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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 OSTI2022

Environmental Life Cycle Assessment of small water resource recovery facilities: Comparison of mechanical and lagoon systems

Small water resource recovery facilities (WRRFs) serving communities with populations of less than 10,000 people account for 70% of centralized wastewater treatment systems in the United States. Here, with growing interest globally in improving the sustainability of these systems, this study evaluated the environmental life cycle impact and land use tradeoffs of different lagoon and mechanical WRRFs across the diverse climate of Nebraska. Life cycle inventory including construction and operations was collected for 35 existing systems representing a range of commonly used mechanical WRRFs: oxidation ditch, extended aeration, and sequencing batch reactors, and lagoon treatment systems: complete retention, irrigation, and controlled discharge lagoons.

42 ENGINEERING↗
DOE OSTI2025

Three-Dimensional Bubble Fluidics in Architected Porous Media

Gas bubble flows in porous media often exhibit complex and seemingly unpredictable behaviors that are difficult to control. This lack of control limits the ability to design effective devices which manage multiphase flows. Here, we show how the design of 3D printed pores can deterministically control the flow path of an injected gas stream. Open cell structures can be designed to shape the gas/liquid interface with fidelity to control how the two phases are distributed throughout a porous material. The distributed gas volume is free to interact physically and chemically with the surrounding liquid phase, an effect we exploit to create a logical control gate to redirect flows within a lattice. This also allows us to design architectures for reactive capture and aerating bioreactors, resulting in patterned boundaries which can make more effective use of the liquid and gas reagents.

3D microfluidics↗
DOE OSTI2023

Dinitrogen Emissions Dominate Nitrogen Gas Emissions From Soils With Low Oxygen Availability in a Moist Tropical Forest

Lowland tropical forest soils are relatively N rich and are the largest global source of N 2 O (a powerful greenhouse gas) to the atmosphere. Despite the importance of tropical N cycling, there have been few direct measurements of N 2 (an inert gas that can serve as an alternate fate for N 2 O) in tropical soils, limiting our ability to characterize N budgets, manage soils to reduce N 2 O production, or predict the future role that N limitation to primary productivity will play in buffering against climate change. We collected soils from across macro‐ and micro‐topographic gradients that have previously been shown to differ in O 2 availability and trace gas emissions. We then incubated these soils under oxic and anoxic headspaces to explore the relative effect of soil location versus transient redox conditions. No matter where the soils came from, or what headspace O 2 was used in the incubation, N 2 emissions dominated the flux of N gas losses. In the macrotopography plots, production of N 2 and N 2 O were higher in low O 2 valleys than on more aerated ridges and slopes. In the microtopography plots, N 2 emissions from plots with lower mean soil O 2 (5%–10%) were greater than in plots with higher mean soil O 2 (10%–20%). We estimate an N gas flux of ∼37 kg N/ha/yr from this forest, 99% as N 2 . These results suggest that N 2 fluxes may have been systematically underestimated in these landscapes, and that the measurements we present call for a reevaluation of the N budgets in lowland tropical forest ecosystems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

SGD-OD: investigating the potential oxygen demand of submarine groundwater discharge in coastal systems

Submarine groundwater discharge (SGD) supplies nutrients, carbon, metals, and radionuclide tracers to estuarine and coastal waters. One aspect of SGD that is poorly recognized is its direct effect on dissolved oxygen (DO) demand in receiving waters, denoted here as SGD-OD. Sulfate-mediated oxidation of organic matter in salty coastal aquifers produces numerous reduced byproducts including sulfide, ammonia, dissolved organic carbon and nitrogen, methane, and reduced metals. When these byproducts are introduced to estuarine and coastal systems by SGD and are oxidized, they may substantially reduce the DO concentration in receiving waters and impact organisms living there. We consider six estuarine and coastal sites where SGD derived fluxes of reduced byproducts are well documented. Using data from these sites we present a semiquantitative model to estimate the effect of these byproducts on DO in the receiving waters. Without continued aeration with atmospheric oxygen, the study sites would have experienced periodic hypoxic conditions due to SGD-OD. The presence of H2S supplied by SGD could also impact organisms. This process is likely prevalent in other systems worldwide.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

High temperature gamma radiation-induced chromium redox chemistry via in situ spectroscopic measurements

Chromium ions can make their way into the primary coolant of nuclear power reactors from the corrosion of stainless-steel reactor components, decreasing the material's corrosion resistance and resulting in increased transport of further corrosion products. Despite these potential effects, the radiation-induced redox speciation of chromium ions in aqueous solution is not well understood, especially at the elevated temperatures experienced by reactor coolants. Here, in the present work, we report new experimental results demonstrating that in aerated aqueous solution, the radiolytic oxidation of Cr(III) to Cr(VI) occurs at pH 4, while the reduction of Cr(VI) to Cr(III) occurs at pH 2. The oxidation of Cr(III) is primarily attributed to the reaction of the hydroxyl radical (˙OH) with the Cr(OH) 2+ species, while the reduction of Cr(VI) is attributed to reactions involving the hydrated electron (e aq - ) and hydrogen atom (H˙). Additionally, the steady-state equilibrium yield of Cr(VI) from the gamma irradiation of pH 4 Cr(III) solutions decreased with increasing temperature (over a range of 37–195 °C). This observation indicates that the activation energy of the Cr(VI) reduction reactions is higher than that for the Cr(III) oxidation reactions, such that it becomes relatively more favorable at higher temperatures. Overall, these data are important for the development of complementary multiscale models for the prediction of metal ion speciation in high temperature radiation environments.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2023

Assessing the methane mitigation potential of innovative management in US rice production

Abstract Rice is an important global crop while also contributing significant anthropogenic methane (CH 4 ) emissions. To support the future of rice production, more information is needed on the impacts of sustainability-driven management used to grow rice with lower associated methane emissions. Recent support for the impacts of different growing practices in the US has prompted the application of a regional methodology (Tier 2) to estimate methane emissions in different rice growing regions. The methodology estimates rice methane emissions from the US Mid-South (MdS) and California (Cal) using region-specific scaling factors applied to a region-specific baseline flux. In our study, we leverage land cover data and soil clay content to estimate methane emissions using this approach, while also examining how changes in common production practices can affect overall emissions in the US. Our results indicated US rice cultivation produced between 0.32 and 0.45 Tg CH 4 annually, which were approximately 7% and 42% lower on average compared to Food and Agriculture Organization of the UN (FAO) and US Environmental Protection Agency (EPA) inventories, respectively. Our estimates were 63% greater on average compared to similar methods that lack regional context. Introducing aeration events into irrigation resulted in the greatest methane reductions across both regions. When accounting for differences between baseline and reduction scenarios, the US MdS typically had higher mitigation potential compared to Cal. The differences in cumulative mitigation potential across the 2008–2020 period were likely driven by lower production area clay content for the US MdS compared to Cal. The added spatial representation in the Tier 2 approach is useful in surveying how impactful methane-reducing practices might be within and across regions.

Environmental Sciences & Ecology↗
DOE OSTI2022

Simple steps to enable reproducibility: culture conditions affecting Chlamydomonas growth and elemental composition

Even subtle modifications in growth conditions elicit acclimation responses affecting the molecular and elemental makeup of organisms, both in the laboratory and in natural habitats. Here, we systematically explored the effect of temperature, pH, nutrient availability, culture density, and access to CO 2 and O 2 in laboratory-grown algal cultures on growth rate, the ionome, and the ability to accumulate Fe. We found algal cells accumulate Fe in alkaline conditions, even more so when excess Fe is present, coinciding with a reduced growth rate. Using a combination of Fe-specific dyes, X-ray fluorescence microscopy, and NanoSIMS, we show that the alkaline-accumulated Fe was intracellularly sequestered into acidocalcisomes, which are localized towards the periphery of the cells. At high photon flux densities, Zn and Ca specifically over-accumulate, while Zn alone accumulates at low temperatures. The impact of aeration was probed by reducing shaking speeds and changing vessel fill levels; the former increased the Cu quota of cultures, the latter resulted in a reduction in P, Ca, and Mn at low fill levels. Trace element quotas were also affected in the stationary phase, where specifically Fe, Cu, and Zn accumulate. Cu accumulation here depends inversely on the Fe concentration of the medium. Individual laboratory strains accumulate Ca, P, and Cu to different levels. All together, we identified a set of specific changes to growth rate, elemental composition, and the capacity to store Fe in response to subtle differences in culturing conditions of Chlamydomonas, affecting experimental reproducibility. Accordingly, we recommend that these variables be recorded and reported as associated metadata.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Net Zero Energy Model for Wastewater Treatment Plants

The primary objective of this study is to achieve net-zero energy (NZE) wastewater treatment plants (WWTPs) by utilizing energy efficiency opportunities (EEO), combined heat and power (CHP) systems, and other renewable energy (RE) sources, e.g., solar, water, and wind powers. Herein, this study discusses an innovative energy solution for WWTPs in the United States, and one of the WWTPs with a flow capacity of 1.5 million gallons per day (MGD) was selected as a case study. An optimization tool, Hybrid Optimization of Multiple Energy Resources (HOMER) software, is used in this study to find the best energy system configuration to run the system. An energy audit for one WWTP was conducted in early 2020 and the report is used to do this study. The proposed EEOs were able to reduce WWTP energy consumption by about 11%. The excess anaerobic digester gas was utilized in a CHP system to cover about 42% of the facility’s consumption. Also, 3% of the utility energy consumption can be claimed by microturbines in the aeration tanks. Another two renewable energy systems, solar photovoltaic (PV) with 29% and water turbines with 15%, contribute to covering 100% of the WWTP energy consumption and achieving an NZE WWTP.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Lactiplantibacillus plantarum uses ecologically relevant, exogenous quinones for extracellular electron transfer

Extracellular electron transfer (EET) is a metabolic process that frequently uses quinones to couple intracellular redox reactions with extracellular electron acceptors. The physiological relevance of this metabolism for microorganisms capable of EET but unable to synthesize their own quinones remains to be determined. To address this question, we investigated quinone utilization by Lactiplantibacillus plantarum, a microorganism required for food fermentations, that performs EET and is also a quinone auxotroph. L. plantarum selectively used 1,4-dihydroxy-2-naphthoic acid (DHNA) and more hydrophilic naphthoquinones for EET reduction of insoluble iron (ferrihydrite). However, quinones used for EET also inhibited L. plantarum growth in non-aerated conditions. Transcriptomic analysis showed that DHNA-induced oxidative stress in L. plantarum, but this was alleviated when the electron acceptor, ferric ammonium citrate (FeAC), was included in the growth medium. Although DHNA and FeAC induced L. plantarum EET, this metabolism was still dependent on direct access to environmental electron shuttles. To determine whether quinone-producing food fermentation bacteria could be sources of those electron shuttles, L. plantarum EET was measured after incubation with Lactococcus lactis and Leuconostoc mesenteroides. Quinone-producing L. lactis, but not a quinone-deficient L. lactis ΔmenC mutant, increased L. plantarum ferrihydrite reduction and medium acidification through an EET-dependent mechanism. L. plantarum EET was also stimulated by L. mesenteroides, resulting in greater environmental acidification and transient increases in L. plantarum cell numbers. Our findings show that L. plantarum overcomes the toxic effects of exogenous quinones to use those compounds for EET-conferred, ecological advantages during the early stages of food fermentations.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2026

Metagenomes and metagenome-assembled genomes from microbial communities in a biological nutrient removal plant operated at Hamptons Road Sanitation District (HRSD) with high and low dissolved oxygen conditions

Aeration is a major cost at biological nutrient removal (BNR) plants. We report on microbial communities in a pilot-scale BNR system before and after a dissolved oxygen transition from 2.5 to 0.2 mg/L implemented over 18 months. Four PacBio metagenomes and 316 metagenome-assembled genomes are announced.

dissolved oxygen↗
DOE OSTI2020

Scaling Energy Efficient Retrofits for Small Commercial Apartment Buildings

With support from the U.S. Department of Energy’s (DOE) Building Technologies Office (BTO), the International Center for Appropriate and Sustainable Technology (ICAST) recently completed a three-year cooperative agreement to scale energy efficiency retrofits (EER) on small multifamily (MF) buildings. ICAST EER strategies ranged from low-hanging “direct install” of measures such as LED lighting, low-flow showerheads and aerators, and smart thermostats to major strategies such as HVAC replacement with high-efficiency boilers or heat pumps. As feasible, some projects also included the addition of renewable energy sources such as photo voltaic (PV) solar. When ICAST began the BTO project, it operated in two states and oversaw EER at approximately 80 MF buildings per year. With assistance from BTO, ICAST has grown significantly and now has staff in six states with MF EER projects in another seven, and performed EER on 956 MF buildings. ). ICAST was able to successfully execute this project by 1) Improving viability and efficiency of its processes, 2) Launching two new services and 3) Creating an affiliate program. For the most part, ICAST focused on a specific type of MF property: naturally occurring affordable housing (NOAH), because it is a significantly underserved market within the hard-to-serve MF market. NOAHs are typically smaller properties (5 to 64 units), owned by small organizations or individual investors looking for positive cash flow. ICAST believes the NOAH market can be successfully served with a one-stop-shop approach that makes it easy, hassle-free, and cost-effective for owners to acquire green upgrades for their property(ies). With the assistance of BTO funding, ICAST successfully used the cited EER methods and strategies to scale-up its OSS approach to service a greater number of MF housing and expand into new geographies. Additionally, support from BTO helped ICAST create self-sustaining programs which will not need to rely on on-going funding.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Implementing an aerosol dynamic shape factor for cerium oxide powder

The shape factor (X B ) of bulk powder CeO 2 (cerium oxide) particles is estimated to be X B = 1.34 (dimensionless). This is defined in relation to the measured aerated bulk density (0.91 g cm -3 , Hosokawa Micron, Summit NJ, 2018) of the CeO 2 powder. This information is used to determine the RRF (respirable release factor), and other parameters during drop test experiments of nuclear material storage containers at Los Alamos National Laboratory. The calculation is based on an experimental shape factor (X P = 2.66 dimensionless) for CeO 2 particles of the same (chain aggregate) morphology studied by other researchers. In that work, the shape factor was defined in terms of the maximum possible (compacted) density of CeO 2 material (7.13 g cm -3 ).

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2021

Concentrating Rare Earth Elements in Coal mine drainage Using Coal Combustion Products through Abandoned Mine Land Reclamation

Rare earth elements (REEs) (including scandium, yttrium and a group of 15 lanthanides) are often considered to be critical components in the productions of renewable energy hardware, electric vehicles, health care and military equipment, and consumer electronic products. The demand of REEs has been projected to be growing at an annual rate of 5-9% in the next 25 years. In 2011, the global demand of total rare earth oxides (REOs) was estimated to be approximately 105,000 tons, which is expected to grow to 210,000 tons by 2025. China overwhelmingly dominates the current worldwide rare earth productions but has strategically restricted its exports, causing significant instability for the global market. In response to the increasing demand for REEs and the supply dominance of China, identifying alternative sources of REEs has become a critical issue for the United States and other countries. Coal, coal ash, and coal mine drainage (CMD) are considered to be the alternative sources of REEs. In the U.S., high REE concentrations have been reported to be closely associated with coal deposits, including the Appalachian Basins. When surface and/or groundwater come in contact with geologic strata containing sulfide minerals exposed by coal mining, the accelerated oxidation of sulfide minerals in the presence of ferric iron and/or oxygen can produce sulfuric acid. The process promotes the weathering of REE-bearing rocks and minerals in the host geologic strata. Compared to average river water and seawater, the concentrations of REEs can be orders of magnitude higher in CMD. In this study, we demonstrated a trap-extract-precipitate (TEP) process that can effectively recover REEs from CMD. The three-stage TEP process uses alkaline industrial by-products to capture REEs from CMD and then applies an extraction/precipitation procedure to produce a feedstock that can be economically processed to produce marketable rare earth oxides. The alkaline industrial by-products tested in this study include the residual from a water softening process (DRWP sludge) and two types of stabilized flue gas desulfurization materials (sFGDs). sFGD material is a mixture of lime (CaO) and two coal combustion by-products, calcium sulfite FGD by-product and fly ash. The objectives of this study are to (1) validate the effectiveness and feasibility; (2) determine mechanisms controlling the rare earth recovery, (3) quantify the associated economic and environmental benefits, and (4) evaluate the full-scale application. To achieve these objectives, tasks to be carried out in this proposed project are organized into three phases. In the first phase, the research team collaborated with Ohio Department of Natural Resources, American Electric Power, The Wilds (a nonprofit wildlife conservation organization), and a private landowner to carry out field investigations aimed to screen and evaluate the seasonal changes of rare earths in the CMD discharges that have high recovery potentials. Next, the recovery of REEs from CMD was tested using a series of lab-scale column and batch tests under, respectively, percolation and completely mixed conditions. Results obtained from these lab-scale studies show that all three tested solids are very effective in retaining REEs. Over 98% of the CMD REEs that contacted the solids were captured before the solids exhausted their neutralization capacities. We also determined an extraction process using a non-acid, organic ligand extraction solution that can effectively remobilize the retained REEs from the spent solids (over 90%). The REE concentrate (>7.5 wt. % of total REEs) is then formed in an aeration process. The TEP process uses environmentally benign industrial by-products and a naturally-occurring organic ligand to mitigate CMD and recover REEs. Techno-economic analysis (TEA) and life-cycle assessment (LCA) was carried out in the third phase. The engineering-economic costs and net energy, net CO2 emissions, and water and other requirements were investigated to understand the economic and environmental implications of this process. This work uses mass and energy balances from laboratory-scale experiments to estimate the economic costs and environmental impacts. The results suggest that passive treatment systems that use DRWP sludge are preferred over those that use sFGD material, because of lower economic costs ($89,300/yr with a unit cost of $86/gT-REE vs. $89,800/yr, or $278/gT-REE) and improved environmental performance across all indicators from two different impact assessment methods. These differences are largely attributable to the larger capacity of DRWP sludge in the passive treatment application. We envision this TEP process can be integrated with abandoned mine land (AML) reclamation to create an approach that can add economic incentives for AML reclamation, remediate CMD discharge, and eliminate public safety hazards and threats to local environment and ecological systems posed by AMLs. It can restore lands and communities that are adversely impacted by legacy mining.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities

Improvements in process monitoring and control at water resource recovery facilities (WRRFs) could result in reductions in electricity consumption, chemical inputs, and greenhouse gas emissions, as well as improved energy recovery. Many current WRRF data collection, monitoring, and control approaches use 20th century process monitoring and control systems, which require large design safety factors to ensure reliability in the absence of more advanced, precise controls. Implementation of more modern data-driven control tools could lead to more efficient operations that provide intrinsic reliability with better overall process performance at full-scale. This presentation provides an overview of a recently initiated project "Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities" which will (1) develop and demonstrate data-driven process controls at full-scale facilities for five promising WRRF Applications (i.e., process technologies) that provide whole-plant approaches and offer substantial energy and resource recovery benefits, and (2) create a toolbox of new process control approaches and an implementation guide including five examples for application at utilities. The presentation also provides a detailed overview of the research approach and progress being made on one of the five Applications, namely Application 2: Biological Nutrient Removal (BNR): ammonium-based aeration control (ABAC) / ammonia vs. NOx (AvN) + partial denitration with anammox (PdNA), which is being implemented at Hampton Roads Sanitation District. This project is a collaboration of work being conducted by DC Water, Hampton Roads Sanitation District, Metro Water Recovery, University of Michigan, Northwestern University, US Military Academy - West Point, Black & Veatch, and Oak Ridge National Laboratory. Research partner: U.S. Department of Energy.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Corrosion of U233-Doped Uranium Oxide using Microfluidics Methods

The aim of work this year has been to investigate the role of alpha (α)-radiation and hydrogen (H 2 ) on the corrosion of uranium oxide (UO 2 ) using a microfluidic device. The microfluidic device, termed the Particle-Attached Microfluidic Electrochemical Cell, (PAMEC), enables monitoring of the UO 2 electrochemical corrosion potential (E corr ) under different environments, including de-aerated conditions and in the presence of dissolved H 2 . The Si 3 N 4 window allows us to study morphological and chemical changes under an electron microscope. We have previously demonstrated that the PAMEC matches the results from bulk electrochemical tests with UO 2 [1]. We used the high specific activity uranium (U) isotope, 233 U, (t 1/2 = 160,000 years) incorporated into UO 2 , to generate a localized a-field. The objective of the experiments were to mimic the radiation environment that would be experience at the surface of aged spent nuclear fuel (SNF) during long-term geologic disposal under anoxic conditions. Wittman et al. [2] predicted that in the presence of a pure a-radiation field and under H 2 conditions, the concentration of the radiolytic oxidant H 2 O 2 would be suppressed or even eliminated. In a UO 2 corrosion experiment this would be exhibited through a lowering of the measured UO 2 corrosion potential compared to identical conditions in the absence of dissolved H 2 . We found that the predictions of Wittman and co-workers were supported and that the corrosion potential of the 233 U-doped UO 2 in solution lowered with presence of H 2 gas and increased in the absence of H 2 , when under anoxic conditions. The PAMEC experiments indicate that H 2 O 2 has been eliminated in a solution sparged with H 2 while exposed to an a-radiation field. The corrosion potential of the a-doped 233 U(10%)- 238 UO 2 in a solution sparged with Ar/H 2 matched the corrosion potential of 238 UO 2 in solution sparged with air. This clearly demonstrated that the H 2 O 2 had been eliminated and that the only oxidant present was O 2 in this system in complete agreement with the modeling results of Wittman et al. These results point to the need to improve the Fuel Matrix Degradation (FMD) Process Model training data set that is being used in the FMD surrogate model that is being developed for the repository program. The incorporation of realistic radiation chemistry will improve the scientific basis for the FMD Model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Demonstration of Scaled-Production of Rare Earth Oxides and Critical Materials from U. S. Coal-Based Sources (Final Report)

The project objective was to demonstrate scaled production of high purity rare earth oxides (REO), nominally exceeding 90% grade, from coal refuse sources using innovative technologies that reduce cost and improve environmental outcomes relative to traditional rare earth processing technologies. The project utilized a critical material pilot plant constructed and tested as part of a previous U.S. Department of Energy project. Target performance criteria was a 50% reduction in production cost based on previous optimum values, 150% increase in recovery and greater than 2% concentrates of rare earth oxides, cobalt and manganese. Concentrate production goals were to produce a rare earth mix oxide product at a rate of 200 grams per day having a minimum purity of 50% as well as products of cobalt and manganese having a minimum purity of 2%. A previous pilot plant investigation identified acid cost as the major contributor to an operating cost that made the recovery of rare earth and other critical metals from bituminous coal sources economically challenging. As such, acid cost reduction was a major target using bio-oxidation reactors to produce sulfuric acid from naturally occurring coal pyrite. Based on laboratory data, a bio-oxidation circuit was designed for the pilot plant to produce 7.5 l/min of acid using two 11-m3 (3000 gallon) reactors equipped with 40 hp aerators for air dispersion. The pilot-scale tests revealed that acid concentration equivalent to as high as 1.0 M sulfuric acid could be continuously produced. However, the bio-acid contained exceptionally high iron concentrations, which complicated downstream processing of the pregnant leach solution (PLS). A TEA of the bio-oxidation circuit showed that production cost was approximately $0.13 per kg acid equivalent if produced using a four-day retention time in the reactors. This value represents a 48% reduction from that of purchased bulk sulfuric acid. Calcination (or roasting) studies were conducted on coarse refuse from West Kentucky No. 13 and Fire Clay coal seam sources. The test results revealed the potential to increase recovery by nearly 100% using temperatures between 500°C to 700°C with light REE recovery value being the most improved. Acid baking of the calcined products using sulfuric acid at 250°C increased heavy rare earth recovery from around 40% to 80% while decreasing the acid requirements by over 50%. The existing pilot plant was upgraded for the pilot scale demonstration of REE and CM recovery. The primary feedstocks were West Kentucky No.13 and heap leach pregnant leach solution (PLS) while a secondary feedstock was a lignite waste material from a construction sand operation. The pilot scale operation started with PLS generation through leaching followed by iron and aluminum removal, nominally at 3.3 and 4.5 pH, respectively. Leaching lixiviants used for the test were industrial grade sulfuric acid or bio-acid generated at the pilot scale facility. For most of the tests, the solid feed rate was 200 lb/hr whereas lixiviant was added at 2 gpm to provide an optimal residence time of 45 minutes. Following the contaminant removal step, several different process schematics were tested with the goal of maximizing REE recovery and purity. In the first test, direct processing of aluminum precipitation raffinate for REE recovery using oxalic acid at pH 1.5 was investigated. Overall REE recovery was approximately 45%. Unfortunately, elevated calcium content in the PLS significantly impacted the RE-Oxide product grade. Similarly, high calcium content decreased both the product purity and grades of CM products. As such, a new flowsheet was tested with the same initial process schematic but different precipitation stages for REEs and CMs at pH 6.0 and 9.0, respectively. It was noted that the overlapping precipitation behavior of Co, Ni and Zn with REEs limited the applicability of this process schematic. While this change increased the RE-Oxide grade from 36% in the first test to 87%, the loss of critical metals to the REE cake and bypass of the REEs to the CM cake significantly impacted the recovery of both REEs and CMs. Therefore, the modified process flowsheet combined oxalic acid precipitation stage raffinate and redissolved CM cake filtrate to maximize both the recovery and purity of the products. Consequently, a RE-Oxide product with 85% purity and CM cakes with over 19% Co, 38% Ni, 14% Zn and 9% Mn content were generated with significantly higher recoveries. While the modified process flowsheet improved recoveries and grades, elemental losses observed in separate precipitation and redissolution losses inspired the adaptation of a single precipitation stage at pH 9.0 for both REEs and CMs. This change was anticipated to maximize the REE recovery while minimizing the costs associated with separated redissolution and processing stages. As expected, REE recovery in this new circuit arrangement was over 56% with a product grade of over 87% RE-Oxide content. Similarly, Co, Ni, Mn, and Zn recoveries of 54%, 40%, 67%, and 66%, respectively, were achieved. Unfortunately, the elevated calcium content present in the solution due to its precipitation at pH 9.0 caused a decrease in the CM cake quality. Therefore, the final process flowsheet involved the addition of calcium oxalate precipitation following the oxalic acid precipitation stage, which effectively eliminated calcium contamination of the CM products. Finally, the pilot scale experiments conducted using bio-acid achieved comparable REE leaching recoveries to the conventional sulfuric acid leaching. Elevated iron concentration in the solution caused the co-precipitation of REEs with the iron and aluminum cake, resulting in the REE losses. Furthermore, elevated iron content bypassing the iron and aluminum precipitation stages contaminated the metal sulfide and manganese cake, respectively. A techno-economic analysis was performed based on a commercial facility capable of treating 500 tph of coal-based material. The production cost for West Kentucky No. 13 coarse refuse material ranged from approximately $500-$700/kg of total rare earth oxide whereas the lignite source had significantly lower production cost of $100-$300/kg. The significant difference in cost was due to the easier leaching characteristics of the lignite material and the higher feed concentrations. All process scenarios resulted in a negative net present value (NPV). For the lignite feedstock, laboratory REE leach recovery values were about 30% higher than the pilot plant data. Using the lab leach results, a positive net present value was achieved and the production cost decreased from $100-$300 $/kg to less than $150/kg of total REO.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Challenges, Progress, and Future Perspectives for Cyanobacterial Polyhydroxybutyrate Production

Polyhydroxyalkanoates (PHA) are a promising bio-based alternative to traditional plastics derived from petroleum. Cyanobacteria are photosynthetic organisms that produce PHA from CO 2 and sunlight, which can potentially reduce production costs and environmental footprint in comparison to heterotrophic bacteria cultures because (1) they utilize inorganic carbon sources for growth and (2) they do not require intensive aeration for oxygenation. Moreover, supplementing precursors such as propionate, acetate, valerate, etc., can be used to obtain various copolymers with plastic customizable properties in comparison to the classical homopolymers, such as polyhydroxybutyrate, PHB. This critical review covers the latest advances in PHA production, including recent discoveries in the metabolism interplay between PHA and glycogen production, and new insights into cultivation strategies that enhance PHA accumulation, and purification processes. This review also addresses the challenges and suggests potential solutions for a viable industrial PHAs production process.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2026

Bioreactor Optimization through Multi-Phase Flow Models (CRADA Final Report)

Chemical manufacturing uses 29% of energy in the United States and produces 925 million metric tons of CO2 annually. Biomanufacturing offers the potential to leverage America’s rich agricultural resources to produce critical chemicals such as lubricants, pharmaceutical precursors, and components of energetic materials that today are sourced extensively from overseas. The bioreactors used in biomanufacturing applications, such as one developed by Capra Biosciences, involve multiphase flow of biofilm-coated solid support particles that are continuously circulated in a fluidized state within the reactor along with a constant supply of oxygen via an aeration mechanism. In this project, Capra Biosciences and LBNL developed a multiscale modeling framework to simulate the multiphase flows of solid particles in a liquid-gas bubble mixture that occurs in the bioreactor using the current MFIX-Exa software, an opensource multiphase flow solver developed and maintained at LBNL and NETL. By leveraging HPC capabilities, this high-fidelity multiscale model was used to inform design decisions for bioreactor architecture to make them operationally efficient.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗