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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
DOE OSTI2025

Calculating the Effects of Solids Input and Removal as a Temperature Control in the Advanced Scale Up Reactor Experiment (ASURE) Facility at NETL Using Aspen

The Advanced Scale Up Reactor Experiment (ASURE) facility at NETL is being designed to be a fuel-flexible multi-purpose reactor that can be used for pyrolysis/gasification or evaluation of other high pressure “circulating fluidized bed” (CFB) chemical processes. The initial system design calculations for pyrolysis/gasification are presented in this work showing the expected performance of the ASURE facility when used as a biomass conversion reactor. Several other areas of application include gasification of any carbonaceous fuel including biomass, coal, plastics, and other waste materials. The reactor can therefore be used to produce SYNGAS of various compositions and hydrogen as well as other high value chemicals resulting from a typical tuned gasification process. This paper discusses an ASPEN model of the facility, focusing on the riser of the CFB reactor and the solids recirculation loop. The ASPEN model divides the riser into two sections. A bottom section which receives ash, char and sand which have been recirculated from a return loop. In this section an inert fluidization gas, (N2 or CO2), is introduced which acts as the primary mover of the solids through the system. The bottom section is equipped with a restricted air feed so that the recirculated char can be partially oxidized. This oxidation process along with the inventory of recirculating sand are used to effectively control the temperature in the following two chemical conversion sections of the reactor which are the pyrolysis zone followed by a tar cracking zone. Fresh fuel is added to the pyrolysis zone and undergoes drying and devolatilization. The products ash, char, volatile matter, and water vapor exit the pyrolysis zone and enter the reaction block for tar cracking. Steam and CO2 gasification reactions will be incorporated into the tar cracking zone, however at the design operating temperature, conversion from these reactions is expected to be essentially zero. The unit when completed in 2026 will test mixtures of biomass, plastics, and waste coal. This presentation discusses the basic ASPEN engineering design model for this project and provides preliminary sensitivity studies to determine how the various parts of the reactor will perform.

ASSURE↗
DOE OSTI2025

Calculating the Effects of Solids Input and Removal as a Temperature Control in the Advanced Scale Up Reactor Experiment (ASURE) Facility at NETL Using Aspen

The Advanced Scale Up Reactor Experiment (ASURE) facility at NETL is being designed to be a fuel-flexible multi-purpose reactor that can be used for pyrolysis/gasification or evaluation of other high pressure “circulating fluidized bed” (CFB) chemical processes. The initial system design calculations for pyrolysis/gasification are presented in this work showing the expected performance of the ASURE facility when used as a biomass conversion reactor. Several other areas of application include gasification of any carbonaceous fuel including biomass, coal, plastics, and other waste materials. The reactor can therefore be used to produce SYNGAS of various compositions and hydrogen as well as other high value chemicals resulting from a typical tuned gasification process. This paper discusses an ASPEN model of the facility, focusing on the riser of the CFB reactor and the solids recirculation loop. The ASPEN model divides the riser into two sections. A bottom section which receives ash, char and sand which have been recirculated from a return loop. In this section an inert fluidization gas, (N2 or CO2), is introduced which acts as the primary mover of the solids through the system. The bottom section is equipped with a restricted air feed so that the recirculated char can be partially oxidized. This oxidation process along with the inventory of recirculating sand are used to effectively control the temperature in the following two chemical conversion sections of the reactor which are the pyrolysis zone followed by a tar cracking zone. Fresh fuel is added to the pyrolysis zone and undergoes drying and devolatilization. The products ash, char, volatile matter, and water vapor exit the pyrolysis zone and enter the reaction block for tar cracking. Steam and CO2 gasification reactions will be incorporated into the tar cracking zone, however at the design operating temperature, conversion from these reactions is expected to be essentially zero. The unit when completed in 2026 will test mixtures of biomass, plastics, and waste coal. This paper presents the basic ASPEN engineering design model for this project and provides preliminary sensitivity studies to determine how the various parts of the reactor will perform.

ASSURE↗
DOE OSTI2025

Manufacturing Valuable Coal-Derived Products in Southern Appalachia

This project’s objective is to develop and deploy new technologies for manufacturing rare earth elements (REE), critical minerals (CM), and valuable non-fuel, carbon-based products (CBP) from coal and/or coal waste in the SoApp Basin, thus revitalizing distressed SoApp coal communities and reducing reliance on foreign imports of REE and CM. Resource availability and technological advances alone will not ensure this objective is met. The right mix of business climate, market forces, and policy will also be needed. This report identifies the critical technologies, infrastructure, supply chains, human capital, and policy gaps that must be addressed to manufacture REE, CM, and CBP from coal resources and wastes in SoApp The primary goal of the project is to characterize the resource base in the SoApp Basin.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

High Pressure DME-Driven Fractional Crystallizations

Rare Earth Elements (REEs), include the 15 lanthanides plus yttrium and scandium and are crucial for various technologies and applications. Their low concentrations in the earth's crust require alternative sources. This study explores antisolvent fractional crystallization (FC) using dimethyl ether (DME) under high pressures to extract REEs from secondary sources such as mining waste, coal byproducts, and e-waste. DME's properties, including its solubility in water, small molecular size, and high vapor pressure, make it an effective antisolvent that can be easily recovered and reused. The method involves pressurizing DME to 1000-2000 psi in a reaction chamber with the test solution, followed by sample collection and analysis using ICP-MS and ICP-OES. This approach aims to address the limitations of current extraction methods, such as high energy consumption, chemical usage, and waste production, offering a potentially more efficient and sustainable solution for REE extraction.

37 - INORGANIC, ORGANIC, PHYSICAL AND ANALYTICAL C↗
DOE OSTI2024

Carbon Ore-Derived Critical Materials for Clean Energy Technologies

Conference presentation at American Institute of Chemical Engineers (AIChE) Annual Meeting, San Diego, California, October 27–31, 2024. Trends in the manufacture of electric vehicles that use graphite-based LIBs are rising steeply in the United States and globally, but the U.S. domestic supply chains for graphite, the largest component in an LIB by mass, is severely limited and faces complicated geopolitical dynamics with foreign sources. Consequently, the United States has designated graphite as a critical mineral to focus attention and resources to develop technologies to meet the challenge of limited domestic graphite supply chains. Results obtained so far based on the UCOP process have successfully validated the technology at the laboratory scale, with the produced graphite material showing up to 95% degree of graphitization, high carbon purity of ~99.98%, residual ash content of ≤0.02%, negligible moisture, low trace elements, and high electrochemical stability. These results suggest that the emerging UCOP technology is a promising approach to effectively synthesize high-quality graphite from abundant coal and coal waste resources in the United States to create a sustainable domestic critical graphite supply chain. A brief description of the status of UCOP process development and representative results will be presented.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Carbon Ores-Derived Critical Materials for Clean Energy Technology Applications

Presented at the 48th International Technical Conference on Clean Energy (Clearwater Clean Energy Conference), Clearwater, Florida, June 16-19, 2024. This presentation describes the Energy & Environmental Research Center’s development of the Upgraded Carbon Ores-to-Products (UCOP) technology to produce high‑quality graphite and other critical materials from coal and coal wastes for clean energy applications such as batteries and electrodes. It outlines the technical approach, including feedstock cleaning, controlled heat treatment, and graphitization, and presents results demonstrating high graphite purity, novel microstructures, and competitive performance relative to commercial graphite. The work highlights the potential for lower environmental impact and domestic supply chains for critical materials amid increasing global demand and supply‑chain constraints.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Assessing the Extractability of Rare Earth Elements from Coal Preparation Fines Refuse Using an Organic Acid Lixiviant

We report that this work is a first-order study to assess the suitability of an organic acid lixiviant to extract rare earth elements (REE) from coal preparation fines refuse sourced from a Pennsylvania mine with a total REE of ~ 300 ppm. The extraction of REE using an organic acid, in this case 0.1 M citric acid and 0.5 M trisodium citrate solution, is compared against 0.5 M (NH 4 ) 2 SO 4 , 1 M HCl, 1.2 M H 2 SO 4 , and 0.5 M ethylenediaminetetraacetic acid (EDTA). Ashing the coal waste material prior to leaching tests with the citrate solution nominally improved REE extraction. Buffered citrate solution recovered 7% of the total REE in the as-received Isabella Fines as compared to 11% in ashed samples, whereas (NH 4 ) 2 SO 4 extracted 5–6%, respectively. EDTA recovered up to 33% of the total REE, most likely due to the higher coordination chelate bond. Mineral acids, however, outperformed the organic acids on ashed material (16–52% REE recovery), suggesting that organic acids may not be a suitable competitive option for REE extraction from these types of feedstocks.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Biogas Utilization in Refuse Power Plants (BURP 2 )

The BURP 2 project investigated the technical and financial viability of co firing biogas with waste coal for power generation while using carbon capture and sequestration to achieve net negative emissions. A comparative assessment integrating geospatial mapping, technoeconomic analysis, and life cycle analysis was carried out to evaluate retrofitting an existing coal fired facility in West Virginia, versus developing a new greenfield power plant in Kentucky located near a low quality coal resource. The study found that CO 2 capture rates of 90% or higher, in combination with biogas feedstocks such as animal manure, could significantly reduce global warming potential compared to plants using neither biogas nor CO 2 capture systems. Economic feasibility depended heavily on federal tax credits and proximity to fuel sources. In both greenfield and retrofit scenarios, access to biogas played a key role. Because the retrofit site was located close to existing biogas resources, it represented a feasible option, whereas the greenfield site, being far from pipelines or biogas sources, would require prohibitively expensive biogas transport infrastructure. Overall, the research showed that repurposing waste or low-quality coal with renewable biogas and CO 2 capture systems could provide a viable approach for reducing carbon emissions in power production, if biogas resources are easily accessible and available in sufficient quantities.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Economic Extraction, Recovery and Upgrading of Rare Earth Elements from Coal-Based Resources

The overall objective of this project is to produce a rare earth elements product with greater than 8% rare earth elements from coal-based resources using an economically viable and environmentally benign processing methodology. The objective of the coal processing work will be to acquire appropriate coal feed and produce a viable clean coal product, a concentrated REE feed stream, and a pyrite stream (where available) that can be used to enhance leaching. The objective of the bio-oxidation portion of the project is to utilize bacteria to oxidize sulfide minerals and ferrous ions to ferric ions to accelerate leaching and remove the sulfides to prevent future acid mine drainage and related liabilities. The objective of the solution conditioning work is to remove iron and control leaching solution conditions to facilitate extraction of REEs without significant thorium extraction. The objective of the column leaching work is to engineer/model and simulate heap leaching to demonstrate low-cost extraction of REEs from coal-based resources. The objective of the solvent extraction work is to selectively extract and recover through controlled stripping of REEs that are solubilized through leaching. The objective of the precipitation portion of the project is to recover the REEs from the solvent extraction stripping solutions and dry them to achieve the final product of rare earth elements that is > 8 % REEs. The objective of the technical, economic, and environmental analysis is to determine the overall viability of the processing approach that is demonstrated in this project. This project encompasses a range of technologies that are currently in industrial practice that are applied and engineered to produce rare earth element product from coal feed sources. The potential sources include large coal feed resources in active coal mines in addition to coal waste. This technology involves the utilization of advanced coal processing technology that can be used to deliver clean coal for the market as well as rare-earth-element-bearing non-coal rock that is of the correct size for heap leaching applications in addition to providing concentrated sulfide minerals (for mid to high sulfur coals) for cleaner coal and for enhanced bio-oxidation to accelerate leaching of REEs from the non-coal rock. The removal of the sulfide minerals cleans the coal, accelerates subsequent REEs extraction, and it removes the future potential for most acid-rock drainage. (For low sulfur coals some pyrite may be purchased if needed.) The processing method also utilizes bio-oxidation to enhance ferric ion production to enhance leaching, while also consuming the sulfide mineral and its associated environmental liability. The project includes a technical, economic, and environmental analysis to facilitate an appropriate assessment of commercial viability for this processing technology.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Lab-scale Production of Coal-derived Graphene Particle Bonded Filaments

The main goal of the project was to develop a lab-scale manufacturing process to fabricate filaments with high carbon content for Fused Deposition Modeling (FDM) three-dimensional (3D) printing use. Graphene particles derived from domestic US coal waste was used as feedstock for filament development.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Microanalytical Approaches to Characterizing REE in Appalachian Basin Underclays

The search for a reliable U.S. domestic source of rare earth elements (REE) is necessary to support the demand of advanced energy applications (e.g., catalysts, electronics, magnets). Sedimentary deposits may be sources for selectively recovering REE and critical metals—specifically the interbedded seat rock, or underclay, that underlies or forms the floor of a coal seam. This material is often a major component of coal waste fines and refuse and thus readily available. This study examines several Appalachian Basin underclays associated with actively mined coal seams as potential feedstocks for the REE. Multimodal microanalytical electron microscopy (SEM, FIB-SEM, EMPA) synchrotron-based µXRF, and image processing techniques are coupled with detailed elemental and mineral data to classify the 2D and 3D petrophysical properties of the materials. The REE contents of Appalachian Basin underclays were measured from 235–399 ppm and predominantly observed as discrete REE-bearing minerals such as monazite and xenotime on the order of 10–100 µm in size. These REE-bearing minerals typically accounted for less than 1% of the scanned areas and volumes under SEM and FIB-SEM analysis, with the exception of regions enriched in crandallite. Synchrotron-based µXRF elemental maps further identified several REE deposition environments in different underclays, including micro-scale (10–100 µm) light REEs co-localizing with Ca and P, micro-scale heavy REEs with Fe, and large-scale light REEs (>200 µm) co-localizing with Sr, Ba, Ca and P.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Integration of LIBS with Machine Learning for Real-Time Monitoring of Feedstock in H 2 Gasification Applications

This project, funded by the U.S. Department of Energy (DOE) – Office of Fossil Energy under Award Number DE-FE0032177, aimed to assess the feasibility of an integrated Laser-Induced Breakdown Spectroscopy (LIBS) system with advanced machine learning (ML) models for real-time characterization and potential control of hydrogen gasifiers running on waste materials as feedstocks. This was a multidisciplinary effort that encompassed the acquisition and standardized analysis of individual and blended feedstocks—comprising biomass, coal waste, and plastic waste, followed by the development of a dynamic LIBS bench system for material sample analysis and development of predictive ML models. Comprehensive laboratory testing enabled the creation of a robust elemental dataset that served as the foundation for ML model training. Techniques such as Random Forest, Gradient Boosting, Support Vector Regression, and Neural Networks were employed to predict key feedstock properties, including higher heating value (HHV), moisture content, thermal conductivity, and ash composition with high accuracy. The results were validated against experimental data and demonstrated strong potential for real-time application in gasifier control systems. The project concluded with a study on the integration of the LIBS+ML approach for gasifier control and a techno-economic analysis of the implementation of the approach into hydrogen (H 2 ) gasification systems. Dissemination of results was carried out at a DOE meeting. This work establishes a scalable framework for automated, in-line feedstock quality assessment, offering significant implications for process optimization and emissions reduction in hydrogen production.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

The Production of Low Ash Coals Using the Hydrophobic-Hydrophilic Separation Process with Novel Developments

Froth flotation is a common mineral processing method in coal preparation. This process becomes less efficient, however, as particle size is reduced, and ultrafine particles are often discarded prior to froth flotation, contributing to a substantial amount of coal waste in impoundments. Because of the land-use and risk of an impoundment failure, these impoundments pose an environmental liability. To address ultrafine coal rejection, researchers at Virginia Tech developed the hydrophobic-hydrophilic separation (HHS) process. Unlike in froth flotation, HHS uses an organic solvent to separate and dewater hydrophobic particles from hydrophilic minerals. Past work on the HHS process yielded promising results. In particular, the HHS process has produced a low-ash (<2%) and low moisture (<8%) product, which is a viable feed stock for carbon products. In this work, an investigation of the effects of auxiliary processes on the HHS process was conducted. The auxiliary processes included grinding, pre-concentration, and reagent conditioning. This work also contains an investigation on the interaction between two primary unit operations in the HHS process: oil agglomeration and de-emulsification. Lastly, to make the HHS process more viable for commercial scale-up, a novel unit operation was developed and tested that performs comparably to the current HHS process.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Co-Gasification of Waste Plastic and Coal Refuse for Thermochemical Upcycling

This study investigated behavior of different mixtures of waste plastics and coal refuse and their potential synergy in steam co-gasification. Co-gasification is an interesting alternative technology to recycle under-utilized waste streams and generate syngas that can be used to produce energy and valuable fuels/chemicals.

Means, Nicholas C.↗
DOE OSTI2023

Extraction, Separation, and Production of High Purity Rare Earth Elements and Critical Minerals from Coal-Based and Related Resources

The general objectives of this project are to develop concepts for rare earth metal and critical mineral production from coal-based and related (minerals associated with coal) resources and incorporate them into a Technical Research Plan with an associated overall flow sheet. The project team has extensive expertise in market evaluation, mineral separation, leaching, chemical separations, alternative metallothermic reaction technology, electrowinning, and electrorefining that was critical to the success of the proposed project. The project included critical industrial partners needed for project success. The project team has extensive expertise in market evaluation, mineral separation, leaching, chemical separations, alternative reduction technology, electrowinning, and electrorefining as well as appropriate pilot-scale facilities to enable this project. The project encompassed broader opportunities for developing domestic resources of REE/CM materials for a more resilient, diverse, and secure supply chain for REE/CM materials with built-in redundancies and appropriate resource stockpiles. The production of REE/CM materials will help to revitalize and rebuild world-class American manufacturing capacity and the related workforce through new jobs and infrastructure. Furthermore, due to the nature and location of the production sites, economic growth in diverse communities of color and economically distressed areas will be cultivated. Finally, this technology can be applied to reuse and remediate coal waste tailings for REE/CM production.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Building Environmental Justice and Equity into the Development of Critical Mineral Industries

The global transition toward low-carbon energy not only means an increase in demand for clean electricity and renewable resources, but also an increase in demand for the critical minerals (CMs) and rare earth elements (REEs) that these technologies rely upon. Indeed, low-carbon energy technologies, such as those used for wind turbines and electric vehicle motors, require significantly more lithium, nickel, cobalt, manganese, graphite, and other CMs than fossil-based energy technologies. The growing demand for new forms of low- carbon energy will necessitate a proportional scale-up of CM and REE extraction and processing. Presently, the majority of extraction and processing activities for CMs and REEs are concentrated in very few countries, primarily in China and the Global South. CM and REE supply chain activities conducted in or controlled by these countries are commonly associated with widespread and well- documented human rights abuses and environmental degradation. As a result of concerns related to supply chain security, worker welfare, and the overall need for additional sources of CMs and REEs, governments worldwide have begun to explore policy pathways for the development of new supply chains. The development of new supply chains for CMs and REEs re s a multifold opportunity to accelerate the global deployment of low-carbon energy fleets, reduce global carbon emissions, build political resilience—and also to enhance policy objectives of environmental justice and equity in the clean energy transition. Fulfilling these policy objectives requires energy producers to navigate a maze of global supply chain policies designed to shape and accelerate the growth of new markets. In the United States, for instance, President Biden recently implemented fiscal and trade policies that incentivize both domestic and global reliance on U.S.-produced CMs and REEs, leveraging key relationships in Asia and Europe to ensure the accelerated buildout of the U.S. supply chain. The Biden Administration’s framework also emphasizes that new supply chains for CMs, REEs, and other low-carbon energy pathways must generate benefits for marginalized and disadvantaged communities, build energy equity, and contribute to the Biden Administration’s vision of environmental justice. present CM and REE supply chains include several stages, including mining, processing, transport, utilization, and disposal, each of which involves different environmental justice considerations and potential injustices. This study explores how technical innovation, paired with responsible community engagement and empowerment, can help inform the development of energy equity and environmental justice at all stages of new supply chains. The study highlights these opportunities on a broad scale. We also lend a specific focus to research at the University of Wyoming School of Energy Resources that aims to guide the development of CM and REE industries in communities with high economic dependence on coal and other fossil fuel industries, identifying pathways to grow a U.S. domestic supply chain by producing CMs from coal, coal by-products, and coal waste streams. These production pathways represent a potential new supply for CMs across the U.S. and elsewhere, thereby enhancing national security and accelerating the widespread deployment of low-carbon energy technologies, while also generating alternative applications for remaining coal reserves and aiding in a just transition for rural energy-producing communities.

Gerace, Selena↗
DOE OSTI2025

Plastic waste gasification for low-carbon hydrogen production: a comprehensive review

Hydrogen is one of the most important feedstocks for the chemical industry, power production, and the decarbonization of other sectors that rely on natural gas. The production of hydrogen from plastics enables sustainable use of plastic waste and offers significant environmental benefits. Gasification emerges as a promising route for chemical recycling, converting plastic into hydrogen and other valuable chemicals. Although the gasification of plastic waste has recently gained attention, the number of studies regarding low-carbon hydrogen production is still limited. The effective integration of carbon capture, utilization, and storage (CCUS) is essential for achieving low-carbon hydrogen production via gasification, which enables the efficient capture and storage of CO 2 emissions. Incorporating coal waste and biomass into plastic gasification can synergistically enhance reforming reactions for hydrogen production, reduce tar content, and resolve feeding issues caused by plastic stickiness. Based on the previous studies, this paper briefly reviews the mechanisms of plastic gasification including plastic depolymerization, reforming, tar and char formation, and gasification; the discussions on feedstocks and effects of operating conditions on H 2 production including plastic-type, temperature, steam/carbon ratio, equivalence ratio, and catalysts; and the integration of CCUS and alternative recovery processes in plastic gasification for low-carbon hydrogen.

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

Technoeconomic Assessment of a Sequential Step-Leaching Process for Rare Earth Element Extraction from Acid Mine Drainage Precipitates

Herein, Coal waste products have been studied as a new source of Rare Earth Elements (REEs) and other Critical Minerals (CM) essential for the development of renewable energy technologies, but the economic viability of these source materials is not well understood. This paper examines the technoeconomic performance of a novel process for rare earth element extraction from acid mine drainage precipitates (AMDp) in the Appalachian Coal Basin. The three phase extraction process includes excavation and transportation of AMDp, multi-phase pH driven step-leaching of REEs at ambient conditions, and commercial solvent extraction to produce a saleable grade rare earth oxide material that can be reduced to a pure metal. We estimate the life-cycle cost of bench-scale extraction of REEs from two representative Appalachian AMDp feedstock chemistries at between 4000 – 6000 $/kg of mixed REE concentrate produced. Both the AMDp composition and process parameters affect the profitability of REE extraction, with the REE concentration and distribution of REE in the feedstock, extraction and precipitation reagent consumption rates, and the potential for reagent recycling as the key variables. Economically profitable valorization of REE from AMDp will require a combination of continued process innovation and sizable financial incentives to substantially influence domestic supply of REEs.

36 MATERIALS SCIENCE↗