well as international negotiations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Recycling Epoxy by Vitrimerization: Influence of an Initial Thermoset Chemical Structure

Epoxy/anhydride cured thermosets are widely used in aerospace and wind energy structures. Recycling the enormous amounts of epoxy thermoset waste remains a global challenge. Vitrimerization, a practical, low-cost, eco-friendly and scalable method was developed for closed-loop recycling of the crosslinked epoxy by converting the permanent network into a vitrimer type dynamic network. Here we study the effect of virgin epoxy network properties on network reforming efficiency and the activation energy of the dynamic network by varying the epoxy/anhydride ratio. The results point out that the permanent network crosslink density and glass transition temperature have a more pronounced effect on vitrimerization efficiency by comparison with the concentration of free hydroxyl groups in the system. Furthermore, the result can be potentially used to better control vitrimerization efficiency in recycling epoxy thermoset polymers and tailor the vitrimerized products properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Complete the Design, Cost Estimate, Assembly Plan, and Operating Instructions for a Bench-Scale Packed-Bed Tubular Methanol Catalyst Testing System

This report details the design of a test stand that converts carbon dioxide and hydrogen into methanol via a two-step process. The first step is a reverse water-gas shift reaction, carried out at 600°C and 25 bar to reduce carbon dioxide to carbon monoxide, and the second is a synthesis reaction that forms methanol at 260°C and 75 bar. The purpose of the system is to test catalysts for each of these steps. The test stand produces approximately 1.5 gallons of crude methanol (methanol mixed with water) per day, and recycles unreacted syngas for increased efficiency. At peak recycle, the stand is expected to consume 0.29 cylinders per day of carbon dioxide and 1.43 cylinders per day of hydrogen. It is planned to be built next to the Blue Star electrolysis unit in the Energy Systems Laboratory (ESL) and includes future plans of acquiring hydrogen from that stand rather than gas cylinders. At this phase of research, three key documents have been produced, as summarized in Table 1. These documents are primarily intended to describe the system and its operation, demonstrate that selected components are appropriate for the intended application, identify potential hazards, safeguards, and mitigation strategies, and ensure that the system is designed to appropriate standards. The body of the report and its appendices provide a narrative of the work completed in FY25. The parts required to build the test stand will be procured and assembled in FY26. Testing will be conducted in the final quarter.

10 - SYNTHETIC FUELS↗
DOE OSTI2023

Comparing Parallel Plastic‐to‐X Pathways and Their Role in a Circular Economy for PET Bottles

Abstract The United States generates the most plastic waste of any country and is a top contributor to global plastic pollution. Multiple end‐of‐life strategies must be implemented to minimize environmental impacts and retain valuable plastic material, but it is challenging to compare options that generate products with different lifetimes and utilities. Herein, they present a material flow model equipped with consequential life cycle assessment, cost analysis, and a plastic circularity indicator that considers product quality and lifetime. The model is used to estimate the greenhouse gas (GHG) emissions, circularity, and cost of polyethylene terephthalate (PET) bottle mechanical downcycling to lower‐quality resin, closed‐loop glycolysis to food‐grade PET, upcycling to glass fiber‐reinforced plastic, and conversion to non‐plastic products (electricity, oil) on a United States economy‐wide basis for the year 2020. A brute force algorithm suggests that a combination of 68% glycolysis, 11% mechanical recycling, 6% upcycling, 9% landfilling, and 5% incineration can minimize the cost and GHG emissions and maximize the circularity of the current PET economy. However, uncertainty around transportation distances, materials recovery facility efficiencies, and recycling yields can result in different “optimal” pathway mixes. This flexible framework enables informed decision‐making to move toward a cost‐ and environment‐conscious circular economy for plastic.

09 BIOMASS FUELS↗