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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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DOE OSTI2018

Mathematical Modeling of Nonstationary Separation Processes in a Cascade of Gas Centrifuges for Separation of Tungsten Isotopes

We have developed and program-realized a mathematical model of nonstationary separation processes proceeding in cascades of gas centrifuges for separation of multicomponent isotope mixtures. With the help of this model we have calculated the parameters of nonstationary separation processes proceeding in the cascades of gas centrifuges for tungsten isotope separation. It has been shown that the model adequately describes the nonstationary processes in the cascade and is suitable for calculating their parameters during separation of multicomponent isotope mixtures.

42 ENGINEERING↗

DOE OSTI2019

A review of separation processes proposed for advanced fuel cycles based on technology readiness level assessments

The results of an international review of separation processes for spent nuclear fuel (SNF) recycling in future closed fuel cycles are reported. This study was made by the Expert Group on Fuel Recycling Chemistry (EGFRC) organised by the Nuclear Energy Agency (NEA) of the Organisation for Economic Co-operation and Development (OECD). A unique feature of this study was that processes were classified according to a hierarchy of separations aimed at different elements within spent fuel (uranium; uranium-plutonium co-recovery; minor actinides; high heat generating radionuclides) and also the Head-end processes, used to prepare the SNF for chemical separation, were included. Separation processes covered both wet (hydrometallurgical) and dry (pyro-chemical) processes. A bespoke methodology suitable for assessing the technological maturities of separation processes for SNF recycling was then designed based on the well-established Technology Readiness Level (TRL) scale but adapted for spent nuclear fuel separations. The innovative feature of this was the use of a matrix approach that enabled information on both the scale of testing and materials used in testing to be combined in the evaluation of the TRL. TRLs for the Head-end, hydrometallurgical and pyrochemical processes that had been reviewed by the study have been evaluated. It is clear that, whilst more R&D is needed in most cases to raise TRLs, suitable options exist to enable the recovery of all actinide elements plus the HHRs by wet or dry processes, even up to the extraordinarily difficult isolation of americium alone. The technology readiness levels (TRL) for most processes fall in the ‘proof of principle’ range with TRLs between 4 and 6, although this is an evaluation at the system level and some gaps in the individual process steps may still exist that strictly would reduce the overall TRL. That is, flowsheets have been proposed for processes and tested with active materials under increasingly relevant conditions, through to initial hot tests with small quantities of SNF. The results of this work were shown to be comparable to a parallel European study that evaluated TRLs for minor actinide partitioning processes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Process Intensification and Scale-Up of a Continuous Enzymatic Hydrolysis and Separation Process

Combining separate unit operations into one where the best of each part can be maximized is one of the benefits of process intensification. An example is the combination of lignocellulosic biomass enzymatic hydrolysis with the downstream solid-liquid separation step to produce clarified sugars ready for fermentation or catalytic upgrading. The productivity and endpoint yield of enzymatic hydrolysis both enjoy the benefits of reduced feedback inhibition through the continuous removal of sugars by incorporating separations into the reactor. Likewise, the efficiency of recovering clarified sugars from the enzymatic hydrolysis slurry can be enhanced by operating separations equipment at steady-state conditions simultaneously with the continuously fed hydrolysis process. A key parameter that enables greater processing capacity while also raising the risks of failure is the solids loading or concentration. Higher solids loading allows for smaller reactor vessels and results in clarified sugars of higher concentration; however, required pumping power increases, reactor agitation may become ineffective, and membrane flux suffers. Feedstock material attributes influenced by upstream pretreatment must also be scrutinized more carefully: dilute-acid pretreated and deacetylated-and-disc-refined feedstocks exhibit different characteristics that affect agitation and pumping. The authors invite you to further explore the process science enabling the scale-up of this technology from conceptual work at the bench to pilot-scale industrially-relevant equipment where the challenges and solutions of integration and process optimization are expounded upon.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Solvent Screening for Separation Processes Using Machine Learning and High-Throughput Technologies

As the chemical industry shifts toward sustainable practices, there is a growing initiative to replace conventional fossil-derived solvents with environmentally friendly alternatives such as ionic liquids (ILs) and deep eutectic solvents (DESs). Artificial intelligence (AI) plays a key role in the discovery and design of novel solvents and the development of green processes. This review explores the latest advancements in AI-assisted solvent screening with a specific focus on machine learning (ML) models for physicochemical property prediction and separation process design. Additionally, this paper highlights recent progress in the development of automated high-throughput (HT) platforms for solvent screening. Finally, this paper discusses the challenges and prospects of ML-driven HT strategies for green solvent design and optimization. To this end, this review provides key insights to advance solvent screening strategies for future chemical and separation processes.

Artificial intelligence↗

DOE OSTI2020

Countercurrent Actinide Lanthanide Separation Process (ALSEP) Demonstration Test with a Simulated PUREX Raffinate in Centrifugal Contactors on the Laboratory Scale

An Actinide Lanthanide Separation Process (ALSEP) for the separation of trivalent actinides (An(III)) from simulated raffinate solution was successfully demonstrated using a 32-stage 1 cm annular centrifugal contactor setup. The ALSEP solvent was composed of a mixture of 2-ethylhexylphosphonic acid mono-2-ethylhexyl ester (HEH[EHP]) and N,N,N',N'-tetra-(2-ethylhexyl)-diglycolamide (T2EHDGA) in n-dodecane. Flowsheet calculations and evaluation of the results were done using the Argonne’s Model for Universal Solvent Extraction (AMUSE) code using single-stage distribution data. The co-extraction of Zr(IV) and Pd(II) was prevented using CDTA (trans-1,2-diaminocyclohexane-N,N,N',N'-tetraacetic acid) as a masking agent in the feed. For the scrubbing of co-extracted Mo; citrate-buffered acetohydroxamic acid was used. The separation of An(III) from the trivalent lanthanides (Ln(III)) was achieved using citrate-buffered diethylene-triamine-N,N,N',N",N"-pentaacetic acid (DTPA), and Ln(III) were efficiently back extracted using N,N,N',N'-tetraethyl-diglycolamide (TEDGA). A clean An(III) product was obtained with a recovery of 95% americium and curium. The Ln(III) were efficiently stripped; but the Ln(III) product contained 5% of the co-stripped An(III). The carryover of Am and Cm into the Ln(III) product is attributed to too few actinide stripping stages, which was constrained by the number of centrifugal contactors available. Improved separation would be achieved by increasing the number of An strip stages. The heavier lanthanides (Pr, Nd, Sm, Eu, and Gd) and yttrium were mainly routed to the Ln product, whereas the lighter lanthanides (La and Ce) were mostly routed to the raffinate.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Validation and optimization of batch and continuous particle separation processes

Recent advances in simulation capabilities coupled with advanced manufacturing can be leveraged to create highly efficient compact reactors with low emissions, low cost, high reliability, and high flexibility for energy conversion. This type of reactor is especially important for conversion of bio-mass, a storable, renewable and fast-growing energy source, considering the distributed nature of raw material and cost of biomass collection and transportation. To achieve this goal, it is critical to developing new process technologies that are significantly more efficient than traditional processes for which the added manufacture provides a fast way of realization and evaluation. Based upon the flagship MFiX multiphase computational fluid dynamic software suite, NETL has developed an Optimization Toolset to facilitate the CFD simulation based reactor design and optimization, and process intensification. This technical report presents the recent development and application of the Optimization Toolset and the framework for process optimization of particle separation in batch and continuous processes. In these processes, a fluidized bed reactor under proper operating condition was used to separate particles of different physical properties. MFiX-DEM simulations were conducted for a batch system to simulate the process covering a wide range of superficial gas velocities from which the optimal operational parameter can be determined through analyzing the system response. After successful demonstration of the framework, a continuous system for particle separation was designed based on CFD simulations. Similar optimization exercises were conducted for the continuous particle separation considering multiple operating parameters. The design was then fabricated in the laboratory through 3D printing for testing. The particle separation performance was carefully measured through high-speed video for particle tracking. Quantitative comparison between numerical results and experimental measurements were conducted for confirmation and validation.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2019

Synthesis and analysis of separation processes for extracellular chemicals generated from microbial conversions

Recent advances in metabolic engineering have enabled the production of chemicals via bio-conversion using microbes. However, downstream separation accounts for 60–80% of the total production cost in many cases. Previous work on microbial production of extracellular chemicals has been mainly restricted to microbiology, biochemistry, metabolomics, or techno-economic analysis for specific product examples such as succinic acid, xanthan gum, lycopene, etc. In these studies, microbial production and separation technologies were selected apriori without considering any competing alternatives. However, technology selection in downstream separation and purification processes can have a major impact on the overall costs, product recovery, and purity. To this end, we apply a superstructure optimization based framework that enables the identification of critical technologies and their associated parameters in the synthesis and analysis of separation processes for extracellular chemicals generated from microbial conversions. We divide extracellular chemicals into three categories based on their physical properties, such as water solubility, physical state, relative density, volatility, etc. We analyze three major extracellular product categories (insoluble light, insoluble heavy and soluble) in detail and provide suggestions for additional product categories through extension of our analysis framework. The proposed analysis and results provide significant insights for technology selection and enable streamlined decision making when faced with any microbial product that is released extracellularly. The parameter variability analysis for the product as well as the associated technologies and comparison with novel alternatives is a key feature which forms the basis for designing better bioseparation strategies that have potential for commercial scalability and can compete with traditional chemical production methods.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Pilot Scale Testing of the Hydrophobic-Hydrophilic Separation Process to Produce Value-Added Products from Waste Coal

The primary objective of this project was to demonstrate the technical and economic feasibility of using the hydrophobic-hydrophilic separation (HHS) process to produce high-purity, value-added clean coal that could serve as feedstock for specialty carbon products from waste coal. An existing one-skid (i.e., the entire unit fits on a single tractor-trailer) HHS pilot-scale facility was used to process bituminous and anthracite waste coals to produce: 1) a clean coal containing less than 5% ash (super-clean) and 2) another containing less than 1.5% ash (ultra-clean), all of which contain single-digit moistures. Sufficient quantities of these products were to be generated to permit detailed evaluations by potential customers producing or developing new, high-value market applications. In addition, the project included the evaluation of several process improvements to reduce the capital and operating costs for a commercial HHS plant. A final objective was to complete an economic analysis, market-penetration analysis, and technology-gap analysis of the HHS technology and its products.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

The Production of Low Ash Coals Using the Hydrophobic-Hydrophilic Separation Process with Novel Developments

Froth flotation is a common mineral processing method in coal preparation. This process becomes less efficient, however, as particle size is reduced, and ultrafine particles are often discarded prior to froth flotation, contributing to a substantial amount of coal waste in impoundments. Because of the land-use and risk of an impoundment failure, these impoundments pose an environmental liability. To address ultrafine coal rejection, researchers at Virginia Tech developed the hydrophobic-hydrophilic separation (HHS) process. Unlike in froth flotation, HHS uses an organic solvent to separate and dewater hydrophobic particles from hydrophilic minerals. Past work on the HHS process yielded promising results. In particular, the HHS process has produced a low-ash (<2%) and low moisture (<8%) product, which is a viable feed stock for carbon products. In this work, an investigation of the effects of auxiliary processes on the HHS process was conducted. The auxiliary processes included grinding, pre-concentration, and reagent conditioning. This work also contains an investigation on the interaction between two primary unit operations in the HHS process: oil agglomeration and de-emulsification. Lastly, to make the HHS process more viable for commercial scale-up, a novel unit operation was developed and tested that performs comparably to the current HHS process.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Developing Digital Twin Visualizations: A Methodology and Case Study on Chemical Separation Processing

As advances in digital engineering continue to push the technological boundaries, digital twin (DT) visualizations for diagnostics and safeguards advancement become much more feasible and practical. DTs generate large and complex data streams that require effective user interfaces to provide monitoring and diagnostic capabilities. Unfortunately, while these frameworks exist, there is not much research on the systematic documentation of human–computer interaction (HCI) for DT visualization. This work presents a dual-mode visualization methodology (two dimensional [2D] graphical user interface dashboard and 3D mixed reality) designed to support diagnostic tasks in DT systems and building on a validated framework and applying established HCI principles. The methodology is demonstrated through a case study of aqueous processing at Idaho National Laboratory, using experimental data from the chemical solvent extraction runs. Our interfaces display real-time alerts and monitoring to inform users of safeguards anomalies. The interfaces use immersive 3D mixed-reality visualization for further system and experiment investigation. This work demonstrates how the systematic application of HCI principles can inform DT visualization design for diagnostic and safeguards applications. While formal user evaluation studies remain as future work, this paper documents the systematic design methodology and demonstrates a proof-of-concept implementation.

3D visualization↗

DOE OSTI2018

Combining Experiments and Simulations of Extraction Kinetics and Thermodynamics in Advanced Separation Processes for Used Nuclear Fuel

This 3-year project was a collaboration between University of California Irvine (UC Irvine), Pacific Northwest National Laboratory (PNNL), Idaho National Laboratory (INL), Argonne National Laboratory (ANL) and with an international collaborator at ForschungZentrum Jülich (FZJ). The project was led from UC Irvine under the direction of Profs. Mikael Nilsson and Hung Nguyen. The leads at PNNL, INL, ANL and FZJ were Dr. Liem Dang, Dr. Peter Zalupski, Dr. Nathaniel Hoyt and Dr. Giuseppe Modolo, respectively. Involved in this project at UC Irvine were three full time PhD graduate students, Tro Babikian, Ted Yoo, and Quynh Vo, and one MS student, Alba Font Bosch. The overall objective of this project was to study how the kinetics and thermodynamics of metal ion extraction can be described by molecular dynamic (MD) simulations and how the simulations can be validated by experimental data. Furthermore, the project includes the applied separation by testing the extraction systems in a single stage annular centrifugal contactor and coupling the experimental data with computational fluid dynamic (CFD) simulations. Specific objectives of the proposed research were: Study and establish a rigorous connection between MD simulations based on polarizable force fields and extraction thermodynamic and kinetic data. Compare and validate CFD simulations of extraction processes for An/Ln separation using different sizes (and types) of annular centrifugal contactors. Provide a theoretical/simulation and experimental base for scale-up of batch-wise extraction to continuous contactors. We approached objective 1 and 2 in parallel. For objective 1 we started by studying a well established extraction system with a relatively simple extraction mechanism, namely tributyl phosphate. What we found was that well optimized simulations can inform experiments and new information on TBP behavior was presented in this project, as well be discussed below. The second objective proved a larger challenge and most of the efforts were devoted to experimental studies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Quantifying the environmental benefits of a solvent-based separation process for multilayer plastic films

Food packaging often appears in the form of multilayer (ML) plastic films, which leverage the functional properties of different polymers to achieve specific food protection goals (e.g., oxygen, water, and temperature barriers). These properties are essential to enable long shelf lives, reduce refrigeration usage, mitigate food waste, and increase food accessibility. However, ML film production processes generate large amounts of plastic waste that cannot be mechanically recycled. Recently, we have proposed a process, called solvent-targeted recovery and precipitation (STRAP), that enables the separation and recycling of the constituent polymers of ML films. This technology uses a series of solvent washes that selectively dissolve and precipitate target polymers. Quantifying the environmental benefits of STRAP over virgin resin production is essential for the commercial deployment of this technology. Further, this work uses life cycle assessment (LCA) methods to evaluate these impacts in terms of carbon footprint, energy use, water use, and toxicity. We analyze three STRAP process variants that use antisolvent and temperature-driven precipitation to treat different ML films. Our analysis reveals that the STRAP-A and STRAP-B process variants can provide environmental benefits over virgin film production. Furthermore, it gives valuable insight into the critical components of ML films (specific polymers) and of the STRAP processes (equipment) that are responsible for the highest impacts. Ultimately, we believe that the proposed analysis framework can lead to the design of more environmentally-friendly ML films and recycling processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Separation Process of Plant Fibers for Textile and Composite Application: A Review of Recent Advances

Plant fiber resources have gained significant attention for value-added utilization due to their renewability, sustainability, abundance, and widely acknowledged physical properties. The efficient and pragmatic separation of plant fibers is a critical process for their efficient utilization, yet a substantial gap persists between laboratory research advancements and their commercialization. To increase the possibility of research advancements for industrial application, this review summarizes the recent advances in different extraction methodologies of plant fiber research in textile and composite fields. It systematically outlines, compares, and contrasts physical (cryogenic, supercritical carbon dioxide, ultrasonic, steam explosion and microwave heating treatment), chemical (alkali, oxidation, organic solvents and deep eutectic solvents methods), and biological (natural retting, enzymatic and microorganism approaches) methods, addressing their respective mechanisms, strengths, limitations, research progress, and future prospects. In general, traditional chemical approaches have proven significantly effective but are accompanied by high pollution. Conversely, novel chemical treatments such as deep eutectic solvents and organic solvents offer a promising blend of efficiency and environmental friendliness but require deeper studies currently. Meanwhile, physical and biological treatments, though largely eco-friendly, tend to suffer from lower separation efficiencies. The research needs and future direction are also addressed to bridge the gap between scientific advancements and their widespread industrial application.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

A reactive separation process for pre-combustion CO 2 capture employing oxygen-blown coal gasifier off-gas

In this paper, we present an experimental study of a reactive separation system, consisting of a membrane reactor (MR) and an adsorptive reactor (AR) operating in tandem, with the MR’s reject stream serving as the AR’s feed. We investigates the feasibility of applying this MR-AR system for high-purity H 2 production and simultaneous CO 2 capture via the water gas shift (WGS) reaction in the context of Integrated Gas Combined Cycle (IGCC) power generation employing oxygen-blown gasifier syngas from biomass and coal. We previously studied this MR-AR system for the IGCC process employing air-blown gasifier syngas, for which it demonstrated good performance, attaining high conversion exceeding equilibrium, producing ultra-pure H 2 for power generation, and a CO 2 stream ready for sequestration. In this study, we focus on oxygen-blown gasifier off-gas that contains no N 2 , with composition distinctly different from the air-blown gasifier syngas which has a large N 2 content. We employ a carbon molecular sieve membrane (CMSM), a commercial sour-shift WGS catalyst, and a hydrotalcite (HTC) adsorbent. We carried out experiments to determine membrane performance and to identify promising operating conditions in an IGCC-relevant environment. The CMSM proved robust during a long-term (~344 hr run) experimental run under high temperature and pressure maintaining a high He/N 2 selectivity (~170). Multi-cycle runs were carried out during which the MR-AR system displayed superior performance to that of a PBR, by producing a high purity H 2 product directly usable in power generation. Therefore, the findings from this study demonstrate the ability of the MR-AR system to operate stably for a broad range of gasifier off-gas compositions, and indicate its potential for integration into IGCC plants for power generation with CO 2 capture.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2019

Closing the Nuclear Fuel Cycle with a Simplified Minor Actinide Lanthanide Separation Process (ALSEP) and Additive Manufacturing

Expanded low-carbon baseload power production through the use of nuclear fission can be enabled by recycling long-lived actinide isotopes within the nuclear fuel cycle. This approach provides the benefits of (a) more completely utilizing the energy potential of mined uranium, (b) reducing the footprint of nuclear geological repositories, and (c) reducing the time required for the radiotoxicity of the disposed waste to decrease to the level of uranium ore from one hundred thousand years to a few hundred years. A key step in achieving this goal is the separation of long-lived isotopes of americium (Am) and curium (Cm) for recycle into fast reactors. To achieve this goal, a novel process was successfully demonstrated on a laboratory scale using a bank of 1.25-cm centrifugal contactors, fabricated by additive manufacturing, and a simulant containing the major fission product elements. Americium and Cm were separated from the lanthanides with over 99.9% completion. The sum of the impurities of the Am/Cm product stream using the simulated raffinate was found to be 3.2 × 10 –3 g/L. The process performance was validated using a genuine high burnup used nuclear fuel raffinate in a batch regime. Separation factors of nearly 100 for 154 Eu over 241 Am were achieved. All these results indicate the process scalability to an engineering scale.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Polymeric materials for electrochemical cells and ion separation processes

Polymers of intrinsic microporosity are provided herein. Disclosed polymers of intrinsic microporosity include modified polymers of intrinsic microporosity that include negatively charged sites or crosslinking between monomer units. Systems making use of polymers of intrinsic microporosity and modified polymers of intrinsic microporosity are also described, such as electrochemical cells and ion separation systems. Methods for making and using polymers of intrinsic microporosity and modified polymers of intrinsic microporosity are also disclosed.

25 ENERGY STORAGE↗

DOE OSTI2022

Polymeric materials for electrochemical cells and ion separation processes

Helms, Brett A.↗

DOE OSTI2018

Molecularly Mixed Composite Membranes for Advanced Separation Processes

Porous organic cages (POCs) are individual soluble, porous molecules. Additionally, when fabricated into mixed-matrix membranes (MMMs), the soluble POC molecules have the potential to exhibit intimate molecular-level mixing with the polymer matrix. POCs have only recently been incorporated into mixed matrix membrane materials, but this process has not yet resulted in significant improvements of membrane performance. Now, vertex-functionalized amorphous scrambled porous organic cages (ASPOCs) have been utilized as membrane performance enhancers and the amorphous ASPOC mixtures are observed to distribute throughout the matrix without any indication of particle formation or agglomeration, creating unique, molecularly mixed composite membranes. Overall, the molecularly mixed composite membrane provide significant increases in both membrane permeability and selectivity, offering new avenues for creation of membranes with unique properties in industrially relevant separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗