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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 OSTI2023

A decision support tool for e-waste recycling operations using the hen-and-chicks bio-inspired optimization metaheuristic

E-waste from end-of-life electrical and electronic devices is one of the fastest growing waste streams from households and businesses. E-waste recycling yields environmental sustainability and economic benefits. Due to continuous changes in e-waste types and compositions, recycling businesses face challenges to optimize their operational configuration to achieve better economic and environmental performance. To help e-waste recyclers mitigate this problem, we have developed a modular decision support tool called the Comprehensive Manufacturing Assessment Tool (CMAT) that can simulate both e-waste recycling operations and economics. This tool can give valuable insights regarding the profitability of the entire operation and different e-waste types. In addition, a new bio-inspired metaheuristic optimization algorithm, hen-and-chicks optimization (HACO), was developed to assign manpower to different workstations to maximize operational efficiencies. According to the results of our case study, laptops, desktops, and computer peripherals are the three electronic waste products that produce the most profit. Our examination of the sensitivity of material prices shows that the price of steel has the most significant influence on total profit, because it is the most widely used material in the majority of electronic devices. We have released the decision support tool as open-source software under a general public license. It could be customized for other recycling industries beyond e-waste to achieve business sustainability by making their operations more efficient.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Self Configuring Digital Twin for Optimizing E-Waste Recycling

Electronic waste recycling industry needs a decision support tool for optimizing their processes to become cost competitive. We developed a software called CMAT, Comprehensive Manufacturing Assessment Tool. The aim of CMAT is to provide the e-waste recycling companies with a fully customizable decision support framework that analyzes the optimal supply chain configurations. The software optimizes the logistics operations, helps to identify the best recycling process configuration, and generates valuable insights regarding the economic performance of different categories of e-waste. The ultimate purpose of the tool is to assist the users developing a digital twin of their processes and to provide insights on questions pertinent to the e-waste recycling industry including how to increase efficiency and reduce costs, energy consumption, and greenhouse gas emissions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Electronic Waste (E-Waste) Recycling: Barriers and Opportunities for State, Local, and Tribal Governments

Electronic waste, or e-waste, encompasses end-of-life electrical and electronic equipment, including computers, monitors, televisions, printers, cell phones, household appliances with electronic components, and small consumer devices containing batteries or circuitry. E-waste is one of the fastest-growing components of the U.S. waste stream, with nearly 8 million tons generated in 2022. E-waste presents two related public-interest considerations. First, e-waste contains economically and strategically important materials: base metals (copper, aluminum, iron, steel), precious metals (gold, silver, platinum group metals), and critical materials such as rare earth elements, gallium, and indium that appear on the U.S. Geological Survey's (USGS) 2025 List of Critical Minerals. Second, many electronic devices contain hazardous constituents - including lead, mercury, cadmium, and brominated flame retardants - as well as rechargeable batteries that can pose fire risks during handling. Effective management of these constituents helps protect workers, communities, and the environment. In the United States, it is estimated that less than 20% of e-waste is formally collected and recycled, leaving over 6 million tons landfilled or otherwise unrecovered. This fact sheet provides state and local decision-makers an overview of (1) e-waste composition and recoverable materials, (2) technology pathways used to recover those materials, and (3) examples of operational and partnership structures used to provide e-waste recycling capacity in the United States. It is intended to complement existing collection-program guidance available through U.S. Environmental Protection Agency (EPA) and other sources.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

KBase Narrative - BIT 295 MRA Isolate 106- Final

Arthrobactor is a bacteria that commonly resides in soil, plants, and wastewater (Gobbetti 2014). It is commonly used in the agricultural industry for degrading pesticides which will detox the soil and allow wildlife not to be harmed by said pesticides. The sample that is being tested came from an acid drain from a mine. The test sample was able to live and thrive in a metal ridden environment which could lead it to having some genes that could aid in e-waste recycling. A species of arthrobacter known as Arthrobacter citreus can be used for polyamide waste (Baxi 2019). Polyamide is used in fishing nets and industrial applications and the waste generated by this impacts ocean environments and ecosystems (Rietzler et all... 2021). Based on the resilience of arthrobacter as a genus, the hopes for this sample to aid in e-waste recycling are high.

Chadha, Aditya↗
DOE OSTI2025

Microwave-Mediated Extraction of Critical Metals from LED E-Waste

This study introduces a microwave-assisted technique for extracting critical minerals from LED electronic waste. The process begins with microwave irradiation, which thermally decomposes the LED’s plastic lens into a brittle, charred residue. During this stage, the LED chip undergoes deflagration—being rapidly ejected from the reflective cavity and becoming embedded within the decomposed lens material. Consequently, the chip is encapsulated in the resulting charred residue. This composite, consisting of the charred lens and the LED chip, can be easily separated from the metallic pins (Fe, Ni, Ag), which remain almost undamaged. Subsequent calcination of the charred material in air exposes the materials making up the LED chip, which contain critical metals (e.g., Ga, As, In, Y, Au). These metals are then extracted through a two-step acid leaching process involving aqua regia followed by hot concentrated hydrochloric acid, yielding them in potentially recoverable forms. The synergistic effect of microwave irradiation and acid treatment achieves an average extraction efficiency of 96% for critical metals. Notably, this approach enables complete and loss-free recovery of the LED chip, offering a practical and efficient solution for LED e-waste recycling.

Bourlinos, Athanasios B.↗
DOE OSTI2026

A Practical Guide to E-waste Education and Events in Schools

The Practical Guide to E-waste Education and Events in Schools is a comprehensive resource that equips educators and outreach professionals to deliver impactful lessons on electronic waste (e-waste), critical materials, and battery recycling, while launching effective school-based e-waste recycling programs. It offers step-by-step guidance for starting and managing outreach efforts, including tips on student engagement, selecting recycling partners, planning collection logistics, creating promotional materials, and overcoming common challenges. The guide also supports curriculum development and scaling initiatives across schools to foster lasting recycling habits.

school outreach↗
DOE OSTI2022

Recycling rare earths: Perspectives and recent advances

Abstract Rare-earth element (REE) demand is expected to increase by a factor of up to 7 by 2040. Recycling avoids the significant hurdles associated with opening new mines, but collection and disassembly of REE-containing devices are barriers. Absolute and relative abundances of REEs and co-occurring constituents differ significantly in secondary compared to primary sources, presenting challenges and opportunities. REE concentrations are typically low, but manufactured devices include only the desired REE, avoiding the “REE balance problem” that besets natural ores. Fewer REEs need to be separated, as compared to separation of the entire lanthanide series. Co-recovery of precious (e.g., Au, Ag, Pt) or base metals (e.g., Cu, Sn, Zn) from e-wastes can offset recycling costs. Some examples of recently developed approaches for REE extraction and separation are presented here, with an emphasis on methods offering environmental benefits such as lower toxic chemical usage and reduced energy costs. Graphical abstract

36 MATERIALS SCIENCE↗
DOE OSTI2025

Mechanically and Chemically Robust Lanmodulin-Functionalized Silk Sponges for Rare Earth Element Sequestration

The extraction of rare-earth elements (REEs) from low-grade sources like electronic waste (E-waste) could supplement current unsustainable mining practices. REEs are crucial for various industries, but supply struggles to meet growing demand. Herein, we present an environmentally friendly method for REE extraction using silk protein sponges functionalized with lanmodulin (LanM), a protein that selectively binds REEs. These sponges are relatively facile to fabricate and scale, while offering highly selective REE binding. The REEs can then be recovered via simple acid leaching, allowing sponge reuse for multiple cycles as well as specific desorption of different REEs by changing the pH of the desorption buffer. Finally, this method avoids harmful solvents used in traditional extraction and enables recycling of REEs from industrial and E-waste.

REEs↗
DOE OSTI2025

Game theoretic modeling and optimization of competition and collaboration in dual channel electronic waste supply chains

The rapid growth of electronic waste (e-waste) presents critical challenges for sustainable resource recovery and environmental protection. This study develops a dual-channel closed-loop supply chain (CLSC) model formulated as a hierarchical Stackelberg game, that integrates dynamic pricing and cost-sharing mechanisms to optimize both economic and environmental outcomes. The model explicitly captures strategic interactions between manufacturer-led and third-party recycling channels, accounting for consumer behavior, regulatory incentives, and market competition. Numerical simulations conducted (implemented over a four-iteration horizon using a commercial optimization solver) show that, relative to the baseline equilibrium, manufacturer profit increases from 11.6 thousand USD to 37.9 thousand USD (+226.8%), total recycled volume rises from 7,848 to 7,942 units (+1.2%), and collector profit nearly doubles under cost-sharing, enabling more equitable profit distribution. Furthermore, scenario-based simulations across Sub-Saharan Africa, high-income economies, and emerging Asian industrial countries reveal that infrastructure quality, policy intensity, and labor costs critically shape recycling efficiency and profit allocation. These findings demonstrate that subsidies alone are insufficient to ensure system efficiency. Instead, coordinated strategies that integrate internal incentive alignment with context-sensitive policy support are required. Overall, this study offers a robust framework for designing resilient, efficient, and regionally adaptable e-waste management systems.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Innovative recycling of high purity silver from silicon solar cells by acid leaching and ultrasonication

Precious and scarce silver (Ag) is used as a front electrical contact in silicon solar panels. With massive amounts of solar panel waste coming to end-of-life, it is imperative to recover all the Ag from these modules. In this paper, we propose a novel method to easily reclaim Ag from end-of-life silicon solar cells using low concentration sulfuric acid (H 2 SO 4 ) leaching followed by ultrasonication. Our process simplifies the Ag recycling procedure by directly recovering the Ag contacts from solar cells, eliminating the need for secondary precipitation/electrodeposition. First, scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDX) and X-ray photoelectron spectroscopy (XPS) was used to study the leaching and ultrasonication process on rejected solar wafers. Next, a solar panel from landfill was heated in a furnace to burn off the polymer encapsulant. The silicon wafers were then collected from the burning process and leached in 2 M H 2 SO 4 at two different shaking speeds for 48 hours at room temperature. Finally, the end-of-life silicon wafer pieces were collected, sonicated in water, and then the sonication water was centrifuged to show a proof-of-concept to recover the Ag contacts. Inductively coupled plasma optical emission spectroscopy (ICPOES) is used to monitor dissolved elements in the leachate as a function of time and shaking speed. XPS is used to evaluate the composition of the silicon cell wafer surface before and after H 2 SO 4 leaching. SEM is used to image the recovered Ag contacts morphology and EDX confirms the recovered particles contain high amounts of Ag. Furthermore, a proposed schematic illustrates the authors’ hypothesis for the peeling mechanism.

14 SOLAR ENERGY↗
DOE OSTI2025

Mapping Rare Earths and Toxics in E-Waste via Hyperspectral Imaging and Machine Learning

Electronic waste (e-waste) presents a mounting challenge to environmental sustainability due to its complex composition, which includes high-value rare earth elements, hazardous organic compounds, and non-recyclable plastics. Accurate and scalable material classification is essential for enabling efficient resource recovery and safe recycling practices. This study introduces a confidence-aware classification pipeline that combines mid-infrared hyperspectral imaging (HSI), spectral angle mapping (SAM), and iterative machine learning to perform pixel-level material identification across e-waste devices. A curated spectral library encompassing artificial materials (e.g., plastic iron oxide, galvanized metals), minerals (e.g., allanite, hematite), and organic compounds (e.g., benzanthracene, toluene) was used to generate pseudo-labels, each assigned a confidence score based on SAM-derived spectral similarity. High-confidence samples from seven consumer electronics—digital cameras, keyboards, laptop fans, modems, motherboards, TV remotes, and speakers—were iteratively expanded and classified using models such as Support Vector Machine (SVM), Random Forest, Gradient Boosting Classifier, Partial Least Squares Discriminant Analysis (PLSDA) and Logistic Regression. The best-performing classifiers achieved macro F1 scores approaching 1.0. Results revealed widespread plastic content (dominated by plastic iron oxide), the presence of rare earth-bearing minerals like cerium-containing allanite, and pervasive detection of hazardous organics such as benzanthracene. Principal Component Analysis (PCA) visualizations and confusion matrices confirmed high separability and robust classification performance. This methodology enables precise, non-destructive, and scalable classification of heterogeneous e-waste streams. It supports automated, hazard-aware sorting in recycling workflows, facilitating selective recovery of critical materials and compliance with circular economy goals. The confidence-aware framework provides a foundation for real-time deployment in industrial settings, offering significant implications for smart e-recycling infrastructure and policy-driven material stewardship.

Circular economy↗
DOE OSTI2023

Urban mining from biomass, brine, sewage sludge, phosphogypsum and e-waste for reducing the environmental pollution: Current status of availability, potential, and technologies with a focus on LCA and TEA

We discuss how rapid industrialization, improved standards of living, growing economies and ever-increasing population has led to the unprecedented exploitation of the finite and non-renewable resources of minerals in past years. It was observed that out of 100 BMT of raw materials processed annually only 10% is recycled back. This has resulted in a strenuous burden on natural or primary resources of minerals (such as ores) having limited availability. Moreover, severe environmental concerns have been raised by the huge piles of waste generated at landfill sites. To resolve these issues, ‘Urban Mining’ from waste or secondary resources in a Circular Economy’ concept is the only sustainable solution. The objective of this review is to critically examine the availability, elemental composition, and the market potential of the selected secondary resources such as lignocellulosic/algal biomass, desalination water, sewage sludge, phosphogypsum, and e-waste for minerals sequestration. This review showed that, secondary resources have potential to partially replace the minerals required in different sectors such as macro and microelements in agriculture, rare earth elements (REEs) in electrical and electronics industry, metals in manufacturing sector and precious elements such as gold and platinum in ornamental industry. Further, inputs from the selected life cycle analysis (LCA) & techno economic analysis (TEA) were discussed which showed that although, urban mining has a potential to reduce the greenhouse gaseous (GHG) emissions in a sustainable manner however, process improvements through innovative, novel and cost-effective pathways are essentially required for its large-scale deployment at industrial scale in future.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Ion-Specific Precipitation of Extractants Enables Rare-Earth Separation and Wastewater Remediation from Solvent Extraction of Critical Elements

The increasing demand for rare-earth elements (REEs) necessitates sustainable recovery strategies, particularly from secondary sources, such as electronic waste. Solvent extraction is the primary industrial method for REE separation; however, the unintentional dissolution of extractants into wastewater poses serious environmental risks, leading to organic contamination and process inefficiencies. Existing wastewater treatment methods struggle to remove these persistent pollutants, underscoring the need for innovative recovery approaches. Herein, we present a ligand-mediated precipitation strategy that simultaneously recovers REEs and removes dissolved extractants from solvent extraction wastewater. We show that residual extractants in the aqueous phase can selectively bind REEs, inducing their precipitation while leaving transition metals in solution. By integrating FTIR spectroscopy, EDS, XPS, EXAFS, and SAXS, we elucidate the mechanism of ion-specific precipitation and the local coordination environment of metal ions in the precipitate. Importantly, we demonstrate that the precipitated extractants can be efficiently recovered and reused, providing a closed-loop solution that enhances sustainability. Applying this method to leachates from samarium–cobalt (Sm–Co) and neodymium–iron–boron (NdFeB) mixed magnets, we achieve highly selective REE precipitation under mild conditions, demonstrating a scalable and cost-effective pathway for REE recovery, wastewater purification, and extractant recycling. In conclusion, by integrating element-specific ligand-mediated precipitation with extractant reuse, this work offers a transformative approach to REE separation that reduces the environmental impact while improving resource efficiency.

E-waste↗
DOE OSTI2022

Economic analysis of precious metal recovery from electronic waste through gas-assisted microflow extraction

The recycling of end-of-life (EoL) electronic products is motivated by the enormous investment of resources in their creation and the environmental concerns associated with electronic waste (e-waste). Hydrometallurgical methods that utilize conventional leaching and solvent extraction are often applied to extract target materials from e-waste; however, these techniques have significant technical and economic limitations when extracting high-value, low concentration metals from complex waste streams. This study proposes and evaluates a novel process based on gas-assisted microflow extraction (GAME) that efficiently recovers precious metals from waste printed circuit boards (WPCBs). Further, an economic analysis is conducted to verify the economic feasibility of the GAME-based process at an industrial scale. The economic outputs are further investigated to identify the most cost-effective production strategies, particularly with respect to the plant feedstock rate. It is envisioned that this study may establish a paradigm for making economically-informed decisions for sustainable technologies.

42 ENGINEERING↗
DOE OSTI2026

Separation and Recovery of High-Purity Dysprosium from Electric Vehicle Scrap Permanent Magnets Using Cyanex 572, a Cationic Extractant in a Membrane Solvent Extraction Process

Rare earth elements (REEs), especially heavy rare earth elements such as dysprosium (Dy), have gained immense attention globally due to their widespread use in many state-of-the-art technologies. Consequently, demand for REEs is increasing rapidly in comparison to their supply. Recycling of REEs from end-of-life (EoL) electronic waste (e-waste) can help to mitigate the increasing gap between the demand and supply of REEs. This study reports the separation and recovery of high-purity Dy from various feedstocks such as scrap permanent magnets (SPMs), electric vehicle (EV) magnets, and mixed rare earth oxides (REOs) using an economically viable and scalable membrane solvent extraction (MSX) process. First, the optimized conditions (organic phase composition and feed solution acid concentration) for the separation of Dy from light REEs such as neodymium (Nd) and praseodymium (Pr) were evaluated using liquid–liquid extraction. Thereafter, a multistage MSX process was developed to separate high purity (>99.5 wt %) Dy from Nd and Pr using Cyanex 572, a cationic extractant. Using feedstocks with varying initial compositions, the MSX process obtained 100% pure Dy with 63–96% Dy recovery in three to six stages with a maximum extraction rate of 2.9 g m–2 h –1 . Purity of the recovered Dy was confirmed via additional characterization such as scanning electron microscopy, energy dispersive X-ray spectroscopy, and X-ray diffraction. This novel MSX process holds immense potential for industry deployment for the separation of heavy and light rare REEs from a wide range of e-waste.

electrical vehicle magnets↗
DOE OSTI2022

CRADA Number NFE-18-07313 with Nth Cycle, Inc. (CRADA Final Report)

Cooperative Research and Development Agreement (CRADA) NFE-18-07313 between Oak Ridge National Laboratory (ORNL) and Nth Cycle Inc. focused on developing a technology for sustainable recycling of rare earth and specialty metals (e.g., Y, Co, Li; RESE), as well as bulk and precious metals from industrial manufacturing and waste streams through the use of electrochemical carbon nanotube-enabled filters. The project outcome was expected to be a stronger mechanistic understanding of the electrochemical recovery of metals from real manufacturing process streams and e-waste streams, and the development of an optimized high-throughput pilot-scale device ready for commercialization. Testing, design, and development of a v1 prototype to prove the technology was unsuccessful (we were not able to reach the go/no-go outlined in Objective 1) and we were unable to continue our redesign due to COVID-19 lockdown and no access to lab from March 2020 – until our graduation from the program.

36 MATERIALS SCIENCE↗