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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Development of Leaching Processes for the Recovery of Rare Earth Elements from Acid Mine Drainage Precipitates

Acid mine drainage (AMD) has been a challenge for mine operators to address and has had significant environmental impacts when there is a failure to address it. Fortunately, there is a regulation in the US that requires the treatment of AMD before water can be discharged into the environment. AMD is generated when sulfide minerals are exposed to water and air from mining. The acidic water then leaches metals from the surrounding rock, creating the potential for environmental contamination of this acidic water containing dissolved metals. AMD can contain high concentrations of metals like iron, aluminum, and manganese and also have been shown to contain trace concentrations of critical minerals, including rare earth elements (REEs). This environmental waste stream is now being researched as a potential source for REEs. There is a patented process for processing and extracting REEs from AMD which produces rare earth oxide preconcentrate (REOP) from AMD treatment precipitates and a final stage mixed rare earth oxide (MREO) product. This body of research examines a selective leaching process for each of these products and determines the activation energy associated with the leaching processes. Acid leaching with HCl was examined to selectively leach REEs from REOP while contaminant metals remained in the solid residue. The maximum leaching recovery of the REEs from the REOP was approximately 90% and an activation energy of 6.4 kJ/mol at pH 3.0. Ammonium chloride leaching was examined to selectively remove contaminant metals from a MREO product. The ammonium chloride process successfully leached major contaminant metals in excess of 85% recovery and had a maximum activation energy of 40.0 kJ/mol.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

A methodology for selection of solid desiccants in energy recovery ventilators

Controlling indoor humidity levels is essential for maintaining acceptable indoor air quality in buildings. The use of energy recovery ventilators (ERVs) is an energy-efficient way to regulate indoor air humidity. Fixed-bed regenerators and rotary wheels are widely used ERVs because of their high sensible and latent effectiveness. These ERVs are made of desiccant-coated substrates, which enable them to transfer moisture between the supply and exhaust air streams. However, the moisture transfer ability of ERVs depends on the physiochemical and sorption properties of desiccants. Extensive, full-scale experiments are required to determine the best desiccant material for these systems. This paper presents a simplified method of selecting suitable desiccant materials for ERVs. The methodology involves important characterization methods, literature correlations for performance prediction, and cost-effective testing methods prior to full-scale testing, and full-scale test methods are discussed in detail. Furthermore, the performance of a few newly derived materials is evaluated and compared with that of conventional desiccants such as silica gel and molecular sieves. The highest latent effectiveness was obtained for composite of super absorbent polymer (SAP) with potassium formate (SAP-HCO2K-50 %), all-polymer porous solid desiccant (APPSD) and metal organic framework (MOF)–MIL–101 (Cr), followed by activated carbon fibre felt (ACFF) Silica sol-LiCl30, SAP, silica gel, MOF–303, and molecular sieve. Researchers and manufacturers would benefit from the proposed methodology and presented data in developing new desiccant materials for ERV applications.

Energy recovery↗
DOE OSTI2025

Hydrometallurgical Recycling of Black Mass of Spent Lithium-Ion Batteries Using Methanesulfonic Acid: Leaching, Kinetic Studies, and Potential for Total Recovery of Valuable Components

Methanesulfonic acid (MSA) exhibits several advantageous properties rendering it a promising candidate for circular hydrometallurgical processes. These properties include a high acidity (pKa = - 1.9) comparable to that of classical mineral acids as well as biodegradability, high stability, and high solubility of metal-MSA complexes in aqueous solutions. In this study, MSA was employed as a lixiviant for the leaching of metals (lithium, nickel, cobalt, and manganese) from the black mass of spent lithium-ion batteries (LIBs). The effect of various parameters, including MSA concentration, H 2 O 2 concentration, temperature, and pulp density, was systematically investigated. Under the optimized conditions (1.5 M MSA, 0.2 M H 2 O 2 , 60 °C, and 50 g/L pulp density), quantitative leaching of lithium was achieved within 30 min, while for nickel and cobalt it was after 2 h, and 4 h for manganese leaching. The leaching kinetics of Li, Ni, Co, and Mn were studies using the shrinking particle models (SPM) and the Avrami model. The results indicated that the Avrami model provided the best fit to the kinetic data, with apparent activation energies of 46.81 kJ/mol for Li, 58.61 kJ/mol for Ni, 59.69 kJ/mol for Co, and 58.86 kJ/mol for Mn, within the temperature range of 25-70 °C (except for Li, which was analyzed in the range of 25-60 °C), consistent with chemical reaction control. Subsequently, residual contaminants in the leaching residue were eliminated through pyrolysis. The quantitative leaching of metals in MSA solution (a green lixiviant), combined with the pyrolytic treatment of leaching residues, represents a circular strategy for the total recovery of valuable components from the black mass of spent LIBs.

25 ENERGY STORAGE↗
DOE OSTI2024

Maximizing energy efficiency in wastewater treatment plants: A data-driven approach for waste heat recovery and an economic analysis using Organic Rankine Cycle and thermal energy storage

Maximizing energy efficiency through waste heat recovery (WHR) processes is crucial for sustainable and ecofriendly operations across multiple industries, notably in wastewater treatment plants (WWTPs). This work proposes a comprehensive approach for assessing the WHR feasibility in WWTPs, structured in two main objectives. Firstly, an Artificial Neural Network (ANN) model is developed to accurately predict WHR based on operational data, including biogas temperature, biogas pressure, daily production in kWh, and WHR values in kWh th . The second objective focuses on economically evaluating the WHR feasibility based on the estimated WHR values obtained by the ANN model, and then realistically assessing the economic feasibility of integrating the Organic Rankine Cycle (ORC) and Seasonal Thermal Energy Storage (STES) systems. With an application to the As-Samra WWTP located in Jordan, the developed ANN model demonstrates promising results in the validation phase, with a root mean square error (RMSE) of 2206 kWh/day, a mean absolute error (MAE) of 1674 kWh/day, and an R-squared (R 2 ) value of 68%. On the other hand, the economic analysis reveals that an optimal ORC system of 412.14 kW e capacity yields a Net Present Value (NPV) of 2.09 million US dollars, a Levelized Cost of Energy (LCOE) of 0.0749 USD/kWh, a Payback Period (PBP) of 4.8 years, and annual revenues of 428 kUSD. This work also investigates the techno-economic feasibility of integrating ORC-STES. Results indicate that the LCOE and PBP are highly affected by the ORC's capital cost, and integrating STES increases the LCOE to 0.0824 USD/kWh, rendering its integration with ORC infeasible. In conclusion, this study aims to advance the understanding and application of WHR in WWTPs, paving the way for more efficient and sustainable practices in the field.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Surrogate modeling and optimization of the leaching process in a rare earth elements recovery plant

Critical minerals (CMs) and Rare Earth Elements (REEs) play a vital role in crucial infrastructure technologies such as renewable energy generation and batteries. Recovering them from waste materials has recently been found to significantly reduce environmental impact and supply chain costs related to these materials. In this work, we investigate surrogate modeling techniques aimed to simplify the modeling, simulation, and optimization of the leaching processes involved in CM and REE recovery flowsheets. As there is currently a lack of systematic studies on this topic, we perform extensive computational testing to ascertain which surrogate models are easier to construct and offer high predictive accuracy. Further, our results suggest that sparse quadratic models balance predictive accuracy and computational efficiency. Training and using these surrogates for global optimization of the leaching process requires two orders of magnitude fewer measurements and is up to four orders of magnitude faster than optimizing the original simulation using equation-oriented optimization or derivative-free optimization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Optimal environmental and economic performance trade-offs for fifth generation district heating and cooling network topologies with waste heat recovery

Network topology greatly influences both the economic and environmental performance of fifth generation district heating and cooling (5GDHC) systems. In this study the optimal trade-offs between the environmental and economic performance of 5GDHC network topologies for a five-building district with waste heat recovery were explored. A life cycle assessment method was used to calculate the total life cycle CO 2 emissions (LCCO2) associated with the installation and operation of various network topologies. Twelve months of empirical data from a data center cooling system were analyzed to assess its suitability for integration into a 5GDHC system. The most suitable method for utilizing this waste heat was selected based on the ambient loop warm pipe setpoint, waste heat temperature, and district energy system configuration. A multi-objective optimization algorithm was used to select the 5GDHC network topology that provided the optimal trade-off between LCCO2 and life cycle cost (LCC). A trade-off parameter was employed to weigh the importance of each objective in the selection process. The results showed waste heat from the data center was suitable for integration into the 5GDHC system due to its availability and consistent temperature profile. When return temperatures of 25 °C or higher were available from the liquid-cooled system, direct pre-heating of the ambient loop warm pipe was found to be the most effective waste heat integration method. The selection of the network topology that provided the optimal trade-off between LCCO2 and LCC (optimal trade-off topology) was highly dependent on factors such as fuel prices, CO 2 prices, electricity CO 2 emissions factors, availability of waste heat, embodied CO 2 emissions associated with network installation and network infrastructure costs. Optimal trade-off topologies produced substantial LCCO2 reductions relative to corresponding LCC increases. LCCO2 reduction to LCC increase ratios from 5.78 to 117.79 were identified with CO 2 offset costs ranging from 4.77 to 60.08 ($/tCO 2 e).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Material Recovery Facilities (MRFs) in the United States: Operations, revenue, and the impact of scale

An analysis was conducted using nationwide survey data to evaluate how material recovery facilities (MRFs) operations vary regionally and with scale. The survey characterized materials, processes, and energy use involved with operations, and revenue for recyclables. This is the first nationwide analysis of MRFs in the US that accounts for mass processed, energy consumed, and revenue. Of a population of 521 MRFs, 48 responses representing MRFs from five US regions were received and analyzed (9.2 % response rate). Responses were analyzed by size according to yearly mass of inbound materials (small: <1,000 Mg/year, medium: 1,000–10,000 Mg/year, and large: >10,000 Mg/year). Most MRFs identify as single-stream; source from residences; utilize tipping floors, picking lines, baling and warehousing; and are powered by electricity. Most revenue and inbound mass (>50%) came from fiber (cardboard and paper). Glass had little revenue, and plastics were difficult to transition to market. Percent residue ranged from 1-39%, averaged <20%, and increased as the mass of inbound material increased. Large MRFs reported more sources of material, employed advanced sorting technology, had greater plastics revenue (33% versus 5% for small MRFs), and had more market access for plastics compared to small MRFs. Large MRFs had two orders of magnitude less annual electricity consumption per Mg recyclables than small MRFs (5–90 kWh/Mg versus ∼300–550 kWh/Mg). Results demonstrate environmental and economic benefits of larger-scale MRFs, which could be implemented more broadly in the US through regional hub-and-spoke arrangements for collecting and processing recyclables, lowering energy consumption and increasing revenue for recyclables.

Hub-and-Spoke↗
DOE OSTI2024

Toward Enhancing Wastewater Treatment with Resource Recovery in Integrated Assessment and Computable General Equilibrium Models

Sustainable water management is essential to increasing water availability and decreasing water pollution. The wastewater sector is expanding globally and beginning to incorporate technologies that recover nutrients from wastewater. Nutrient recovery increases energy consumption but may reduce the demand for nutrients from virgin sources. We estimate the increase in annual global energy consumption (1,100 million GJ) and greenhouse gas emissions (84 million t CO2e) for wastewater treatment in the year 2030 compared to today’s levels to meet sustainable development goals. To capture these trends, integrated assessment and computable general equilibrium models that address the energy-water nexus must evolve. We reviewed 16 of these models to assess how well they capture wastewater treatment plant energy consumption and GHG emissions. Only three models include biogas production from the wastewater organic content. Four explicitly represent energy demand for wastewater treatment, and eight include explicit representation of wastewater treatment plant greenhouse gas emissions. Of those eight models, six models quantify methane emissions from treatment, five include representation of emissions of nitrous oxide, and two include representation of emissions of carbon dioxide. Our review concludes with proposals to improve these models to better capture the energy-water nexus associated with the evolving wastewater treatment sector.

42 ENGINEERING↗
DOE OSTI2024

Enhancing Resource Recovery through Electro-Assisted Regeneration of an Ammonia-Selective Cation Exchange Resin

Ammonia-selective adsorbents can manage reactive nitrogen in the environment and promote a circular nutrient economy. Weak acid cation exchangers loaded with zinc exhibit high ammonia selectivity but face two implementation barriers: the stability of the zinc–carboxylate bond in complex wastewaters and energy- and logistics-intensive adsorbent regeneration with acidic solutions. In this paper, we examined the stability of zinc–carboxylate bonds in varying solutions (pure ammonium solution, synthetic urine, and real urine) and during electro-assisted regeneration. For electrochemical regeneration, both electrolyte concentration and current density influenced the trade-off between ammonia regeneration and zinc elution. Using 10 mM K 2 SO 4 anolyte at a 0.08 mA/cm 2 current density, we achieved 4% zinc elution and 61% ammonia regeneration. In contrast, using 100 mM K 2 SO 4 at 4.96 mA/cm 2 improved the regeneration efficiency to 97% but eluted 60% of zinc. We found that electrolyte concentration was the key factor influencing the regeneration efficiency of the NH 3 -selective adsorbents. Due to prevalent zinc elution, we designed an in situ procedure for reforming the zinc–carboxylate bond and achieved similar adsorption densities between pre- and post-regenerated resins, thus enabling multiple cycle resin use. Ultimately, this study advances understanding of ammonia-selective resins that can facilitate high-purity, selective, and durable recovery of nutrients from waste streams.

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

Production of Vanillin From Ferulic Acid by Pseudomonas putida KT2440 Using Metabolic Engineering and In Situ Product Recovery

Vanillin is the most in-demand flavouring compound in the world and because vanillin extracted from vanilla pods cannot meet the global demand, most vanillin on the market today is chemically synthesised. Increasing demands by consumers for natural ingredients have inspired efforts to develop vanillin derived from microbial sources. These efforts have been challenged by low titers, likely caused by the toxicity of vanillin to most microbial biocatalysts. In this study, we engineered a Pseudomonas putida KT2440-derived strain that accumulated vanillin from ferulic acid to 0.64 g/L. To increase the overall titre, we applied a hydrophobic polystyrene-based resin to vanillin-accumulating cultures, which enabled an increase in total vanillin recovery to an apparent titre of 3.35 g/L. This study demonstrates that P. putida can accumulate vanillin from ferulic acid to higher titers when vanillin is removed from the cultivation medium, mitigating its toxicity.

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

CO2 Enhanced Oil Recovery Evaluation System (CO2_E_EvSystem), Version 2025

The United States Department of Energy’s (DOE’s) Office of Fossil Energy and the National Energy Technology Laboratory (NETL) developed a suite of screening-level, techno-economic models/tools, known as the CO2_E_EvSystem, to evaluate technical aspects and costs of using carbon dioxide (CO2) enhanced oil recovery (EOR) to store CO2 and produce oil. CO2_E_EvSystem has three software components and several input and output files. The software components are CO2_E_EvTool, CO2_Prophet, and CO2_E_COM. Almost all computational work is performed by CO2_Prophet and CO2_E_COM, which are both Fortran programs. The primary role of CO2_E_EvTool is to manage input and output files for the two programs, run the two programs, allow multiple oilfields to be evaluated in a single run, and generate files that summarize the results for all the oilfields run. This version of the CO2_E_EvSystem includes a residual oil zone dataset from the San Andres formation, Permian Basin, to demonstrate the system and guide users on attributes needed for dataset inputs.

AS↗
DOE OSTI2025

Reinventing wastewater treatment plants: energy neutral treatment and enhanced fertilizer production through a novel resource recovery center

Wastewater treatment plants (WWTPs) are typically energy intensive, mainly due to the secondary treatment processes such as activated sludge (AS) for treatment of organics as well as nutrients like nitrogen. Nitrogen removal presents a big problem for WWTPs. The main form of nitrogen in wastewater is ammonium, and an AS process uses oxygen to convert ammonium into nitrite and nitrate which is then converted to nitrogen through denitrification process. During anaerobic digestion (AD), organic nitrogen gets degraded, resulting in an effluent stream (centrate) with a high nitrogen content, mostly in the form of ammonium. This contributes 15-30% of total nitrogen to the wastewater influent which further increases energy consumption for aeration. The project aims to transform this conventional municipal WWTPs into energy-neutral, resource-recovering facilities by integrating three core technologies: • Cloth Media Filtration (CMF) to replace conventional primary sedimentation (CPS) and increase the diversion of organics from the energy intensive secondary treatment to AD. This results in reduced energy demand for aeration in the secondary process while simultaneously increasing the biogas production in the anaerobic digesters. • Anerobic Digester to increase biogas and ammonia production. • Membrane Evaporation (ME) to recover ammonia from AD centrate and produce marketable fertilizer. The benefits of proposed WWTP process modifications were evaluated using techno economic analysis (TEA) and life cycle assessment (LCA). For CMF portion of the research a statistical analysis was employed to develop data-driven tools that could be used to enhance and optimize its performance in terms of energy savings and effluent quality. The main objective of this project is to reduce the energy demand for secondary treatment at municipal WWTPs by at least 50%, increase anaerobic digester (AD) biogas and ammonia production by 100% and 120%, respectively, and recover 90% of ammonia from the AD. Integrated CMF, AD, and ME was shown to work synergistically toward achieving these decarbonization targets through energy-positive treatment and fertilizer recovery techniques.

42 ENGINEERING↗
DOE OSTI2025

Transforming Aeration Energy in Water Resource Recovery Facilities (WRRFs) through Suboxic Nitrogen Removal (Final Report)

The objective of this project was to advance two key technological components—aeration control strategies and process design methodologies—to support the development and broader adoption of suboxic biological nitrogen removal (SBNR). The project focused on achieving the following three goals: • Enhance Model Predictive Control (MPC) Technology: Advance the DO/Nmaster MPC platform from its initial 2018 pilot deployment at the Chico Water Resource Recovery Facility in California to full-scale integration. This included partnering with a blower technology commercialization partner and incorporating machine learning (ML) capabilities to enable nationwide deployment. • Bridge Knowledge Gaps in SBNR Process Design: Address fundamental gaps in SBNR process understanding through controlled pilot-scale testing at a dedicated pilot facility. These efforts supported the development of robust kinetic models to inform reliable SBNR control, operational strategies, and design frameworks. • Demonstrate Full-Scale Implementation of Low DO/SBNR with ML: Transition low dissolved oxygen (DO)/SBNR coupled with ML from pilot-scale trials to full-scale demonstration in flow-through biological nutrient removal (BNR) systems, with the goal of enabling scalable, nationwide adoption in activated sludge treatment processes. The project included demonstration of SBNR at the pilot scale as performed by Hampton Roads Sanitation District (HRSD) and at the full-scale as performed by the Los Angeles County Sanitation Districts' (LACSD) Pomona Water Reclamation Plant (POWRP).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Renewable low-Z wall for fusion reactors with built-in tritium recovery (Final Technical Report)

This project pursued development of a novel renewable plasma-facing wall technology for fusion reactors. The technology is based on a slurry which can be easily delivered by delivery tubes to the reactor wall. The slurry dries at the hot reactor wall into pebble rods which are extruded out into the hot plasma, where the pebbles break off and fall along the reactor wall and can be recovered by gravity and re-used. The falling pebbles carry away heat and tritium and also protect the wall against large scale erosion or redeposition of material. The research focused on carbon-based pebble rods and demonstrated that pebble rods could be produced from slurry with tolerable levels of outgassing on a reactor-relevant timescale (< 5 minutes). Steady-state handling of reactor relevant (up to 50 MW/m 2 ) normal-incidence heat loads was demonstrated. Pebble release velocities were found to be sufficiently small (< 1 m/s) to allow recovery below the vacuum chamber. Tunability of the pebble rod breaking rate was demonstrated by changing the fill fraction of the interpebble matrix which binds the pebbles together. This work could benefit the public by helping move forward the design of commercially viable fusion energy reactors. Designing a first wall for magnetic fusion reactors which can handle the huge heat loads present and also avoid buildup of tritium-containing deposits is extremely challenging and requires novel approaches like the one being investigated here.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Scalable Fabrication of a Fibrous Amine-functionalized Matrix (FAM) Sorbent for Critical Mineral Recovery

We report a novel flat sheet Fibrous Amine-functionalized Matrix (FAM) sorbent platform designed for efficient and selective capture of CM from dilute solutions. The FAM sorbent features crosslinked amine microfilms coated onto/within a glass fiber matrix, providing fast mass transfer and excellent mechanical stability. Systematic batch and flow-through tests with FAM revealed rapid metal uptake kinetics and high capacity for representative species, achieving ~90 mg/g of Gallium, ~100 mg/g of Cobalt, and ~90 mg/g for Neodymium. Moreover, multiple eluents, including mineral acids and complexing agents, enabled highly effective desorption of adsorbed metals, demonstrating the feasibility of regenerating FAM sorbents. Importantly, tests with authentic coal ash leachate demonstrated strong selectivity toward U.S. Department of Energy (DOE)-listed CM and rare earth elements over abundant base cations, confirming the robustness of FAM in realistic complex solutions. The flat sheet geometry was amenable to scaling into durable spiral wound modules, highlighting the potential for future regeneration and reuse. This work establishes FAM sorbents as a promising platform for the recovery of CM from wastewaters, advancing both resource sustainability and environmental stewardship.

critical mineral recovery↗
DOE OSTI2024

Recycling of Lithium-Ion Batteries via Electrochemical Recovery: A Mini-Review

With the rising demand for lithium-ion batteries (LIBs), it is crucial to develop recycling methods that minimize environmental impacts and ensure resource sustainability. The focus of this short review is on the electrochemical techniques used in LIB recycling, particularly electrochemical leaching and electrodeposition. Our summary covers the latest research, highlighting the principles, progress, and challenges tied to these methods. By examining the current state of electrochemical recovery, this review intends to provide guidance for future advancements and enhance LIB recycling efficiency.

25 ENERGY STORAGE↗