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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Applying Improved Optical Recognition with Machine Learning on Sorting Cu Impurities in Steel Scrap

Annually, 20–55 million tons of electronic waste (e-waste) is produced worldwide (5% of all municipal solid waste). Although e-waste embodies only 2% of America’s municipal waste, it accounts for a significantly larger proportion of the heavy metals and flame retardants present in the waste stream. Currently, less than 20% of all e-waste is recycled in the United States because the heterogeneity of the feedstock limits the opportunity for reuse in high value products and processing of the waste itself is often too costly to justify handling. To address this concern, the aims of this study are: 1) to identify the major plastic and metal compositions within electronic shredder residue (ESR), 2) to formulate solvents and processing conditions to separate 90% of the plastics targeted from consumer shred ESR, and 3) to develop a process design model to estimate the cost and energy efficiency of the proposed solvent-based processing. In this study, a pre-sorted heterogeneous ESR feedstock (one where aluminum, magnetic components, and hazardous battery materials removed by an e-waste recycling facility) was used, with the major compositions of the ESR characterized. It was found that 25 wt.% of the feedstock was composed of plastics, 6 wt.% rubber, 27 wt.% printed circuit boards, 23% wire, and the remainder metals and capacitors. Within the plastic portion, polystyrene (PS, 40 wt.%), acrylonitrile butadiene styrene (ABS, 25 wt.%), and styrene-acrylonitrile (SAN, 9wt.%) were identified to compose the majority of the screened plastics using Fourier transform infrared spectroscopy (FTIR). Next, selective solvents were screened using Hansen Solubility Parameter Theory (HSP) for dissolving PS and ABS. The pre-screening results show that methylene chloride (dichloromethane, DCM) and tetrahydrofuran (THF) are capable of dissolving the most PS and ABS, while methanol (MeOH) and ethylene glycol (EG) are capable of precipitating the most PS and ABS. These solvents were subsequently used to recover polymers and remove. flame retardants within the ESR feedstock. By optimizing the dissolution time and the solvents used, the highest polymer dissolution yield (99 wt.%%) was achieved using DCM for 48 hr. Both pre-screened anti-solvents (MeOH and EG) showed the highest polymer precipitation yield (71 wt.%). In terms of flame retardant removal rate, EG was found to have a high phosphorus-containing flame retardant removal rate (up to 98%). Characterization shows that the proposed solvent-based processing can preserve a high molecular weight fraction of the polymers and effectively remove flame retardants. Cost analysis indicates that the amount of the solvent/anti-solvent recovered after the reaction would play a critical role in reducing the operating costs. The energy analysis shows that the proposed solvent-based processes can save up to 60% of the embodied energy used to manufacture plastics used in electronics (PS and ABS were used for calculations). The results from this project prove the potential of solvent-based processing to produce secondary materials (plastics and metals) from e-waste for cross-industry reuse.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Revealing the working mechanism of a multi-functional block copolymer binder for lithium-sulfur batteries

The lithium-sulfur (Li-S) battery is one of the most promising substitutes for current energy storage systems because of its low cost, high theoretical capacity, and high energy density. However, the high solubility of intermediate products (i.e., lithium polysulfides) and the resultant shuttle effect lead to rapidly fading capacity and a low coulombic efficiency, which hinder the practical application of Li-S batteries. In this study, block copolymers are constructed with both an ethylene oxide unit and a styrene unit and then used as binders for Li-S batteries. Electrochemical performance improvements are attributed to the synergistic effects contributed by the different units of the block copolymer. Here, the ethylene oxide unit traps polysulfide, which bonds strongly with the intermediate lithium polysulfide, and enhances the transport of lithium ions to reach high capacity. Meanwhile, the styrene unit maintains cathode integrity by improving the mechanical properties and elasticity of the constructed block copolymer to accommodate the large volume changes. By enabling multiple functions via different units in the polymer chain, high sulfur utilization is achieved, polysulfide diffusion is confined, and the shuttle effect is suppressed during the cycle life of Li-S batteries, as revealed by operando ultraviolet–visible spectroscopy and S K-edge X-ray absorption spectroscopy.

25 ENERGY STORAGE↗
DOE OSTI2021

Nanocarrier-loaded block copolymer dual domain organogels

Loaded polymer gels are prevalent materials in the controlled release community and, fairly recently, have been formulated to include nanocarrier domains such as micelles and vesicles. One mechanism used to establish the solid-like characteristic of gels is block copolymer self-assembly, which can result in a system-spanning, physically-crosslinked network. Additionally, the combination of nanocarrier and crosslink domain presence offers gels with a rich nanoscale phase space capable of intricate macroscopic property tuning. The current manuscript provides an overview of nanocarrier-loaded block copolymer organogels wherein nanocarriers are reverse micelles formed by sodium dioctyl sulfosuccinate (AOT), the block copolymer is a styrenic ABA triblock copolymer, and the gel solvent is aliphatic mineral oil. This introductory overview starts by identifying the envelope in ternary phase space wherein nanocarrier-loaded block copolymer organogels form (2-49 wt% triblock copolymer and 8x10 -3 -1 wt% AOT). Next, a detailed nanostructural description of gels varying in AOT and triblock copolymer concentration is presented. The manuscript concludes with demonstration of AOT reverse micelle release and gel uniaxial tensile response for gels containing 0-1 wt% AOT and 5-40 wt% styrenic triblock copolymer.

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

Proton Conducting Sulfonated Poly(Ionic Liquid) Block Copolymers

Herein, we report the synthesis of proton-conducting sulfonated poly(ionic liquid) block copolymers (S-PILBCPs) containing one block with sulfonic acid (sulfonated styrene, SS) and the other with an IL moiety (vinylbenzylmethylimidazolium bis(trifluoromethylsulfonyl)imide, VBMIm-TFSI) using reversible addition–fragmentation chain-transfer (RAFT) polymerization and post-polymerization modifications (i.e., functionalization, anion exchange reactions, and sulfonation). The S-PILBCPs uniquely conjoin the SS block with mobile protons (H + ) and the PIL block with mobile anions (TFSI – ), where multiple highly desired properties, including high proton conductivity (from the SS block), and high IL-philicity and oxygen solubility (from the PIL block) can exist compartmentally within a microphase separated morphology (evidenced by differential scanning calorimetry (DSC) and small-angle X-ray scattering (SAXS)). High ion conductivity of 79.7 mS/cm at a PIL block composition of 21.6 mol % was observed at 80 °C and 90% relative humidity (RH) (comparable to the benchmark Nafion ionomer). This work successfully demonstrates the design of S-PILBCPs as a new material platform and showcases its promise as an ionomer for proton exchange membrane fuel cells (PEMFCs) as they simultaneously and compartmentally combine proton conductivity and oxygen solubility. Furthermore, these benefits have recently been leveraged to achieve substantial improvement in oxygen reduction reaction (ORR) activity and subsequently fuel cell performance.

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

SAN-Based Block Polymers as a Platform for Manufacturing Strong Isoporous Membranes

Ultrafiltration (UF) membranes are ubiquitous in water purification and bioprocessing. However, co-designing their mechanical and transport properties remains challenging because of the broad pore size distributions at the surface and within the bulk that result from nonsolvent-induced phase separation (NIPS) – their typical manufacturing process. These distributions influence the hydrodynamic resistance to water flow and the stress concentrations around the pores. Developing advanced UF membranes requires innovative molecular designs that offer control over the surface and bulk pores, as well as the mechanical properties of the load-bearing, polymer. Here, we introduce a platform for designing UF membranes by leveraging solution self-assembly of block polymers and chain architectures with pendant polar groups. The block polymers consist of a poly(styrene-co-acrylonitrile) hydrophobic block, which is known for its strength, and a poly(4-vinyl pyridine) hydrophilic block, which drives solution self-assembly. We focus on a series of block polymers with constant molecular weight, M n ≈ 115 kDa, SAN fraction, 75 wt.%, and varying acrylonitrile content, 0 to 40 mol%, to demonstrate that: (i) RAFT dispersion copolymerization of acrylonitrile and styrene provides a facile route to synthesize strong block polymers, (ii) incorporation of acrylonitrile into the hydrophobic block enhances membrane strength by facilitating chain entanglements and dipole-dipole interactions, and (iii) acrylonitrile alters the balance between membrane permeance and rejection, even when the membranes feature similar surface and bulk pores. Overall, our results provide insights into the molecular design of UF membranes with enhanced mechanical and separation properties, contributing to the development of materials for water and energy technologies.

deformation↗
DOE OSTI2025

A Change in C–H Activation Mechanism: Experimental and Computational Investigations of Rh-Catalyzed Disubstituted Benzene Functionalization

We report the ethenylation of 1,3- and 1,2-disubstituted benzenes using [(η 2 -C 2 H 4 ) 2 Rh(μ-OAc)] 2 as a catalyst precursor and Cu(OPiv) 2 as the oxidant. The regioselectivity of alkenylation for 1,3-disubstituted benzenes produces 3,5-disubstituted styrene products, while the alkenylation of 1,2-disubstituted benzenes produces 3,4- disubstituted styrene products. The rate of alkenylation is influenced by steric and electronic factors based on the substituents of the benzene unit. In all cases, 1,2-disubstituted benzenes react faster than 1,3-disubstituted benzenes, with a rate difference that is from 2 times up to >70 times more rapid for 1,2-disubstituted substrates. This is likely due to the difference in the number of accessible C−H bonds based on the steric protection of C−H bonds adjacent to functionality. Furthermore, the rate of alkenylation is influenced by the arene substituent electronics. The rates of alkenylation for 1,2-disubstituted benzenes follow the trend OMe > Me > CF 3 > Cl, while for 1,3-disubstituted benzenes the trend is CF 3 > Cl > Me > OMe. Using quantum mechanics DFT calculations, we found that the C−H activation step can occur by two different mechanisms. The electronic properties of substituents on the arene ring change the preferred C−H bond-breaking mechanism for 1,2-disubstituted and 1,3-disubstituted benzenes.

Aromatic compounds↗
DOE OSTI2026

Rhodium-Catalyzed Arene Alkenylation Using Benzoquinone Derivatives as Oxidants

The Rh-catalyzed conversion of olefins and arenes to alkenyl arenes using [(η 2 -C 2 H 4 ) 2 Rh(μ-OPiv)] 2 as the catalyst precursor and 12 ortho- and para-substituted benzoquinone derivatives as the in situ oxidant is reported. Included are comparative studies of the quinone derivatives for (1) rate of styrene production from benzene and ethylene, (2) Markovnikov to anti-Markovnikov selectivity for reactions of benzene and propylene, and (3) ortho/meta/para selectivity when using tert-butylbenzene as the arene. Cyclic voltammetry was utilized to measure reduction potentials for each quinone to determine any possible influence of the quinone redox potential on arene alkenylation rate and selectivity. While significant differences in selectivity are observed between ortho -quinone derivatives, such differences are minimal when para-substituted quinones are utilized. These results suggest that ortho -benzoquinone derivatives likely serve as bidentate ligands, which explains the stronger influence on catalyst activity of ortho -benzoquinone identity compared to para -benzoquinones. Although ortho -benzoquinones generally give styrene production rates faster than those of para -benzoquinones, 3,5-di- tert -butyl- ortho -benzoquinone and ortho -chloranil react with ethylene to form bicyclo[2.2.2]oct-5-ene-2,3-dione derivatives as a significant side product.

aromatic compounds↗
DOE OSTI2023

Ultrathin Atomic Layer Deposited Al 2 O 3 Overcoat Stabilizes Al 2 O 3 -Pt/Ni-Foam Hydrogenation Catalysts

Galvanic exchange seeds the growth of Pt nanostructures on Ni foam monolith. Subsequent atomic layer deposition of ultrathin Al 2 O 3 followed by annealing under air affords supported Pt catalysts with ultralow loading (0.020 ppm). Here, the Al 2 O 3 overcoat plays a crucial role in catalyst stability. In addition to the expected enhancement of the stability of the Pt particles on the surface, the ca. 2 nm Al 2 O 3 overcoat appears to also play a crucial role in the overall structural integrity of the NiO x nanoplates which grow on the Ni foam surface as a result of the preparative route. The resulting material is physically robust towards repeated handling and showcases retention of catalytic activity over ten standard catalyst recycling trials; standing in marked contrast to the uncoated samples. Catalyst activity was tested via the hydrogenation of various functionalized styrenes at low temperatures and low hydrogen pressure in ethanol as solvent, with a TOF as high as 9.5 × 10 6 h -1 for unfunctionalized styrene. Notably, the catalysts show excellent tolerance towards F, Cl, and Br substituents, and no hydrogenation of the aromatic ring.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Tailored Mesoporous Microspheres by Polymerization-Induced Microphase Separation in Suspension

We describe the preparation of block polymer beads by aqueous suspension polymerization to create poly(caprolactone) (PCL)-block-poly(styrene-co-divinylbenzene) beads that can be selectively etched under basic conditions to yield mesoporous polymer microspheres with uniform pore size. Polyvinylalcohol was used to stabilize the suspension polymerization in which styrene and divinylbenzene monomers were polymerized from a PCL macrochain transfer agent (macroCTA). The resulting polymerization-induced microphase separation process led to a nanostructured bicontinuous morphology. The particle size and pore size were independently tunable: the particle size was controlled by the stir rate of the suspension polymerization-yielding average diameters ranging from 60 to 300 μm-while the pore size was determined by the molar mass of the PCL block, with the mode pore diameters being 6 nm and 11 nm after etching beads made using 13 and 45 kg/mol PCL blocks, respectively. Based on nitrogen sorption measurements, the surface areas of the beads were ~300 m 2 /g when using a PCL macroCTA of 13 kg/mol. The beads were homogenous throughout on the micron length scale as determined by confocal Raman microscopy and lacked an impermeable skin layer as confirmed by scanning electron microscopy. Furthermore, the scalability of suspension polymerization allows for the simple synthesis of large quantities of thermoset microspheres with uniform pore size. We also demonstrate the ability to incorporate functional pore walls into the beads using multiblock precursor polymers. These functionalized mesoporous polymer beads show high affinity for ionic dyes in aqueous solutions (as a proof of principle) and remove dye from the solution at rates exceeding those of commercial ion-exchange resins. The developed procedure could be used to generate other functional surface chemistries with important applications in heterogeneous catalysis, chromatography, and water remediation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Virgin-like High-Density Polyethylene from Recycled Mixed Polyolefins

Reported herein is the compatibilization of mixed polyolefins containing a rheology modifier (M-PO RM ) derived from municipal solid waste (MSW) by using different types of compatibilizers. One compatibilizer was produced “in situ” during reactive extrusion (REX), and the other compatibilizers were commercial styrenic block copolymer and maleated polymer-based compatibilizers. Both “in situ” and commercial compatibilizers were first used in laboratory-controlled polyolefins containing a rheology modifier (denoted as L-PO RM ) and were investigated for their mechanical properties. The study was then extended to a rheology modifier containing recycled mixed polyolefins (M-PO RM ), where the effects of both compatibilizers were evaluated. Compared to the in situ and other commercial compatibilizers, the styrenic block copolymer offered superior performance, as it enabled the synthesis of virgin-like high-density polyethylene (HDPE) from the M-PO RM . The findings suggest that M-PO RM can be transformed into blends with virgin HDPE-like properties, thus offering an industrially relevant approach for the re- and upcycling of mixed polyolefins. Finally, the M-PO RM pellets with uniform MFI and good mechanical properties can be used as injection mold feedstocks for different applications such as in the construction and automotive sectors.

compatibilization↗
DOE OSTI2021

Computational Investigation of the Role of Active Site Heterogeneity for aSupported Organovanadium(III) Hydrogenation Catalyst

A crucial consideration for supported heterogeneous catalysts is the nonuniformity of the active sites, particularly for supported organometallic catalysts. Standard spectroscopic techniques, such as X-ray absorption spectroscopy, reflect the nature of the most populated sites, which are often intrinsically structurally distinct from the most active catalytic sites. Additionally, with computational models, often, only a few representative structures are used to depict catalytic active sites on a surface, even though there are numerous observable factors of surface heterogeneity that contribute to the kinetically favorable active species. A previously reported study on the mechanism of a surface organovanadium-(III) catalyst [(SiO 2 )V III (Mes)(THF)] for styrene hydrogenation yielded two possible mechanisms: heterolytic cleavage and redox cycling. These two mechanistic scenarios are challenging to differentiate experimentally since the kinetic readouts of the catalyst are identical. To showcase the importance of modeling surface heterogeneity and its effect on catalytic activity, density functional theory (DFT) computational models of a series of potential active sites of [(SiO 2 )V III (Mes)(THF)] for the reaction pathways are applied in combination with kinetic Monte Carlo (kMC) simulations. Computed results were then compared to the previously reported experimental kinetic study: (1) DFT free-energy reaction pathways indicated the likely active site and pathway for styrene hydrogenation, a heterolytic cleavage pathway requiring a bare tripodal vanadium site. (2) From the kMC simulations, a mixture of different bond lengths from the support oxygen to the metal center was required to qualitatively describe the experimentally observed kinetic aspects of a supported organovanadium(III) catalyst for olefin hydrogenation. This work underscores the importance of modeling surface heterogeneity in computational catalysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Pd(II) and Rh(I) Catalytic Precursors for Arene Alkenylation: Comparative Evaluation of Reactivity and Mechanism Based on Experimental and Computational Studies

We combine experimental and computational investigations to compare and understand catalytic arene alkenylation using the Pd(II) and Rh(I) precursors Pd(OAc) 2 and [(η 2 -C 2 H 4 ) 2 Rh(µ-OAc)] 2 with arene, olefin and Cu(II) carboxylate at elevated temperature (> 120 °C). Under specific conditions, previous computational and experimental efforts have identified heterotrimetallic cyclic PdCu 2 (η 2 -C 2 H 4 ) 3 (μ-OPiv) 6 and [(η 2 -C 2 H 4 ) 2 Rh(µ-OPiv) 2 ] 2 (µ-Cu) (OPiv = pivalate) species as likely active catalysts for these processes. Further studies of catalyst speciation suggest a complicated equilibrium between Cu(II)-containing complexes containing one Rh or Pd atom with complexes containing two Rh or Pd atoms. At 120 °C, Rh catalysis produces styrene > 20-fold more rapidly than Pd. Also, at 120 °C, Rh is ~98% selective for styrene formation while Pd is ~82% selective. Furthermore, our studies indicate that Pd catalysis has a higher predilection toward olefin functionalization to form undesired vinyl ester, while Rh catalysis is more selective for arene/olefin coupling. However, at elevated temperatures, Pd converts vinyl ester and arene to vinyl arene, which is proposed to occur through low valent Pd(0) clusters that are formed in situ. Regardless of arene functionality, the regioselectivity for alkenylation of mono-substituted arenes with the Rh catalyst gives an approximate 2:1 meta:para ratio with minimal ortho C–H activation. In contrast, Pd selectivity is significantly influenced by arene electronics with electron-rich arenes giving an approximate 1:2:2 ortho:meta:para ratio while the electron deficient (α,α,α)-trifluorotoluene gives a 3:1 meta:para ratio with minimal ortho functionalization. Kinetic intermolecular arene ethenylation competition experiments find that Rh reacts most rapidly with benzene, and the rate of mono-substituted arene alkenylation does not correlate with arene electronics. In contrast, with Pd catalysis, electron-rich arenes react more rapidly than benzene while electron-deficient arenes react less rapidly than benzene. These experimental findings, in combination with computational results, are consistent with the arene C–H activation step for Pd catalysis involving significant η 1 -arenium character due to Pd-mediated electrophilic aromatic substitution character. In contrast, the mechanism for Rh catalysis is not sensitive to arene substituent electronics, which we propose indicates less electrophilic aromatic substitution character for the Rh-mediated arene C–H activation.

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

Green syntheses of stable and efficient organic dyes for organic hybrid light-emitting diodes

Organic hybrid light-emitting diodes (hybrid-LEDs) employ organic dyes as light converters on top of commercial blue inorganic LEDs, replacing incumbent inorganic phosphor light converters synthesized from rare-earth and/or toxic metallic elements to optimize device environmental sustainability. Here, we present two naturally derived organic dyes for hybrid-LEDs, highlighting stability and efficiency enhancement based on a novel “acceptor–acceptor” molecular design. This “acceptor–acceptor” skeleton comprises theobromine and thiadiazole, two electron-withdrawing groups that lower energy levels and suppress photooxidation. This differentiates these dyes from the widely adopted “donor–acceptor” skeleton, where photooxidation is facilitated by the presence of electron-donating units. Simultaneously, sidechains on organic dyes used to enhance solution processability, crucial for film transparency, introduce an additional photooxidation pathway. With this “acceptor–acceptor” skeleton, the destabilization from sidechains was offset by the stability enhancement from the electronic effects in the backbone. Additionally, when blended within an industrial polymer, poly(styrene-butadiene-styrene) (SBS), their enhanced solubility enables the formation of highly transparent films, crucial for reducing scattering loss in LEDs. Furthermore, resultant dye-SBS films achieved photoluminescence quantum yields (PLQYs) of around 90% under ambient conditions. Taking advantage of their transparency and solution processability, we fabricated a waveguide with this theobromine-dye-SBS composite, which was subsequentially assembled into an edge-lit LED device of no glare and enhanced aesthetics.

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

A divergent synthetic route to functional copolymer libraries via modular polymers

High-throughput polymer synthesis enables rapid exploration of chemical space but remains limited by batch-to-batch inconsistencies that can obscure structure–property relationship trends. To address this challenge, we developed a synthetic approach to produce multifunctional copolymers using post-polymerization modification of activated ester modular polymers with commercially available amines. Easily derivitized parent polymers—poly(tetrafluorophenyl acrylate) and poly(tetrafluorophenyl styrene sulfonate)—were synthesized by RAFT polymerization to yield single polymer batches containing highly reactive tetrafluorophenyl esters or sulfonate esters on each repeat unit. Tuning post-polymerization modification reaction conditions enabled the addition of sub-stoichiometric amounts of amines (relative to the repeat unit) to yield partially functionalized intermediates that could then be further derivatized. Reaction monitoring by 19 F NMR spectroscopy confirmed good control over these sequential post-polymerization modifications. This synthetic route produced a variety of copolymers with defined comonomer ratios while preserving the underlying polymer structure (degree of polymerization, dispersity, tacticity) for both the acrylate and styrene sulfonate backbones. We further applied this approach in a divergent manner to create a small library of structurally distinct copolymers from a single parent batch in three synthetic steps. This modular, divergent synthesis demonstrates a general route to structurally consistent copolymer libraries that enable systematic studies of structure–property relationships and can accelerate functional materials discovery.

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

Electrospinning of ultra-high molecular weight polymers into aligned nanofibers and their application in chemical separations

Ultra-high molecular weight (UHMW, >10 6 g mol −1 ) vinyl polymers are increasingly accessible through photoiniferter polymerization, yet their behavior in electrospinning has received comparatively little attention. Here, we explore the electrospinning of UHMW poly(methyl acrylate), poly(methyl methacrylate), poly(N,N-dimethylacrylamide), and poly(styrene-co-pentafluorostyrene) synthesized by photoiniferter polymerization, with number-average molecular weights (M n ) greater than 1000 kDa and dispersities below 1.4. UHMW polymers form stable Taylor cones and discrete fibers at solution concentrations as low as 0.5 wt% due to their large number of entanglements, a threshold unachievable with low molecular weight (M n = 20–54 kDa) polymers of the same chemistry. Using poly(methyl methacrylate) and poly(styrene-co-pentafluorostyrene) as model systems, we demonstrate that fiber diameter can be tuned from 350 nm to 20 μm through systematic variation of polymer concentration (0.01 to 4 wt%) and flow rate (0.5 to 10 mL h −1 ). Additionally, we find that collector rotation rate governs fiber alignment, with highly aligned mats obtained with drum rotation speeds of 1000 RPM. Reversing the polarity of the electric field during electrospinning reorients the surface chemistry of these fiber mats without altering their microscale morphology, shifting the water contact angle by 7° (89° to 96°) and providing a two-fold binding capacity enhancement in cationic dye uptake. These results show that the high entanglement densities of UHMW vinyl polymers shift the accessible electrospinning window to dilute solutions and that electric-field polarity is a useful lever to control the surface chemistry in the resulting fibers.

Marquez, Joshua D. [University of Florida, Gainesv↗
DOE OSTI2021

Chemical Recycling of Mixed Plastics and Valuable Metals in the Electronic Waste Using Solvent-Based Processing

Annually, 20-55 million tons of electronic waste (e-waste) is produced worldwide (5% of all municipal solid waste). Although e-waste embodies only 2% of America’s municipal waste, it accounts for a significantly larger proportion of the heavy metals and flame retardants present in the waste stream. Currently, less than 20% of all e-waste is recycled in the United States because the heterogeneity of the feedstock limits the opportunity for reuse in high value products and processing of the waste itself is often too costly to justify handling. To address this concern, the aims of this study are: 1) to identify the major plastic and metal compositions within electronic shredder residue (ESR), 2) to formulate solvents and processing conditions to separate 90% of the plastics targeted from consumer shred ESR, and 3) to develop a process design model to estimate the cost and energy efficiency of the proposed solvent-based processing. In this study, a pre-sorted heterogeneous ESR feedstock (one where aluminum, magnetic components, and hazardous battery materials removed by an e-waste recycling facility) was used, with the major compositions of the ESR characterized. It was found that 25 wt.% of the feedstock was composed of plastics, 6 wt.% rubber, 27 wt.% printed circuit boards, 23% wire, and the remainder metals and capacitors. Within the plastic portion, polystyrene (PS, 40 wt.%), acrylonitrile butadiene styrene (ABS, 25 wt.%), and styrene-acrylonitrile (SAN, 9wt.%) were identified to compose the majority of the screened plastics using Fourier transform infrared spectroscopy (FTIR). Next, selective solvents were screened using Hansen Solubility Parameter Theory (HSP) for dissolving PS and ABS. The pre-screening results show that methylene chloride (dichloromethane, DCM) and tetrahydrofuran (THF) are capable of dissolving the most PS and ABS, while methanol (MeOH) and ethylene glycol (EG) are capable of precipitating the most PS and ABS. These solvents were subsequently used to recover polymers and remove. flame retardants within the ESR feedstock. By optimizing the dissolution time and the solvents used, the highest polymer dissolution yield (99 wt.%%) was achieved using DCM for 48 hr. Both pre-screened anti-solvents (MeOH and EG) showed the highest polymer precipitation yield (71 wt.%). In terms of flame retardant removal rate, EG was found to have a high phosphorus-containing flame retardant removal rate (up to 98%). Characterization shows that the proposed solvent-based processing can preserve a high molecular weight fraction of the polymers and effectively remove flame retardants. Cost analysis indicates that the amount of the solvent/anti-solvent recovered after the reaction would play a critical role in reducing the operating costs. The energy analysis shows that the proposed solvent-based processes can save up to 60% of the embodied energy used to manufacture plastics used in electronics (PS and ABS were used for calculations). The results from this project prove the potential of solvent-based processing to produce secondary materials (plastics and metals) from e-waste for cross-industry reuse.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Alkaline anion exchange membranes derived from diphenylethylene and co-monomer feedstock

The anion exchange membranes exhibit enhanced chemical stability and ion conductivity when compared with traditional styrene-based alkaline anion exchange membranes. A copolymer backbone is polymerized from a reaction medium that includes a diphenylalkylene and an alkadiene. The copolymer includes a plurality of pendant phenyl groups. The diphenyl groups on the polymer backbone are functionalized with one or more haloalkylated precursor substrates. The terminal halide from the precursor substrate can then be substituted with a desired ionic group. The diphenylethylene-based alkaline anion exchange membranes lack the .alpha.-hydrogens sharing tertiary carbons with phenyl groups from polystyrene or styrene-based precursor polymers, resulting in higher chemical stability. The ionic groups are also apart from each other by about 3 to 6 carbons in the polymer backbone, enhancing ion conductivity. These membrane are advantageous for use in fuel cells, electrolyzers employing hydrogen, ion separations, etc.

Lee, Sangwoo↗
DOE OSTI2023

Investigating Marine Environmental Degradation of Additive Manufacturing Materials for Renewable Energy Applications: Preprint

Marine renewable energy is a relatively young industry where there is a great need for rapid prototyping in design-build-test campaigns to quickly mature groundbreaking technologies. Additive manufacturing has an important role to play in the industry; however, little information is available to marine energy developers to help inform them on which additive manufacturing materials are appropriate for harsh marine environments. This paper presents an initial study on the mechanical characterization of polymeric additive manufacturing materials and the degradation effects of marine environments. Ultem 9085, acrylonitrile styrene acrylate, and chopped carbon-filled nylon, as well as continuous carbon and glass fiber-reinforced nylon were chosen for this study. Samples were manufactured to perform a variety of tension, shear, and compression mechanical characterization tests on the materials. Half of the samples were conditioned in Pacific Ocean water for approximately 6 months at Pacific Northwest National Laboratory's Marine Sciences Laboratory before being returned for mechanical characterization. The mechanical testing results showed that the Ultem 9085 and acrylonitrile styrene acrylate materials experienced little to no degradation in stiffness or strength after exposure to the marine environment. On the other hand, the nylon-based materials suffered significant stiffness and strength degradation (over 50% in some cases) after environmental conditioning. Ultimately, these data sets should serve as starting points to allow marine renewable energy developers to make informed additive manufacturing material choices for their prototype deployments.

additive manufacturing↗