Callie W. Babbitt

Material and energy intensity of fullerene production.

Fullerenes are increasingly being used in medical, environmental, and electronic applications due to their unique structural and electronic properties. However, the energy and environmental impacts associated with their commercial-scale production have not yet been fully investigated. In this work, the life cycle embodied energy of C(60) and C(70) fullerenes has been quantified from cradle-to-gate, including the relative contributions from synthesis, separation, purification, and functionalization processes, representing a more comprehensive scope than used in previous fullerene life cycle studies. Comparison of two prevalent production methods (plasma and pyrolysis) has shown that pyrolysis of 1,4-tetrahydronaphthalene emerges as the method with the lowest embodied energy (12.7 GJ/kg of C(60)). In comparison, plasma methods require a large amount of electricity, resulting in a factor of 7-10× higher embodied energy in the fullerene product. In many practical applications, fullerenes are required at a purity >98% by weight, which necessitates multiple purification steps and increases embodied energy by at least a factor of 5, depending on the desired purity. For applications such as organic solar cells, the purified fullerenes need to be chemically modified to [6,6]-phenyl-C(61)-butyric acid methyl ester (PCBM), thus increasing the embodied energy to 64.7 GJ/kg C(60)-PCBM for the specified pyrolysis, purification, and functionalization conditions. Such synthesis and processing effects are even more significant for the embodied energy of larger fullerenes, such as C(70), which are produced in smaller quantities and are more difficult to purify. Overall, the inventory analysis shows that the embodied energy of all fullerenes are an order of magnitude higher than most bulk chemicals, and, therefore, traditional cutoff rules by weight during life cycle assessment of fullerene-based products should be avoided.

Economic and environmental characterization of an evolving Li-ion battery waste stream.

While disposal bans of lithium-ion batteries are gaining in popularity, the infrastructure required to recycle these batteries has not yet fully emerged and the economic motivation for this type of recycling system has not yet been quantified comprehensively. This study combines economic modeling and fundamental material characterization methods to quantify economic trade-offs for lithium ion batteries at their end-of-life. Results show that as chemistries transition from lithium-cobalt based cathodes to less costly chemistries, battery recovery value decreases along with the initial value of the raw materials used. For example, manganese-spinel and iron phosphate cathode batteries have potential material values 73% and 79% less than cobalt cathode batteries, respectively. A majority of the potentially recoverable value resides in the base metals contained in the cathode; this increases disassembly cost and time as this is the last portion of the battery taken apart. A great deal of compositional variability exists, even within the same cathode chemistry, due to differences between manufacturers with coefficient of variation up to 37% for some base metals. Cathode changes over time will result in a heavily co-mingled waste stream, further complicating waste management and recycling processes. These results aim to inform disposal, collection, and take-back policies being proposed currently that affect waste management infrastructure as well as guide future deployment of novel recycling techniques.

Methanol removal efficiency and bacterial diversity of an activated carbon biofilter.

Motivated by the need to establish an economical and environmentally friendly methanol control technology for the pulp and paper industry, a bench-scale activated carbon biofiltration system was developed. This system was evaluated for its performance in removing methanol from an artificially contaminated air stream and characterized for its bacterial diversity over time, under varied methanol loading rates, and in different spatial regions of the filter. The biofilter system, composed of a novel packing mixture, provided an excellent support for growth and activity of methanol-degrading bacteria, resulting in approximately 100% methanol removal efficiency for loading rates of 1-17 g/m(3) packing/h, when operated both with and without inoculum containing enriched methanol-degrading bacteria. Although bacterial diversity and abundance varied over the length of the biofilter, the populations present rapidly formed a stable community that was maintained over the entire 138-day operation of the system and through variable operating conditions, as observed by PCR-DGGE methods that targeted all bacteria as well as specific methanol-oxidizing microorganisms. Phylogenetic analysis of bands excised and sequenced from DGGE gels indicated that the biofilter system supported a diverse community of methanol-degrading bacteria, with high similarity to species in the genera Methylophilus (beta-proteobacteria), Hyphomicrobium and Methylocella (both alpha-proteobacteria).

Recycling single-wall carbon nanotube anodes from lithium ion batteries

Large scale incorporation of nanomaterials into industrial systems and commercial products is relatively new, and therefore little attention has been given for options when these products reach their end-of-life. During the course of this study, the ability to recycle end-of-life (EOL) single-wall carbon nanotubes (SWCNTs), recovered from lithium ion battery electrodes, was investigated. Specifically, SWCNT–Li+ coin cells were forced to their EOL though extended cycling at high charge rates and recycled using a series of acid and thermal treatments originally developed for the purification of as-produced SWCNT material. The recycling treatments were successful in removing the EOL byproducts (e.g. solid electrolyte interphase, lithium) and upgrading the SWCNT material to its pre-cycling functionality. The material was characterized at each step in the recycling process through a combination of scanning electron microscopy, thermogravimetric analysis, Raman spectroscopy, and optical absorption spectroscopy. The energy required for each of the recycling procedures was measured and compared to the energy of SWCNT synthesis. The recycled-SWCNT material was successfully incorporated into Li+ battery coin cells with insertion and extraction capacities of 650 mA h g−1, comparable to the virgin pure-SWCNT electrodes. Therefore, the ability to refunctionalize “used” SWCNTs from a device, through chemical processing, to their initial purity and functionality has been demonstrated. The direct energy required to refunctionalize the SWCNTs was measured and is less than half of the direct energy required to synthesize new material. Thus, the ability to preserve the nanoscale properties of SWCNTs with reduced impact offers new opportunities for end-of-life management.

Institutional Disposition and Management of End-of-Life Electronics

Institutions both public and private face a challenge to develop policies to manage purchase, use, and disposal of electronics. Environmental considerations play an increasing role in addition to traditional factors of cost, performance and security. Characterizing current disposition practices for end-of-life electronics is a key step in developing policies that prevent negative environmental and health impacts while maximizing potential for positive social and economic benefits though reuse. To provide a baseline, we develop the first characterization of quantity, value, disposition, and flows of end-of-life electronics at a major U.S. educational institution. Results of the empirical study indicate that most end-of-first-life electronics were resold through public auction to individuals and small companies who refurbish working equipment for resale or sell unusable products for reclamation of scrap metal. Desktop and laptop computers sold for refurbishing and resale averaged U.S.

Targeting high value metals in lithium-ion battery recycling via shredding and size-based separation.

20-100 per unit, with computers sold directly to individuals for reuse reaching

Life cycle assessment integrated with thermodynamic analysis of bio-fuel options for solid oxide fuel cells

250-350 per unit. This detailed assessment was coupled with a benchmarking survey of end-of-life electronics management practices at other U.S. universities. Survey results indicate that while auctions are still commonplace, an increasing number of institutions are responding to environmental concerns by creating partnerships with local recycling and resale entities and mandating domestic recycling. We use the analyses of current disposition practices as input to discuss institutional strategies for managing electronics. One key issue is the tension between benefits of used equipment sales, in terms of income for the institution and increased reuse for society, and the environmental risks because of unknown downstream practices.

Life-cycle assessment of organic solar cell technologies

Development of lithium-ion battery recycling systems is a current focus of much research; however, significant research remains to optimize the process. One key area not studied is the utilization of mechanical pre-recycling steps to improve overall yield. This work proposes a pre-recycling process, including mechanical shredding and size-based sorting steps, with the goal of potential future scale-up to the industrial level. This pre-recycling process aims to achieve material segregation with a focus on the metallic portion and provide clear targets for subsequent recycling processes. The results show that contained metallic materials can be segregated into different size fractions at different levels. For example, for lithium cobalt oxide batteries, cobalt content has been improved from 35% by weight in the metallic portion before this pre-recycling process to 82% in the ultrafine (<0.5mm) fraction and to 68% in the fine (0.5-1mm) fraction, and been excluded in the larger pieces (>6mm). However, size fractions across multiple battery chemistries showed significant variability in material concentration. This finding indicates that sorting by cathode before pre-treatment could reduce the uncertainty of input materials and therefore improve the purity of output streams. Thus, battery labeling systems may be an important step towards implementation of any pre-recycling process.

Assessment of bio-fuel options for solid oxide fuel cell-based auxiliary power units

A methodology that integrates life cycle assessment (LCA) with thermodynamic analysis is developed and applied to evaluate the environmental impacts of producing biofuels from waste biomass, including biodiesel from waste cooking oil, ethanol from corn stover, and compressed natural gas from municipal solid wastes. Solid oxide fuel cell-based auxiliary power units using bio-fuel as the hydrogen precursor enable generation of auxiliary electricity for idling heavy-duty trucks. Thermodynamic analysis is applied to evaluate the fuel conversion efficiency and determine the amount of fuel feedstock needed to generate a unit of electrical power. These inputs feed into an LCA that compares energy consumption and greenhouse gas emissions of different fuel pathways. Results show that compressed natural gas from municipal solid wastes is an optimal bio-fuel option for SOFC-APU applications in New York State. However, this methodology can be regionalized within the U.S. or internationally to account for different fuel feedstock options.

Hybrid life cycle assessment of energy use in laptop computer manufacturing

Organic photovoltaics are often proposed as a solution to achieve low cost and low environmental impact in a solar cell. In this work, life cycle assessment (LCA) was conducted for various donor and acceptor materials, taking into account required purity of reactants and solvents, low yields for reactions, repeated purification steps, and toxic chemicals and solvents used for production of electronic grade semi-conductor materials. The full life cycle of complete single junction organic solar cells was done, based on current state-of-the art efficiencies reported for various donor/acceptor combinations. At this point, it is shown that the increase in device efficiency results in an increase in energy payback, mainly because higher concentrations of [C70]PCBM are being used which have a higher embodied energy compared to lower efficiency [C60]PCBM - based solar cells.