Manufacturing Efficiency

Designs by Natural Processes, Inc., aims to make novel cement at ambient temperature using 55% municipal solid waste (MSW) incinerator ash. The team will add low-cost chemicals to better sequester environmentally problematic combustion gases, chemicals, and heavy metals during incineration, eliminating undesired chemicals in the ash-rich cement leachate. The team's objective is to develop an alternative to traditional ordinary Portland cement (OPC), which cannot sequester nearly as much ash (16%).

Lack of diverse supplies for critical materials, such as rare earth elements (REEs), have prompted researchers to explore new sources and develop environmentally friendly technologies for critical metal extraction, processing, and manufacturing. Municipal solid waste (MSW), a large solid waste stream that may constitute the largest resource for REEs and other critical materials, offers an alternative. MSW incineration ashes, however, pose operational and financial challenges.

Glass WRX SC’s technology transforms post-consumer waste glass stored in landfills into porous ceramics called engineered cellular magmatics used in a wide variety of applications. By incorporating municipal solid waste incinerator (MSWI) ash into their existing and new processes, they will introduce industrial-scale upcycling into MSWI operations. MSWI will become “beyond zero waste,” eliminating landfilling ash byproducts of the incineration process and landfill space currently taken up by unrecycled glass at the same time.

Direct contact ultrasonic drying is a novel, non-evaporative dewatering process that uses no heat to significantly lower the energy required for industrial drying. The technology mechanically removes water by shaking the object rapidly, on the micron scale, using piezoelectric transducers. The technology can achieve 5X higher efficiency and 2-3X faster drying rates than traditional dryers on typical textiles.

Pacific Northwest National Laboratory will use advanced climate-simulation photobioreactors with access to natural seawater to determine optimized cultivation and rare earth elements (REE) uptake conditions of seaweeds. The team will treat the seaweed biomass with heat and pressure in a process called hydrothermal liquefaction to concentrate its critical mineral portion, while concurrently generating a feedstock for biofuels, bioplastics, and biomedical compounds.

Virginia Tech will perform systematic physical, chemical, and mineralogical characterizations on natural and synthetic municipal solid waste incineration (MSWI) ash materials to obtain sufficient characterization results and propose potential downstream processing flowsheets. The team will focus on revealing the conversion mechanisms of valuable metals in MSW during incineration, as well as the occurrence modes, partitioning behavior, and recoverability of critical metals in MSWI ash.

Critical minerals—used in important defense and energy applications–are scarce. Municipal wastes are excellent candidates for domestic sources of high-grade ores due to their high metal concentration. Because the metals in wastes and waste ashes contain a wide range of impurities, however, conventional extraction processes are not effective. Columbia University will develop an innovative MIDAS process based on the integrated CO2-facilitated hydrometallurgical and electrochemical technology.

Current environmental, capital equipment, and reagent unit costs of metal extraction and refinement, including from waste minerals, are high. A technical solution will increase the domestic supply of metals as well as reduce consumer cost of downstream power and new technology devices. Lixivia Inc. proposes to use bio-inspired molecules, complemented by conventional chemical reagents to reduce reagent costs, the environmental burden of using such reagents, and the capital equipment needed to produce metals from MSWI ash.

Increasing the efficiency of power generation and air transportation can only be achieved by increasing the temperature at which generation/propulsion turbines operate. The emerging Refractory High Entropy Alloys (RHEAs) can enable much higher operating temperatures than the state-of-the-art. Identifying the alloys' chemistry is difficult due to the vastness of the RHEA chemical space.

The University of Maryland will leverage a newly invented, ultrafast high-temperature sintering (UHS) method to perform fast exploration of new environmental-thermal barrier coatings (ETBCs) for 1300°C-capable refractory alloys for harsh turbine environments. UHS enables ultrafast synthesis of high-melting oxide coatings, including multilayers, in less than a minute, enabling rapid evaluation of novel coating compositions.