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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

MICROBIALLY MEDIATED LEACHING OF RARE EARTH ELEMENTS FROM RECYCLABLE MATERIALS

Bioleaching offers a potential approach for recovery of rare earth elements (REE) from recyclable materials, such as fluorescent lamp phosphors or degraded industrial catalysts. Microorganisms were enriched from REE-containing ores and recyclable materials with the goal of identifying strains capable of extracting REE from solid materials. Over 100 heterotrophic microorganisms were isolated and screened for their ability to produce organic acids capable of leaching REE. The ten most promising isolates were most closely related to Pseudomonas, Acinetobacter and Talaromyces. Of the acids produced, gluconic acid appeared to be the most effective at leaching REE (yttrium, lanthanum, cerium, europium, and terbium) from retorted phosphor powders (RPP), fluidized cracking catalyst (FCC), and europium-doped yttrium oxide (YOEu). We found that an Acinetobacter isolates, BH1, was the most capable strain and able to leach 33% of the total REE content from the FCC material. These results support the continuing evaluation of gluconic acid-producing microbes for large-scale REE recovery from recyclable materials.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

AL-CRADA-2025-01 Final Report: American-Made Wind Turbine Materials Recycling Prize Accelerate! Phase 2

This report summarizes the Phase 2 achievements of the Wind Turbine Materials Recycling Prize project led by Critical Materials Recycling (CMR) in partnership with Ames National Laboratory. The team demonstrated the technical feasibility and economic viability of recovering and reusing rare-earth Nd-Fe-B magnets from end-of-life (EOL) wind turbine generators. Through mechanical disassembly, demagnetization, and precision processing, magnets were harvested and characterized to assess structural, compositional, and magnetic properties. Results showed that recovered magnets performed on par with commercial-grade counterparts, enabling their integration into actuator and motor prototypes without redesign. System-level modeling and finite-element simulations validated operational performance, while Life Cycle Cost (LCC) analysis revealed up to 20% material cost savings and 2–3% reductions in overall motor system costs. Life Cycle Assessment (LCA) further confirmed substantial environmental benefits, including a ~94% reduction in global warming potential relative to virgin magnet production. The project’s success was enabled by a tightly integrated partnership between industry and national lab experts, illustrating a viable path for domestic magnet-to-magnet recycling. These findings support a scalable, circular solution for rare-earth material recovery, reducing dependence on imported critical minerals and advancing sustainable clean energy technologies.

Lograsso, Thomas [Ames Laboratory (AMES), Ames, IA↗
DOE OSTI2015

A cost-benefit analysis of landfill mining and material recycling in China

Highlights: • Assessing the economic feasibility of landfill mining. • We applied a cost-benefit analysis model for landfill mining. • Four material cycling and energy recovery scenarios were designed. • We used net present value to evaluate the cost-benefit efficiency. - Abstract: Landfill mining is an environmentally-friendly technology that combines the concepts of material recycling and sustainable waste management, and it has received a great deal of worldwide attention because of its significant environmental and economic potential in material recycling, energy recovery, land reclamation and pollution prevention. This work applied a cost-benefit analysis model for assessing the economic feasibility, which is important for promoting landfill mining. The model includes eight indicators of costs and nine indicators of benefits. Four landfill mining scenarios were designed and analyzed based on field data. The economic feasibility of landfill mining was then evaluated by the indicator of net present value (NPV). According to our case study of a typical old landfill mining project in China (Yingchun landfill), rental of excavation and hauling equipment, waste processing and material transportation were the top three costs of landfill mining, accounting for 88.2% of the total cost, and the average cost per unit of stored waste was 12.7 USD ton{sup −1}. The top three benefits of landfill mining were electricity generation by incineration, land reclamation and recycling soil-like materials. The NPV analysis of the four different scenarios indicated that the Yingchun landfill mining project could obtain a net positive benefit varying from 1.92 million USD to 16.63 million USD. However, the NPV was sensitive to the mode of land reuse, the availability of energy recovery facilities and the possibility of obtaining financial support by avoiding post-closure care.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

MSGP Stormwater Pollution Prevention Plan TA-60 Material Recycling Facility

This Stormwater Pollution Prevention Plan (SWPPP) was developed in accordance with the provisions of the Clean Water Act (33 U.S.C. §§1251 et seq., as amended), and the United States Environmental Protection Agency (EPA) National Pollutant Discharge Elimination System (NPDES) Multi-Sector General Permit for Stormwater Discharges Associated with Industrial Activity (MSGP) (U.S. EPA, June 2015) issued by EPA, and using the industry specific permit requirements for Sector N: Scrap Recycling and Waste Recycling Facilities as a guide. The applicable stormwater discharge permit is EPA General Permit Tracing Number NMR050013 [Triad National Security, LLC (Triad)]. This SWPPP applies to discharges of stormwater from the operational areas of the TA- 60 Material Recycling Facility at Los Alamos National Laboratory. Los Alamos National Laboratory (also referred to as LANL or the “Laboratory”) is owned by the Department of Energy (DOE), and is operated by Triad. Throughout this document, the term “facility” refers to the TA-60 Material Recycling Facility. The current MSGP expires at midnight on June 4, 2020.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

Stormwater Pollution Prevention Plan - TA-60 Material Recycling Facility

This Storm Water Pollution Prevention Plan (SWPPP) was developed in accordance with the provisions of the Clean Water Act (33 U.S.C. §§1251 et seq., as amended), and the Multi-Sector General Permit for Storm Water Discharges Associated with Industrial Activity (U.S. EPA, June 2015) issued by the U.S. Environmental Protection Agency (EPA) for the National Pollutant Discharge Elimination System (NPDES) and using the industry specific permit requirements for Sector P-Land Transportation and Warehousing as a guide. This SWPPP applies to discharges of stormwater from the operational areas of the TA- 60 Material Recycling Facility at Los Alamos National Laboratory. Los Alamos National Laboratory (also referred to as LANL or the “Laboratory”) is owned by the Department of Energy (DOE), and is operated by Los Alamos National Security, LLC (LANS). Throughout this document, the term “facility” refers to the TA-60 Material Recycling Facility. The current permit expires at midnight on June 4, 2020.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Using low cost, bio-derived and recycled materials in advanced scalable small- and medium- wind turbine manufacturing

In partnership with Bergey Windpower, this project explored the use of recyclable and recycled materials in small- to medium-wind turbine blades (WTBs). A recyclable epoxy resin and infusible thermoplastic resin were investigated using identical fiber reinforcements and manufacturing practices used as Bergey, and the substitution of continuous virgin glass fiber (GF) layers with recycled nonwoven GF (rGF, NW) mats was trialed. The alternative resins both showed very promising performance in terms of static tensile and flexural behavior as well as thermal properties and fatigue behavior in comparison with that of the incumbent materials used at Bergey. The NW rGF materials, however, were found to be a poor substitute for the continuous GF materials for two primary reasons. Firstly, the NW mats took up significantly more resin than their continuous counterparts, which would increase both the weight and the cost of the WTBs. Additionally, an unexpected reaction occurred between the rGF and epoxy materials that resulted in a highly porous, foamed structure. The foaming phenomenon was not observed with the rGF NW and infusible thermoplastic material, but the resin uptake was still prohibitively high. Based on the results of this study, recyclable infusible resins could be viable candidate materials for Bergey in the future. The foaming reaction with the rGF NW mats could prove highly useful in other applications requiring structural foams and has been used to produce demonstrative sandwich panels.

17 WIND ENERGY↗
NASA NTRSDate not supplied

Waste Materials Recycling for In-Space Manufacturing

Logistics and resupply payloads for Lunar and Martian missions are significantly more cost and schedule prohibitive compared to LEO destinations. Recycling of waste and trash materials generated throughout the duration of a mission, as well as previous missions, will be critical for enabling sustained human presence beyond Earth. Currently, no solution exists for recycling waste materials back into feedstock form beyond entry-level hobbyist equipment, which is not suitable nor practical for space applications. There is already over 500,000 lbs of trash on the moon from previous missions, which will grow exponentially over the coming decade throughout the Artemis Campaign. Waste and trash materials are precious resources that, if recovered and properly processed, can be transformed back into usable feedstock form for on-demand manufacturing capabilities. Hence, it is prudent that a recycling solution be developed and infused into future missions.

additive↗
DOE OSTI2026

Recyclable Materials for Resource Constrained Environments

In-space manufacturing exhibits severe limitations in resources as astronauts are only afforded with the materials that are brought on-board the space craft. Consequently, the use of recyclable and re-usable materials is paramount. Researchers at NLR leverage their expertise in polymer and recycling chemistry to develop material systems capable of high performance applications with intentional consideration on multi-life use through chemical recycling, mechanical recycling, bio-degradation, and thermoforming. Disclosed within this poster presentation are highlighted projects that illustrate several recyclable by design material systems that have been developed.

09 BIOMASS FUELS↗
DOE OSTI2024

Alkyl-Substituted Polycaprolactone Poly(urethane-urea)s as Mechanically Competitive and Chemically Recyclable Materials

We report the mechanical performance and chemical recycling advantages of implementing alkyl-substituted poly(ε-caprolactones) (PCLs) as soft segments in thermoplastic poly(urethane-urea) (TPUU) materials. Poly(4-methylcaprolactone) (P4MCL) and poly(4-propylcaprolactone) (P4PrCL) were prepared, reacted with isophorone diisocyanate, and chain-extended with water to form TPUUs. The resulting materials’ tensile properties were similar or superior to a commercially available polyester thermoplastic poly(urethane) and had superior elastic recovery properties compared to a PCL analogue due to the noncrystalline nature of P4MCL and P4PrCL. Additionally, monomers were recovered from the TPUU materials in high yields via ring-closing depolymerization using a reactive distillation approach at an elevated temperature and a reduced pressure (240–260 °C, 25–140 mTorr) with zinc chloride (ZnCl 2 ) as the catalyst. The thermodynamics of polymerization were estimated using Van’t Hoff analyses for 4MCL and 4PrCL; these results indicated that the propyl group in 4PrCL results in a lower practical ceiling temperature (T c ) for P4PrCL.

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

Wind Turbine Materials Recycling Prize Phase 2 (Commercialization of Wind Turbine Blade Waste (WTBW)-Based, Lightweight, Cementitious Composite Materials): Cooperative Research and Development Final Report, CRADA Number CRD-24-31305

The National Laboratory of the Rockies (NLR) and AltiSora, LLC., will develop new lightweight cementitious composite material technologies that will utilize wind turbine blade waste as a raw material to; (1) allow a high value addition (2) at low cost, enabling (3) a significant waste consumption volume; while (4) consuming the entire wind turbine blade, without (5) creating any waste or emissions and to also (6) offer specific benefits to communities involved.

17 WIND ENERGY↗
DOE OSTI2019

Storm Water Pollution Prevention Plan TA-60 Material Recycling Facility

This Storm Water Pollution Prevention Plan (SWPPP) was developed in accordance with the provisions of the Clean Water Act (33 U.S.C. §§1251 et seq., as amended), and the Multi-Sector General Permit for Storm Water Discharges Associated with Industrial Activity (U.S. EPA, June 2015) issued by the U.S. Environmental Protection Agency (EPA) for the National Pollutant Discharge Elimination System (NPDES) and using the industry specific permit requirements for Sector P-Land Transportation and Warehousing as a guide. The applicable stormwater discharge permit is EPA General Permit Registration Number NMR053915 (Los Alamos National Security (LANS) (U.S. EPA, June 2015).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

“Production of High Specific Activity 155 Tb, 161 Tb and 203 Pb for Research and Clinical Applications: Effective Target Design, Target Material Recycling and Radioisotope Separation”

Radioisotopes are essential for the development and application of radiopharmaceuticals that target specific diseases, such as cancer, offering unique potential for precision medicine. The growing demand for theranostic radioisotopes underscores their critical role in personalized medicine, where they enhance diagnostic imaging, minimize patient radiation exposure, and improve targeted tissue uptake, particularly in receptor- and antigen-directed therapies. The theranostic pair terbium-155 (diagnostic) and terbium-161 (therapeutic) holds significant promise for advancing individualized, targeted, and dosimetry-driven radiotherapies. However, the United States currently lacks routine and reliable production of these isotopes. This project made significant progress toward addressing this supply issue by developing production and separation methods for terbium-155 and terbium-161 while also training the next generation of the nuclear and radiochemistry workforce. This grant also strengthened collaboration between scientists at the University of Washington, the University of Missouri and Brookhaven National Laboratory. The research effort focused on evaluating target preparation methods, optimizing irradiation parameters, and refining isolation processes. In addition, the project provided extensive hands-on training to graduate students and postdoctoral fellows, equipping them with expertise in radioisotope production technologies and fostering the growth of the nuclear science workforce.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2016

Optimization of Material Recycling During the Decommissioning Process of Nuclear Power Plants - 16123

The German Government decided in 2011 to phase out nuclear power. Therefore, in the near future there will be several nuclear power plants queued up, in parallel, for dismantling. In nuclear decommissioning there is no standardized procedure available, so that a high level of optimization potential can be assumed. We present the results of a preliminary study, in which the optimization potential of metal recycling during the dismantling process should be estimated. The project can be roughly divided into four sections: - Determination of the metal inventory of an exemplarily selected plant; - Analysis of the recycling routes of scrap metal fractions and assessment of the potential for optimization of each process step during the dismantling; - Conduction of activation calculations to uncover the potential of interim storage allowing for radioactive decay; - In collaboration with the Institute of Process Metallurgy and Metal Recycling at the RWTH Aachen, appropriate process steps and process chains of an optimized metal recycling for each of the resulting scrap metal fractions are identified. The paper and the presentation summarize the status and the results of the project implementation and will address for the optimization potentials for decommissioning projects. (authors)

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

Production of High Specific Activity 155 Tb, 161 Tb and 203 Pb for Research and Clinical Applications: Effective Target Design, Target Material Recycling and Radioisotope Separation (Final Technical Report)

The overall objectives of this project were (1) to develop methods for the production and separation of a diagnostic and therapeutic or “theranostic” pair of radioisotopes, terbium-155 ( 155 Tb) and terbium-161 ( 161 Tb) and (2) to train graduate students and postdoctoral fellows in technologies and methods used in radionuclide production. Radionuclides can be incorporated into drugs called radiopharmaceuticals that target a specific disease (e.g., cancer). The need for theranostic radionuclides is escalating with the clinical translation of radiopharmaceuticals due to their implementation in personalized medicine, which has demonstrated enhanced patient treatments. High purity and high specific activity radionuclides are critical for theranostic agent development, for example to maintain diagnostic image quality, to minimize radiation dose to the patient, and to increase uptake in the targeted tissue (e.g., tumor), especially in the case of receptor- and antigen-targeted agents. The 155 Tb (diagnostic) and 161 Tb (therapeutic) radioisotopes that were generated through this project are a theranostic pair with demonstrated potential for the development and translation into individualized, targeted, and dosimetry-driven radiotherapies. However, the development of such radiotherapies has been hindered by the lack of a routine and reliable supply of these isotopes in the United States. Methods for the production, separation, and supply of 155 Tb and 161 Tb were investigated and developed in this project. Further, the strong emphasis throughout the project on the training of graduate students and postdoctoral fellows has helped to ensure and enhance the nuclear science workforce through the training of the next generation of highly qualified scientists in nuclear and radiochemistry. This grant also continued a collaboration between scientists at the University of Washington (UW), the University of Missouri (MU) and Brookhaven National Laboratory (BNL). All three institutions were involved in the project, but to different degrees on the various tasks through which the overall objectives were met.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2017

Lithium recycling and cathode material regeneration from acid leach liquor of spent lithium-ion battery via facile co-extraction and co-precipitation processes

Highlights: • A novel process for combining Li and cathode material recycling is developed. • Ni, Co and Mn are co-extracted and separated with Li. • Li recovered as Li{sub 2}CO{sub 3} with the purity of 99.2% is achieved. • The spherical cathode material LiNi{sub 1/3}Co{sub 1/3}Mn{sub 1/3}O{sub 2} is directly regenerated. - Abstract: A novel process for extracting transition metals, recovering lithium and regenerating cathode materials based on facile co-extraction and co-precipitation processes has been developed. 100% manganese, 99% cobalt and 85% nickel are co-extracted and separated from lithium by D2EHPA in kerosene. Then, Li is recovered from the raffinate as Li{sub 2}CO{sub 3} with the purity of 99.2% by precipitation method. Finally, organic load phase is stripped with 0.5 M H{sub 2}SO{sub 4}, and the cathode material LiNi{sub 1/3}Co{sub 1/3}Mn{sub 1/3}O{sub 2} is directly regenerated from stripping liquor without separating metal individually by co-precipitation method. The regenerative cathode material LiNi{sub 1/3}Co{sub 1/3}Mn{sub 1/3}O{sub 2} is miro spherical morphology without any impurities, which can meet with LiNi{sub 1/3}Co{sub 1/3}Mn{sub 1/3}O{sub 2} production standard of China and exhibits good electrochemical performance. Moreover, a waste battery management model is introduced to guarantee the material supply for spent battery recycling.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Reduced alkali-silica reaction damage in recycled glass mortar samples with supplementary cementitious materials

Recycling waste glass aggregate into concrete can reduce environmental impacts but also may lead to serious alkali silica reaction (ASR) damage. This study aims to characterize ASR damage development in the mortar samples containing reactive glass aggregates and investigate the damage reduction effect of the waste supplementary cementitious materials (SCMs), including recycled glass powders and fly ash. The recycled glass aggregate mortar samples with/without SCMs were prepared in this study. The length change tests were first conducted with the prepared mortar samples based on the ASTM C1260 standard. The results demonstrated the added SCMs can largely decrease early-age ASR expansion rate. The optical microscope and Scanning Electron Microscope (SEM) with Energy Dispersive X-ray Spectroscopy (EDS) were further conducted to characterize the ASR damage in mortar samples and investigate the damage mitigation mechanism with added SCMs. The combined SEM imaging and chemical analysis indicated added SCMs can decrease both the alkali and calcium content of the generated ASR gel. In addition, the ASR damage development inside mortar samples were monitored with dynamic micron X-ray CT (μCT) over a reaction period of 63 hour at the temperature of 80°C. The scanning patterns demonstrated the ASR damage can be easily developed from the area with initial cracks and sharp corners. In conclusion, the images of glass power and fly ash samples showed significantly reduced ASR damage. This study showed that adding of SCMs can largely reduce ASR deterioration and thus facilitate the recycling glass particles into concrete.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗