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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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14 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Red Mud: From Industrial Waste to a Flux for Manufacturing Sustainable Iron/Steel

Here, this study highlights the potential of red mud/bauxite residue, an industrial waste product generated during alumina extraction as a flux for iron and steelmaking. The thermodynamic feasibility of using red mud as a flux in the presence of different reducing agents is evaluated. Potential approaches to decarbonize iron and steel production while utilizing red mud as a flux, as well as the benefits of red mud remnant after iron extraction, are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

In Situ Catalytic Fast Pyrolysis using Red Mud Catalyst: Impact of catalytic fast pyrolysis temperature and biomass feedstocks

Catalytic fast pyrolysis (CFP) has been considered as a very promising approach for converting lignocellulosic biomass into higher-quality bio-oils followed by hydrotreating to produce fuelrange products. A reactive, robust, and low-cost catalyst is required to drive the CFP process. Red mud, a side-product produced during the refining of bauxite to alumina, appears to be an effective catalyst for in situ CFP of biomass. In this paper, we report the impact of CFP reaction temperature on the conversion of a pinyon juniper feedstock to bio-oils using red mud as the catalyst and then to fuel-range hydrocarbons by hydrotreating of the produced bio-oil. The yield and quality of the CFP bio-oil produced and the yield and quality of hydrotreated final products were determined. When the CFP process temperature was lowered from 450 to 400ºC, the bio-oil yield increased with minimal differences in the oxygen content, hydrogen-to-carbon ratio, water content, etc. In addition, CFP bio-oils at both temperatures were processed in a single-stage continuous hydrotreater without reactor plugging during the testing period (i.e., ~100 hours on stream). The yield of CFP bio-oil produced at 400ºC was lower than the yield at 450ºC. However, the overall yield, from biomass to hydrocarbon fuel, was still higher for CFP processing at 400ºC than for processing at 450ºC. This indicates the potential for enhancing overall carbon efficiency, including CFP processing and hydrotreating, by employing red mud catalysts for biomass pyrolysis and tuning the CFP parameters. Detailed analysis of bio-oil and hydrotreated products showed a lower content of lignin-derived species in both samples. Furthermore, CFP processing of three different biomass feedstocks corroborated red mud catalyst development for producing improved quality bio-oil and, when combined with hydrotreating, for the production of fuel range hydrocarbons.

Santosa, Daniel M.↗
DOE OSTI2020

Reformulated Red mud: a robust catalyst for in situ catalytic pyrolysis of biomass

Biomass feedstocks contain inorganic compounds generally classified as ash. The ash consists of compounds of potassium, calcium, magnesium, silicon, phosphorous and other elements. These elements have been reported to influence both the pyrolysis reactions as well as destabilizing the pyrolysis oils during storage. The inorganic elements have also been reported to deposit on catalyst surfaces during in situ catalytic pyrolysis leading to the eventual deactivation of acidic catalysts such as zeolites. The deposition of inorganic elements and their effect on formulated red mud (FRM) catalyst during in situ catalytic pyrolysis of pinyon juniper wood was investigated. The inorganic elements were measured for the fresh, coked, and regenerated catalysts. The BET specific surface area of the FRM catalyst decreased from 76 m2/g for the fresh catalyst to 53 m2/g for the stable regenerated catalyst. After three regenerations, the BET specific surface area stabilized at 53 m2/g and remained constant after all other regenerations. Potassium, calcium, magnesium, and phosphorous were deposited on the catalyst. Potassium deposition was linear with the number of regenerations while magnesium and calcium depositions were initially rapid but leveled off after three regenerations of the catalyst. Phosphorous deposition was almost linear, but the data were more scattered compared to potassium. The potassium deposition was attributed to physical phenomenon whereas calcium and magnesium depositions were more akin to chemical reactions related to the loss of BET surface area of the catalyst. The deposition of these elements on the surface of the catalyst did not deactivate it. After each catalyst regeneration, the oil yield was not significantly affected and the oil oxygen content and viscosity decreased slightly. This clearly showed that formulated red mud is a robust catalyst suitable for in situ catalytic fast pyrolysis of biomass.

Agblevor, Foster↗
DOE OSTI2021

Boosting the use of bauxite residue (red mud) in cement - Production of an Fe-rich calciumsulfoaluminate-ferrite clinker and characterisation of the hydration

Highlights: • Incorporation of 35 wt% of bauxite residue for production of CSAF clinker • Thermochemical calculations as suitable tool for predicting phase assemblage • Hydration of the cement was found to be accelerated in contrast to other CSA cements. • High early compressive strengths of 40 MPa In the present work, calciumsulfoaluminate-ferrite clinker was produced using 35 wt% of bauxite residue in combination with alumina, clay, limestone and gypsum. At a temperature of 1300 °C, the hydraulic phases ye'elimite, ferrite and C{sub 2}S were formed. Computed thermochemical predictions were a significantly better match for the real mineralogy than modified Bogue equations. Hydration of the clinker led to the formation of ettringite and monosulfate, resulting in compressive strengths of 17 MPa after 28d. Compressive strengths of 40 MPa after 2d, and 28d-strengths exceeding 50 MPa, were reached in blends with 10 wt% of anhydrite. The strength development was due to the rapid formation of ettringite, mainly originating from ye'elimite, which did not convert to AFm phases and led to a compact microstructure. Only when the ye'elimite dissolution decreased, did the ferrite phase react. In pastes with additional sulfates, ferrite hydration led to the formation of ettringite and to hydrogarnet. Cement nomenclature is used in this work.{sup 1}.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Synergistic Effects of Inexpensive Mixed Metal Oxides for Catalytic Hydrothermal Liquefaction of Food Wastes

Industrial wastes and natural mixed oxide materials were evaluated as inexpensive heterogeneous catalysts for catalytic hydrothermal liquefaction (CHTL) of food wastes. Red mud and red clay achieved biocrude carbon yields of 47.0 and 39.5% with higher heating values (HHVs) of 40.2 and 37.7 MJ kg –1 , respectively, which were much greater than those without the catalyst (biocrude carbon yield of 19.7% and HHV of 36.1 MJ kg –1 ). Biocrude characterization revealed that similar families of molecules were formed in the presence and absence of catalysts, implying that the main role of the catalyst is to promote rates of thermal reactions, leading to biocrude production without opening new pathways. The crystalline structures of inexpensive mixed oxides were stable under hydrothermal conditions, with modest calcium leaching (7.5%) and trace leaching of other metals. Using red clay or red mud resulted in >40% recovery of the energy in food waste as biocrude, greater than that obtained under noncatalytic conditions (18%) or from any individual constituent oxide (19–27%). The improved CHTL performance of the mixed metal oxides compared with single-metal oxides was attributed to the synergistic effects of base and acid sites present on catalyst surfaces; mixed oxides presented balanced densities of acids and bases, whereas the constituent oxides were either primarily acidic or primarily basic. Lastly, the percent of energy recovered as biocrude oil was strongly correlated with the base-to-acid site density ratio, providing an important performance predictor for CHTL conversion of food waste to bioenergy.

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

Recovery of Scandium from Bauxite Residue Using Sulfation Roasting-Assisted Water Leaching Process

Here, this study presents a method for recovering scandium from Indonesian bauxite residue (red mud) through a sulfation roasting-assisted water leaching process. Ammonium sulfate, (NH 4 ) 2 SO 4 , was chosen as the sulfate source for its lower melting point, less corrosivity, decreased toxicity, and the potential for ammonia recovery. A modified mixing system was introduced to improve the distribution of (NH 4 ) 2 SO 4 on red mud particles by combining them in water. A series of experiments were conducted to optimize the sulfation roasting process by examining the effects of the (NH 4 ) 2 SO 4 /red mud ratio, temperature, and roasting time. Subsequently, water leaching was optimized while considering the effect of leaching time and liquid-to-solid (L/S) ratio. The leaching of scandium from the roasted red mud showed rapid kinetics, even when using only water. Under the roasting conditions of 1/1 (g/g) (NH 4 ) 2 SO 4 /red mud ratio, 700°C, 60 min roasting time, and the leaching conditions of 65°C, 60 min, and 10 mL/g (L/S), over 90% of scandium was recovered, along with 64.4% Al leaching and below 8% Fe leaching. These results were further corroborated through comprehensive analyses such as x-ray diffraction (XRD) and scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDS). This study offers insights into an alternative, more environmentally friendly method for Sc recovery from red mud, promoting the sustainable use of hazardous waste like red mud.

ammonium sulfate↗
DOE OSTI2026

Extracting Critical Metals from Authentic Bauxite Residue

Securing domestic sources of critical minerals (CM) is paramount to ensuring a robust and self-sustaining technology infrastructure. Utilizing untapped non-conventional sources, like acid mine drainage, coal ash, bauxite residue/red mud, and more is an emerging approach that addresses this national concern while identifying new value-added pathways originating from waste streams. Red mud is a byproduct of the Bayer process that produces alumina and contains a wealth of CM – 50 µg/g Ga, 2.9 mg/g total rare earth elements plus yttrium, 12 mg/g Mn, 58 mg/g Al, and others. About 170 MM tonnes of red mud are co-produced annually alongside the 142 MM tonnes of alumina generated, highlighting the abundancy of this feedstock. In this work, different strategies were explored for extracting CM from authentic bauxite residue that involve thermal heating, microwave heating, and sonication all with different acids and buffers. CM recovery was then explored one step further by testing the adsorption of the extracted metals onto NETL’s Multi-functional Sorbent Technology (MUST). Microwave treatment of red mud proved the most effective CM extraction, whereas sonication was less desirable due to scale-up concerns. Successful recovery of CM from this leachate with MUST supports further studies toward optimizing the overall process.

bauxite residue↗
DOE OSTI2020

Rare earth metals from secondary sources: Review of potential supply from waste and byproducts

Current concerns about lack of diversity in supply of critical metals have spurred research into utilizing domestic sources, particularly from waste streams. Sustainability strategies like urban mining, industrial symbiosis, and the circular economy suggest avenues to realize new supplies of critical metals. In this work we explore the resource and economic potential for extracting rare earth elements (REEs) from industry byproducts (e.g. coal combustion products, red mud) and secondary sources (e.g. waste electronics and light bulbs). Combining materials flow analysis and characterization data, we find that while REE concentrations in waste and byproduct streams are mostly much lower than current REE ores, some secondary sources are richer than ores in high value REEs such as scandium. The quantities of REEs contained in secondary sources could meet current global demand even with low extraction yield rates. Phosphogypsum, coal ash and red mud from aluminum production stand out as promising candidates for recovery due to high concentrations of valuable REEs and sufficient quantities to potentially meet demand. Processes to extract REEs from secondary sources are under development, it is not clear yet which will be profitable at scale and which can be achieved at least environmental impact. This work provides high level guidance on the potential of secondary sources by characterizing quality (concentrations of different rare earths) and quantity (mass of rare earths in global scale wastes and byproducts). This significant first step helps clarify directions for policy and research and development investments.

42 ENGINEERING↗
DOE OSTI2021

Hydrothermal liquefaction of sewage sludge – effect of four reagents on relevant parameters related to biocrude and $\mathrm{PFAS}$

Catalytic hydrothermal liquefaction (HTL) can convert wet biomass into crude-like oil and has potential to degrade pollutants during the thermal depolymerization process. To avoid negative environmental impacts from per- and polyfluoroalkyl substances (PFAS) in sewage sludge after its final disposal, we comprehensively evaluated catalytic destruction of PFAS in sludge through HTL. Here the results showed that adding red mud to HTL was beneficial for the biocrude yield and significantly increased the carbon conversion efficiency and energy recovery of the hydrothermal process. HTL at 300 °C for 2 h degraded > 96% of spiked perfluorooctanoic acid (PFOA). The mass of spiked perfluorobutanesulfonic acid (PFBS) and perfluorooctanesulfonic acid (PFOS) and pre-existing perfluorohexanoic acid (PFHxA) and perfluoroheptanoic acid (PFHpA), however, increased in the HTL product streams. The remaining PFAS after HTL mainly stayed in the biocrude phase. Our findings indicated that HTL under the studied condition was not able to degrade all PFAS existed in sewage sludge. Although adding red mud could improve the HTL performance with respect to biocrude, this reagent did not improve the removal of perfluoroalkyl acids (PFAAs). As a matter of fact, the hydrothermal process amended with the selected reagents resulted in increased mass of PFBS, PFHxA, and PFHpA in the HTL products due to degradation of PFAA precursors. Thus, other treatment approaches for PFAS removal from sewage sludge need to be identified to prevent possible contamination of environments receiving PFAS-containing sludge.

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

Gulf Coast Basin CORE-CM Initiative (Final Report)

This report describes critical mineral/rare earth element resources, including Gulf Coast coal resources, and waste streams including coal ash from power plants, red mud from alumina processing, heavy mineral concentrates from sand mining industry, zeolite, graphite, and produced water with oil and gas.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Developing a one-step, acid-free microbial process to recover and separate REE (CRADA Final Report)

The project aimed to develop and test microbial strains for increased bioleaching, bioconcentration, and/or bioaccumulation of REEs, and for enhanced separation of REEs from other metals and of individual REEs from one another. The team secured and tested unconventional REE feedstocks to evaluate strains/processes for bioleaching, bioconcentration, and bioaccumulation, including but not limited to wastewater, geothermal brines, red mud, and electronic waste. purified and chemically analyzed REE granules from the microbial platform; determined metabolite and biosynthetic impacts of growth with REEs and the composition of extracellular material(s) produced by platform strains; optimized the growth process with alternative carbon feedstocks to reduce the cost of the fermentation process; and scaled the process from 1 mL to 10 L.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Geophysical Characterization and Monitoring of the 200 Area Treated Effluent Disposal Facility to Support Permit Renewal; TEDF Geophysical Monitoring

The Treated Effluent Disposal Facility (TEDF), located in the 200 East Area of the Hanford Site, is a site where non-hazardous and non-radioactive liquid wastes are disposed into two state-permitted infiltration basins. In 2016, the Washington State Department of Ecology denied a permit renewal request for TEDF due to the inability to adequately assess the impact of TEDF discharge water on the underlying groundwater quality. TEDF overlies the relatively impermeable Ringold Lower Mud (RLM) unit, whose upper contact lies in the vadose zone approximately 30 m below ground surface and approximately 10 m above the water table boundary. The RLM is assumed to isolate TEDF discharge water from the natural groundwater aquifer, which is monitored using wellbores screened below the RLM. Therefore, samples collected from monitoring wells near TEDF are not considered representative of TEDF discharge water. Rather, TEDF discharge water is assumed to mound on top of the RLM to form a perched aquifer. To support permitting of the TEDF, a new monitoring well is required that can be used to sample water from the presumed perched water aquifer above the RLM. Ideally, the screened section of the well would be located at the peak of the perched water mound(s), which presumably occurs at the point of maximum vertical flux from TEDF to the RLM, or equivalently where the dominant infiltration flow paths reach the RLM. This report describes how time-lapse 3D electrical resistivity tomography (ERT) was used in conjunction with nominal TEDF discharge operations to image the dominant flow paths from each pond to the RLM. Results are summarized in Figure ES.1. Figure ES.1A shows a satellite image of the TEDF overlain by an array of surface ERT electrodes. The solid and dashed black circles denote the zones of maximum vertical flux at the RLM within the south and north ponds, respectively, and presumably the regions where perched water peaks during discharge. Figure ES.1B shows time-lapse difference imaging results approximately 15 days after switching discharge from the south pond to the north pond. Blue iso-surfaces beneath the north pond denote regions of increasing bulk electrical conductivity caused by increasing saturation due to infiltrating water. Red iso-surfaces beneath the south pond denote regions that were previously saturated during the south pond discharge and are now de-saturating, causing a decrease in bulk electrical conductivity. In both cases, the zones of maximum change mark the dominant flow paths to the RLM. Figure ES.1C shows time-lapse imaging results approximately 15 days after switching discharge from the north pond to the south pond. In this case, blue iso-surfaces mark the dominant flow paths to the RLM from the south pond. The red iso-surfaces mark the dominant flow paths that existed during discharge to the north pond. The regions of maximum change in bulk conductivity (due to saturation or desaturation) that mark the primary flow paths are equivalent in both cases and denoted by the dashed solid and black circles. If a perched water zone forms on the RLM, it is likely to mound within or near the dashed circle during discharge to the north pond, and in the solid circle during discharge to the south pond. In other words, if perched water mounding occurs, the circles mark the optimum locations suggested by the ERT imaging for monitoring boreholes to be placed, enabling samples to be collected that are representative of TEDF discharge impacts on groundwater quality.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗