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DOE OSTI2024

Mauka Energy FEVER Tool DOE SBIR Phase 1 Final Scientific/Technical Report

This report is on the Forestry Electric Vehicle Energy Routing (FEVER) Tool, a novel software system developed to support heavy-duty electric vehicle (EV) operations in remote, forested, and mountainous regions. The Phase I project aimed to demonstrate the feasibility of modeling EV energy consumption using terrain elevation, road conditions, and route features specific to forestry logistics. The tool combines geographic information systems (GIS), electric motor physics, and vehicle-specific data to calculate feasible, energy-efficient routes. Collaborations with Oregon State University’s Research Forests and Titan Freight Systems enabled collection and validation of GPS and elevation-based trip data. The FEVER Tool offers substantial opportunities for the efficient management of medium- and heavy-duty electric vehicles in sectors like forestry, agriculture, mining, defense and waste management—areas which are beginning to adopt HDEVs. The project demonstrated technical feasibility and lays the groundwork for commercial development and deployment in other industries and environmental conditions in Phase II.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Characterization Inform Sustainable Recovery of Critical Minerals from Fossil Energy Waste Feedstocks

Rare earth elements (REE) and other critical minerals (CM, e.g., Co, Ni, Li) have important uses in green energy and modern technologies, yet are vulnerable to potential supply chain disruptions. One potential domestic CM source is fossil energy wastes, such as acid mine drainage (AMD) and treatment solids (AMD solids), coal combustion ash, and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters). While they can contain lower CM concentrations then traditional ore, the quantity and fast availability as waste feedstock makes them a promising CM resource. To explore their promise, researchers at DOE’s National Energy Technology Laboratory (NETL) have collected and analyzed CM data for aforementioned fossil energy wastes, and utilized advanced geochemical characterization (e.g., synchrotron microprobe and sequential extraction) to identify the CM speciation and binding environments, and developed sustainable and targeted CM recovery. Successful examples include: (1) the discovery of easily mobile REE phases in Ca-rich coal combustion ash and developing a patented REE recovery process from Ca-rich Powder River Basin coal ash; (2) the successful identification of REE/Co/Ni/Zn hosting phases in acid mine drainage treatment solids (AMD solids) with diverse chemical composition (Al, Mn, or Fe-rich) informing the sequential recovery of different REE/CMs from AMD solids; (3) the recovery potential of Li and other CMs in O&G produced waters and drill cuttings. The innovations driven by characterization have the potential to offset the cost of waste management and wastewater treatments while reducing the cost and environmental footprint of CM extraction.

Stuckman, Mengling↗

DOE OSTI2024

Advanced Characterization to Inform Sustainable Recovery of Critical Minerals from Fossil Energy Waste Feedstocks

Rare earth elements (REE) and other critical minerals (CM, e.g., Co, Li) have important uses in green energy and modern technologies, yet are vulnerable to potential supply chain disruptions. One potential domestic source of CM is fossil energy wastes, such as acid mine drainage (AMD) and treatment solids (AMD solids), coal combustion ash, and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters). CM recovery from these waste feedstocks is promising due to their abundances and fast availability as waste products. On the other hand, the CM occurrence in these wastes is in small quantities compared to traditional ore bodies. Thus, novel and strategic separation and extraction processes are under exploration. Researchers at DOE’s National Energy Technology Laboratory (NETL) are collecting and analyzing CM data for aforementioned fossil energy wastes, and utilizing advanced geochemical characterization (e.g., synchrotron microprobe and sequential extraction) to understand the CM speciation and binding environments in these materials to better inform sustainable and effective recovery. Successful examples discussed in this talk include: (1) the discovery of easily mobile REE phases in Ca-rich coal combustion ash and developing a patented REE recovery process from Ca-rich Powder River Basin coal ash; (2) the successful identification of REE/Co/Ni/Zn hosting phases in acid mine drainage treatment solids (AMD solids) with diverse chemical composition (Al, Mn, or Fe-rich) informing the sequential recovery of different REE/CMs from AMD solids; (3) the recovery potential of Li and other CMs in O&G produced waters and drill cuttings. The innovations driven by characterization have the potential to offset the cost of waste management and wastewater treatments while reducing the cost and environmental footprint of CM extraction.

characterization and extraction↗

DOE OSTI2020

An Overview of R and D on Retrievability and Retrieval Technology in Germany - 20462

Retrievability is a term that is included in most radioactive waste management programs around the world. Although national definitions vary, the overall understanding of retrievability concerns the ability to recover waste packages from the repository mine after their emplacement. Different countries may implement retrievability in very different ways, ranging from a built-in reversibility into the emplacement process to the stipulation that retrievability may in no way impede passive safety in the post-closure phase. Germany takes a middle course such that retrievability in a HLW repository (repository for high level radioactive waste) may have no significant detrimental effect on passive safety. In Germany, the current siting process considers rock salt, clay rock, and crystalline rock as potential host rocks. Therefore, Research and Development (R and D) has been investigating repository concepts and retrievability in all host rocks. After introduction of retrievability in 2010, existing repository concepts were modified to facilitate retrieval. The changes made comprised, for example, equipping boreholes with steel liners, developing new technologies, and modifying existing emplacement devices. Apart from retrieval of HLW, retrieval of other wastes from underground repositories that were designed and operated without retrievability in mind, poses major technical and scientific challenges. Currently, studies are under way to investigate the feasibility and costs of partial retrieval of waste from an underground repository for hazardous and highly toxic waste in France, Stocamine. With regard to retrieval, the rock-mechanical conditions are deteriorating rapidly, so time is of the essence. In the Asse II mine in Germany, about 126,500 waste casks with low and intermediate level waste await retrieval. The repository mine suffers from difficult rock-mechanical conditions and inflow of brine, locally into emplacement areas. The Federal Company for Radioactive Waste Disposal (BGE) is legally required to retrieve all wastes from the Asse. Due to the specific challenges, R and D is needed to develop technical solutions for the safe retrieval from each of the emplacement chambers. R and D on retrievability and retrieval technology does not only address challenges in radioactive or toxic waste retrieval but may also help to germinate innovation to better master complex underground situations in general, e.g. in deep mining, tunneling, or repository construction. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

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↗

DOE OSTI2020

Review of the Safety Analyses of the Konrad Repository - 20530

The Bundesgesellschaft fuer Endlagerung (BGE) is the license holder of all geological repository sites in Germany since 2017. Besides the construction of the Konrad repository for the emplacement of low- and intermediate-level waste (LILW), the operation of the Asse II mine including the retrieval of the emplaced waste, and the preparation for the closure of the Morsleben repository, BGE is responsible to carry out the operative tasks of selecting a site for a high-level waste (HLW) repository. The Konrad repository is Germany's first repository for radioactive waste with negligible heat generation, which was fully licensed under atomic law within the scope of a plan approval procedure from the original application in 1982 until the license was granted in 2002 and finally confirmed by the Federal Administrative Court in 2007. The emplacement of LILW was licensed up to a volume of 303,000 m{sup 3} with a total β/γ-activity of 5 x 10{sup 18} Bq and a total α-activity of 1.5 x 10{sup 17} Bq. Currently, the former iron ore mine Konrad is being converted to a repository and is expected to come into operation in 2027. But what if there is no safety case in place nor a regulatory framework tailored for a change of documents in order to ensure the safety according to the state-of-the-art of science and technology during the evolution of a long-term project such as a geological repository? In this presentation, a review procedure of the safety analyses, that have been the basis of the plan approval decision for the Konrad repository at that time, will be described. Furthermore, the first results of this graduated review procedure for updating the safety analyses will be presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Upcycling and urban mining for nanomaterial synthesis

Responsible processing of complex waste streams, especially through resource recovery and upgrading, is essential to lessen the environmental and societal impacts of materials production and disposal. Upcycling waste into materials that have higher value than their original form, and urban mining, the recovery of metals from electronic waste, are two recent strategies in waste management. Sustainable cradle-to-grave manufacturing means recovering resources that would otherwise contaminate the planet. Here, we discuss upcycling of plastic, rubber, and related carbon waste streams into graphene, as well as the recovery of precious metals and rare earth elements, while removing toxic heavy metals, all using flash Joule heating. Furthermore, this article provides a brief overview of the current state of upcycling and urban mining as it applies to materials conversion, recovery, or nanomaterial synthesis, with a concluding perspective highlighting the considerations, opportunities, and challenges that accompany upcycling and urban mining research.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

DECOVALEX-2023: Task F2-Salt Final Report

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

DECOVALEX-2023: Task F2 Salt Final Report

The subject of Task F of DECOVALEX-2023 concerns performance assessment modelling of radioactive waste disposal in deep mined repositories. The primary objectives of Task F are to build confidence in the models, methods, and software used for performance assessment (PA) of deep geologic nuclear waste repositories, and/or to bring to the fore additional research and development needed to improve PA methodologies. In Task F2- (salt), these objectives have been accomplished through staged development and comparison of the models and methods used by participating teams in their PA frameworks. Coupled-process submodels and deterministic simulations of the entire PA model for a reference scenario for waste disposal in domal salt have been conducted. The task specification has been updated continuously since the initiation of the project to reflect the staged development of the conceptual repository model and performance metrics. Thermal, hydrological, mechanical, and chemical properties of individual components of the engineered and natural system were chosen for relevance by participating teams. The salt reference case system was characterized using data and measurements collected at relevant underground research laboratories (URLs), field sites, and simulation results from teams with specialized modelling capability. Participating teams made a wide range of model assumptions from compartmentalized networks to full 3D models of the salt formation. No single contributed model includes full-fidelity representation of all the features, events, and processes (FEPs) detailed in the task specification, but almost all features and processes are represented in at least one model. Despite differences in the modelling strategies developed by participating teams, all models indicate that salt compaction and radionuclide diffusion are key processes in the repository, and for the FEPs and model scenario considered, little of the disposed radionuclides will migrate beyond the repository seal over the 100,000 year simulations. In general, the model output quantities have the largest differences over the short term and near the waste. The models tend to be more similar further from waste and at later time. Disparities between the models are believed to be due to differing simplifications from the task specification, some of which are chosen simplifications to reduce complexity, and some are restrictions imposed by the modelling tools. A second round of this task has been accepted for DECOVALEX-2027 in conjunction with Task F1 on crystalline PA modelling. The future round includes waste package heating, improved modelling of salt creep closure, additional comparisons of coupled-process sub-models, and the impact of repository engineering design on radionuclide migration in the repository. Participants will also propose and finalize a set of uncertain inputs for the reference case simulations, propagate these uncertainties in a set of realizations, and conduct sensitivity analyses on the simulation results.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Developing an experimental-computational framework to investigate the deformation mechanisms and mechanical properties of Al-8Ce-10Mg alloys at micro and macroscales

There is a promising future for the use of aluminum-cerium-magnesium alloys in a broad range of applications, including devices that operate at high temperatures. With cerium currently considered a waste product of rare earth mining validation studies of possible applications are essential to reduce the environmental waste. Here, a computational-experimental framework is developed to investigate the role both the intermetallic and matrix have on the mechanical properties of these alloys. A set of experiments, including SEM/EBSD imaging, nanoindentation, in-situ SEM tensile testing, and in-situ SEM-DIC tests are performed to characterize the microstructure and mechanical properties of these alloys. Furthermore, the elastic, plastic, and failure deformation mechanisms of the microstructure, and their correlation with the bulk scale mechanical properties are investigated. Experimental results are also used to calibrate parameters for a crystal plasticity finite element model, by performing a computational framework that minimizes the error between the computational and experimental results. This model is then utilized to investigate how the area percentage of intermetallics and the crystallographic texture control the mechanical properties of the alloy. Simulation results show that an increase in the percentage of intermetallics increase the strength but decrease the ductility of the alloy. Also, a change in material texture improves strength and reduces damage that leads to material failure. The development of the crystal plasticity model, as discussed in this work, opens opportunities for future investigations of similar aluminum-cerium-magnesium alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Rare earth elements from waste

Rare earth elements (REEs) are critical materials in electronics and clean technologies. With the diminishing of easily accessible minerals for mining, the REE recovery from waste is an alternative toward a circular economy. Present methods for REE recovery suffer from lengthy purifications, low extractability, and high wastewater streams. Here, we report an ultrafast electrothermal process (~3000°C, ~1 s) based on flash Joule heating (FJH) for activating wastes to improve REE extractability. FJH thermally degrades or reduces the hard-to-dissolve REE species to components with high thermodynamic solubility, leading to ~2× increase in leachability and high recovery yields using diluted acid (e.g., 0.1 M HCl). The activation strategy is feasible for various wastes including coal fly ash, bauxite residue, and electronic waste. The rapid FJH process is energy-efficient with a low electrical energy consumption of 600 kWh ton –1 . The potential for this route to be rapidly scaled is outlined.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

A portable fiber optic sensor for the luminescent sensing of cobalt ions using carbon dots

Cobalt is critical to energy-relevant technologies, and demand for cobalt will increase significantly with growing global adoption of renewables. However, supply chain stability is threatened by economic and geopolitical factors, incentivizing domestic cobalt production from alternative resources such as coal, coal utilization byproducts (e.g., ash, acid mine drainage) and electronic waste. Rapid, inexpensive, and portable characterization techniques are needed to reduce production costs associated with cobalt prospecting and process monitoring. Here, in this research, we develop a compact, portable fiber optic luminescent probe for cobalt using phosphorus and nitrogen co-doped carbon dots as the sensing material. The carbon dot emission overlaps well with the cobalt absorption band at ~510 nm, leading to a selective decrease in emission as a function of cobalt concentration. The system responds nearly instantly to the presence of cobalt, with detection limits of 0.7 and 3.5 ppm in water and pH 1.68 buffer, respectively, providing comparable performance to a commercial spectrometer at a significantly lower cost. Moreover, the sensor is selective for cobalt in the presence of 13 of the most common metal ions encountered in coal utilization byproducts and is responsive to cobalt when spiked into an acid mine drainage leachate sample, highlighting the sensor's potential for real-world deployment in challenging matrices. In addition, integrating the carbon dots with a filter paper substrate produced ‘test strip’ sensors that exhibited a selective and sensitive visual response to cobalt using a handheld UV lamp. Taken together, the sensing system represents a significant step forward in the development of low-cost practical sensors for high-value metals in complex streams.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Techno-Economic Screening Analysis of CO2 Removal Through Enhanced Weathering

Terrestrial enhanced weathering has emerged as a technology of interest due to its simplicity, low energy requirement, and potentially low capital investment requirement. Due to the novelty of this technology, there is limited literature exploring the techno-economics of the process. This presentation reports on a screening techno-economic analysis that examines the impact of key factors that influence terrestrial enhanced weathering performance and cost. Two cases are considered for analysis, based on the material used: (1) Naturally occurring mined igneous rock (2) Industrial waste materials (like biomass ash or cement kiln dust) The analysis considers locating the terrestrial enhanced weathering system in the Midwestern United States, because of proximity to alkaline materials, availability of farmland, and appropriate ambient conditions for weathering. For the igneous rock case, the size of the system is based on the average amount of igneous rock available from a single mine—250,000 tonnes/year. For the industrial waste case, the size of the system is based on the amount of suitable waste material produced by an industrial hub—150,000 tonnes/year.

Leptinsky, Sarah↗

DOE OSTI2024

Enhanced Weathering Screening Techno-Economic Analysis

This presentation reports on a screening techno-economic analysis that examines the impact of key factors that influence terrestrial enhanced weathering performance and cost. Two cases are considered for analysis based on the material used: (1) Naturally occurring mined igneous rock (2) Industrial waste materials (like biomass ash or cement kiln dust) The analysis considers locating the terrestrial enhanced weathering system in the Midwestern United States, because of proximity to alkaline materials, availability of farmland, and appropriate ambient conditions for weathering. For the igneous rock case, the size of the system is based on the average amount of igneous rock available from a single mine—250,000 tonnes/year. For the industrial waste case, the size of the system is based on the amount of suitable waste material produced by an industrial hub—150,000 tonnes/year.

Leptinsky, Sarah↗

DOE OSTI2021

Structure and Potential–Dependent Selectivity in Redox–Metallopolymers: Electrochemically Mediated Multicomponent Metal Separations

Electro-responsive functional materials can play a critical role in selective metal recovery and recycling due to the need for molecular differentiation between transition metals in complex mixtures. Redox-active metallopolymers are a promising platform for electrochemical separations, offering versatile structural tuning and fast electron transfer. First, through a judicious selection of polymer structure between a main-chain metallopolymer (polyferrocenylsilane) and a pendant-group metallopolymer (polyvinylferrocene), charge-transfer interactions and binding strength toward competing metal ions are tuned, which as a result, dictate selectivity. For example, almost an order of magnitude increase in separation factor between chromate and meta-vanadate can be achieved, depending on polymer structure. Second, these metallopolymer electrodes exhibit potential-dependent selectivity that can even flip ion preference, based solely on electrical means—indicating a control parameter that is orthogonal to structural modifications. Finally, this work presents a framework for evaluating electrochemical separations in multicomponent ion mixtures and elucidates the underlying charge-transfer mechanisms resulting in molecular selectivity through a combination of spectroscopy and electronic structure calculations. Furthermore, the findings demonstrate the applicability of redox-metallopolymers in tailored electrochemical separations for environmental remediation, value-added metal recovery, waste recycling, and even mining processing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Aquifer Injection Modeling (AIM) Toolbox User Guide

The Aquifer Injection Modeling Toolbox (“AIM Toolbox”) software was developed by the Pacific Northwest National Laboratory (PNNL) for the U.S. Environmental Protection Agency’s (EPA) to provide a collection of analytical solutions suitable for evaluating the potential extent of the area impacted by subsurface injection operations. Subsurface injection operations are regulated under the EPA’s Underground Injection Control (UIC) program and are typically related to oil/gas development, waste disposal, or subsurface mining or storage. The analytical algorithms provided in the AIM Toolbox each have different approaches/assumptions/focus with respect to the nature and processes in subsurface and the nature of the injection operations. Collectively the set of analysis algorithms provides a broader evaluation of the area that can potentially be impacted by an injection operation. By providing estimates for the injectate plume extent, the software supports technical aspects of planning, evaluation, and overseeing injection activities. That is, the results help assess when further regulatory controls (e.g., monitoring, reporting) may be required and, in the case of disposal into an underground source of drinking water, the extent of the impacted area would require exemption from protection under the Safe Drinking Water Act. The AIM Toolbox software is available as a single-page web application, providing an interface to provide the necessary inputs, and both chart and map panes for visualizing the results. This User Guide describes the AIM Toolbox software, information required, user interactions, and the underlying basis of the calculations.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Aquifer Injection Modeling (AIM) Toolbox User Guide

58 GEOSCIENCES↗

DOE OSTI2024

Bringing Alaska's Carbon Ore, Rare Earth, and Critical Minerals (CORE-CM) into Perspective

The final report outlines the outcomes of the Alaska CORE-CM Program, funded by the U.S. Department of Energy under award DE-FE0032050. Led by the University of Alaska Fairbanks and the Alaska Division of Geological and Geophysical Surveys, with assistance from other organizations, the project assessed Alaska's potential for Carbon Ore, Rare Earth Elements, and Critical Minerals (CORE-CM). Leveraging advanced analytical techniques, the project identified high-potential resource basins, evaluated geochemical and satellite data, and conducted targeted field investigations. Findings revealed promising concentrations of critical minerals in legacy samples and newly collected materials. The project also investigated innovative extraction technologies, including BioExtraction and use of supercritical CO2, which show significant promise for sustainable resource recovery. Additionally, the study explored the reuse of waste streams from active mining operations and coal byproducts such as using alkali-activated coal ash to manufacture concrete. Infrastructure and logistical challenges in Alaska’s remote regions are discussed, alongside strategies to establish a Technology Innovation Center aimed at advancing CORE-CM development in Alaska. The report includes actionable insights to support Alaska’s critical role in securing domestic supplies of essential minerals while addressing economic, environmental, and technological challenges.

01 COAL, LIGNITE, AND PEAT↗