Production of composite polymers and methods derived from processed bauxite and other cavitation methods and systems

Abstract

A method to produce a novel composite polymer. RMCP offers a solution to environmental challenges posed by red mud disposal while delivering superior performance compared to traditional polymers. According to one embodiment, a composite powder material for use in Direct Drill 3D, SLS, and MJF additive manufacturing systems has 20-30% by weight alumina (AI2O3); 10-20% silica (SiO2); 5-10% iron oxides (Fe2O3 or Fe3O4); 5-15% calcium carbonate (CaCO3); and 2-5% nanoclay (Montmorillonite). A method for producing a composite RMCP material may have the steps of extracting alumina, silica, iron oxides, and calcium carbonate from red mud, synthesizing a polymer matrix, and blending the inorganic fillers with the polymer matrix using high-energy blending and cavitation.

Description

Attorney Docket No. 21681-163057-WOCustomer No. 42798PRODUCTION OF COMPOSITE POLYMERS AND METHODS DERIVED FROM PROCESSED BAUXITE AND OTHER CAVITATION METHODS AND SYSTEMSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a USPTO PCT Application and claims priority from US provisional application 63 / 697,078 filed September 20, 2024; US provisional application 63 / 767,671 filed March 6, 2025; US provisional application 63 / 871 ,744 filed August 28, 2025; US provisional application 63 / 877,697 filed September s, 2025; and US provisional application 63 / 883,073 filed September 17, 2025, which are all hereby incorporated herein by reference in their entirety for all purposes.FIELD

[0002] The disclosure relates generally to methods and systems to produce composite materials, and specifically to methods and systems to produce polymer matrix composite materials derived from processed bauxite reinforced with organic and / or inorganic fillers, the resultant composite suitable for use in additive manufacturing using direct drill 3D printers, SLS and MJF technologies. Other cavitation methods and systems are provided.BACKGROUND

[0003] Processed bauxite (also known as bauxite reside, bauxite tailings, red sludge, red mud, or alumina refinery residues) (“red mud”) is a by-product of refining bauxite en route to alumina production. This process is known in the art as the Bayer process. Red mud is typically composed of various oxide compounds, including the iron oxides which give its red color. Red mud can present significant environmental challenges due to its high alkalinity andAttorney Docket No. 21681-163057-WOCustomer No. 42798 toxic elements. Thus, red mud disposal can be difficult and pose risks of leaching and contamination of soil and water. Attempts are known in the art to repurpose red mud, but these attempts are limited to cement and concrete production. These methods known in the art often fail to fully utilize and leverage red mud’s chemical composition.

[0004] Accordingly, a need exists for a predictable, efficient, and cost-effective systems and methods repurpose processed bauxite into useful compositions and materials

[0005] As another technical problem: Increasing global demand for lithium driven by electric vehicles and energy-storage applications has led to a search for cost-effective methods to extract lithium from various sources. Oil-and-gas “produced water,” though widely available, poses significant treatment challenges due to the high total dissolved solids (TDS), hydrocarbons, suspended solids, and metals. Existing strategies often rely on extensive evaporation or chemical flocculation (a process by which, for example, colloidal particles come out of suspension to sediment in the form of floc or flake), which risk precipitating lithium, causing fouling, and leading to suboptimal lithium yields.

[0006] Limitations of Existing Technology: Traditional dissolved air flotation (DAF) processes in the oil field sector are typically designed for removing hydrocarbons and solids. They are not optimized to preserve lithium ions in solution, especially under the high TDS, organic content, and variable pH conditions of shale-produced water. Aggressive chemical pretreatment, such as high lime or ferric dosing, can inadvertently co-precipitate lithium or cause scale formation, complicating downstream lithium extraction. Furthermore, energy requirements can be substantial when conventional DAF setups are pushed to handle these complex waters.

[0007] Accordingly, there is a desire and a need in the art for a specialized DAF-based approach to: remove floating contaminants (e.g., oils, suspended solids, select heavy metals) while retaining lithium in soluble form; allow for efficient downstream lithium concentration and extraction (e.g., via ion exchange, selective adsorption, nanofiltration, and the like); andAttorney Docket No. 21681-163057-WOCustomer No. 42798 maintain manageable chemical and energy usage suitable for on-site or modular field deployment in oil-and-gas operations.

[0008] The present disclosure also relates to the field of modern data centers for artificial intelligence (Al) and high-performance computing (HPC) that can routinely exceed 100 kW of heat dissipation per rack, creating substantial heat-rejection challenges. Traditional cooling approaches in this setting have significant drawbacks. For example, when evaporative cooling towers are used, they consume millions of gallons of freshwater annually and require continuous biocide dosing to control, for example, Legionella bacteria growth. Closed-loop dielectric or glycol coolant systems reduce consumptive water use but incur high fluid costs and still rely on separate heat-rejection stages that vent water vapor to the atmosphere. Known aquifer storage cooling systems (open-loop geothermal systems) can partially offset chiller loads by storing heat in groundwater, yet they risk subsurface biofouling and aquifer contamination when warm water with nutrients and microbes is reinjected untreated into the ground.

[0009] None of the foregoing architectures combine all the desired features in one solution. In particular, no existing system achieves: (i) essentially zero net water consumption; (ii) online microbiological control without chemical additives; and (iii) simultaneous fouling and scale suppression in a single integrated process.

[0010] Applicant’s earlier cavitation technology, for example, the cavitation manifold described in U.S. Pat. No. 11 ,686,167 B2, was originally developed to collapse emulsions in drilling fluids. Its principles have not heretofore been applied to thermally-loaded, closed-loop groundwater cooling for data centers or similar high-density heat sources.

[0011] Accordingly, there is a need for an improved cooling system that can handle large heat loads with minimal water consumption and without chemical treatment, while avoiding biofouling or scaling in reinjected groundwater. The present disclosure addresses this need byAttorney Docket No. 21681-163057-WOCustomer No. 42798 providing cavitation-enhanced cooling systems and methods that overcome the limitations of the prior art.

[0012] The present disclosure also relates to the thermal management of high-density electronic equipment (for example, in artificial intelligence or high-performance computing clusters). More particularly, it concerns warm-water direct-to-chip (DLC) liquid cooling systems coupled to air-side dry coolers, with a sidestream cavitation-based coolant conditioning system that sterilizes, degasses, and conditions the coolant while protecting microchannel cold plates. Portions of this disclosure build on the Applicant’s prior cavitation work described in a draft specification titled “Cavitation-Enhanced Closed-Loop Cooling Systems and Methods,” which included descriptions of shock-hydrodynamic cavitation manifolds, opposed nozzles, control logic, and microbial reduction via cavitation. The present application expands upon and refines those concepts in the context of a new cooling architecture.

[0013] In current data center cooling approaches, evaporative cooling towers consume large quantities of water and require chemical water treatment. Fully closed-loop cooling systems can avoid water consumption, but direct-to-chip microchannel cold plates (with channel dimensions on the order of ~10-200 pm) demand exceptionally clean, bubble-free coolant to prevent fouling, corrosion, and flow instabilities. Known degassing solutions (such as membrane degassers or vacuum deaerators) can remove dissolved gases but add hardware complexity and do not actively sterilize the fluid or agglomerate fine particulate matter. Applicant’s prior SHURE® hydrodynamic cavitation technology has been shown to generate strong localized shock events that sterilize microbes, strip dissolved gases, and agglomerate sub-micron particulates — however, previous implementations placed the cavitation apparatus in a separate groundwater loop (with production and injection wells) rather than in the main cooling loop.

[0014] Accordingly, there is a need for a non-evaporative, DLC-compatible cooling architecture that provides near-zero water usage, continuous in-line coolant conditioningAttorney Docket No. 21681-163057-WOCustomer No. 42798(sterilization and degassing) without chemical biocides, and protection of microchannel cold plates from fouling or two-phase flow, all while maintaining reliability and efficiency.

[0015] Sediment accumulation in reservoirs and ponds reduces capacity, degrades water quality, increases flood risk, and elevates operations and maintenance costs. Conventional dredging removes bulk solids but often generates turbidity plumes, disrupts ecosystems, and discards recoverable fractions as waste. Subsurface drainage wells alone provide slow fines capture and incur clogging risk. Surface cavitation and DAF systems can achieve high-clarity effluent but lack under-bed counter-flow to strip fines continuously and prevent plume formation.

[0016] Accordingly, there also remains a need for co-optimized systems that coordinate subsurface extraction with surface cavitation / DAF under closed-loop turbidity control, while selectively recovering monetizable fractions.SUMMARY

[0017] Accordingly, the present embodiment methods and compositions generally relate to the field of useful compositions derived from repurposed processed bauxite (red mud). The present embodiments provide novel red mud derived composite polymers (RMCPs), which utilize valuable components extracted from red mud combined with bio-based or synthetic polyamides to create the composite. The resultant RMCP exhibits superior mechanical strength, thermal stability, wear resistance, and environmental sustainability. RMPC provides uses for in various industrial applications, including advanced additive manufacturing techniques such as HP Multi Jet Fusion (MJF), Formlabs Selective Laser Sintering (SLS), Direct Drill 3D printers, Bambu Lab Carbon X1 printers, injection molding, and the like as well as useful in the production of custom products.

[0018] A composite material comprising a polymer matrix, selected from a bio-based polyamide or synthetic polyamide, and fillers derived from red mud, including alumina (AI2O3),Attorney Docket No. 21681-163057-WOCustomer No. 42798 silica (SiO2), iron oxides (Fe2O3or Fe3O4), calcium carbonate (CaCO3), and nanoclay (Montmorillonite).

[0019] The composite material polymer matrix is derived from 11-aminoundecanoic acid or other polyamides such as PA12 or PA6. The inorganic fillers are extracted from red mud using cavitation-assisted leaching, magnetic separation, or supercritical fluid extraction.

[0020] According to one approach, a method for producing a composite material may have the steps of extracting alumina, silica, iron oxides, and calcium carbonate from red mud, synthesizing a polymer matrix, and blending the inorganic fillers with the polymer matrix using high-energy blending and cavitation.

[0021] Optionally the method may also have the step of surface functionalizing the inorganic fillers with a silane coupling agent to enhance bonding with the polymer matrix.

[0022] The composite material may be processed using injection molding, extrusion, or additive manufacturing techniques such as Selective Laser Sintering (SLS) or Multi Jet Fusion (MJF).

[0023] The composite material may further include graphene or carbon nanotubes to enhance tensile strength, thermal conductivity, or electrical conductivity.

[0024] The composite material may be processed into spherical powder particles using spray drying for additive manufacturing applications.

[0025] A method of recycling RMCP powder, according to one approach may include the steps of the steps of collecting unused powder from an additive manufacturing process, reprocessing it into the required particle size, and reusing it for further manufacturing cycles.

[0026] A specific composite powder material for use in Direct Drill 3D, SLS, and MJF additive manufacturing systems may have 20-30% by weight alumina (AI2O3); 10-20% silica (SiO2);

[0027] 5-10% iron oxides (Fe2O3or Fe3O4); 5-15% calcium carbonate (CaCO3); and 2-5% nanoclay (Montmorillonite).Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0028] The present invention also relates generally to systems and methods for treating industrial or oil field wastewater. More particularly, it concerns a process for selective lithium recovery from oil-and-gas produced water using an enhanced dissolved air flotation (DAF) technology, wherein lithium is maintained in aqueous solution while contaminants — such as emulsified oils, suspended solids, and certain heavy metals — are removed.

[0029] The present disclosure provides methods and systems for an Enhanced DAF Lithium Recovery System using manifold cavitation technology such as one sold under the name SHURE. The present embodiments may sometimes be referred to as the “SHURE DAF for Lithium.”

[0030] A system and method for selectively recovering lithium from oil-and-gas produced water while removing emulsified oils, suspended solids, and metals. The system employs shock-hydrodynamic cavitation in a specialized manifold to disrupt emulsions, followed by optimized dissolved air flotation (DAF) for contaminant removal. Careful pH, redox control, and lithium-preserving coagulants and flocculants prevent lithium co-precipitation. The clarified effluent, containing dissolved lithium, is amenable to further extraction or concentration steps, such as ion exchange, selective adsorption, or membrane filtration, achieving lithium recovery of 90-95% or higher.

[0031] According to one approach, the system integrates:1 . Density and Cavitation-Based Conditioning: A shock-hydrodynamic manifold, inspired by “SHURE” cavitation technology, to break stable emulsions and colloids without causing lithium precipitation.2. Optimized DAF Operation: Precisely controlled microbubble injection (via pressurized recycle loops) to remove contaminants, floating or settling them out.3. Specialized Chemical Conditioning: Lithium-friendly coagulants / flocculants, and pH / redox control to avoid Li+co-precipitation.Attorney Docket No. 21681-163057-WOCustomer No. 427984. Integration with Downstream Lithium Recovery: Effluent containing dissolved lithium can be further processed by selective adsorption, ion exchange, membrane filtration, or other conventional lithium extraction methods.

[0032] According to one approach, a method is provided for selectively recovering lithium from produced water, comprising the steps of: (a) providing a feed of oil-and-gas produced water containing lithium ions, suspended solids, and dissolved organics; (b) adjusting pH and redox potential to conditions that favor lithium solubility; (c) introducing a coagulant and a lithium-preserving flocculant such that suspended solids and emulsified droplets become flocculated without lithium co-precipitation; (d) passing said chemically conditioned water through a shock-hydrodynamic manifold at a pressure in the range of about 10-100 psi, thereby generating cavitation that destabilizes emulsions and promotes density-based separation; (e) introducing a pressurized, air-saturated recycle stream into a dissolved air flotation (DAF) cell, forming microbubbles that attach to said contaminants; (f) skimming floated contaminants from the surface of the DAF cell, producing a clarified effluent; and (g) directing said clarified effluent to a downstream lithium-extraction system, wherein at least about 90% of the initial lithium remains in soluble form.

[0033] The shock-hydrodynamic manifold may include at least two opposing high-pressure nozzles configured to collide fluid jets inside a reduced-pressure chamber, thereby enhancing cavitation. The pH may be maintained between about 6.5 and 7.5, and the oxidation-reduction potential is between about +200 and +350 mV. The coagulant may be a ferric or polyaluminum compound at a dosage of about 5-30 mg / L, and the flocculant is a high-molecular-weight polymer added at about 0.1 -1.0 mg / L. The DAF cell may be recycled at about 10-20% of the treated effluent pressurized to about 70-90 psi to generate microbubbles in the range of 20-100 micrometers in diameter. The downstream lithium-extraction system comprises at least one of:Attorney Docket No. 21681-163057-WOCustomer No. 42798 selective adsorption columns, ion exchange, nanofiltration, reverse osmosis, or precipitation of lithium carbonate or lithium hydroxide.

[0034] According to another approach, a system for selective lithium recovery, may include: (a) a shock-hydrodynamic manifold with at least two opposing nozzles that generate cavitation in a reduced-pressure collision zone; (b) a chemical dosing unit configured to add coagulants, flocculants, or pH / ORP adjusters to the produced water; (c) a dissolved air flotation (DAF) vessel including an inlet, a pressurized recycle loop for microbubble generation, and a skimmer assembly; and (d) a control system operable to maintain a pH of about 6.5-7.5 and an ORP of about +200 to +350 mV, thereby preserving lithium ions in solution while floating or settling contaminants.

[0035] The system may optionally include: (a) a polishing filter or media filter downstream of the DAF vessel; and (b) a lithium-selective adsorption or membrane module operable to recover at least about 90% of the dissolved lithium from the DAF effluent.

[0036] The shock-hydrodynamic manifold may be adapted from a design used in drilling-fluid solids separation and is configured to handle high-TDS brines without precipitating lithium.

[0037] According to another approach, a density-based lithium recovery process may include (a) using cavitation to break stable oil / water emulsions in produced water; (b) exploiting density differentials to float lower-density hydrocarbons and remove heavier solids; and (c) maintaining lithium in aqueous solution through controlled pH and redox conditions enables subsequent lithium concentration.

[0038] When operated under preferred conditions, e.g., near neutral pH and moderate oxidizing potential, lithium remains in ionic solution, leading to overall lithium recovery rates of 90-95% or higher, while oil, solids, and other contaminants are effectively removed. Pilot or field tests indicate energy usage in the range of 0.25-0.35 kWh per cubic meter of treated water.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0039] The present disclosure also relates generally to thermal management of high-density electronic equipment and, more particularly, to closed-loop groundwater cooling systems that employ controlled hydrodynamic cavitation for in-situ degassing, sterilization, and particulate conditioning.

[0040] The disclosure provides, in various aspects, cavitation-enhanced closed-loop cooling systems and methods for high-density computing facilities and other heat-intensive installations. In one aspect, a cooling system is provided that draws groundwater from an aquifer via a production well, subjects the groundwater to shock-induced hydrodynamic cavitation in a cavitation manifold, transfers heat from electronic equipment into the cavitated (conditioned) water via a heat exchanger, and then reinjects the heated water back into substantially the same aquifer through a spatially separated injection well. The system operates with essentially no net water consumption — groundwater is continuously recycled — and requires no chemical biocides or scale inhibitors because the cavitation process itself sterilizes the water and mitigates fouling.

[0041] In one embodiment of the system, maintaining a cavitation number (o) between about 0.5 and about 1.0 within the cavitation manifold induces intense cavitation that achieves at least a 3-log (>99.9%) reduction in microbial concentration in the water. The cavitation also strips dissolved gases (such as O2, CO2, and H2S) from the water and agglomerates sub-5 pm suspended fines into larger particles that are easily separable or less prone to clogging. By conditioning the coolant water in this manner, the system obviates the need for chemical treatments and minimizes scaling or biofouling upon reinjection.

[0042] In another aspect, the disclosure provides a method of operating the cooling system. The method includes extracting groundwater from an aquifer, generating hydrodynamic cavitation in the water to sterilize and degas it, transferring waste heat from computing, or other heat generating, equipment to the cavitated water, and reinjecting the water into the aquifer withAttorney Docket No. 21681-163057-WOCustomer No. 42798 a temperature increase of no more than about 1 °C above the native groundwater temperature. The method further includes actively controlling the flow conditions to maintain the cavitation number in the desired range (approximately 0.5-1 .0) by adjusting pump speed or flow rate. This control balances cavitation intensity against component wear, ensuring effective cavitation without causing damage from excessive cavitation (such as erosive hammering). A feedback control system with sensors (for pressure, temperature, turbidity, dissolved oxygen, etc.) and a variable-frequency drive (VFD) pump can automatically modulate the flow. Additionally, a subsurface thermal plume is monitored via a numerical groundwater model (for example, a MODFLOW-based digital twin of the aquifer) to ensure that reinjection of heated water remains within regulatory limits and environmental compliance (e.g., the warmed groundwater plume stays within a permitted area and temperature differential).

[0043] Additional aspects and optional features can be incorporated into the system. For instance, the cavitation manifold may be of modular design with replaceable hard-faced or tungsten carbide (WC-Co) nozzle inserts to prolong service life despite the high stresses of cavitation. The system may include a network of sensors providing real-time data to a programmable logic controller (PLC) that manages operations. In some embodiments, an energy-recovery turbine is installed downstream of the cavitation manifold to recapture excess pressure energy from the flow after cavitation, converting it to electricity and thereby improving overall system efficiency. The system’s heat exchanger (also referred to as a cold distribution unit, or“CDU”) can be a “plate-and-frame” type or an immersion cooling setup, designed to absorb waste heat from server racks or other electronics efficiently. By combining these features, the disclosed system and method enable high-capacity cooling with near-zero consumptive water use and chemical-free operation, which is a significant improvement over conventional cooling infrastructures for data centers and similar facilities.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0044] According to one approach, a method of cooling computing equipment is provided with the steps of: extracting groundwater from an aquifer; directing the groundwater through a cavitation manifold that generates hydrodynamic cavitation in the groundwater; transferring waste heat from the computing equipment into the cavitated groundwater; reinjecting the heated groundwater into the aquifer; and controlling flow conditions to maintain a cavitation number between about 0.5 and about 1 .0 such that a microbial concentration in the groundwater is reduced by at least three orders of magnitude.

[0045] The cavitation manifold may comprise opposed nozzles having exit diameters of 3-15 mm directed toward each other across a collision chamber.

[0046] The method may further comprise the step of agglomerating suspended solids of <5 pm in the groundwater into particles of >20 pm suitable for downstream separation or filtration.

[0047] The reinjecting the groundwater may occur at a temperature no greater than 1 °C above a native aquifer temperature.

[0048] The method may further comprise the step of modeling a subsurface thermal plume in real time based on the reinjecting, and throttling a flow rate of the groundwater if a regulatory limit on the thermal plume is approached.

[0049] The method may include the step of directing the groundwater through a cavitation manifold is repeated multpile times, e.g., 1 -4 more times.

[0050] The system may also include multiple manifolds (.e.g., four) in line or in series.

[0051] In another approach, a closed-loop cooling system is provided having a production well configured to draw groundwater from an aquifer; a cavitation manifold fluidically coupled to the production well, the cavitation manifold including opposed nozzles positioned to collide jets of the groundwater and induce hydrodynamic cavitation; a pump operable to deliver the groundwater through the cavitation manifold at a pressure drop sufficient to induce cavitation; a heat exchanger configured to receive heat from datacenter equipment and transfer the heat intoAttorney Docket No. 21681-163057-WOCustomer No. 42798 the groundwater downstream of the cavitation manifold; and an injection well fluidically coupled to the heat exchanger and configured to return the groundwater to the aquifer.

[0052] The system may further comprise a variable-frequency drive (VFD) controller operatively connected to the pump and configured to adjust a speed of the pump to maintain a cavitation number between about 0.5 and about 1 .0 in the cavitation manifold during operation.

[0053] The system may further comprise a plurality of sensors selected from the group consisting of: turbidity sensors, temperature sensors, dissolved-gas sensors, and pressure sensors, wherein each sensor provides real-time data to a programmable logic controller (PLC) configured to adjust system parameters in response to the data.

[0054] The cavitation manifold may be fabricated from duplex stainless steel and include replaceable erosion-resistant nozzle inserts made of tungsten carbide or a similar hard material.

[0055] The system may have opposed nozzles spaced apart by a distance of three to six times a diameter of an exit orifice of one of the opposed nozzles.

[0056] The present disclosure relates generally to thermal management of high-density electronic equipment and, more particularly, to closed-loop groundwater cooling systems that employ controlled hydrodynamic cavitation for in-situ degassing, sterilization, and particulate conditioning. More particularly, it concerns warm water direct to chip (DLC) cooling coupled to air side dry coolers, with a side stream cavitation polisher that sterilizes, degasses, and conditions coolant while protecting microchannel cold plates.

[0057] In one aspect, the invention provides a two-loop Cavitation-Conditioned Warm-Water Direct Liquid Cooling (CCWDLC) system. The system includes an IT coolant loop that circulates coolant through direct-to-chip cold plates on electronic devices (e.g., servers) and a facility coolant loop that is thermally coupled to the IT loop via one or more cooling distribution units (CDUs). The facility loop rejects heat to one or more air-side dry coolers operating at warmwater temperatures, thus achieving heat dissipation without evaporative water loss. AAttorney Docket No. 21681-163057-WOCustomer No. 42798 sidestream treatment train is fluidly connected to the facility loop (in parallel with a portion of that loop) to continuously condition a fraction of the circulating coolant. The sidestream treatment train comprises a hydrodynamic cavitation manifold (for example, an opposed-nozzle cavitation device) operated at a cavitation number (o) of about 0.5 to 1 .0 to induce intense cavitation micro-shock events. As used herein, the cavitation number (o) is defined as o = (p_s - p_v) I (% p v2), where p_s is static pressure upstream of the nozzle, p_v is liquid vapor pressure at temperature, p is density, and v is jet velocity.

[0058] In one aspect, the invention provides a cooling system for electronic equipment, having a plurality of direct-to-chip cold plates fluidically coupled to an IT coolant loop; a cooling distribution unit (CDU) configured to transfer heat from the IT coolant loop to a facility coolant loop; a dry cooler heat-rejection unit thermally coupled to the facility coolant loop; a sidestream treatment train fluidically coupled in parallel with at least a portion of the facility coolant loop, the sidestream treatment train comprising a hydrodynamic cavitation manifold and a degassing stage; and a controller configured to operate the hydrodynamic cavitation manifold at a cavitation number between about 0.5 and about 1 .0 and to reintegrate treated coolant to the facility coolant loop in a substantially / essentially bubble-free state (e.g., dissolved oxygen < about 0.5-1 .0 mg / L and bubble count below a defined threshold for bubbles larger than about 10 pm) upstream of the CDU.

[0059] In one approach “substantially” or “essentially” bubble-free may mean dissolved oxygen < about 1 .0 mg / L and fewer than about 10 bubbles per milliliter larger than about 10 pm as measured by an optical bubble counter, and that the controller maintains at least one of: dissolved oxygen < about 1 .0 mg / L, bubble counts below a threshold in a defined size range, and particulate counts below a vendor-specified threshold upstream of the direct-to-chip cold plates. Bubble counts may be determined with an inline optical bubble counter (e.g., >10 pmAttorney Docket No. 21681-163057-WOCustomer No. 42798 threshold, reported as bubbles per mL). Dissolved oxygen (DO) is measured via galvanic or optical DO sensors; thresholds are set per cold-plate vendor limits.

[0060] These events result in at least a three-order-of-magnitude (3-log) microbial reduction, stripping of dissolved gases from the coolant, and agglomeration of fine particulates into larger particles. Downstream of the cavitation manifold, the sidestream treatment train further includes a degassing stage and a bubble trap (air separator) to remove or vent separated gas bubbles, ensuring that the treated coolant returned to the facility loop is essentially bubble-free and safe for microchannels. A fine filtration unit (for example, a filter with a nominal rating of <1 pm) is included to capture the agglomerated particulates and maintain particulate counts below the limits required by the microchannel cold plates.

[0061] The system of claim may have the hydrodynamic cavitation manifold having opposed nozzles separated by a collision chamber and is configured to achieve at least a three-order-of-magnitude (3-log) microbial reduction in the treated sidestream. The sidestream treatment train may further comprise a filter of < about 1 pm nominal pore size. The controller is further configured to modulate a sidestream flow fraction between about 5% and about 30% of facility-loop flow responsive to IT load and ambient temperature conditions. The system may also have a bubble trap or air separator positioned downstream of the hydrodynamic cavitation manifold and upstream of the CDU. The degassing stage may have at least one of a vacuum degasser chamber and a hydrophobic membrane contactor. The direct-to-chip cold plates may be microchannels having characteristic dimensions between about 10 pm and about 200 pm and are fabricated from copper or aluminum, including additively manufactured structures. The controller enforces a bubble-barrier interlock that disables flow through the CDU unless measured bubble counts and dissolved oxygen levels remain below respective threshold values. The system may also have erosion-resistant nozzle inserts in the hydrodynamic cavitation manifold at locations subject to cavitation impact. The dry cooler heat-rejection unitAttorney Docket No. 21681-163057-WOCustomer No. 42798 operates at warm-water temperatures to achieve near-zero water usage without evaporative makeup. The facility coolant loop may have deionized water or a water-glycol blend compatible with system materials and corrosion inhibitors. The system may further have a plurality of sensors selected from the group consisting of: pressure sensors, temperature sensors, flow-rate sensors, dissolved oxygen sensors, particle counters, and gas-vent flow sensors, each providing data to the controller. The controller executes a purge schedule that periodically vents separated gas in short intervals without materially increasing water consumption of the system.

[0062] The system also includes a controller (e.g., a programmable logic controller driving variable-speed pumps or valves) configured to regulate the cavitation conditions and the sidestream flow. The controller maintains the cavitation manifold intensity (via cavitation number (o)), controls dissolved oxygen (DO) levels, monitors particle counts, and adjusts the sidestream flow fraction (for instance, about 5% to 30% of the total flow) as needed, all without allowing any cavitation-induced bubbles or contaminants to enter the main IT loop.

[0063] In another aspect, the invention provides methods of operating a cooling system as described herein. One method involves circulating coolant through the direct-to-chip cold plates and transferring heat to the facility loop via the CDU, then diverting a sidestream of the facility loop through a hydrodynamic cavitation manifold to sterilize, degas, and agglomerate contaminants in the coolant. The cavitation-treated coolant is then passed through a degassing stage and bubble separator and reintroduced into the facility loop upstream of the CDU inlet, all while maintaining the coolant within specified dissolved gas and particulate thresholds compatible with microchannel cooling. The method may further include controlling the cavitation manifold to operate at a cavitation number (o) of approximately 0.5-1 .0, achieving at least a three-order-of-magnitude reduction in microbial concentration in the sidestream, and dynamically adjusting the sidestream flow fraction between about 5% and 30% of the total flow based on IT heat load and ambient conditions. The controller can also maintain dissolvedAttorney Docket No. 21681-163057-WOCustomer No. 42798 oxygen < about 0.5-1 .0 mg / L and enforce fine filtration (<1 pm) so that the coolant delivered to the cold plates remains substantially free of bubbles and particulates. In embodiments, bubblebarrier interlocks are utilized so that coolant is not permitted to flow through the CDUs to the IT loop unless real-time sensor readings confirm the absence of excess bubbles or dissolved gases. Microbial reduction may be verified via standard plate count or ATP assay on sidestream samples pre- and post-cavitation.

[0064] In still another aspect, a variant of the system includes an alternative heat-rejection embodiment using a two-well groundwater loop. In addition to the dry cooler (primary heat rejection), a facility may incorporate a production well and an injection well as a seasonal or redundant heat sink.

[0065] In this embodiment, a hydraulically isolated groundwater loop exchanges heat with the facility loop via a heat exchanger; groundwater is reinjected at not more than about 1 °C above the native aquifer temperature, and the controller automatically throttles flow to confine the modeled thermal plume. The system’s controls can automatically throttle or adjust flow to the groundwater wells to ensure that any modeled thermal plume remains within acceptable or regulatory limits. This alternative embodiment provides flexibility for sites that have access to aquifers and seek additional cooling capacity or load shifting, while still maintaining the benefits of cavitation-based conditioning. In general, the various aspects of the invention provide a cooling architecture with near-zero water usage (no continuous evaporative consumption) and active coolant quality management, thereby eliminating the need for chemical biocides and protecting sensitive microchannel equipment from damage or performance degradation.

[0066] According to one method, the steps may include method of cooling electronic equipment may include circulating coolant through a plurality of direct-to-chip cold plates to absorb heat from electronic components; transferring heat from the coolant across a cooling distribution unit (CDU) into a facility loop; rejecting heat from the facility loop via a dry cooler;Attorney Docket No. 21681-163057-WOCustomer No. 42798 diverting a sidestream of the facility loop through a hydrodynamic cavitation manifold, thereby producing cavitation within the sidestream effective to sterilize microorganisms, degas the coolant, and agglomerate fine particulates; subsequently passing the cavitation-treated coolant through a degassing stage and a bubble trap to remove entrained gases; and reintroducing the treated coolant to the facility loop upstream of the CDU while maintaining the coolant within predetermined bubble and dissolved-gas thresholds suitable for microchannel cold plates.

[0067] The method may also include operating the hydrodynamic cavitation manifold at a cavitation number between about 0.5 and about 1 .0 and achieving at least a three-order-of-magnitude reduction in microbial concentration in the sidestream. 7. The method of claim 15, wherein the sidestream flow fraction is dynamically varied between about 5% and about 30% of facility-loop flow based on instantaneous IT load and ambient cooling conditions.

[0068] The method may also include maintaining dissolved oxygen < about 0.5-1 .0 mg / L in the coolant and filtering the coolant to < about 1 pm nominal before it reenters the CDU.

[0069] The method may also include executing a bubble-barrier interlock that prevents opening of CDU valves unless measured bubble counts remain below a predetermined threshold.

[0070] According to another approach, a non-transitory computer-readable medium storing instructions that, when executed by a controller, cause a cooling system to: calculate a cavitation number for a sidestream hydrodynamic cavitation manifold and adjust a pump via a variable-frequency drive (VFD) to maintain cavitation within a target range; regulate a sidestream flow fraction to meet target levels for dissolved oxygen, bubble count, and particulate count upstream of microchannel cold plates; and schedule gas-vent purge events based on signals from a bubble counter and a gas-vent flow sensor.

[0071] The system may further have a groundwater production well and a spaced injection well hydraulically isolated from the facility loop and configured such that groundwater receivesAttorney Docket No. 21681-163057-WOCustomer No. 42798 heat from the facility loop via a heat exchanger and is reinjected at not more than about 1 °C above a native aquifer temperature, with automatic throttling to constrain a modeled thermal plume within regulatory limits.

[0072] The method may further have wherein the heat-rejecting step is performed by at least one of: a dry cooler, a closed-loop borefield, a heat pump, or the groundwater-based system.

[0073] The disclosure also relates to sediment and slurry management in water bodies including reservoirs, dams, industrial ponds, and waterways. More particularly, it relates to integrated systems combining subsurface directional under-drain wells with surface hydrodynamic cavitation and dissolved air flotation (DAF) for (i) sediment removal with low turbidity, (ii) recovery of valuable fractions (e.g., phosphorus, barite, rare earth elements, lithium-bearing fines), and (iii) adaptive feedback-optimized operations.

[0074] The disclosure relates to sediment and slurry management in water bodies including reservoirs, dams, industrial ponds, and waterways. More particularly, it relates to integrated systems combining subsurface directional under-drain wells with surface hydrodynamic cavitation and dissolved air flotation (DAF) for (i) sediment removal with low turbidity, (ii) recovery of valuable fractions (e.g., phosphorus, barite, rare earth elements, lithium-bearing fines), and (iii) adaptive feedback-optimized operations.

[0075] Disclosed are methods, systems, and control schemes that concurrently operate: (i) a surface loop drawing water / sediment into a hydrodynamic cavitation device and a DAF unit to separate bulk solids and return clarified effluent, and (ii) a subsurface loop drawing fines and porewater through at least one horizontal under-drain well disposed beneath the sediment bed. Sensors measure turbidity at a compliance point and separation loading; a controller dynamically allocates flow between surface (Qs) and subsurface (Qu) loops and schedules well back-flush to maintain turbidity below a target (e.g., <50 NTU) while maximizing solids capture. Separated fractions are routed to selective recovery modules to produce marketable productsAttorney Docket No. 21681-163057-WOCustomer No. 42798(e.g., struvite / brushite fertilizer, barite, rare-earth concentrates, lithium-compatible brines). The architecture reduces plume risk, enables continuous operation while water supply or hydropower remains online, and lowers net cost relative to conventional dredging.

[0076] Disclosed are methods, systems, and control schemes that concurrently operate: (i) a surface loop drawing water / sediment into a hydrodynamic cavitation device (220) and a DAF unit (230) to separate bulk solids and return clarified effluent (232), and (ii) a subsurface loop drawing fines and porewater through at least one horizontal under-drain well (e.g., 260, 132) disposed beneath the sediment bed (510). Sensors (240) measure turbidity at a compliance point and separation loading; a controller (250) dynamically allocates flow between surface (Qs) and subsurface (Qu) loops and schedules well back-flush via header (540) to maintain turbidity below a target while maximizing solids capture. Separated fractions are routed to selective recovery modules including phosphorus precipitation (310), barite concentration (320), rare-earth / metal ion exchange (330), and lithium-friendly processing (340).

[0077] According to one approach, a method of removing sediment from a water body under a turbidity constraint, may have the steps of (a) drawing a first flow (Qs) from the water body into a hydrodynamic cavitation device and a dissolved air flotation (DAF) unit to separate bulk solids and produce a clarified effluent returned to the water body; (b) simultaneously drawing a second flow (Qu) through at least one horizontal under-drain well disposed beneath a sediment bed to collect fines and porewater; (c) acquiring sensor data including turbidity at a compliance point and a loading value of the DAF unit; and (d) with a controller, adjusting Qs and / or Qu responsive to the sensor data to maintain turbidity below a target threshold while constraining DAF loading below a setpoint and maximizing solids capture.

[0078] In this approach, the turbidity threshold may be < 50 NTU at the compliance point.

[0079] In this approach, the clarified effluent turbidity may be < 5 NTU at the DAF outlet.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0080] In this approach, the cavitation device may impose a pressure drop of 100-500 psi and the DAF injects microbubbles of 30-100 pm at an air-to-water ratio of 0.02-0.06.

[0081] In this approach, the controller may implement proportional-integral-derivative (PID) control and / or machine learning to adjust Qs and Qu based on turbidity, DAF loading, and energy consumption.

[0082] In this approach, the under-drain well comprises a 50-300 m screened lateral with0.1-2.0 mm slots and a graded filter pack, and Qu is selected to maintain laminar entrance velocities at the screen.

[0083] In this approach, the DAF loading may be constrained to a maximum loading L_max expressed as kg / m2h and / or as influent TSSxflow (kg / h).

[0084] In this approach, the coagulants and operating chemistry may be selected to retain lithium in solution upstream, and a downstream lithium extraction step is applied to a side stream.

[0085] In this approach, the operations may be conducted without drawdown and while a water supply or hydropower intake remains online.

[0086] In this approach, the method may further comprise periodic back-flush of the under-drain well for 10-60 s per cycle responsive to a pressure differential threshold across the screen or a flow decay rate.

[0087] In this approach, the method may further comprise deploying an isolation curtain to localize a surface intake zone and reduce plume formation.

[0088] In this approach, the method may further comprise pulsed cavitation energy to limit in-situ plume formation near the intake.

[0089] In this approach, the method may further comprise precipitating phosphorus as struvite or brushite and granulating to a particle size of at least 1 .5 mm.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0090] In this approach, the method may further comprise concentrating barite from a dense fraction by classification or gravity separation for industrial reuse.

[0091] In this approach, the method may further comprise a fines stream with ion-exchange media or chelants selected from phosphonate or aminopolycarboxylate ligands to produce a rare earth element concentrate.

[0092] In another approach, a system for turbidity-constrained sediment removal is provided having: a surface intake, a cavitation manifold fluidly coupled to a DAF unit that outputs clarified effluent and separated solids; at least one horizontal under-drain well coupled to a fines-handling loop; sensors including a turbidity sensor positioned at a compliance point and at least one sensor indicative of DAF loading; a back-flush manifold for the under-drain well; and a controller configured to adjust flows in the surface and subsurface loops to maintain turbidity below a threshold while constraining DAF loading below a setpoint.

[0093] In this system approach, the controller may maintains L < L_max while iteratively increasing Qs until T approaches T_target, and otherwise increases Qu within a configured Qu_max.

[0094] In this system approach, the sensors may further have inline TSS, pH / ORP, pressure and flow for both loops, and at least one of inline particle size, conductivity, temperature, or UV-Vis / NIR analyzers.

[0095] In this system approach, the surface intake may have an adjustable elevation near the bed.

[0096] In this system approach, the fines-handling loop of the under-drain may be routed to (i) a dedicated settling / filtration skid, (ii) the DAF influent as a controlled fraction, or (iii) a resource recovery module.

[0097] According to another approach, a non-transitory computer-readable medium storing instructions is provided that, when executed by one or more processors, cause a system to:Attorney Docket No. 21681-163057-WOCustomer No. 42798 acquire turbidity-at-compliance and DAF loading data; compute adjusted setpoints for Qs and Qu subject to a turbidity constraint T < T_target and a flotation loading constraint L < L_max; issue control signals to pumps and valves; and schedule under-drain back-flush cycles responsive to pressure rise or flow decay, thereby maintaining turbidity below the target while optimizing solids removal and energy use.

[0098] According to another approach, a mobile sediment management system is provided having multiple skids each including the system described herein and a wellfield of multi-lateral under-drain wells, the skids being deployable without reservoir drawdown and operable while a water supply or hydropower intake remains online.

[0099] In this approach, the instructions further compute a multi-objective optimization of (solids mass removed I energy) subject to T < T_target and L < L_max.

[0100] Other technical advantages will be readily apparent to one skilled in the art from the figures, descriptions and claims included herein. Moreover, while specific advantages have been enumerated above, various embodiments may include all, some, or none of the enumerated advantages.BRIEF DESCRIPTION OF THE DRAWINGS

[0101] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, which are not true to scale, and which, together with the detailed description below, are incorporated in and form part of the specification, serve to illustrate further various embodiments and to explain various principles and advantages in accordance with the present invention:

[0102] Fig. 1 shows a flowchart showing main steps of the method according to the present embodiments.

[0103] Fig. 2 shows a flowchart showing detail to the Red Mud Processing step.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0104] Fig. 3 shows a flowchart showing detail to the Inorganic Filler Extraction step.

[0105] Fig. 4 shows a flowchart showing detail to the Polymer Matrix Preparation step.

[0106] Fig. 5 shows a flowchart showing detail to the RMCP Composite Formation step.

[0107] Fig. 6 shows a flowchart showing detail to the RMCP Powder Production for AdditiveManufacturing step.

[0108] Fig. 7 shows a flowchart showing detail to the Testing and Validation step.

[0109] Fig. 8 shows an analysis of a sample of a red mud sample.

[0110] Fig. 9 illustrates RMCP powder production process.

[0111] Fig. 10 shows a photograph of the red mud (processed bauxite).

[0112] FIG. 11 is a schematic layout of the present SHURE DAF Lithium Recovery process, showing feed tanks, chemical dosing, pressurized recycle, cavitation manifold, flotation cell, skimmer, and effluent line to downstream lithium extraction.

[0113] FIG. 12 is a cross-sectional detail of microbubble injection nozzles and the internal collision chamber of the shock-hydrodynamic manifold.

[0114] FIG. 13 is a process flow diagram illustrating density-based separation and selective removal of contaminants while preserving lithium ions in solution.

[0115] FIG. 14 is a representative graph or data chart depicting final effluent clarity versus lithium retention and overall contaminant removal efficiency.

[0116] FIG. 15 is a schematic plan view of an exemplary two-well cavitation-enhanced cooling circuit, illustrating a production well (100) and an injection well (102) accessing a subsurface aquifer (104), with a surface pump (106) drawing water via a production header (108) into a cavitation manifold (110). A discharge conduit (116) carries conditioned water from the manifold to a heat exchanger (120) that absorbs heat from the computing equipment, and an injection header (122) returns the heated water to the aquifer through the injection well.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0117] FIG. 16 is a sectional side view of a shock-hydrodynamic cavitation manifold, showing opposed nozzles (112a, 112b) directed toward each other into a collision chamber (114) where hydrodynamic cavitation bubbles form and collapse intensively.

[0118] FIG. 17 is a flow diagram illustrating the control logic and sensor placement for the system. It depicts sequential operating steps — Startup, Cavitation Conditioning, Heat Exchange, Re-Injection & Monitoring, and Maintenance — and indicates feedback loops to a programmable logic controller (PLC) which adjusts system parameters (such as pump speed via the VFD) in real time.

[0119] FIG. 18 is a computational fluid dynamics (CFD) velocity contour plot showing opposed cavitation jets impinging within the collision chamber to form a high-shear cavitation zone between the nozzles.

[0120] FIG. 19 is a MODFLOW simulation output (contour map) illustrating a predicted one- year subsurface thermal plume in the aquifer resulting from continuous operation of the system, with temperature isotherms (e.g., 15 °C to 18 °C) radiating from the injection well (102).

[0121] FIG. 20A is a schematic diagram of the CCWDLC two-loop architecture, illustrating an IT loop with server cold plates, one or more CDUs, a facility loop with supply and return headers, a sidestream cavitation polisher (including a cavitation manifold, a degassing unit, and a fine filter), and one or more dry coolers for heat rejection.

[0122] FIG. 20B is a detailed view of the sidestream tie-in portion of the system, including isolation valves, bypass lines, a VFD-driven sidestream pump, and sensor instrumentation taps (e.g., pressure, temperature, dissolved oxygen, particle counts, bubble counter, and gas-vent flow).

[0123] FIG. 21 is a sectional view of an opposed-nozzle hydrodynamic cavitation manifold, showing a collision chamber where jets from opposing nozzles collide and illustrating optional erosion-resistant nozzle inserts in high-impact regions.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0124] FIG. 22 is a flowchart depicting controller logic, including cavitation-intensity (o) set-point control via VFD, dissolved-oxygen regulation, bubble-barrier interlocks to protect the IT loop, periodic purge / vent events, and scheduling of the sidestream fraction based on IT load and ambient temperature.

[0125] FIG. 23. Illustrates relationship between side stream fraction and dissolved oxygen (DO), showing a target DO band of approximately 0.5-1 .0 mg / L and typical side stream operating range of 5-30% of facility loop flow.

[0126] FIG. 24 illustrates an optional embodiment incorporating a two-well groundwater loop with a production well and a spaced injection well, together with a modeled one-year thermal plume demonstrating reinjection limited to not more than about 1 °C above native aquifer temperature.

[0127] FIG. 25 is a schematic of a rack-level implementation showing IT equipment connections and a bubble-barrier interlock that gates coolant flow through the CDUs unless measured bubble and dissolved-oxygen thresholds are satisfied.

[0128] FIG. 26 is a plan view showing the SHURE+DAF skid (110), adjustable surface intake (120), isolation curtain (122), and beneath-bed under-drain laterals (132).

[0129] FIG. 27 is a process flow diagram showing dual loops and recovery modules including cavitation manifold (220), DAF unit (230), sensors (240), controller (250), and modules (310— 340).

[0130] FIG. 28 is a control block diagram depicting turbidity-constrained allocation by controller (350) using inputs (302-306) and actuators (360-364).

[0131] FIG. 29 is a cross-section of a horizontal screened well including filter pack (520), screened lateral (530) with slots (532), and back-flush header (540).

[0132] FIG. 30 illustrates turbidity set-point tracking (512) and DAF loading (514) with flows Qs (520) and Qu (522).Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0133] FIG. 31 shows resource recovery branches including phosphorus (620), barite (630), REE / metal IX (640), and lithium-friendly regime (650).

[0134] FIG. 32 depicts a mobile deployment with multiple skids (610, 612), isolation curtains (620, 622), and a shared wellfield (630) with a legend (700).

[0135] Corresponding reference characters may indicate corresponding components throughout the indicated views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present embodiments.

[0136] While the features described herein may be susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to be limiting to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the subject matter as defined by the appended claims.DETAILED DESCRIPTION

[0137] The present embodiments provide a composite material (RMCP) composed of a polymer matrix reinforced with inorganic fillers derived from red mud. RMCP offers superior mechanical strength, thermal stability, wear resistance, and sustainability, outperforming traditional polymers like Nylon 11 or PA12. The resultant RMCPs are ideal for manufacturing inAttorney Docket No. 21681-163057-WOCustomer No. 42798 industries like automotive, aerospace, consumer products, and various industrial manufacturing, particularly in additive manufacturing using Selective Laser Sintering (SLS), Multi Jet Fusion (MJF), Direct Drill 3D printers, and Bambu Lab Carbon X1 printers. Unlike existing polymers, RMCP leverages red mud, transforming it from a waste product into a valuable raw material for high-performance composites.

[0138] The present embodiments provide innovative methods and introduces a method for extracting inorganic components from red mud, using cavitation-assisted extraction leaching, magnetic separation, and supercritical fluid extraction, resulting in high-quality fillers that bond effectively with the polymer matrix.

[0139] The present embodiments address the environmental issue of red mud disposal by repurposing it into a valuable resource. This innovation reduces industrial waste, lowers production costs, and enhances sustainability by offering a closed-loop recycling process.

[0140] According to one approach, an exemplary process 20 shown in Fig. 1 may involve the general steps of initial processing of red mud 22; inorganic filler extraction 24; polymer matrix preparation 26; RMPC composite formation 28; RMPC Powder Production for additive manufacturing 30; and testing and validation 32. Each will be described herein and illustrated in Figs. 2-7.

[0141] The process flowchart of Fig. 1 outlines the key steps in the production of RMCP, covering red mud processing, filler extraction, polymer matrix preparation, composite formation, and powder production for additive manufacturing as follows: a. Red Mud Processing: Drying, grinding, and leaching or magnetic separation. b. Inorganic Filler Extraction: Separation, purification, and size reduction of alumina, silica, iron oxides, and calcium carbonate. c. Polymer Matrix Preparation: Synthesis of bio-based or synthetic polyamide matrix, or a hybrid polymer matrix.Attorney Docket No. 21681-163057-WOCustomer No. 42798 d. Filler Functionalization: Surface treatment of inorganic fillers for improved bonding. e. RMCP Composite Formation: High-energy blending with optional cavitation enhancement, extrusion, and pelletizing. f. Powder Production: Pulverization, spray drying, classification, and powder preparation for additive manufacturing (MJF and SLS).The figures highlight features of these steps.

[0142] Red Mud Preparation / Processing - Step 22 (Fig. 2):

[0143] Process 20 begins with red mud processing 22 as shown in Fig. 2. This involves the extraction of inorganic fillers from the red mud. Fig. 2 shows the steps drying the red mud at step 34 and grinding and pulverizing the dried red mud at step 36.

[0144] Red mud is collected as a byproduct of the Bayer process. It is dried at 100-120°C for 2-7 hours, preferably 4-6 hours to remove excess moisture and stabilize the material for further processing.

[0145] Grinding and Pulverization of the dried red mud is next at step 36. The dried red mud is ground into fine particles (for example, <50 microns) using high-energy ball milling. This increases surface area and extraction efficiency.

[0146] Inorganic Filler Extraction Methods - Step 24 (Fig. 3):

[0147] Fig. 3 shows detail for the step of inorganic filler extraction methods of cavitation assisted leaching 34; Filtration and Separation 36; Precipitation and Purification 38; and, particle size reduction 40. There are detailed as follows.

[0148] Cavitation-assisted leaching 34: The ground red mud and a leaching solution (e.g., HCI or H2SO4) are provided. The ground red mud and leaching solution are subjected to a cavitation-assisted leaching process conducted at 20-40 kHz and 50-70°C in a high-shearAttorney Docket No. 21681-163057-WOCustomer No. 42798 mixing chamber. The cavitation process creates localized high temperatures and pressures, increasing the leaching efficiency whereby alumina (AI2O3), silica (SiO2), iron oxides (Fe2O3or Fe3O4), and calcium carbonate (CaCO3) components are extracted.

[0149] Cavitation-Enhanced Processing: The use of cavitation during filler extraction and blending improves the dispersion of fillers in the polymer matrix, ultimately resulting in enhanced mechanical and thermal properties of the resultant compositions.

[0150] Fraction Percentages (Leaching Solution vs. Red Mud) & Dilution: a. Fraction Percentages: A typical ratio for leaching processes would involve 10- 20% red mud by weight compared to the leaching solution. b. Percentage Diluted with Water: The leaching solution (e.g., HCI or H2SO4) is generally diluted to 2-5% concentration in water, ensuring sufficient leaching power without overly aggressive reactions that could affect the material's composition.

[0151] Flow Rate and Timing: a. Flow Rate: The flow rate through the high-shear mixing chamber can vary, but a typical range would be 1-5 liters per minute (L / min), depending on the equipment and volume being processed. b. Timing: The cavitation-assisted leaching process typically runs for 30 minutes to 2 hours, depending on the desired level of extraction and the specific setup.

[0152] Quantified Temperatures and Pressures: a. Localized Temperatures: During cavitation, localized temperatures can spike up to 5000°C within the microbubbles, though the bulk solution remains at 50-70°C. b. Localized Pressures: The cavitation process can generate localized pressures of up to 1000 atm (atmospheres) within the collapsing bubbles. These extreme localized conditions significantly enhance leaching efficiency.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0153] Filtration and Separation 36:

[0154] The resulting slurry is vacuum-filtered to separate the leachate (containing the dissolved inorganic fillers) from solid residues.

[0155] Magnetic Separation:

[0156] Input: Ground red mud.

[0157] Process: Magnetic separation is used to recover iron oxides (Fe2O3or Fe3O4), leveraging strong magnetic fields to pull iron-rich particles from the red mud.

[0158] Supercritical Fluid Extraction (Optional):

[0159] Input: Ground red mud.

[0160] Process: Supercritical CO2extraction can be used to recover high-value metals and components, reducing the need for chemical solvents and minimizing environmental impact.

[0161] Precipitation and Purification 38:

[0162] Precipitation: The leachate is adjusted to specific pH levels (e.g., using ammonium hydroxide for alumina precipitation) to recover individual components.

[0163] Washing and Drying: The precipitates are washed with deionized water and dried at 150°C.

[0164] Particle Size Reduction 40: The dried precipitates, the purified inorganic fillers, are milled to a particle size of less than 10 microns, optimizing and making them ready for polymer matrix integration.

[0165] Polymer Matrix Preparation - Step 26, Fig. 4:

[0166] Synthesis of Bio-based Polyamide 42:Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0167] Polymer Matrix Selection

[0168] Bio-Based Polyamides: RMCPs can use a bio-based polyamide (e.g., Nylon 11 derived from 11-aminoundecanoic acid), synthesized via polymerization at 200-250°C under a nitrogen atmosphere.1 . Percentage of Nitrogen:In polymerization processes under a nitrogen atmosphere, 100% nitrogen gas is typically used to create an inert environment, preventing oxidation or unwanted reactions during synthesis. This ensures the polyamide forms properly without contamination from oxygen or other gases.2. Duration of Polymerization:The polymerization of Nylon 11 (from 11-aminoundecanoic acid) at 200-250°C generally takes 4-6 hours. This allows enough time for the complete polymerization of the monomers while ensuring that the reaction reaches completion without degradation of the material.These conditions ensure a high-quality bio-based polyamide for use in RMCPs.

[0169] Synthetic Polyamides or Hybrid Polymers:

[0170] RMCPs may also incorporate PA12, PA6, or even hybrid polymer blends (e.g., combining bio-based polyamide with thermoplastic elastomers (TPEs) or high-performance polymers like PEEK (poly ether ether ketone)).

[0171] Surface Treatment 44:

[0172] Functionalization of Inorganic Fillers.Attorney Docket No. 21681-163057-WO Customer No. 42798

[0173] Inorganic fillers are surface-treated with a silane coupling agent (e.g., 3- aminopropyltriethoxysilane) to enhance bonding with the polymer matrix. This process is conducted at 80°C for 2 hours, followed by drying for 4-6 hours at 100°C.

[0174] Optional Nanomaterials: To enhance mechanical properties like tensile strength and electrical conductivity, graphene or carbon nanotubes can be added during functionalization.

[0175] Formation of the RMCP Composite - Step 28, Fig. 5

[0176] Blending and High-Energy Mixing 46:

[0177] Surface-treated fillers and polymer matrix are blended into the molten polymer matrix using a twin-screw extruder at 230-250°C with screw speeds set to 200-300 RPM to ensure homogenous filler distribution for 5 to 10 minutes.

[0178] Cavitation-Assisted Extrusion 48:

[0179] Input: Blended RMCP material.

[0180] Process: Cavitation nozzles integrated into the extruder create localized cavitation zones that enhance filler dispersion and interfacial bonding.

[0181] Shaping and molding 50:

[0182] Pelletizing: The RMCP material is extruded into strands, cooled in a water bath, and pelletized.

[0183] Extrusion and Cooling: a. Extrusion Temperature: The RMCP material is extruded at a temperature of 230- 250°C to maintain the molten state for smooth extrusion into strands. b. Water Bath Temperature: The cooling water bath is typically maintained at 20- 25°C to rapidly cool the extruded strands, solidifying them quickly without causing thermal shock.

[0184] TimesAttorney Docket No. 21681-163057-WOCustomer No. 42798

[0185] Cooling Time: The extruded strands typically take 1-2 minutes to cool fully in the water bath before they are ready for pelletizing.

[0186] Pelletizing Time: Once the strands are solidified, the pelletizing process is relatively quick, typically taking a few seconds to cut the strands into uniform pellets.These times and temperatures ensure efficient pellet production without compromising the material properties of RMCP.

[0187] RMCP pellets can be shaped via injection molding (at 240°C, 100 MPa) or prepared for additive manufacturing processes like Selective Laser Sintering (SLS), Multi Jet Fusion (MJF), Direct Drill 3D printers, Bambu Lab Carbon X1 printers, and the like.

[0188] RMCP Powder Production for Additive Manufacturing - Step 30, Fig. 6.

[0189] Powder Pulverization and Classification 52:

[0190] RMCP pellets are pulverized and classified to achieve a 20-80 micron particle size for HP MJF or 50-100 microns for Formlabs SLS. Spray drying may be employed to ensure spherical particle morphology, improving flowability and powder bed performance.

[0191] Powder Composition

[0192] Matrix: Bio-based or synthetic polyamide matrix.

[0193] Fillers: Alumina (AI2O3): 20-30% by weight for thermal stability and mechanical strength.

[0194] Silica (SiO2): 10-20% by weight for durability and mechanical properties.

[0195] Iron Oxides (Fe2O3or Fe3O4): 5-10% by weight for added rigidity and potential magnetic properties.

[0196] Calcium Carbonate (CaCO3): 5-15% by weight for cost reduction and stiffness.

[0197] Nanoclay (Montmorillonite): 2-5% by weight for barrier properties and toughness.

[0198] Powder PropertiesAttorney Docket No. 21681-163057-WOCustomer No. 42798

[0199] Flowability: Optimized flow rate to prevent clogging and ensure smooth recoating for additive manufacturing processes.

[0200] Compatibility: The powder is suitable for both HP MJF and Formlabs SLS processes, ensuring smooth layer deposition and fusion. The powder is suitable for manufacturing process Using Direct Drill 3D Printers, SLS, MJF, and Bambu Lab Carbon X1 Printers

[0201] Testing and Validation - Step 32, Fig. 7

[0202] The flowchart in Fig. 7 represents a continuous process where unused powder is tested for reusability, reprocessed, and reintroduced into the production cycle, creating a sustainable, closed-loop material system.

[0203] Mechanical Testing 54:

[0204] Tensile Strength: Test RMCP components from both MJF and SLS printers, comparing against PA12 and PA11 for tensile strength.

[0205] Impact Resistance: Measure impact resistance under high-stress conditions to ensure durability.

[0206] Purpose: To evaluate the tensile strength, impact resistance, and overall durability of RMCP in its final form after additive manufacturing processes like MJF, SLS, or Direct Drill 3D printing.

[0207] Details: This step ensures the material meets the required mechanical performance standards for its intended industrial applications, such as automotive or aerospace.

[0208] Thermal Testing 56:

[0209] Heat Deflection Temperature (HDT): Test RMCP to ensure thermal stability, particularly for high-temperature environments.

[0210] Thermogravimetric Analysis (TGA): Assess the thermal stability and degradation of RMCP during the printing process.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0211] Purpose: To assess the thermal stability and heat deflection temperature (HDT) of the RMCP material, particularly under high-temperature conditions.

[0212] Details: Thermal testing is critical to ensure that RMCP can maintain its structural integrity and performance in heat-intensive environments.

[0213] Powder Reusability Testing 58:

[0214] Recycling Rate: Evaluate the properties of RMCP powder after multiple print cycles to ensure high reusability without significant degradation.

[0215] Powder Aging 58: Test powder properties like flowability and particle size distribution over time to assess long-term consistency.

[0216] The resultant RMCP may include, according to one approach, a polymer matrix selected from a bio-based polyamide or synthetic polyamide, and fillers derived from red mud, including alumina (AI2O3), silica (SiO2), iron oxides (Fe2O3or Fe3O4), calcium carbonate (CaCO3), and nanoclay (Montmorillonite). According to one approach, the following percent weights of the RMCP may be as follows: a. Alumina (AI2O3): 15-35% by weight. Alumina adds mechanical strength and thermal stability to the composite. b. Silica (SiO2): 10-25% by weight. Silica improves durability and tensile strength. c. Iron Oxides (Fe2O3or Fe3O4): 5-12% by weight. These oxides contribute to rigidity and provide potential magnetic properties, depending on the application. d. Calcium Carbonate (CaCO3): 5-20% by weight. Calcium carbonate is primarily used for cost reduction and added stiffness. e. Nanoclay (Montmorillonite): 1-5% by weight. Nanoclay enhances barrier properties and toughness, and may improve the material’s resistance to moisture or gases.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0217] These percentages can be adjusted based on the desired material properties, application, and manufacturing process, but these ranges provide a balanced composition for a high-performance RMCP.

[0218] Purpose: To determine how well the RMCP powder can be recycled after multiple 3D printing or manufacturing cycles without significant degradation in quality.

[0219] Details: The powder's flowability, particle size distribution, and mechanical properties are examined over several reuse cycles to validate the closed-loop recycling system. This ensures that the RMCP material remains viable for sustainable manufacturing.

[0220] A method for producing a composite material, according to one approach, may include the steps of extracting alumina, silica, iron oxides, and calcium carbonate from red mud, synthesizing a polymer matrix, and blending the inorganic fillers with the polymer matrix using high-energy blending and cavitation.

[0221] An optional Closed-Loop Recycling System also falls within the scope of the present embodiments. RMCP powder and unused material can be collected, reprocessed, and reintroduced into the production cycle, creating a closed-loop recycling system that enhances sustainability and reduces waste. According to one approach Closed-Loop Recycling may include the steps for a closed-loop recycling method for RMCP powder used in additive manufacturing, having the steps of: collecting unused powder from the printing process; reprocessing the powder via pulverization or spray drying to restore flowability and particle morphology; and reintroducing the reprocessed RMCP powder into the manufacturing cycle for subsequent use in printing.

[0222] Fig. 9 illustrates RMCP powder production process, illustrating how RMCP pellets are pulverized and spray-dried to achieve the ideal particle size for Direct Drill 3D, SLS, MJF, and Bambu Lab Carbon X1 printers. Reference numbers as shown below relate to the following features of this process in Fig. 9.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0223] 64 and 66: Different RMCP Powder Sizes - Two examples of powder classified into the desired size ranges.

[0224] 64: Powder optimized for MJF (20-80 microns).

[0225] 66: Powder optimized for SLS (50-100 microns).

[0226] 68: Direct Drill 3D, SLS, MJF, and Bambu Lab Carbon X1 Printers - The final destination where the classified RMCP powder is used for additive manufacturing.

[0227] 70: Grinder of RMCP Pellets - Initial pellets that are to be pulverized for use in 3D printing processes.

[0228] 72: Pulverized RMCP Powder - The fine powder produced after pulverizing the pellets. This powder is sized according to the needs of different 3D printing technologies.

[0229] 74: Spray Drying System - Equipment used to ensure the particles are the correct size and morphology for optimal flowability.

[0230] 76: Powder Size Classifier - A device that classifies the powder into the desired size range, ensuring specific microns for MJF, SLS, and other printers.

[0231] 78: Storage or Sifting Unit - For storing the classified RMCP powder or sifting out unwanted larger particles.

[0232] As shown in Fig. 9, RMCP pellets are pulverized to achieve specific particle sizes.The resultant fine powder of 20-80 microns for MJF, 50-100 microns for SLS.

[0233] Nest the powder is spray dried to ensure spherical particle morphology, enhancing flowability for additive manufacturing.

[0234] Process flowchart for closed-loop recycling of RMCP powder, showing the collection, reprocessing, and reintroduction of unused powder into the production cycle.

[0235] A composite material composed of red mud-derived fillers and a bio-based or synthetic polymer matrix, according to one approach is optimized for use in Direct Drill 3D, SLS, MJF, and Bambu Lab Carbon X1 printers by controlling particle size distribution, flowability, andAttorney Docket No. 21681-163057-WOCustomer No. 42798 thermal properties to ensure smooth layer deposition and superior mechanical properties in printed parts.

[0236] Detailed diagrams should be included for key steps, such as:

[0237] Cavitation-Assisted Extraction: Showing the high-shear mixing chamber and ultrasonic frequency setup.

[0238] Magnetic Separation: Illustrating the magnetic field apparatus for iron oxide recovery.

[0239] Twin-Screw Extruder with Cavitation Nozzles: Depicting how the cavitation zones enhance filler distribution.

[0240] Spray Drying and Powder Production: Diagram illustrating powder morphology control for additive manufacturing.

[0241] Additive Manufacturing (MJF / SLS) Process Flow: Demonstrating how RMCP powder is layered, fused, and cooled.

[0242] The following presents under an Additive Manufacturing (MJF / SLS) Process Flow, a detailed description of how the RMCP powder is processed through Multi Jet Fusion (MJF) and Selective Laser Sintering (SLS):

[0243] Process Flow for Additive Manufacturing (MJF / SLS):

[0244] 1 . Layering:

[0245] The RMCP powder is deposited onto the build platform in thin layers, typically 20-100 microns thick, depending on the specific printer and application.

[0246] For MJF, the powder is spread using a roller or blade, while SLS typically uses a similar mechanism to ensure an even and consistent layer of powder.

[0247] 2. Fusing (MJF):Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0248] In MJF, an inkjet array deposits a fusing agent onto specific regions of the powder that need to be solidified, followed by exposure to an infrared lamp that heats these regions, causing them to fuse together.

[0249] A detailing agent may also be applied along the edges of each part to improve resolution and surface finish.

[0250] 3. Fusing (SLS):

[0251] In SLS, a high-powered laser selectively fuses the powdered material by tracing the cross-sections of the object on each layer of powder. The laser heats the powder to a point where the particles fuse together without fully melting.

[0252] The surrounding unfused powder acts as a support structure for the part being built.

[0253] 4. Cooling:

[0254] After the fusing process, both MJF and SLS require a cooling phase. Cooling times can vary based on the printer and material thickness but typically take 2-3 hours to allow the part to cool gradually inside the build chamber. This minimizes the risk of warping or other defects.

[0255] SLS parts cool slowly in the powder bed to ensure even cooling, while MJF parts may cool slightly faster due to the infrared fusing process.

[0256] 5. Post-Processing:

[0257] Once cooled, the part is removed from the build chamber, and any unfused powder is brushed or blown off. This powder can often be reused in future builds, contributing to the sustainability of the process.

[0258] Optional post-processing steps, such as sanding, dyeing, or polishing, can further improve the surface finish and mechanical properties of the RMCP part.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0259] This process flow explains the key stages of RMCP powder being layered, selectively fused, and cooled in MJF and SLS additive manufacturing systems. The ability to recycle unfused powder contributes to the efficiency and sustainability of the process.

[0260] RMCP’s use of red mud, an industrial waste product, provides an environmentally friendly solution by repurposing waste materials. This helps reduce the hazardous waste associated with alumina production.

[0261] Reduced Carbon Footprint: By utilizing bio-based polyamides or hybrid polymers, RMCP minimizes reliance on petroleum-based polymers, significantly lowering its carbon footprint compared to conventional plastics.

[0262] Closed-Loop Recycling: RMCP’s recyclability offers further environmental benefits, allowing for the recovery and reuse of unused powder in the production cycle, making the process more sustainable and reducing waste.

[0263] Improved Mechanical Strength: RMCP’s inclusion of alumina and silica enhances tensile strength, making it ideal for applications requiring high durability, such as in the automotive and aerospace industries.

[0264] Thermal Stability: RMCP offers a higher Heat Deflection Temperature (HDT) compared to PA12 and Nylon 11 , making it suitable for high-temperature applications.

[0265] Superior Surface Finish: RMCP’s fine particle size and spherical morphology contribute to smoother surface finishes in printed parts, reducing post-processing time and improving part quality.

[0266] Compatibility with Multiple Printing Technologies: RMCP is fully compatible with Direct Drill 3D, SLS, MJF, and Bambu Lab Carbon X1 printers, making it versatile across a wide range of additive manufacturing systems.

[0267] Powder Flowability: RMCP powder’s optimized flow rate ensures smooth recoating in powder bed fusion systems, reducing clogging and print errors.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0268] Layer Fusion and Strength: The controlled thermal and mechanical properties of RMCP ensure excellent layer fusion and strength, resulting in parts that exhibit superior durability and precision.

[0269] Material Cost Savings: By using red mud-derived fillers like alumina, silica, and iron oxides, RMCP significantly reduces overall material costs, making it more affordable than traditional high-performance polymers.

[0270] Reduced Waste in Additive Manufacturing: RMCP’s high powder reusability in additive manufacturing processes like Direct Drill 3D, SLS, and MJF leads to cost savings by reducing the need for fresh powder after each cycle.

[0271] Wide Range of Applications: RMCP’s compatibility with multiple additive manufacturing technologies, such as Direct Drill 3D, SLS, MJF, and Bambu Lab Carbon X1 , expands its market potential across industries such as aerospace, automotive, consumer products, and medical devices.

[0272] Sustainability Appeal: As sustainability becomes a priority for companies worldwide, RMCP’s eco-friendly profile gives it a competitive edge for businesses looking to reduce their environmental impact.

[0273] Red Mud Utilization: Unlike existing polymers, RMCP leverages red mud, transforming it from a waste product into a valuable raw material for high-performance composites.

[0274] Cavitation-Enhanced Processing: The use of cavitation during filler extraction and blending improves the dispersion of fillers in the polymer matrix, resulting in enhanced mechanical and thermal properties.

[0275] In short, the described RMPCs deliver superior performance in terms of strength, thermal stability, and environmental sustainability, making it an ideal choice for a wide range of industries and additive manufacturing technologies such as Direct Drill 3D, SLS, MJF, and Bambu Lab Carbon X1 . RMCP, and the like.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0276] The RMCPs of the present embodiments outperform traditional polymers like PA12 and Nylon 11 in terms of tensile strength, impact resistance, and thermal stability. It offers up to 20% greater tensile strength than PA12, with a higher heat deflection temperature (HDT) by 15°C, making it ideal for high-stress, high-temperature applications. Testing Standards: ASTM D638: Standard Test Method for Tensile Properties of Plastics and ISO 527: International standard for determining tensile properties of plastics.

[0277] Exemplary results against PA 12 may include:

[0278] 1 . Study 1 : a. Title: "Mechanical Properties of Red Mud Reinforced Polymer Composites" b. Materials: Red mud fillers in a polypropylene (PP) matrix. c. Findings: d. Tensile strength increased by 10-15% with up to 20% red mud filler content. e. Optimal filler content was around 15%.

[0279] 2. Study 2: a. Title: "Enhancement of Mechanical Properties in Nylon Composites with Red Mud Fillers" b. Materials: Red mud fillers in a Nylon 6 matrix. c. Findings: d. Tensile strength improved by 12% at 10% filler content. e. Higher filler content led to agglomeration and decreased mechanical properties.

[0280] 3. Study 3: a. Title: "Use of Red Mud as a Reinforcing Filler in Polyamide Composites" b. Materials: Red mud fillers treated with coupling agents in PA12 matrix. c. Findings: d. Tensile strength increased by 18% with surface-treated fillers at 15% content.Attorney Docket No. 21681-163057-WOCustomer No. 42798 e. Improved dispersion due to surface treatment.

[0281] It is noted that these studies are indicative but may not directly correspond to RMCP's exact composition and processing methods.

[0282] Comparative analysis may include the following:

[0283] RMCP vs. PA12 a. PA12 Tensile Strength: 50-55 MPa b. RMCP Tensile Strength: Projected at 60 MPa c. Improvement: Approximately 9-20% increase

[0284] RMCP vs. Nylon 11 a. Nylon 11 Tensile Strength: 45-50 MPa b. RMCP Tensile Strength: Projected at 60 MPa c. Improvement: Approximately 20-33% increase d. RMCP vs. PEEK e. PEEK Tensile Strength: 90-100 MPa f. RMCP Tensile Strength: 60 MPa g. Comparison: RMCP does not reach PEEK'S tensile strength but offers a significant cost advantage.

[0285] The RMCP’s use of red mud as a filler significantly reduces environmental waste and its carbon footprint compared to conventional petroleum-based polymers. The embodiments provide a comprehensive method and system for producing RMCP and using it in advanced applications, and additive manufacturing systems like Direct Drill 3D, SLS, MJF, and Bambu Lab Carbon X1. RMCP delivers superior performance in terms of strength, thermal stability, and environmental sustainability, making it an ideal choice for a wide range of industries and additive manufacturing technologies.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0286] According to another embodiment, a system and method for selectively recovering lithium from oil-and-gas produced water while removing emulsified oils, suspended solids, and metals is provided. The system employs shock-hydrodynamic cavitation in a specialized manifold to disrupt emulsions, followed by optimized dissolved air flotation (DAF) for contaminant removal. Careful pH, redox control, and lithium-preserving coagulants and flocculants prevent lithium co-precipitation. The clarified effluent, containing dissolved lithium, is amenable to further extraction or concentration steps, such as ion exchange, selective adsorption, or membrane filtration, achieving lithium recovery of 90-95% or higher.

[0287] The present invention relates generally to systems and methods for treating industrial or oil field wastewater. More particularly, it concerns a process for selective lithium recovery from oil-and-gas produced water using an enhanced dissolved air flotation (DAF) technology, wherein lithium is maintained in aqueous solution while contaminants — such as emulsified oils, suspended solids, and certain heavy metals — are removed.

[0288] I. Process Overview

[0289] 1 . Produced Water Feed: Sourced from shale plays (e.g., Permian, Eagle Ford) or other oil fields. Characterized by high total dissolved solids (TDS ranging from ~10,000 mg / L to ~200,000 mg / L) and the presence of hydrocarbons, suspended solids, and metals.

[0290] 2. Density-Based Pretreatment with Controlled Cavitation: Feed passes through a shock-hydrodynamic manifold (similar to prior SHURE devices used in drilling-fluid treatments). Opposing, high-pressure fluid jets collide in a reduced-pressure zone, creating cavitation that disrupts stable emulsions. This cavitation step helps coalesce or disaggregate particulate matter based on density — without precipitating lithium ions.

[0291] 3. DAF Cell with Microbubble Injection: A side recycle stream (10-20% of the main flow) is pressurized to 70-90 psi and saturated with air. Releasing the pressurized recycle through fine nozzles produces microbubbles (~20-100 pm), which attach to hydrophobic andAttorney Docket No. 21681-163057-WO Customer No. 42798 particulate contaminants. By carefully controlling pH (6.5-7.5) and ORP (+200 to +350 mV), lithium remains in ionic form and does not precipitate within floc structures.

[0292] 4. Chemical Conditioning: Lithium-Preserving Coagulants: Low to moderate dosing of ferric or polyaluminum compounds (5-30 mg / L). Specialized Flocculants: Polymers with minimal affinity for lithium ions, typically ~0.1 — 1 .0 mg / L. pH / Redox Buffers: Ensuring conditions remain in a range preventing lithium salt precipitation or entrapment.

[0293] 5. DAF Skimming and Effluent: Surface skimming removes oil, solids, and metals as a float layer. Clarified underflow retains lithium in solution. An optional polishing filter or media filter can remove residual turbidity or fine solids prior to lithium extraction.

[0294] 6. Downstream Lithium Concentration: The clarified, lithium-rich effluent is amenable to ion exchange, selective adsorption columns, nanofiltration, reverse osmosis, or precipitation processes (e.g., lithium carbonate or hydroxide). This enables final lithium recovery at high purity and yield.

[0295] II. Exemplary Operating ParametersFeed TDS: up to 200,000 mg / LFlow Rate: 10-1000 gpm (modular, scalable system)DAF Residence Time: ~30 minutesRecycle Pressure: 80-90 psiChemical Dosage:Polyaluminum chloride: ~10 mg / LSpecialized polymer: ~0.5 mg / L pH: 7.0 ± 0.2Energy Usage: ~0.25-0.35 kWh / m3Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0296] III. SHURE Technology

[0297] The shock-hydrodynamic manifold concept has been modified from a SHURE system that is used in drilling fluids to remove ultra-fine solids without affecting valuable barite. By analogy, cavitation disrupts emulsions and density-separates contaminants, preserving target ions (in this case, lithium) in solution.

[0298] IV. System Components and Construction

[0299] Manifold & Cavitation Nozzles: Typically manufactured from 316L stainless steel or similar, rated ~150 psi or higher, with opposing jets to form a collision zone.

[0300] DAF Vessel: Rectangular or circular, ASME-coded (American Society of Mechanical Engineers), sized appropriately for the desired flow capacity using sound engineering practices.

[0301] Skimmer Assembly: Mechanical or chain-and-flight for removing float.

[0302] Instrumentation: pH and ORP probes, optional lithium ion sensors, plus PLC control.

[0303] Downstream Units: Polishing filters, adsorption or ion exchange columns, membrane modules (NF / RO) for lithium concentration.

[0304] V. Examplary Testing (Hypothetical or Pilot)

[0305] Feedwater: 200 barrels of Permian Basin produced water containing ~150 mg / L lithium, 2,000 mg / L total suspended solids (TSS), and ~2% oil-in-water.

[0306] Process:1 . Adjust pH to ~7.0 with mild acid / alkali.2. Dose ~10 mg / L polyaluminum coagulant + 0.3 mg / L specialized floc polymer.3. Pass water through manifold at ~40 psi.4. Feed DAF with ~15% recycle at 80 psi saturation.5. Skim float layer; collect clarified underflow.6. Retain ~95% of initial lithium in dissolved form.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0307] Results: ~90% oil removal, ~98% TSS removal, and no significant lithium salt precipitation. The clarified stream is ready for further lithium concentration (e.g., nanofiltration).

[0308] FIG. 11 is a schematic layout of the SHURE DAF Lithium Recovery process, showing feed tanks, chemical dosing, pressurized recycle, cavitation manifold, flotation cell, skimmer, and effluent line to downstream lithium extraction.

[0309] FIG. 12 is a cross-sectional detail of microbubble injection nozzles and the internal collision chamber of the shock-hydrodynamic manifold.

[0310] FIG. 13 is a process flow diagram illustrating density-based separation and selective removal of contaminants while preserving lithium ions in solution.

[0311] FIG. 14 is a representative graph or data chart depicting final effluent clarity versus lithium retention and overall contaminant removal efficiency.

[0312] The Enhanced DAF Lithium Recovery System offers an integrated solution for efficiently removing oil field contaminants while preserving lithium in solution. Through controlled cavitation, targeted chemical conditioning, and microbubble flotation, lithium losses are minimized, positioning the clarified effluent for subsequent lithium processing steps. This approach addresses growing market demands for sustainable lithium supply from non- traditional sources and can be deployed cost-effectively in oil-and-gas fields.

[0313] According to another embodiment, a cavitation-enhanced closed-loop cooling system for high-density computing facilities is disclosed. Groundwater is extracted via a production well and subjected to hydrodynamic cavitation to sterilize the water and remove dissolved gases while agglomerating fine particulates. The conditioned water then absorbs heat from electronic equipment through a heat exchanger and is reinjected into the same aquifer through a spatially separated injection well. The system operates with essentially zero net water consumption and without chemical biocides. By maintaining a cavitation number between about 0.5 and about 1 .0 in a cavitation manifold, at least a 3-log microbial kill is achieved in the water. The heated waterAttorney Docket No. 21681-163057-WOCustomer No. 42798 is reinjected at a temperature preferably within 1 °C of the aquifer temperature, preventing thermal pollution. These combined features enable an environmentally sustainable cooling method with high efficiency for data centers and other high-heat-load installations.

[0314] Embodiments of the disclosed cavitation-enhanced closed-loop cooling system are described in detail below, with reference to the accompanying drawings where appropriate. It is to be understood that the various features in the embodiments may be combined or modified in alternative arrangements, all within the scope of the inventive concepts.

[0315] Present System Architecture:

[0316] Referring to FIGS. 15 and 16, an exemplary cooling system is implemented using a two-well configuration in communication with an aquifer. A production well 100 is drilled or formed into a high-permeability aquifer 104 at a suitable depth (for example, roughly 60-120 meters below ground surface, depending on local geology and water tables). Groundwater from the aquifer, which may naturally be at a moderate temperature (e.g., ~15 °C in temperate regions), is drawn up through the production well by a submersible pump 106 or a similar pumping mechanism. The groundwater flows into a cavitation manifold 110, which is a specialized pipe assembly that induces hydrodynamic cavitation in the flowing water.

[0317] In the depicted embodiment, the cavitation manifold comprises opposed nozzles 112a and 112b that are aligned facing each other (See, Fig. 16), separated by a small distance (on the order of 3 to 6 times the nozzle exit diameter) forming a collision chamber 114 between them. The pump delivers the groundwater to the nozzles at a high pressure (for example, an inlet pressure on the order of 345-550 kPa, or about 50-80 psi). As the water is forced through the opposed nozzles, it accelerates and the local pressure in the jets drops. By proper design of the nozzle size and flow rate, a cavitation condition is achieved in the collision chamber 114: vapor cavities (bubbles) form in the low-pressure regions of the waterjet and then rapidly collapse when they mix and decelerate in the chamber. The flow rates through the manifold mayAttorney Docket No. 21681-163057-WOCustomer No. 42798 range, in one design, from about 100 to 300 liters per minute (L min-1) for each megawatt of heat load to be dissipated. Under these conditions, a cavitation number o between approximately 0.6 and 0.9 is achieved in the throat region, which is within the target range to initiate substantial cavitation without causing destructive effects (such as excessive vibration or material damage known as cavitation hammering). The cavitation number (o) is a dimensionless quantity that can be used to predict the likelihood of cavitation in fluid flow. It is calculated using the formula: o = (P - Pv) / (% x p x v2), where P is the local pressure, Pv is the vapor pressure, p is the fluid density, and v is the fluid velocity. A lower cavitation number indicates a higher likelihood of cavitation, while a higher number suggests a lower risk. This number is used for designing systems to cavitation damage in, for example, hydraulic systems.

[0318] The hydrodynamic cavitation generated in manifold 110 results in powerful localized effects: the implosion of microbubbles creates shockwaves on the order of hundreds of megapascals (>100 MPa) and localized hot spots with temperatures of several thousand kelvins (>5,000 K). These extreme micro-environmental conditions physically disrupt and rupture microbial cell membranes, achieving sterilization of the water (for example, bacteria such as E. coli can be reduced by 3 or more orders of magnitude in concentration). Cavitation also facilitates water treatment by stripping out dissolved gases; as bubbles form and collapse, gases like dissolved oxygen (O2), carbon dioxide (CO2), and hydrogen sulfide (H2S) come out of solution and can then be vented or separated from the flow. Furthermore, the turbulent implosion forces cause very fine particulate matter (colloids and silts below about 5 micrometers in size) to collide and agglomerate into larger particles (for example, forming >20 pm flocs). These larger particles are far less likely to pass through the pores of the aquifer or to clog equipment, and they can be filtered out if needed by standard separators. In summary, by the time the water exits the cavitation manifold, it has been sterilized, degassed, and conditioned (with reduced turbidity and scaling potential).Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0319] After leaving the cavitation manifold 110, the conditioned groundwater flows through a heat exchanger 120 that transfers heat from the electronic equipment into the water. In a data center implementation, this heat exchanger (120) can be a plate-and-frame heat exchanger or an immersion cooling distribution unit (CDU) which interfaces with the heat producer 130 (e.g., servers or racks) via loop 132 to absorb waste heat. A "plate-and-frame” type Coolant Distribution Unit (CDU) uses a known plate-and-frame heat exchanger to cool liquid coolant and distribute it to IT equipment in a liquid-cooled data center. This type of CDU is a compact, high- performance solution for efficiently transferring heat from the IT equipment's secondary coolant loop to the facility's primary coolant. The heated coolant water, now raised a few degrees in temperature by the heat exchange (depending on the heat load of the facility), is then routed to an injection well 102 via an injection header 122 and associated piping. The injection well 102 is spaced apart from the production well 100 by a sufficient distance (for example, at least on the order of the radius of the thermal plume that is expected to form in the aquifer). In one example, the wells might be about 100 meters apart to ensure that the injected warm water does not immediately recirculate back to the production well without cooling. The injection well returns the water back into the same aquifer 104 from which it was drawn, completing the closed-loop circuit.

[0320] Notably, the system is designed such that the temperature differential (AT) between the reinjected water and the native aquifer water is small. Preferably, the water is reinjected at a temperature no more than about 1 °C above the aquifer’s natural temperature. By limiting AT to around 1 °C, the system minimizes thermal disturbance to the aquifer environment and meets regulatory requirements that often restrict the amount of heating allowed in groundwater resources. This near-isothermal reinjection helps ensure that there is effectively no long-term buildup of heat in the aquifer (the heat disperses with groundwater flow and thermal conduction such that the production well continues to draw cool water).Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0321] Control and Monitoring:

[0322] To maintain optimal operation, the system employs a control logic, such as illustrated in FIG. 17. A programmable logic controller (PLC) or similar control unit receives input from various sensors placed throughout the system. For example, pressure sensors at the inlet and throat of the cavitation manifold monitor the pressure drop and calculate the current cavitation number o in real time. Temperature sensors measure the water temperature at various points (e.g., at the production well head, post-manifold, post-heat-exchanger, and at the injection well head). T urbidity or particle sensors monitor water clarity which can indicate the effectiveness of particulate agglomeration and filtration. Dissolved oxygen sensors or other gas sensors can verify the degassing performance. All these sensor readings are fed to the PLC continuously.

[0323] The PLC is programmed to adjust operating parameters to keep the system within desired ranges. Most importantly, the pump speed (or a throttling valve) is modulated via a variable-frequency drive (VFD) controller. By adjusting the pump’s rotational speed, the flow rate and pressure can be fine-tuned. The control algorithm maintains the cavitation number between about 0.5 and 1 .0. If the cavitation intensity begins to drop (o trending above 1 .0, indicating less cavitation), the pump speed may be increased to raise the flow rate or pressure drop. Conversely, if o goes too low (increasing risk of excessive cavitation that could damage components), the pump speed is reduced. This dynamic adjustment balances effective water treatment (sterilization and degassing) against mechanical wear considerations.

[0324] Additionally, the PLC uses the temperature data to ensure the reinjection temperature limit is respected. A numerical groundwater model is integrated into the control system (or used periodically) to predict the extent of the thermal plume in the aquifer. For example, a real-time modeling tool such as a MODFLOW-based simulation can take the injection flow rate and temperature data and project how the subterranean heat plume grows and moves over time. MODFLOW shows a modular finite-difference flow model, that is a computer code that solvesAttorney Docket No. 21681-163057-WOCustomer No. 42798 the groundwater flow equation. The program simulates groundwater flow through aquifers. If the model or sensor feedback indicates that the thermal plume is expanding beyond a permitted boundary or the temperature exceeds a threshold at a certain monitoring well or location, the system can automatically take corrective action. Such actions may include throttling back the flow rate (reducing total heat injection), adjusting the duty cycle of operation, or in extreme cases temporarily shutting down injection until conditions normalize. These measures ensure regulatory compliance and environmental safety of the closed-loop system.

[0325] Operating Method:

[0326] The typical operation of the system can be described in sequential stages (FIG. 17 flow chart):

[0327] Startup: Initially, the loop (surface piping, manifold, heat exchanger, etc.) is flooded with groundwater and purged of any air. The pump 106 is ramped up gradually using the VFD to the design flow rate, which might be approximately 150 L min-1per megawatt of computing load to be cooled (this value can be adjusted based on the facility’s cooling requirement). During startup, the system checks that valves are aligned properly (opening the path from production well through manifold to heat exchanger and injection well) and that initial sensor readings are within expected ranges.

[0328] Cavitation Conditioning: Once flow is established, the water passes through the cavitation manifold 110. The control system continuously monitors inlet pressure and the pressure in the collision chamber 114 (via sensors) to calculate the cavitation number o. The PLC adjusts pump speed to ensure cavitation is sustained. During this phase, the water is being actively sterilized and degassed. If, for example, the water quality is poor (high microbial load or turbidity), the system could optionally be run in a recirculation mode initially: water might be cycled through the cavitation manifold multiple times before heat absorption, in order to pre-treat and clean the water.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0329] Heat Exchange: The cavitated water flows through the heat exchanger (CDU) 120, where it absorbs waste heat from the computing equipment. The design of the heat exchanger ensures efficient thermal transfer; for instance, in a plate-and-frame exchanger, a counter-flow arrangement with stainless steel plates (optionally a corrosion-resistant duplex stainless steel for longevity) can achieve a small approach temperature difference. In practice, the system can maintain an approach temperature of <6 °C, meaning the coolant leaving the servers is only about 6 °C warmer than the coolant entering, indicating effective heat uptake.

[0330] Re-Injection & Monitoring: After picking up heat, the water is injected back into the aquifer via injection well 102. At this stage, the PLC verifies that the injection temperature is within the allowed +1 °C differential from the intake temperature (or native aquifer temperature). The system’s model updates the expected thermal plume growth; FIG. 19, for example, shows how a one-year simulation predicts the heat disperses in the aquifer. If at any point the temperature rise at the edge of the plume would exceed permissible levels (taking into account aquifer flow and diffusion), the PLC could reduce flow (thus reducing heat input) until equilibrium is maintained. Throughout steady operation, the control system might also periodically trigger self-checks, such as flushing small volumes to drain to remove accumulated gases or solids that were separated by cavitation (such purged volumes are minimal, so consumptive use of water is practically zero).

[0331] Maintenance: The system is designed for continuous operation, but periodic maintenance ensures reliability. For example, on an annual basis, the cavitation manifold 110 can be inspected internally for wear. The opposed nozzles 112a, 112b may have removable inserts made of a hard material (e.g., tungsten carbide cores) to resist cavitation erosion; these inserts can be quickly swapped out if they show signs of wear (the maintenance downtime for such replacement can be less than 15 minutes). The pump and sensors are also checked periodically, and any filters or separators that collect agglomerated particles are servicedAttorney Docket No. 21681-163057-WOCustomer No. 42798(cleaned or replaced as needed). Because the system does not rely on chemical biocides, there is no need for handling hazardous chemicals, which simplifies maintenance procedures and reduces operational cost and risk. Overall, maintenance requirements are comparable to those of standard groundwater pumps and heat exchangers, plus the unique consideration of inspecting the cavitation manifold.

[0332] Example 1 - Lab Validation:

[0333] A laboratory-scale test validates the cavitation conditioning concept in a controlled setting. A cavitation manifold approximately 0.5 inches in nozzle diameter was operated at an inlet pressure of about 400 kPa (approximately 58 psi). The test loop treated 100 liters of water that had been artificially spiked with a high concentration of microbes (specifically E. coli bacteria) and fine particulate matter to simulate fouled groundwater. The manifold was run such that water passed through the cavitation zone multiple times (four passes in total). After four passes, water sample analysis showed a 4.3-log reduction in E. coli (in other words, the microbial count was reduced by a factor of about 20,000). The water’s turbidity (a measure of cloudiness due to suspended particles) dropped from an initial 6.8 NTU (nephelometric turbidity units) down to 1.9 NTU, demonstrating effective particulate agglomeration and removal. The energy consumption for the cavitation treatment in this setup was measured at 7.2 kWh per 1 ,000 gallons of water treated. This specific energy consumption is quite reasonable given the level of treatment achieved, and in a full-scale deployment, some of that energy could potentially be recovered (for example, using an energy-recovery turbine as noted earlier). The lab validation confirms that hydrodynamic cavitation can serve the dual purpose of water treatment (sterilization and cleaning) and heat exchange facilitation without chemicals. It provides confidence that the system will function as intended when scaled to data center operations, maintaining water quality and thermal performance.Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0334] Based on the aforementioned results, the present embodiments may include configurations and provide that the manifold is run such that water is passed through the cavitation zone multiple times (e.g., four passes in total). Alternatively, the system may have multiple manifolds arranged in series along the path.

[0335] The foregoing example is provided to illustrate the principles and effectiveness of the system. In practice, full-scale systems can be designed with larger flow rates and customized manifold geometries, but the fundamental processes and controls remain consistent with what has been demonstrated.

[0336] It will be appreciated by persons skilled in the art that various modifications and adaptations of the above-described embodiments can be made without departing from the spirit and scope of the invention. For instance, while a two-well system (separate production and injection wells) is described, in certain geological situations a single well with dual piping (one for extraction, one for reinjection at a different depth) could be used, although that is less preferred due to thermal interference. The system could also be applied to cooling other industrial processes or even HVAC systems for large buildings where a suitable aquifer is present. All such alternatives are intended to be within the scope of the invention as defined by the following claims.

[0337] A warm-water direct liquid cooling system for high-density computing system and method is also disclosed. Heat from direct-to-chip cold plates is transferred via a cooling distribution unit (CDU) to a facility loop that rejects heat using air-side dry coolers. A sidestream hydrodynamic-cavitation polisher continuously treats a fraction of the coolant to sterilize microorganisms, remove dissolved gases, and agglomerate fine particles, followed by degassing, bubble separation, and <1 pm filtration. A controller maintains cavitation number (o) = 0.5-1 .0, regulates dissolved oxygen and bubble counts, and dynamically modulates the sidestream fraction (typically 5-30%) while enforcing a bubble-barrier interlock upstream ofAttorney Docket No. 21681-163057-WOCustomer No. 42798CDUs to protect microchannel cold plates. An optional groundwater two-well loop provides seasonal or redundant heat rejection, with reinjection constrained to <1 °C above native aquifer temperature and automatic throttling to limit the thermal plume. The architecture achieves near-zero water usage without continuous chemical biocides and preserves microchannel reliability.

[0338] Embodiments of the disclosed cavitation-enhanced closed-loop cooling system are described in detail below, with reference to the accompanying drawings where appropriate. It is to be understood that the various features in the embodiments may be combined or modified in alternative arrangements, all within the scope of the inventive concepts. System Architecture: The CCWDLC system comprises two primary coolant loops. An IT loop circulates coolant through a plurality of direct-to-chip cold plates attached to heat-generating components in server racks. Heat absorbed in the IT loop is transferred, via one or more cooling distribution units (CDUs), to a separate facility loop that rejects heat to ambient air using dry coolers. In a typical implementation, the facility loop operates at “warm-water” temperatures; for example, the coolant might exit the dry coolers at around 35-50 °C and return at a higher temperature after collecting heat from the IT loop, depending on the IT load. The use of warm-liquid cooling allows efficient heat rejection to air without evaporative cooling, meaning water usage is virtually eliminated (WUE = 0) during normal operation.

[0339] A controlled sidestream branch of the facility loop is connected in parallel with the main flow. A fraction of the facility loop flow (for example, about 5% to 30% of the total coolant flow) is continuously diverted through this sidestream branch for treatment and conditioning before rejoining the main loop. Within the sidestream, coolant first passes through a hydrodynamic cavitation manifold designed to operate at a target cavitation number (o) of approximately 0.5-1 .0. In one embodiment, the cavitation manifold employs opposed high- velocity nozzles directed into a collision chamber, producing intense micro-shock cavitationAttorney Docket No. 21681-163057-WOCustomer No. 42798 events where the jets collide. These controlled cavitation events inactivate microorganisms (sterilize the coolant), strip dissolved gases out of the liquid, and agglomerate fine particulates into larger particles. To withstand the high stresses and potential erosion in the cavitation zone, erosion-resistant inserts (e.g., tungsten carbide-cobalt alloy) can be installed at the nozzle outlets or collision surfaces.

[0340] Downstream of the cavitation manifold, the sidestream enters a multi-stage conditioning sequence. First, a degassing stage (for example, a vacuum degasser chamber or a hydrophobic membrane contactor) removes the dissolved gases that were liberated by cavitation. Next, the flow passes into a bubble trap (air separator) that captures and purges any entrained bubbles remaining after degassing. The degassing unit and bubble trap together ensure that by the time the sidestream coolant is ready to return to the facility loop, it is essentially bubble-free. Finally, before merging back, the sidestream passes through a fine filter (for example, a filter rated to <1 pm) that removes particulate matter, including the larger flocculated particles formed by cavitation. This filtration step maintains particle counts below levels that could clog or damage the narrow channels in the direct-to-chip cold plates. The conditioned sidestream is then reintroduced into the facility loop at a location upstream of the CDU(s), so that the now-sterile, degassed, and filtered coolant is what ultimately flows into the IT loop cold plates.

[0341] Microchannel Safety Features: The system is deliberately configured to protect delicate microchannel cold plates from any adverse effects of the conditioning process. Key architectural and control features include: a. Sidestream Isolation: The hydrodynamic cavitation process occurs entirely in the sidestream branch, which is not in series with the IT loop flow. This means the coolant that directly enters the microchannels in the IT loop never goes throughAttorney Docket No. 21681-163057-WOCustomer No. 42798 the cavitation manifold itself, avoiding any direct exposure of the microchannels to cavitation forces or large volumes of bubbles. b. Downstream Gas Removal: Both the degassing stage and the bubble trap are positioned downstream of the cavitation manifold and upstream of the point where the treated coolant re-enters the main facility loop. Thus, any gas dislodged by cavitation is actively removed before the coolant mixes back into the main loop that feeds the CDUs and IT equipment, ensuring that the coolant delivered to the cold plates is free of entrained air. c. Bubble-Barrier Interlock: The system employs a control interlock (a “bubble barrier”) to prevent coolant from flowing into the IT loop unless certain quality criteria are met. Sensors continuously monitor the coolant for dissolved oxygen (DO) level and the presence of bubbles (e.g., via an optical bubble detector or turbidity sensor). The interlock permits the CDU valves to open (allowing coolant into the IT loop) only if, for example, DO is at or below a target threshold (say <1.0 mg / L) and the bubble count is below a set threshold (e.g., fewer than 10 bubbles per milliliter above a certain size, such as >10 pm). These threshold values can be configured based on the cold plate vendor’s specifications for safe operation. If the coolant conditions are outside the safe range (meaning the coolant is not yet “bubble-safe”), the system will hold off flow to the IT loop or recirculate coolant through the facility loop until conditioning improves the coolant quality. This bubble-barrier interlock ensures that microchannels are not exposed to two-phase flow conditions. d. Particulate Filtration Compliance: The sidestream’s fine filtration step and any inline particle monitors ensure that particulate levels remain within acceptable limits. Microchannel cold plates can be highly sensitive to clogging by fineAttorney Docket No. 21681-163057-WOCustomer No. 42798 particles; by enforcing filtration to <1 pm and possibly using particle counters to track water cleanliness, the system keeps particulate contamination below the levels recommended by the cold plate manufacturer. e. Bypass and Maintenance Operation: The plumbing includes bypass lines and valves that allow the sidestream treatment components to be isolated or taken offline for maintenance without shutting down cooling. In a maintenance scenario, the sidestream can be bypassed so that coolant simply circulates through the main loops (skipping cavitation and associated stages). The bypass configuration is arranged such that if cavitation treatment is disabled or bypassed, any previously trapped gas is not suddenly released into the IT loop. For example, valves can isolate the sidestream entirely while clean, conditioned coolant (or fresh coolant) continues to flow through the CDUs to the servers. This design ensures uninterrupted cooling and microchannel safety even during sidestream downtime or servicing.

[0342] Control System and Instrumentation: A centralized control system (e.g., a programmable logic controller PLC) monitors sensor data and adjusts the operation of pumps and valves to maintain optimal conditions. Sensors placed throughout the system measure parameters including pressure, temperature, flow rates (in both main loops and sidestream), dissolved oxygen level, bubble detection (or turbidity), particle counts, and the rate of gas being vented from the degassing stage. The PLC (or similar controller) uses these inputs to actively regulate the system: a. Cavitation Intensity Control: The controller drives a variable-frequency drive (VFD) on the sidestream pump to modulate flow and pressure in the cavitation manifold. By adjusting pump speed (and / or throttling valves), the controller maintains the cavitation number (o) within the desired range (approximately 0.5-Attorney Docket No. 21681-163057-WOCustomer No. 427981.0). Keeping a in this band ensures effective cavitation for sterilization and degassing, without excessive energy usage or risk of damage. b. Sidestream Flow Adjustment: The controller can adjust the sidestream flow fraction relative to the total system flow. Under higher IT loads (when server heat output is high) or if ambient conditions reduce cooling efficiency (e.g. very hot weather), the PLC may increase the proportion of flow treated in the sidestream (toward the upper end ~30%) to boost conditioning throughput. Under lighter loads or cool ambient conditions, a smaller sidestream fraction (e.g. ~5% or even temporarily turning off the sidestream) might suffice to maintain coolant quality and temperature. This dynamic control of sidestream percentage helps balance thermal performance with energy usage. c. Dissolved Oxygen Control: The PLC manages dissolved oxygen (DO) levels by coordinating cavitation intensity and degassing operation. If DO sensors detect a rise in dissolved oxygen above the target band (for instance, above ~0.5— 1 .0 mg / L), the controller can respond by increasing the sidestream flow or cavitation power to strip more gas, and / or engaging vacuum pumps or opening vent valves in the degassing stage to extract the excess air. This feedback loop quickly brings DO back down to safe levels. Lower DO not only protects against bubble formation but also reduces corrosion potential in the loop. d. Particle and Turbidity Monitoring: If particle counters indicate rising particulate levels (which could happen, for example, if the filter is becoming saturated or if an ingress of debris occurred), the system can signal an alert or adjust operations. The PLC might slightly increase sidestream flow to filter more coolant, or schedule a maintenance alert for filter replacement, thereby preventing any degradation in coolant cleanliness from affecting the IT loop.Attorney Docket No. 21681-163057-WOCustomer No. 42798 e. Purge / Vent Cycles: To handle any gradual accumulation of gas in separators, the controller periodically executes short purge cycles. For instance, at set intervals (or triggered by a sensor that measures trapped gas volume or pressure), a valve on the bubble trap / air separator will open briefly to vent collected gases to atmosphere (or to a gas capture reservoir). This purge is only for a few seconds and is infrequent, so it does not significantly increase water loss (thus preserving near-zero water usage). The controller times these vent actions when they will not impact cooling (e.g., when thermal load is momentarily low or stable), ensuring smooth operation. After venting, the valve closes and normal sidestream conditioning continues. Such automated purge cycles ensure that air separators maintain their efficiency and that any minor gas buildup is routinely cleared.

[0343] Through these measures, the control system keeps the CCWDLC running within safe and optimal bounds without manual intervention. The controller can be integrated into facility monitoring systems to log performance and issue alerts (for example, notifying if a filter is due for replacement or if cavitation efficacy drops, perhaps due to nozzle wear or pump issues). Overall, the instrumentation and active controls maintain coolant quality (sterility, degassed, low particulate) and thermal performance autonomously.

[0344] Heat Rejection and Water Usage: In the primary embodiment, heat is rejected from the facility loop via dry coolers in a closed-loop configuration. The dry coolers are sized to handle the warm-water temperatures coming from the CDUs during typical operating conditions. For example, coolant leaving the servers might be ~50 °C and after passing through the aircooled dry cooler heat exchangers, could return at ~35-40 °C, ready to absorb more heat from the IT loop. Because the cooling is done with ambient air and not by evaporating water, theAttorney Docket No. 21681-163057-WOCustomer No. 42798 system achieves near-zero consumptive water use for cooling. Unlike cooling towers, these dry coolers do not require a constant supply of makeup water or chemical water treatment.

[0345] Adiabatic pad duty may be limited to short durations (e.g., < 50 hours / year) such that effective WUE remains near zero.

[0346] During periods of extremely high ambient temperatures or unusual peak IT loads that approach the limits of the dry coolers’ capacity, the system can optionally employ an adiabatic assist on the dry coolers. In an adiabatic assist mode, a small amount of water is misted or dripped over the air intake of the dry cooler to pre-cool the air by evaporation, thereby boosting cooling performance temporarily. This mode would be used sparingly (only a few hours per year at most) to ensure that overall water usage remains minimal and nearly zero during normal operations. The assist can be automated by the controller to turn on only when necessary (e.g., when ambient temperature exceeds a set threshold and IT load is at maximum).

[0347] The cooling architecture is flexible, and other heat rejection methods can be integrated if advantageous for a given site. For instance, a facility could utilize closed-loop geothermal borefields (underground heat exchangers) as an alternative or supplement to dry coolers. In another variation, a heat pump could be incorporated to transfer heat from the facility loop to another medium or to upgrade the waste heat for reuse (e.g., heating a building), or simply to ensure adequate cooling if ambient air alone is insufficient. These alternatives can be implemented depending on environmental conditions or sustainability goals.

[0348] In one alternative embodiment, the system includes a groundwater-based two-well cooling loop for heat rejection (as mentioned earlier and depicted conceptually in FIG. 24). Here, a production well draws cool groundwater which passes through a heat exchanger to absorb heat from the facility loop coolant, and then the warmed groundwater is returned to the aquifer via a spaced injection well. To protect the environment, the controller limits the reinjection temperature rise (AT) to no more than about 1 °C above the natural aquiferAttorney Docket No. 21681-163057-WOCustomer No. 42798 temperature. By keeping AT so low, the thermal plume (the region of the aquifer experiencing heating) is kept very small. The system can use real-time temperature data and even groundwater flow models to throttle the rate of heat rejection if needed, ensuring compliance with any regulatory limits on aquifer heating. This groundwater loop can operate year-round or be used in specific seasons (e.g., only in the hottest summer months or as a backup). It provides additional cooling capacity and resilience while still benefiting from the cavitation conditioning on the sidestream. Importantly, even in this embodiment, the water that is injected back underground has been sterilized and degassed by the cavitation treatment, which can help prevent biofouling in the wells and reduce scaling, maintaining the long-term viability of the wells.

[0349] Materials and Coolants: The components in contact with the coolant are chosen for compatibility and durability. The microchannel cold plates in the IT equipment are typically made of metals with high thermal conductivity such as copper or aluminum. The CCWDLC system works with both conventional machined cold plates and advanced additively manufactured cold plates that may have complex channel designs for improved heat transfer. All wetted parts of the system (pipes, heat exchangers, cavitation device, valves, etc.) are selected to minimize corrosion — common materials include stainless steels, certain plastics or composites, and corrosion-resistant metal alloys, in order to avoid galvanic corrosion or degradation under warmwater conditions. Where copper and aluminum are both present (e.g., mixed-metal cold plates or heat exchangers), galvanic isolation or compatible inhibitors per supplier guidance are provided.

[0350] The coolant itself is preferably deionized water (DI water), which has excellent heat capacity and is standard in electronics liquid cooling. In colder climates or where the facility could experience near-freezing conditions, the coolant may be a water-glycol blend (for example, a mixture of water with ethylene glycol or propylene glycol) to lower the freezing point.Attorney Docket No. 21681-163057-WOCustomer No. 42798Appropriate corrosion inhibitors and biocides (if needed) would be added to such a blend, although one goal of this system is to eliminate the need for continuous chemical biocides by using cavitation-based sterilization. Thanks to the continuous conditioning provided by this system, the coolant remains low in dissolved oxygen (reducing oxidative corrosion) and low in microbes (reducing microbiologically influenced corrosion and biofilm formation). Particulate levels are also kept low, which means less abrasive wear or sediment accumulation in tight passages. As a result, the maintenance interval for coolant replacement and the replenishment of any corrosion inhibitors can be extended compared to a traditional system that doesn’t have such in-line conditioning. Overall, the materials and coolant management strategies are aimed at long-term reliability and minimal maintenance overhead.

[0351] Examples: (Non-limiting illustrations) a. Example 1 (5 MW Data Center): A data center facility with a 5 MW IT heat load is cooled using the CCWDLC architecture. The sidestream flow fraction is initially set to about 15% of the total coolant flow. The cavitation manifold operates at a cavitation number (o) of approximately 0.7, which in testing has achieved at least a 3-log (99.9%) reduction in viable microbial count in a microbe assay in the sidestream. The system maintains dissolved oxygen at or below ~0.5— 1 .0 mg / L in the coolant. A fine filter (1 pm) ensures particulate counts remain under the specifications required by the microchannel cold plate manufacturer. In this scenario, the dry coolers are able to maintain the coolant supply temperature within desired setpoints for over 95% of the hours in a typical year. Only during the hottest ambient conditions are the optional adiabatic pads briefly activated to assist the dry coolers. Consequently, the effective water usage for cooling is essentially zero during normal operation, meeting sustainability goals while protecting the IT equipment.Attorney Docket No. 21681-163057-WOCustomer No. 42798 b. Example 2 (Hot Restart Stress Test): In a simulated stress test, the system undergoes a sudden hot-restart event - meaning that after a period of downtime, the IT load spikes and stagnant coolant (which had warmed and absorbed some air) begins circulating rapidly. Sensors detect an abrupt increase in bubble count due to outgassing of dissolved air from the warmed coolant. The control system immediately engages the bubble-barrier interlock, temporarily closing the path to the IT loop to prevent two-phase coolant from reaching the microchannels. The servers continue to be cooled briefly by the coolant already in the IT loop and the thermal inertia of the system while this happens. Simultaneously, the PLC triggers a vent cycle: the air separator in the sidestream quickly opens its vent valve to purge the accumulated gas into the atmosphere. Within a short time, the dissolved oxygen and bubble readings drop back below the critical thresholds. The interlock then re-opens, allowing normal coolant flow through the CDUs to resume, and cooling operation continues as normal. Throughout this event, the microchannel plates are safeguarded from any two-phase flow. This example demonstrates the system’s resilience to transients and its ability to self-correct abnormal conditions without manual intervention.

[0352] Systems and methods are provided for turbidity-constrained sediment removal and resource recovery from water bodies. A surface loop draws water and sediment into a hydrodynamic cavitation device and a dissolved air flotation unit to separate bulk solids and return clarified effluent, while a subsurface loop concurrently draws fines and porewater through at least one horizontal under-drain well disposed beneath a sediment bed. Sensors measure turbidity at a compliance point and a loading value indicative of flotation capacity. A controller dynamically allocates flow between the surface (Qs) and subsurface (Qu) loops, adjusts chemistry, and schedules well back-flush events to maintain turbidity below a target (e.g., <50Attorney Docket No. 21681-163057-WOCustomer No. 42798NTU) while maximizing solids capture and energy efficiency. Separated fractions are routed to selective recovery modules to produce marketable products, including phosphorus precipitates (struvite / brushite), barite concentrates, rare-earth / metal ion-exchange products, and lithium- compatible brines. The architecture reduces plume risk, enables continuous online operation for sensitive waters, and lowers net cost relative to dredging by co-optimizing under-drain extraction with surface cavitation / flotation.

[0353] Embodiments of the disclosed system are described in detail below, with reference to the accompanying drawings where appropriate. It is to be understood that the various features in the embodiments may be combined or modified in alternative arrangements, all within the scope of the inventive concepts.

[0354] 1 . Definitions

[0355] Compliance point: a monitored location in the water column where turbidity must not exceed a threshold (e.g., intake structure, isolation cell boundary, downstream station).

[0356] DAF loading: the solids mass flux presented to the flotation separation zone, expressed as kg / m2h or as influent TSSxflow (kg / h), with a setpoint designated to prevent overload, fouling, or carryover.

[0357] Cavitation manifold / device: a pressure-drop, geometry-induced hydrodynamic cavitation reactor generating micro-bubble implosions and high shear.

[0358] Horizontal under-drain well: a directionally drilled lateral (e.g., 50-300 m) with screened section (slot 0.1-2.0 mm) placed beneath or within the sediment bed.

[0359] Selective recovery module: process unit to extract a targeted commodity (e.g., phosphorus as struvite or brushite, barite solids, REE / metal capture via IX or chelation, lithium-friendly retention).

[0360] 2. System Architecture (FIGS. 26-27)Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0361] A surface intake (adjustable elevation near bed) feeds a high-head pump driving a cavitation manifold (e.g., AP 100-500 psi). Cavitated slurry flows to a DAF unit, yielding clarified effluent (often <5 NTU) returned to the water body and float solids to a concentrate handling train. In parallel, one or more horizontal under-drain wells connect to a low-to-moderate head pump (e.g., 10-200 gpm per well). The under-drain loop may be routed to a dedicated fines settling / filtration skid, to the DAF influent as a controlled fraction, or to modular recovery units for targeted fractions. Sensors include turbidity at compliance points and outlets; inline TSS; pressure / flow on both loops; pH / ORP for chemistry; optional inline particle size, conductivity, temperature, and UV-Vis / NIR metal proxies.

[0362] 3. Controls and Operation (FIGS. 28, 30)

[0363] A controller (PLC / SCADA or ML-assisted) executes flow allocation to satisfy: (A) turbidity constraint T < T_target (e.g., <50 NTU at compliance), and (B) DAF loading constraint L < L_max (to avoid overload / fouling), while maximizing solids capture per unit energy. Control actions include adjusting Qs (surface flow) and Qu (under-drain flow), scheduling well back-flush cycles (e.g., reverse flow 10-60 s per cycle), setting A / W and coagulant dose in DAF, and optional pulsed cavitation to limit in-situ plume formation near the intake.

[0364] In one embodiment, the controller solves a multi-objective problem at each interval: maximize (solids removed I energy) subject to T < T_target and L < L_max; decision variables include Qs, Qu, recycle ratio, and coagulant dose.

[0365] Illustrative pseudo-logic:

[0366] loop:

[0367] read T_compliance, T_effluent, L_DAF, Qs, Qu

[0368] if T_compliance > T_target:

[0369] decrease Qs; increase Qu within Qu_max

[0370] elif L_DAF > L_max:Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0371] decrease Qs; increase Qu or trigger well back-flush

[0372] else:

[0373] increment Qs until either constraint approaches threshold

[0374] schedule periodic well back-flush events

[0375] end

[0376] 4. Horizontal Well Subsystem (FIG. 29)

[0377] Laterals are placed at or below the sediment interface with screened intervals sized for site granulometry, optionally with graded filter packs. Preferred layouts use multi-laterals fanned from a shore heading. Back-flush is implemented via branching header or reversible pump. Qu is tuned to maintain laminar entrance velocities at the screen (e.g., Reynolds number <2,000) to prevent piping / voids.

[0378] 5. Exemplary Resource Recovery (FIG. 31)

[0379] Phosphorus: adjust pH (e.g., 8-9) and add Mg2+to precipitate struvite (MgNH4PO4'6H2O) or brushite; granulate to >1.5 mm. Barite (BaSO4): use classification / gravity to concentrate a high-SG fraction for industrial reuse. REE / metals: staged ion-exchange or chelation (e.g., phosphonate, aminopolycarboxylate ligands) with regenerant producing a mixed REE concentrate. Lithium-friendly regime: select coagulants / chemistry to retain Li in solution upstream; extract Li downstream via IX / electrochemistry.

[0380] 6. Typical Performance Ranges (non-limiting)

[0381] Surface loop flow (Qs): 100-300 gpm per skid; DAF effluent often <5 NTU. Under-drain flow (Qu): 10-200 gpm per lateral; cumulative low-turbidity fines removal 24 / 7. Compliance turbidity: maintain <50 NTU during operations. Cavitation energy: ~0.25-0.35 kWh / m3. Solids handled: fine silt / clay dominant; coarse deltas addressed by adjunct mechanical dredging while the system strips fines and controls turbidity.

[0382] 7. Use Cases (FIGS. 26, 32)Attorney Docket No. 21681-163057-WOCustomer No. 42798

[0383] Drinking water reservoirs (intake forebay polishing); hydropower reservoirs (turbidity-controlled maintenance without outage); agricultural nutrient reservoirs (P / N removal with fertilizer recovery); coal / AMD basins (REE / metal value recovery + cleanup); oil & gas pits / ponds (barite and fines recovery); dam-removal staging (pre-extraction of fines / contaminants prior to breach).

[0384] Example Embodiments (non-limiting)

[0385] Example 1 - Intake Forebay Polishing (Potable Water): One 200 gpm skid and two under-drain laterals (Qu total 60 gpm) maintain <50 NTU at an intake compliance point while removing 30-60 m3 / day of fines-dominated sediment. DAF effluent averages <2 NTU. Phosphorus is precipitated as struvite (granules >1.5 mm).

[0386] Example 2 - Coal / AMD Basin (REE / Metals): DAF underflows and under-drain fines contact staged ion-exchange columns to capture REEs; regenerant produces a mixed REE concentrate. Barite is recovered by gravity classification from a dense fraction.

[0387] Example 3 - Coarse Delta + Fines Control (Hybrid): A limited mechanical dredge removes coarse delta deposits while the disclosed system runs before / during / after to strip fines, hold compliance NTU, and harvest nutrient fractions.

[0388] Advantages

[0389] • Turbidity-controlled operations (live service) versus plume-prone dredging.

[0390] • Dual-path capture increases overall removal efficiency and run-time.

[0391] • Programmable back-flush mitigates well clogging.

[0392] • Resource recovery offsets cost, enabling profit-positive sediment management.

[0393] • Modular scaling across reservoirs, forebays, AMD and coal-impacted sites.

[0394] System Architecture (FIGS. 26-27). A surface intake (120) delivers water / sediment to a high-head pump (210), cavitation manifold (220), and DAF unit (230). Clarified effluent (232) is returned to the water body; float solids (234) are directed to concentrate handling and recoveryAttorney Docket No. 21681-163057-WOCustomer No. 42798(310-340). Concurrently, under-drain wells (260) coupled to a low / mod-head pump (262) route fines to a filtration skid (270) and, optionally, into the DAF influent or recovery modules. Sensors (240) include turbidity at a compliance point and DAF loading. The controller (250) adjusts Qs and Qu to satisfy turbidity and loading constraints.

[0395] Controls and Operation (FIG. 28, FIG. 30). Inputs (302-306) feed the controller (350), which outputs actuator commands (360-364). The controller maintains turbidity below a target while constraining DAF loading at or below a setpoint, and schedules back-flush cycles through header (540) responsive to pressure rise or flow decay. Trends (FIG. 30) illustrate maintenance of NTU < target (512) and DAF loading < limit (516) while reallocating Qs (520) and Qu (522).

[0396] Horizontal Under-Drain Subsystem (FIG. 29). Laterals (30) are placed at or below the sediment bed (510) and wrapped in a filter pack (520). Slots (532) admit porewater and fines for capture. A back-flush header (540) enables periodic flow reversal to mitigate clogging; flow to header (542) is controlled to maintain laminar entrance velocities.

[0397] Resource Recovery (FIG. 31). Concentrated streams are routed to phosphorus precipitation (620), barite concentration (630), rare-earth / metal capture via IX / chelation (640), and lithium-friendly regimes (650), generating marketable products while reducing disposal volumes.

[0398] Mobile Deployment (FIG. 32). Multiple skids (610, 612) operate with isolation curtains (620, 622) and a shared wellfield (630). A legend (700) clarifies symbology: solid lines indicate under-drain laterals; dotted lines indicate isolation curtains.

[0399] Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the description inAttorney Docket No. 21681-163057-WOCustomer No. 42798 conjunction with the drawing figures, in which like reference numerals are carried forward. To avoid redundancy, repetitive description of similar features may not be made in some circumstances.

[0400] REFERENCE NUMERALS IN THE FIGURES

[0401] 8 — Facility loop header

[0402] 24 — Cavitation manifold

[0403] 26 — Degasser I gas separator

[0404] 28 — Bubble trap

[0405] 30 — Fine filter (< 1 pm)

[0406] 52 — Tee tie-in

[0407] 56 — Isolation valve

[0408] 58 — Flow indicator I arrow

[0409] 60 — Instrumentation port (e.g., DO / particle / bubble)

[0410] 62 — Bubble counter

[0411] 64 — Dissolved oxygen sensor

[0412] 66 — Particle counter

[0413] 72 — Erosion-resistant insert

[0414] 74 — Collision chamber

[0415] 76 — Nozzle exit diameter

[0416] 78 — Nozzle spacing

[0417] 80 — Cavitation number (o) = 0.5-1.0

[0418] 110 Cavitation+DAF skid

[0419] 120 adjustable surface intake

[0420] 122 isolation curtainAttorney Docket No. 21681-163057-WOCustomer No. 42798

[0421] 130 under-drain header

[0422] 132 horizontal under-drain laterals

[0423] 210 high-head pump

[0424] 220 cavitation manifold

[0425] 230 DAF unit

[0426] 232 clarified effluent return

[0427] 234 float solids

[0428] 240 sensors (turbidity @ compliance, DAF loading)

[0429] 250 controller (PID / ML)

[0430] 260 under-drain wells

[0431] 262 low / mod-head pump

[0432] 270 fines settling / filtration skid

[0433] 310 phosphorus recovery (struvite / brushite)

[0434] 320 barite concentration

[0435] 330 REE / metal IX / chelation

[0436] 340 lithium-friendly regime

[0437] 302-306 control inputs / constraints

[0438] 350 controller block

[0439] 360 actuators (pump speeds)

[0440] 362 chemistry dosing

[0441] 364 maintenance / back-flush scheduling

[0442] 510 sediment bed

[0443] 520 filter pack

[0444] 530 screened lateral

[0445] 532 slot openingsAttorney Docket No. 21681-163057-WOCustomer No. 42798

[0446] 540 back-flush header

[0447] 542 flow to header (Qu)

[0448] 510 / 512 / 514 / 516 tre n d ite ms

[0449] 520 Qs

[0450] 522 Qu

[0451] 610 Skid A

[0452] 612 Skid B

[0453] 620 Curtain A

[0454] 622 Curtain B

[0455] 630 shared wellfield

[0456] 700 legend / key

Claims

Attorney Docket No. 21681-163057-WOCustomer No. 42798CLAIMSWE CLAIM:

1. A composite material comprising a polymer matrix, selected from a bio-based polyamide or synthetic polyamide, and fillers derived from red mud, including alumina (AI2O3), silica (SiO2), iron oxides (Fe2O3or Fe3O4), calcium carbonate (CaCO3), and nanoclay (Montmorillonite).

2. The composite material of claim 1 , wherein the polymer matrix is derived from 1 1- aminoundecanoic acid or other polyamides such as PA12 or PA6.

3. The composite material of claim 1 , wherein the inorganic fillers are extracted from red mud using cavitation-assisted leaching, magnetic separation, or supercritical fluid extraction.

4. A method for producing a composite material, comprising the steps of extracting alumina, silica, iron oxides, and calcium carbonate from red mud, synthesizing a polymer matrix, and blending the inorganic fillers with the polymer matrix using high-energy blending and cavitation.

5. The method of claim 4, further comprising the step of surface functionalizing the inorganic fillers with a silane coupling agent to enhance bonding with the polymer matrix.

6. The method of claim 4, wherein the composite material is processed using injection molding, extrusion, or additive manufacturing techniques such as Selective Laser Sintering (SLS) or Multi Jet Fusion (MJF).Attorney Docket No. 21681-163057-WOCustomer No. 427987. The composite material of claim 1 , further comprising graphene or carbon nanotubes to enhance tensile strength, thermal conductivity, or electrical conductivity.

8. The method of claim 4, wherein the composite material is processed into spherical powder particles using spray drying for additive manufacturing applications.

9. A method of recycling RMCP powder, comprising the steps of collecting unused powder from an additive manufacturing process, reprocessing it into the required particle size, and reusing it for further manufacturing cycles.

10. A composite powder material for use in Direct Drill 3D, SLS, and MJF additive manufacturing systems, comprising:20-30% by weight alumina (AI2O3);10-20% silica (SiO2);5-10% iron oxides (Fe2O3or Fe3O4);5-15% calcium carbonate (CaCO3); and2-5% nanoclay (Montmorillonite).

Images