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At least 19 records

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NASA NTRS1976

Insulation end life determination for completed form-wound generators

Tests were conducted to predict remaining electrical insulation life of a polyimide-epoxy insulated 60 kW form-wound homopolar inductor generator following completion of 23,130 hours of turbo-generator endurance tests. The generator stator was sectioned to provide five sections, designated statorettes, and to permit 33 coil dielectric measurements on each section. Thermal aging tests were conducted on each section at select elevated temperatures to establish an Arrhenius life-temperature plot for end-life prediction and product or application use. The statorette fabrication technique is considered novel and provides means to establish insulation life-temperature profiles on completed electromagnetic components of rotating machines.

Penn, W. B.↗

DOE OSTI2025

Addressing Inherent Challenges to Chemical Relithiation of Cycled End‐of‐Life Cathode Materials

Recycling end‐of‐life (EOL) lithium‐ion batteries (LIBs) is important to retain valuable resources from critical materials present in EOL battery waste. Direct recycling methods offer an opportunity to recover intact valuable cathode materials with minimal re‐processing. An important step of the direct recycling process is relithiation which is used to restore lithium content to EOL cathode materials. However, little has been done to study how preprocessing steps such as washing or binder removal may affect relithiation methods in the direct recycling process. Here, the evolution of fluorine byproducts left over from preprocessing steps during a low‐temperature chemical redox mediator relithiation process is tracked. A facile washing step is presented as a solution for mediating adverse effects of surface contamination on the chemical relithiation performance. The structure, lithium content, and electrochemical performance of relithiated EOL NMC 622 material that underwent a pre‐relithiation washing step to remove fluorine byproducts is shown to match that of pristine NMC 622. In this work, it is showed that redox mediator relithiation as a part of a direct recycling process is a promising low energy method that can be applied to EOL material with inherent surface impurities if the proper pre‐relithiation processing steps are implemented.

25 ENERGY STORAGE↗

DOE OSTI2025

BRE‐X Emissions Database for End‐of‐Life Scenarios of Selective Building Construction Materials to Enable Circular Economy in Construction

In the United States, construction and demolition debris predominately end up in landfills with minimal end‐of‐life Re‐X (recover, recycle, reuse, etc.) scenarios, resulting in large environmental impacts and lost opportunities for material recovery. Except for concrete and metals, which seem to have a few well‐defined end‐of‐life pathways, there seems to be a lack of well‐documented end‐of‐life scenarios for other construction materials, let alone their emissions data. Hence, there is a need for documented end‐of‐life Re‐X scenarios and end‐of‐life data of more building materials to motivate widespread use of Re‐X strategies in building design. This paper outlines the efforts of the National Renewable Energy Laboratory, Carbon Leadership Forum, Building Transparency, and Skidmore, Owings & Merrill to (a) create an open‐access BRE‐X (Building Re‐X) end‐of‐life emissions database consisting of greenhouse gas emissions data associated with various end‐of‐life scenarios for a select list of high‐impact building construction materials, and (b) integrate the BRE‐X end‐of‐life emissions database with CAD/BIM/LCA tools for evaluating various end‐of‐life scenarios. The paper also presents a few existing life cycle inventory databases that contain sparse amounts of end‐of‐life data for a few construction materials and their limitations in terms of scaling and data consolidation. Finally, a sample of how the collected data can be ingested into whole‐building LCA tools using open data formats and a public access link to the BRE‐X end‐of‐life emissions database is also included.

36 MATERIALS SCIENCE↗

DOE OSTI2024

End-of-Life Plastics Management: A Review: Mechanical recycling, pyrolysis and hydrocracking methods

End-of-life plastics present a significant challenge to achieving a sustainable economy. It is crucial to develop environmentally friendly technologies to process the waste streams beyond landfilling. This review provides a detailed overview of end-of-life plastics management, covering mechanical recycling, pyrolysis and hydrocracking methods. Mechanical recycling is the predominant technique employed on a large scale in recycling end-of-life plastics, and this review discusses the technoeconomic assessment and life cycle assessment (LCA) of mechanical recycling. This review also summarises key studies concentrating on chemical recycling techniques for handling end-of-life plastics. Among these, pyrolysis and hydrocracking are discussed in depth. Recent advancements and fundamentals of these two techniques are covered, highlighting their significance in tackling the plastic waste challenge. The prospects of scaling up pyrolysis and hydrocracking technologies are interpreted in terms of technical and economic feasibility. The discussion concludes with recommendations for future research to commercialise chemical recycling of end-of-life plastics.

Chemistry↗

DOE OSTI2025

Toward a sustainable circular economy of multilayer plastic films: Life cycle and techno-economic assessment with a focus on end-of-life treatment and multiple recovery cycles

This study presents a life cycle assessment (LCA) and techno-economic analysis (TEA) of end-of-life technologies for treating polyethylene–polyamide barrier film waste, focusing on quality degradation across recovery cycles. Novel treatment methods are experimentally validated, while others are drawn from literature and industry consultations. A displacement approach, assuming no quality loss, is first applied. Results show that solvent-based recycling via the solvent-targeted recovery and precipitation (STRAP) process outperforms alternatives across environmental indicators, reducing global warming potential (GWP) by 40% compared to landfilling. Incineration performs worst in most categories, particularly eutrophication (80% higher than landfilling), due to nitrogen emissions. Experimentally validated downcycling (pelletizing) proves more economically viable. The assumption of infinite recoverability is overly optimistic. To address this, we propose a mathematical framework accounting for a finite number of recovery cycles. This refined model shows reduced GWP and cost savings for solvent recovery, making its benefits less pronounced than initially estimated. Sensitivity and uncertainty analyses reveal strong dependence on recovered material quality and solvent recovery efficiency, underscoring the need for optimized process design. Finally, hotspot analysis identifies greenhouse gas emissions from the polyamide supply chain as the dominant GWP contributor. In conclusion, the results underscore potential trade-offs across pathways and show that solvent-based recovery’s sustainability depends heavily on process conditions.

36 MATERIALS SCIENCE↗

NASA NTRS2005

Condition Assessment and End-of-Life Prediction System for Electric Machines and Their Loads

An end-of-life prediction system developed for electric machines and their loads could be used in integrated vehicle health monitoring at NASA and in other government agencies. This system will provide on-line, real-time condition assessment and end-of-life prediction of electric machines (e.g., motors, generators) and/or their loads of mechanically coupled machinery (e.g., pumps, fans, compressors, turbines, conveyor belts, magnetic levitation trains, and others). In long-duration space flight, the ability to predict the lifetime of machinery could spell the difference between mission success or failure. Therefore, the system described here may be of inestimable value to the U.S. space program. The system will provide continuous monitoring for on-line condition assessment and end-of-life prediction as opposed to the current off-line diagnoses.

Parlos, Alexander G.↗

DOE OSTI2023

Comparison of Measured and Calculated Dose Rates for Ring Injection Dump Exchange at Spallation Neutron Source

According to the accelerator operation plan, the beam-stop and the proton beam window (PBW) assemblies of the existing Ring Injection Dump RID are replaced with fresh assemblies, when they have reached their end-of-life. End of-life is determinate by the stainless-steel beam-stop window having accumulated 10 dpa radiation damage. The exchange process took place during facility maintenance period that started in March 2023. Each of the spent assembles were put into specially designed storage containers temporarily residing near the RID building.The spent beam-stop is predicted to be the part of highest activation that has been removed in Spallation Neutron Source (SNS). The exchange processes require good work planning to minimize radiation exposure to personal. For each exchange step the residual dose rate distribution is calculated and the peak values are identified. This paper gives some examples of calculated vs measured doses during beam-stop assembly exchange.

Popova, Irina I.↗

NASA NTRS2014

International Space Station End-of-Life Probabilistic Risk Assessment

The International Space Station (ISS) end‐of‐life (EOL) cycle is currently scheduled for 2020, although there are ongoing efforts to extend ISS life cycle through 2028. The EOL for the ISS will require deorbiting the ISS. This will be the largest manmade object ever to be de‐orbited therefore safely deorbiting the station will be a very complex problem. This process is being planned by NASA and its international partners. Numerous factors will need to be considered to accomplish this such as target corridors, orbits, altitude, drag, maneuvering capabilities etc. The ISS EOL Probabilistic Risk Assessment (PRA) will play a part in this process by estimating the reliability of the hardware supplying the maneuvering capabilities. The PRA will model the probability of failure of the systems supplying and controlling the thrust needed to aid in the de‐orbit maneuvering.

Duncan, Gary W.↗

DOE OSTI2026

Design and optimization of processes for recovering rare earth elements from end‐of‐life permanent magnets

Recovery of rare earth elements (REEs) from end-of-life (EOL) products represents a strategic opportunity to strengthen the domestic supply chain for rare earth elements. This work presents a superstructure-based optimization framework for finding the most economical processing pathway for different EOL rare earth permanent magnets (REPMs). The framework evaluates state-of-the-art technologies across four processing stages—disassembly, demagnetization, leaching and extraction, and precipitation and calcination—using net present value (NPV) maximization and cost of recovery (COR) minimization objectives. A novel bottom-up costing framework for hydrogen decrepitation is also introduced. Two feedstocks were considered: REPMs from EOL hard disk drives (HDDs), and electric and hybrid electric vehicles (EVs and HEVs). While HDD recycling proved unprofitable due to limited feedstock availability, EVs/HEVs were profitable across a range of parameters and cost estimates. Therefore, our findings suggest that the proposed EOL EV/HEV recycling process may be economical and is worthy of further investigation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2003

Mercury Conditions for the MESSENGER Mission Simulated in High- Solar-Radiation Vacuum Tests

The MESSENGER (Mercury Surface, Space Environment, Geochemistry, and Ranging) spacecraft, planned for launch in March 2004, will perform two flybys of Mercury before entering a year-long orbit of the planet in September 2009. The mission will provide opportunities for detailed characterization of the surface, interior, atmosphere, and magnetosphere of the closest planet to the Sun. The NASA Glenn Research Center and the MESSENGER spacecraft integrator, the Johns Hopkins University Applied Physics Laboratory, have partnered under a Space Act Agreement to characterize a variety of critical components and materials under simulated conditions expected near Mercury. Glenn's Vacuum Facility 6, which is equipped with a solar simulator, can simulate the vacuum and high solar radiation anticipated in Mercury orbit. The MESSENGER test hardware includes a variety of materials and components that are being characterized during the Tank 6 vacuum tests, where the hardware will be exposed to up to 11 suns insolation, simulating conditions expected in Mercury orbit. In 2002, ten solar vacuum tests were conducted, including beginning of life, end of life, backside exposure, and solar panel thermal shock cycling tests. Components tested include candidate solar array panels, sensors, thermal shielding materials, and communication devices. As an example, for the solar panel thermal shock cycling test, two candidate solar array panels were suspended on a lift mechanism that lowered the panels into a liquid-nitrogen-cooled box. After reaching -140 C, the panels were then lifted out of the box and exposed to the equivalent of 6 suns (8.1 kilowatts per square meters). After five cold soak/heating cycles were completed successfully, there was no apparent degradation in panel performance. An anticipated 100-hr thermal shield life test is planned for autumn, followed by solar panel flight qualification tests in winter. Glenn's ongoing support to the MESSENGER program has been instrumental in identifying design solutions and validating thermal performance models under a very aggressive development schedule. The test data have assisted Johns Hopkins engineers in selecting a flight solar array vendor and a thermal shield design. MESSENGER is one in a series of missions in NASA's Discovery Program. Infrared thermography provides data on the thermal gradients in the MESSENGER components during high solar insolation vacuum testing.

Wong, Wayne A.↗

NASA NTRS1992

Estimation of the end-of-life optical properties of Z-93 thermal control coating for the Space Station Freedom

This paper describes an approach to estimating the 30-year end-of-life optical properties of Z-93 white, thermal control coating on the Space Station Freedom. Estimations of the 30-year end-of-life properties of thermal control coatings are necessary for sizing the thermal radiators. The available flight and ground data and computer generated contamination models are used to predict the effects of ground handling, exposure to UV radiation, and on-orbit contamination on the optical properties of Z-93. The solar absorptance for portions of the thermal control system radiator surfaces is predicted to change from 0.15 to 0.36 after 30 years of low earth orbit environmental exposure. The infrared emittance is predicted to change from 0.92 to 0.90.

Hasegawa, Mark M.↗

DOE OSTI2025

Heterogeneity of the Dominant Causes of Performance Loss in End-of-Life Cathodes and Their Consequences for Direct Recycling

Recycling Li-ion batteries from electric vehicles is critical for reducing costs and supporting the development of a domestic battery supply chain. Direct recycling of cathodes, like LiNixMnyCozO2 (NMC), is attractive due to its low cost, energy use, and emissions compared to traditional recycling techniques. However, a comprehensive understanding of the active material properties at end-of-life is needed to guide direct recycling processes and the performance-dependent reuse applications. Here, NMC material from an end-of-life commercial pouch cell is characterized and bench-marked against pristine non-cycled counterparts with respect to capacity, impedance, crystallography, morphology, and microstructure to identify major degradation modes and understand variability in the end-of-life material. The spatial heterogeneity of each property throughout the cell is also quantified. While the degraded material demonstrated similar capacity as the pristine, its impedance and rate capability are severely diminished. Furthermore, samples from the periphery of the electrode layers showed more severe performance loss compared to samples extracted from central regions. The dominant culprit of performance loss is the material microstructure, where the magnitude of particle cracking showed the strongest correlation to the impedance components that are most unfavorably impacted. This work suggests severe cracks in cathode active materials are the primary challenge that direct recycling methods must overcome.

25 ENERGY STORAGE↗

DOE OSTI2026

Design and Optimization of Processing Pathways for Rare Earth Element Recovery from End-of-Life Products

In this presentation, we first discuss the benefits of targeting end-of-life (EOL) products as a feedstock. We then discuss the problem statement of designing a processing facility for recovering rare earth elements (REEs) from EOL HDDs and motors from EOL EVs/HEVs. We then discuss the most profitable pathway, and then discuss the environmental impacts associated with the processing pathway, comparing it to a processing facility in China, and find it to have lower impacts overall. We also investigate the trade-off solutions for other pathways that are not as profitable, but have lower impacts by generating Pareto Fronts. In the next portion of the presentation, Critical Materials Recycling, Inc. is discussed. We discuss how their process was found to be the optimal pathway after performing superstructure optimization, and how we are currently working with them to further optimize their process to increase profits. Finally, we wrap up with conclusions summarizing the main takeaways of the presentation.

36 MATERIALS SCIENCE↗

NASA NTRS2014

International Space Station End-of-Life Probabilistic Risk Assessment

Although there are ongoing efforts to extend the ISS life cycle through 2028, the International Space Station (ISS) end-of-life (EOL) cycle is currently scheduled for 2020. The EOL for the ISS will require de-orbiting the ISS. This will be the largest manmade object ever to be de-orbited, therefore safely de-orbiting the station will be a very complex problem. This process is being planned by NASA and its international partners. Numerous factors will need to be considered to accomplish this such as target corridors, orbits, altitude, drag, maneuvering capabilities, debris mapping etc. The ISS EOL Probabilistic Risk Assessment (PRA) will play a part in this process by estimating the reliability of the hardware supplying the maneuvering capabilities. The PRA will model the probability of failure of the systems supplying and controlling the thrust needed to aid in the de-orbit maneuvering.

Duncan, Gary↗

DOE OSTI2023

Mobile Hot Cell Digital Twin: End-of-life Management of Disused High Activity Radioactive Sources – 23598

Sealed radioactive sources are utilized for a wide range of applications across nuclear facilities, universities, hospitals, and industry. When these sources reach the end of serviceable life, they become waste. As waste, this radioactive material then goes through a process of recapture and then transfer to long term storage. With the advancement of technology in conjunction with better accessibility of technology, industries are exploring the use of digital automation to enhance productivity, efficiency, and safety while minimizing operation and maintenance costs, health and environmental risks, and uncertainty in the project life cycles. One area for exploration is the use of a digital twin to help design a robust, versatile, and safe solution for recapturing spent sources. We believe this avenue can also provide further advantages in the operations aspect of end-of-life management of spent radioactive sources by reducing the deployment time, increasing operator safety, and reducing operation & maintenance cost. We present a novel digital twin framework for end-of-life management of disused high activity radioactive sources. We have designed and developed a framework that houses a digital twin for visualizing and monitoring the recapture process to inform the engineering and design of a new Mobile Hot Cell. Furthermore, we demonstrate the feasibility of the proposed framework by providing a prototypical implementation, supporting the Mobile Hot Cell and human-machine interface's virtual replication.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2023

ECAR-6076 Rev 0 MARVEL Reactor End of Life Enveloping Radiological Source Term

As part of the Microreactor Applications Research Validation and Evaluation Project (MARVEL) design effort, an enveloping end of life radiological source term for the reactor fuel and sodiumpotassium (NaK) eutectic coolant is calculated in support of the MARVEL preliminary hazard evaluation. The source term calculation assumes slightly more than two-years of uninterrupted operations at a power of about 120 kW for a total energy of 7,600,000 MJ which exceeds the planned two-year operation at 100 kW. The Reactor modeling was performed with MCNP6 Version 1.0 and the depletion was performed using the COUPLE and ORIGEN modules from the SCALE Version 6.2 code package.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2023

Decision-making Framework to Support the End-of-Life Management of High-Activity Radioactive Sources

Sealed radioactive sources are used for an extremely wide range of purposes, including as radiation sources in various nuclear facilities, universities, hospitals, biomedical and industrial applications, as well as for geological prospecting and exploration. The proper management of these sealed radioactive sources once they have reached their end-of-life is still a global challenge. Very few field-tested Mobile Hot Cells (MHC) exist in the world to support the end-of-life management of disused high-activity radioactive sources. One of the critical challenges that a source recovery team encounters on each site is to find adequate space, and access to that space to complete the staging and recapture process with a MHC; this process is tedious, uncertain, and time-consuming. Therefore, it is essential to understand the planning and management of the MHC setup and takedown. Currently, there isn't an single capable planning tool that will provide an effective medium to plan, inform, educate, and communicate knowledge about the environment where the MHC will be deployed. We present a novel approach for the planning and management of the deployment of the MHC to several different sites that relies on technology. Furthermore, this planning tool will support collaboration, promote information sharing, and foster better decision making processes, resulting in a more efficient, and reliable setup and source recovery with the MHC.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2024

Feasibility of Recovering and Recycling Polymer Composites from End-of-Life Marine Renewable Energy Structures: A Review

Over the last few decades, several marine renewable energy (MRE) technologies, such as wave energy converters (WECs) and current energy converters (CECs), have been developed. As opposed to traditional materials such as metal alloys, the structure of these technologies is made up of polymer and polymer composite materials. Most structures have been made using thermoset polymer composites; however, since thermoset polymer composites are not recyclable and lack sustainability, and with recent innovations in recyclable resins, bio-based resins, and the development of additive manufacturing technologies, thermoplastic polymers are increasingly being used. Nevertheless, the methodologies for identifying end-of-life options and recovering these polymer composites, as well as the recycling and reuse processes for MRE structures, are not well-studied. Specifically, since these MRE structures are subjected to salinity, moisture, varying temperature, biofouling, and corrosion effects depending on their usage, the recyclability after seawater aging and degradation needs to be explored. Hence, this review provides an in-depth review of polymer composites used in marine applications, the hygrothermal aging studies conducted so far to understand the degradation of these materials, and the reuse and recycling methodologies for end-of-life MRE structures, with a particular emphasis on sustainability.

16 TIDAL AND WAVE POWER↗