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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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14 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Electrocoagulation in Water Treatment: Targeted Contaminant Removal and Laboratory Best Practices

Electrocoagulation for water treatment offers many advantages over traditional treatment technologies, including improved energy efficiency and modularity. One challenge with electrocoagulation is the lack of standardization in the methodology and reporting. This review provides a novel contribution by examining the past literature using a uniform metric (charge loading) as a basis for comparison, highlighting the importance of uniform reporting practices in this field. Furthermore, this review provides practical guidance for experimentalists in standardizing the electrocoagulation design and operating procedures. First, we present a comprehensive overview of contaminant-specific electrocoagulation as an electrochemical treatment technology for processing industrial, municipal, and agricultural water, with a focus on aluminum and iron electrocoagulation. We detail the fundamental mechanisms that allow for constituent removal during pretreatment. Specifically, we highlight electrocoagulation’s potential for organics, metalloids, microbes, and hardness remediation, examining the optimal removal conditions in terms of charge loading and current density. We conclude this work with some experimental best practices for lab-scale electrocoagulation experiments.

aluminum↗
DOE OSTI2024

Porous Iron Electrodes Reduce Energy Consumption During Electrocoagulation of a Virus Surrogate: Insights into Performance Enhancements Using Three-Dimensional Neutron Computed Tomography

Electrocoagulation has attracted significant attention as an alternative to conventional chemical coagulation because it is capable of removing a wide range of contaminants and has several potential advantages. In contrast to most electrocoagulation research that has been performed with nonporous electrodes, in this study, we demonstrate energy-efficient iron electrocoagulation using porous electrodes. In batch operation, investigation of the external pore structures through optical microscopy suggested that a low porosity electrode with sparse connection between pores may lead to mechanical failure of the pore network during electrolysis, whereas a high porosity electrode is vulnerable to pore clogging. Electrodes with intermediate porosity, instead, only suffered a moderate surface deposition, leading to electrical energy savings of 21% and 36% in terms of electrocoagulant delivery and unit log virus reduction, respectively. Neutron computed tomography revealed the critical role of electrode porosity in utilizing the electrode’s internal surface for electrodissolution and effective delivery of electrocoagulant to the bulk. Energy savings of up to 88% in short-term operation were obtained with porous electrodes in a continuous flow-through system. Further investigation on the impact of current density and porosity in long-term operation is desired as well as the capital cost of porous electrodes.

42 ENGINEERING↗
DOE OSTI2025

Understanding the Dissolution and Passivation of an Aluminum Electrode during Electrocoagulation of Groundwater Using Neutron and X-ray Reflectometry

An aluminum (Al)-based electrocoagulation (EC) system can effectively remove dissolved silica and hardness in groundwater. The effectiveness of Al-EC in terms of pollutant removal, Faradaic efficiency, and energy consumption depends on the interfacial electrolysis or passivation of the electrode in water. Thus, understanding the electrolysis reaction at the liquid/electrode interface during operation is important for sustainable EC deployment. Here, a continuous flow-through Al-EC system was tested with various groundwater simulants, i.e., chloride (Cl – )-based, sulfate (SO 4 2– )-based, and mixed solutions. High pollutant removal with low energy consumption was observed in Cl – -based groundwater treatment, while low pollutant removal with high energy consumption was observed in SO 4 2– -based groundwater. For example, the required energy per unit mass of Al dosing in SO 4 2– -based groundwater is three times higher than that in Cl – -based groundwater at 10 mA/cm 2 . However, increasing the Cl – concentration significantly reduces this energy demand. In SO 4 2– -based groundwater, the silicate removal efficiency drops from 85.1% to 24.0% compared to that for Cl – -based groundwater, while Mg 2+ and Ca 2+ removal efficiencies decrease to 0.6% from 15.8% and 5.7% from 44.8%, respectively. To better understand this EC performance, we used in situ neutron reflectometry (NR) to examine the interfacial dynamics of Al dissolution and passivation at a 100 nm scale occurring on the surface of the sacrificial Al electrodes during EC. Ex situ X-ray reflectometry (XRR) was also used to support the in situ NR results. Both NR and XRR results revealed that Al dissolution is influenced by the presence of Cl – in the simulants, while a passivating layer forms on the electrode in a SO 4 2– -based solution. In the Cl – -based solution, anodic Al dissolution occurred locally and inhomogeneously across the surface of the Al anode film, resulting in a localized thickness reduction over time. In the SO 4 2– -based solution, no apparent dissolution of the Al anode was identified. Instead, Al underwent oxidation, forming an amorphous Al 2 O 3 surface layer within the Al electrode film that increased in thickness over time. In the mixed solution, both anodic Al dissolution and surface Al 2 O 3 layer formation occurred, indicating that Al dissolution and surface Al 2 O 3 layer formation are attributable to the Cl – and SO 4 2– ions, respectively.

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

Arsenic Removal by Continuous Flow-Through Iron Electrocoagulation and Downstream Steps under Environmentally Relevant Conditions

Arsenic (As) contamination in drinking water is a major health concern. This study investigated As(III) and As(V) removal by continuous flow-through iron electrocoagulation (EC) under varying iron doses and water chemistry conditions. Effective arsenic removal (>90% of 100 µg/L) was achieved with a low iron dose of 5 mg/L and a short EC reactor residence time of 11 s that was followed by flocculation and settling. Removal was primarily through adsorption of As(III) and As(V) to the EC-generated Fe(III) oxyhydroxide solids ferrihydrite and lepidocrocite. For influents containing As(III), oxidation of As(III) to As(V) also occurred. The removal processes occurred in both the EC reactor and downstream treatment. EC-generated reactive solids with high surface area and adsorption capacity provided better arsenic removal than with preformed adsorbents. The removed arsenic remained largely immobile in the EC-generated solids. The extent of arsenic removal was generally similar across pH 6 to 8. Phosphate (1 mg/L as P) inhibited the removal of both arsenic species. Dissolved silica (20 mg/L as SiO2) suppressed As(III) removal but had little effect on the amount of As(V) removed. In addition to thermodynamic effects on adsorption equilibria, pH and co-occurring phosphate and silica influenced removal rates by affecting iron oxidation, nucleation, and aggregation kinetics. The results integrate mechanistic understanding with treatment performance, providing insight relevant to both fundamental research and the application of EC in water treatment.

Arsenic, electrocoagulation, iron oxide, phosphate↗
DOE OSTI2026

Removal of Calcium and Silica from Simulated Blowdown Water Using CO 2 -Assisted Magnesium Electrocoagulation

Blowdown water from various industries and cooling facilities contains high concentrations of calcium (Ca), magnesium (Mg), silica, and corrosion inhibitors, which render the water unsuitable for discharge into surface water and wastewater treatment plants. Electrocoagulation (EC) is effective at removing Ca and silica. Here, in this study, Mg-alloy electrodes EC resulted in ∼91% silica removal at a 5400 C/L charge loading. Ca removal, however, was only 31%. To enhance Ca removal, carbon dioxide (CO 2 ) containing gas was introduced. CO 2 addition formed carbonate ions, which reacted with Ca/Mg ions to generate carbonate precipitates. Introducing 5% and 14% CO 2 , simulating natural gas-fired and coal-fired flue gas, enhanced Ca removal to 38% and 47%, respectively. Pure CO 2 facilitated 70% Ca removal, more than two times higher than that without CO 2 , while maintaining high silica removal. FTIR, XRD, and SEM-EDS analyses confirmed enhanced Ca/Mg carbonate formation upon CO 2 . In situ Raman spectroscopy was employed to monitor carbonate-ions formation. The results demonstrated carbonate-ions removal through Ca-carbonate formation after CO 2 addition. A techno-economic assessment showed that recycled electrode materials and flue gas lead to ∼3 times lower cost compared with conventional silica/Ca removal through chemical coagulation, softening, or membrane filtration. The study demonstrated that CO 2 addition removes high concentrations of Ca and silica ions from wastewaters at a competitive cost.

blowdown water↗
DOE OSTI2025

Electrocoagulation Combined with Ultrafiltration Membranes as Pretreatment for RO Desalination of Synthetic Cooling Tower Blowdown Water

Electrocoagulation (EC), an electrochemical water treatment process, is commonly used to remove particulate and colloidal matter from water. Here, in this study, we demonstrate that EC, when coupled with membrane filtration, is also capable of removing dissolved species, such as Ca + , Mg 2+ , and SiO x . The removal of such species is important for downstream membrane-based desalination treatment of the water that can suffer from reduced performance due to membrane scaling. Here, we describe how EC can be combined with a low-pressure membrane (LPM) system to offer efficient (and potentially universal) pretreatment for downstream membrane desalination. Synthetic water, simulating cooling tower blowdown (CTBD) with elevated concentrations of hardness and silicates (Ca: 418 ppm, Mg: 63 ppm, SiO 2 : 50 ppm) is treated using EC coupled to ultrafiltration (UF) to remove Mg up to 30 ± 1%, Ca up to 29 ± 1%, and silica up to 99 ± 1%. We evaluated the effectiveness of the EC-UF pretreatment system in reducing downstream RO scaling using thermodynamic modeling to predict the saturation index (SI) at the RO membrane/water interface. An SI value below zero (SI < 0) indicates under-saturated conditions (with respect to a particular mineral) where mineral scaling does not take place, which correlates with improved water recovery. Our findings suggest that the EC-UF pretreatment system was able to increase water recovery by up to 30%, compared to 0% recovery without pretreatment, under optimal conditions (feed solution pH of 7 and an EC charge loading of 1800 C/L). Finally, we conducted an economic analysis showing that implementing an EC-UF system for CTBD water could yield a cost benefit of up to $\$$14.13 per m 3 compared to direct brine disposal.

cooling tower blowdown↗
DOE OSTI2026

Treatment of Lagoon Dairy Manure Wastewater via Iron Electrocoagulation, Microfiltration, and Adsorption

Dairy manure wastewater generated by flushing barn cow waste contains nutrients, pathogens, and organic and inorganic contaminants. This study utilized a process consisting of iron electrocoagulation (Fe-EC), microfiltration (MF), and activated carbon (AC) adsorption to treat farm wastewater and explore the reclamation of clean water for irrigation and livestock consumption. Significant removal (>99.9%) of chemical oxygen demand (COD), total organic carbon (TOC), phosphorus (P), turbidity, and microorganisms, as well as ions including magnesium, calcium, sulfur, and silica was achieved by the combined EC-MF-AC process. Specifically, a charge loading of ∼37,500 C/L in a continuous-flow EC configuration, followed by MF, achieved more than 95% removal of TOC and COD. Characterization of produced flocs and foam via scanning-electron microscopy with energy-dispersal spectroscopy and Fourier transform infrared spectroscopy confirmed the removal of ions, including calcium, sulfur, and silica. A key finding was the electrocatalytic conversion of nitrogen species to ammonia gas through the intermediate reduction of nitrate/nitrite, which led to ∼60% total nitrogen (TN) removal. AC treatment further improved TN removal to ∼70%. The Fe-EC process also eradicated >99.9% of bacteria. Preliminary process cost assessment, based on recycled materials for EC electrodes, showed significant cost savings (∼2 times) compared to commercial electrodes.

Dutta, Swapnamoy [ORNL]↗
DOE OSTI2024

Field Validation of Electrocoagulation Treatment for Oily Wastewater at Cleveland-Cliffs Steel Mill in Cleveland, OH

The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized technologies in the industrial sector to help inform decisions towards accelerating commercialization and deployment. This initiative aims to identify, validate, and showcase new, emerging, and underutilized technologies in the industrial sector to expedite their commercialization and widespread deployment. By conducting thorough validations and demonstrating the efficacy of these technologies, the ITV program facilitates informed decision-making among industry stakeholders, contributing to the transition towards more sustainable and efficient industrial processes. This ITV demonstration involved the testing of an electrocoagulation (EC) treatment system at a steel plant in Ohio. The system was designed to treat oily wastewater generated from cold rolling operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Field Validation of Electrocoagulation Treatment for Oily Wastewater at a Steel Mill

Oily wastewater is a significant byproduct across various industries, including steel production, posing environmental and health risks. Steelmaking is particularly water-intensive, with an estimated 75,000 gallons required to produce 1 ton of steel, although recycling reduces this to 13,000–23,000 gallons per ton.1 Water serves multiple purposes in steelmaking, including equipment cooling, scale removal, steam generation, lubrication, and pollution control.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

CRADA Final Report: CRADA Number NFE-22-09311 with Agriwater Tech

Livestock wastewater management is a critical concern in the United States, with an annual production of approximately 1.37 billion tons of waste, surpassing human waste by three to twenty times. The mismanagement of manure wastewater poses significant threats to freshwater sources, ecosystems, and public health. Through this project, we proposed an innovative solution using electrocoagulation (EC) treatment. The EC technique is an electrochemical process involving the intentional corrosion of aluminum and iron electrodes to introduce trivalent ions into the solution, facilitating the co-precipitation and coagulation of contaminants and making the removal of water from sludge easier. The project's primary objective is to use EC to convert liquid animal manure into clean water for farm irrigation, drinking, and maintenance. This solution is vital for various farms including those facing drought, pursuing zero-discharge, and seeking Environmental Protection Agency (EPA) permits for livestock farm manure discharge into rivers. Preliminary research shows EC's potential to significantly reduce turbidity and phosphate levels in livestock wastewater, forming the basis for scalable onsite treatment. The goal of this proposed project is to develop an innovative farm-wastewater-treatment process to achieve clean water, fertilizer, and reduced greenhouse gases through electrification of current processes such as coagulation, dewatering, inactivation of viruses and bacteria, and filtration for recycling surface water from farm lagoons.

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

CRADA Final Report: CRADA Number NFE-22-09311 with Agriwater Tech

Livestock wastewater management is a critical concern in the United States, with an annual production of approximately 1.37 billion tons of waste, surpassing human waste by three to twenty times. The mismanagement of manure wastewater poses significant threats to freshwater sources, ecosystems, and public health. Through this project, we proposed an innovative solution using electrocoagulation (EC) treatment. The EC technique is an electrochemical process involving the intentional corrosion of aluminum and iron electrodes to introduce trivalent ions into the solution, facilitating the co-precipitation and coagulation of contaminants and making the removal of water from sludge easier. The project's primary objective is to use EC to convert liquid animal manure into clean water for farm irrigation, drinking, and maintenance. This solution is vital for various farms including those facing drought, pursuing zero-discharge, and seeking Environmental Protection Agency (EPA) permits for livestock farm manure discharge into rivers. Preliminary research shows EC's potential to significantly reduce turbidity and phosphate levels in livestock wastewater, forming the basis for scalable onsite treatment. The goal of this proposed project is to develop an innovative farm-wastewater-treatment process to achieve clean water, fertilizer, and reduced greenhouse gases through electrification of current processes such as coagulation, dewatering, inactivation of viruses and bacteria, and filtration for recycling surface water from farm lagoons.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Field Testing of an Affordable Zero-Liquid-Discharge Arsenic-Removal Technology for a Small-Community Drinking Water System in Rural California

Arsenic contamination in groundwater threatens public health, particularly in small, low-income communities lacking affordable treatment solutions. This study investigated the field implementation of novel air cathode assisted iron electrocoagulation (ACAIE) technology for arsenic removal in Allensworth, California, where groundwater arsenic concentrations exceeded 250 µg/L. Over four months, a pilot-scale ACAIE system, operating at 600 L/h, consistently reduced arsenic levels to below the EPA’s maximum contaminant level of 10 µg/L. Laboratory experiments informed the optimization of charge dosage and flow rates, which were validated during field testing of the ACAIE 600 L/h system. The in-situ generation of hydrogen peroxide at the cathode speeded up the reaction kinetics, ensuring high arsenic removal efficiency while allowing high throughput, even with a compact reactor size. An economic analysis demonstrated a treatment cost of USD 0.02/L excluding labor, highlighting the system’s affordability compared to conventional methods. Adding labor costs increased the treatment cost to USD 0.09/L. The regeneration of air cathodes extended their operational life, addressing a key maintenance challenge, thus reducing the costs slightly. Intermittent challenges were encountered with filtration and secondary contaminant removal; these issues highlight opportunities for further operational improvements. Despite these challenges, ACAIE’s low operational complexity, scalability, and cost-effectiveness make it a promising solution for underserved small communities. These findings provide critical insights into deploying sustainable arsenic remediation technologies that are tailored to the needs of rural, low-resource communities.

Bandaru, Siva R S↗
DOE OSTI2025

Technical, Economic, Energetic, and Environmental Evaluation of Pretreatment Strategies for Scaling Control in Brackish Water Desalination Brine Treatment

Effective pretreatment is essential for achieving long-term stable operation and high water recovery during the desalination of alternative waters. This study developed a process modeling approach for technical, economic, energetic, and environmental assessments of pretreatment technologies to identify the impacts of each technology treating brackish water desalination brine with high scaling propensity. The model simulations evaluated individual pretreatment technologies, including chemical softening (CS), chemical coagulation (CC), electrocoagulation (EC), and ion exchange (IX). In addition, combinations of these pretreatment technologies aiming at the effective reduction of key scaling constituents such as hardness and silica were investigated. The three evaluation parameters in this assessment consist of levelized cost of water (LCOW, $/m 3 ), specific energy consumption and cumulative energy demand (SEC|CED, kWh/m 3 ), and carbon dioxide emissions (CO 2 , kg CO 2-eq /m 3 ). The case study evaluated in this work was the desalination brine from the Kay Bailey Hutchison Desalination Plant (KBHDP) with a total dissolved solids (TDS) concentration of 11,000 mg/L and rich in hardness and silica. The evaluation of individual pretreatment units from the highest to lowest LCOW, SEC|CED, and CO 2 emissions in the KBHDP brine was IX > CS > EC > CC, CS > IX > EC > CC, and CC > CS > EC > IX, respectively. In the case of pretreatment combinations for the KBHDP, the EC + IX treatment combination was shown to be the best in terms of the LCOW and CO 2 emissions. The modeling and evaluation of these pretreatment units provide valuable guidance on the selection of cost-effective, energy-efficient, and environmentally sustainable pretreatment technologies tailored to desalination brine applications for minimal- or zero-liquid discharge.

14 SOLAR ENERGY↗