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

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Integration of Nuclear Material Accounting Data and Process Monitoring Data for Improvement on Detection Probability in Safeguarding Electrochemical Processing Facilities (Final Technical Report)

The KAERI advanced spent fuel conditioning process (ACP) process is a critical component of the US- South Korean nuclear cooperation and the following “123 Agreement.” Its development has received considerable attention in both countries. The ACP is an electrochemical processing (pyroprocessing) that recycles over 96% of the used nuclear fuel (UNF). It is also intrinsically proliferation-resistant in theory. In normal operation, the U/TRU product is very hot radiologically. In addition, the Cm provides a high level of spontaneous neutrons, making the product unsuitable for weapon use. However, as pointed in some study, “the need for safeguards to protect against the diversion and misuse of separated plutonium applies essentially equally to all grades of plutonium.” As pointed by many studies, the well-established traditional Nuclear Material Accounting (NMA) approach cannot be directly applied to electrochemical processing because of the lack of an input accountability tank, the non-continuous material flow, and the unsatisfactory level of confidence in sampling methods. Therefore, nuclear safeguards remain a grand challenge in the developing of commercial electrochemical separations facilities, especially around the heart of such facilities, the electrorefiner (ER) systems. In contrast to NMA data, process monitoring (PM) data is normally an indirect measurement of the SNM and is acquired much more frequently. In a broad sense, PM includes monitoring by various types of equipment, e.g. radiation detectors, cameras, voltage, current sensors. Because it is already being collected by the operator, the additional cost to safeguards is low. It has long been believed that PM data can supplement NMA data and help improve safeguards, although the benefits are hard to quantify. The U.S. DOE’s Material Protection, Accounting, and Control Technology (MPACT) campaign has made substantial investments into innovative PM sensor technology and predictive model development for real- or near real-time measurement and prediction of molten salt density and level, salt composition and actinide concentration especially Pu, the cell voltage, and the cell current to supplement traditional NMA. For aqueous-based reprocessing facilities, it is reported that PM, integrated with traditional NMA, have a high detection probability for specific diversions. For electrochemical reprocessing, preliminary studies have shown that PM data can support traditional NMA in various ways by providing a basis to estimate some of the in-processing nuclear material inventories. Despite early success, further studies on fusion of PM data and NMA data are still needed, which is the goal of this proposed work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

[Challenges and Opportunities in] Process Modeling of Intensified Chemical Processes

Before the benefits of process intensification can be fully realized, a multitude of advances in process modeling will be necessary. Process intensification (PI) has the potential to speed development of chemical engineering innovations. Among its many benefits, PI can increase the driving forces (physical and/or chemical) for transport phenomena, separations, and/or reactions in chemical processes, and inspire novel process configurations with major technical and economic benefits. Examples of PI applications include integrated process units such as heat exchange networks, sorption- or membrane-enhanced reactors, and dividing-wall distillation columns, among others [AIChE(2017)].

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRSDate not supplied

Additive Manufacturing Model-Based Process Metrics: Reduced Order Modeling of the Laser Powder Bed Fusion Process

The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. In this work, we describe a fully parallel reduced order modeling approach that has been developed to evaluate the evolution of AM processes, termed the AM moment measure method. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology and terminology of the approach will be described, and computed build maps will be calculated and compared for various laser powder bed fusion (LPBF) builds of Ti-6Al-4V. Such comparative results develop understanding of how the sequential process actions can affect the LPBF-AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
DOE OSTI2011

IMPACT OF THE SMALL COLUMN ION EXCHANGE PROCESS ON THE DEFENSE WASTE PROCESSING FACILITY - 12112

The Savannah River Site (SRS) is investigating the deployment of a parallel technology to the Salt Waste Processing Facility (SWPF, presently under construction) to accelerate high activity salt waste processing. The proposed technology combines large waste tank strikes of monosodium titanate (MST) to sorb strontium and actinides with two ion exchange columns packed with crystalline silicotitanate (CST) resin to sorb cesium. The new process was designated Small Column Ion Exchange (SCIX), since the ion exchange columns were sized to fit within a waste storage tank riser. Loaded resins are to be combined with high activity sludge waste and fed to the Defense Waste Processing Facility (DWPF) for incorporation into the current glass waste form. Decontaminated salt solution produced by SCIX will be fed to the SRS Saltstone Facility for on-site immobilization as a grout waste form. Determining the potential impact of SCIX resins on DWPF processing was the basis for this study. Accelerated salt waste treatment is projected to produce a significant savings in the overall life cycle cost of waste treatment at SRS.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Gaussian process-based surrogate modeling framework for process planning in laser powder-bed fusion additive manufacturing of 316L stainless steel

Here, Laser Powder-Bed Fusion (L-PBF) metal-based additive manufacturing (AM) is complex and not fully understood. Successful processing for one material, might not necessarily apply to a different material. This paper describes a workflow process that aims at creating a material data sheet standard that describes regimes where the process can be expected to be robust. The procedure consists of building a Gaussian process-based surrogate model of the L-PBF process that predicts melt pool depth in single-track experiments given a laser power, scan speed, and laser beam size combination. The predictions are then mapped onto a power versus scan speed diagram delimiting the conduction from the keyhole melting controlled regimes. This statistical framework is shown to be robust even for cases where experimental training data might be suboptimal in quality, if appropriate physics-based filters are applied. Additionally, it is demonstrated that a high-fidelity simulation model of L-PBF can equally be successfully used for building a surrogate model, which is beneficial since simulations are getting more efficient and are more practical to study the response of different materials, than to re-tool an AM machine for new material powder.

316L stainless steel↗
DOE OSTI2018

Spontaneous Charge Separation and Sublimation Processes are Ubiquitous in Nature and in Ionization Processes in Mass Spectrometry

Ionization processes have been discovered by which small and large as well as volatile and nonvolatile compounds are converted to gas-phase ions when associated with a matrix and exposed to sub-atmospheric pressure. Here, we discuss experiments further defining these simple and unexpected processes. Charge separation is found to be a common process for small molecule chemicals, solids and liquids, passed through an inlet tube from a higher to a lower pressure region, with and without heat applied. This charge separation process produces positively- and negatively-charged particles with widely different efficiencies depending on the compound and its physical state. Circumstantial evidence is presented suggesting that in the new ionization process, charged particles carry analyte into the gas phase, and desolvation of these particles produce the bare ions similar to electrospray ionization, except that solid particles appear likely to be involved. This mechanistic proposition is in agreement with previous theoretical work related to ion emission from ice. .

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Unsupervised multimodal fusion of in-process sensor data for advanced manufacturing process monitoring

Effective monitoring of manufacturing processes is crucial for maintaining product quality and operational efficiency. Modern manufacturing environments often generate vast amounts of complementary multimodal data, including visual imagery from various perspectives and resolutions, hyperspectral data, and machine health monitoring information such as actuator positions, accelerometer readings, and temperature measurements. However, fusing and interpreting this complex, high-dimensional data presents significant challenges, particularly when labeled datasets are unavailable or impractical to obtain. This paper presents a novel approach to multimodal sensor data fusion in manufacturing processes, inspired by the Contrastive Language-Image Pre-training (CLIP) model. We leverage contrastive learning techniques to correlate different data modalities without the need for labeled data, overcoming limitations of traditional supervised machine learning methods in manufacturing contexts. Our proposed method demonstrates the ability to handle and learn encoders for five distinct modalities: visual imagery, audio signals, laser position (x and y coordinates), and laser power measurements. By compressing these high-dimensional datasets into low-dimensional representational spaces, our approach facilitates downstream tasks such as process control, anomaly detection, and quality assurance. The unsupervised nature of our method makes it broadly applicable across various manufacturing domains, where large volumes of unlabeled sensor data are common. We evaluate the effectiveness of our approach through a series of experiments, demonstrating its potential to enhance process monitoring capabilities in advanced manufacturing systems. This research contributes to the field of smart manufacturing by providing a flexible, scalable framework for multimodal data fusion that can adapt to diverse manufacturing environments and sensor configurations. The proposed method paves the way for more robust, data-driven decision-making in complex manufacturing processes.

Contrastive Learning↗
DOE OSTI2014

Fast, multi-channel real-time processing of signals with microsecond latency using graphics processing units

Fast, digital signal processing (DSP) has many applications. Typical hardware options for performing DSP are field-programmable gate arrays (FPGAs), application-specific integrated DSP chips, or general purpose personal computer systems. This paper presents a novel DSP platform that has been developed for feedback control on the HBT-EP tokamak device. The system runs all signal processing exclusively on a Graphics Processing Unit (GPU) to achieve real-time performance with latencies below 8 μs. Signals are transferred into and out of the GPU using PCI Express peer-to-peer direct-memory-access transfers without involvement of the central processing unit or host memory. Tests were performed on the feedback control system of the HBT-EP tokamak using forty 16-bit floating point inputs and outputs each and a sampling rate of up to 250 kHz. Signals were digitized by a D-TACQ ACQ196 module, processing done on an NVIDIA GTX 580 GPU programmed in CUDA, and analog output was generated by D-TACQ AO32CPCI modules.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Non-Equilibrium Processes, Stability, Design and Control of Pulsed Plasmas for Materials Processing

The energy and angle of impact of ions, interspersed with fluxes of neutral radicals, on the surface of wafers during plasma materials processing are critical parameters for the fabrication of microelectronic devices, nanostructure materials and biocompatible materials. This sensitivity extends to nearly all applications of plasmas to materials processing and surface modification. Low temperature plasmas for plasma materials processing have traditionally used continuously excited plasmas. However, pulsed plasma processing is an enabling technology for achieving finer resolution of microelectronics fabrication and for producing unique surface properties in a wide range of applications. This research project is addressing fundamental plasma physics issues in materials processing – the control of pulsed plasmas and the means for optimizing plasma produced reactant fluxes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Impact of Fractionation Process on the Technical and Economic Viability of Corn Dry Grind Ethanol Process

Use of corn fractionation techniques in dry grind process increases the number of coproducts, enhances their quality and value, generates feedstock for cellulosic ethanol production and potentially increases profitability of the dry grind process. The aim of this study is to develop process simulation models for eight different wet and dry corn fractionation techniques recovering germ, pericarp fiber and/or endosperm fiber, and evaluate their techno-economic feasibility at the commercial scale. Ethanol yields for plants processing 1113.11 MT corn/day were 37.2 to 40 million gal for wet fractionation and 37.3 to 31.3 million gal for dry fractionation, compared to 40.2 million gal for conventional dry grind process.

09 BIOMASS FUELS↗
DOE OSTI2021

Process Intensification and Scale-Up of a Continuous Enzymatic Hydrolysis and Separation Process

Combining separate unit operations into one where the best of each part can be maximized is one of the benefits of process intensification. An example is the combination of lignocellulosic biomass enzymatic hydrolysis with the downstream solid-liquid separation step to produce clarified sugars ready for fermentation or catalytic upgrading. The productivity and endpoint yield of enzymatic hydrolysis both enjoy the benefits of reduced feedback inhibition through the continuous removal of sugars by incorporating separations into the reactor. Likewise, the efficiency of recovering clarified sugars from the enzymatic hydrolysis slurry can be enhanced by operating separations equipment at steady-state conditions simultaneously with the continuously fed hydrolysis process. A key parameter that enables greater processing capacity while also raising the risks of failure is the solids loading or concentration. Higher solids loading allows for smaller reactor vessels and results in clarified sugars of higher concentration; however, required pumping power increases, reactor agitation may become ineffective, and membrane flux suffers. Feedstock material attributes influenced by upstream pretreatment must also be scrutinized more carefully: dilute-acid pretreated and deacetylated-and-disc-refined feedstocks exhibit different characteristics that affect agitation and pumping. The authors invite you to further explore the process science enabling the scale-up of this technology from conceptual work at the bench to pilot-scale industrially-relevant equipment where the challenges and solutions of integration and process optimization are expounded upon.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2013

Verification of the Accountability Method as a Means to Classify Radioactive Wastes Processed Using THOR Fluidized Bed Steam Reforming at the Studsvik Processing Facility in Erwin, Tennessee, USA - 13087

Studsviks' Processing Facility Erwin (SPFE) has been treating Low-Level Radioactive Waste using its patented THOR process for over 13 years. Studsvik has been mixing and processing wastes of the same waste classification but different chemical and isotopic characteristics for the full extent of this period as a general matter of operations. Studsvik utilizes the accountability method to track the movement of radionuclides from acceptance of waste, through processing, and finally in the classification of waste for disposal. Recently the NRC has proposed to revise the 1995 Branch Technical Position on Concentration Averaging and Encapsulation (1995 BTP on CA) with additional clarification (draft BTP on CA). The draft BTP on CA has paved the way for large scale blending of higher activity and lower activity waste to produce a single waste for the purpose of classification. With the onset of blending in the waste treatment industry, there is concern from the public and state regulators as to the robustness of the accountability method and the ability of processors to prevent the inclusion of hot spots in waste. To address these concerns and verify the accountability method as applied by the SPFE, as well as the SPFE's ability to control waste package classification, testing of actual waste packages was performed. Testing consisted of a comprehensive dose rate survey of a container of processed waste. Separately, the waste package was modeled chemically and radiologically. Comparing the observed and theoretical data demonstrated that actual dose rates were lower than, but consistent with, modeled dose rates. Moreover, the distribution of radioactivity confirms that the SPFE can produce a radiologically homogeneous waste form. The results of the study demonstrate: 1) the accountability method as applied by the SPFE is valid and produces expected results; 2) the SPFE can produce a radiologically homogeneous waste; and 3) the SPFE can effectively control the waste package classification. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Transuranic Waste Processing Center (TWPC) Legacy Tank RH-TRU Sludge Processing and Compliance Strategy - 13255

The U.S. Department of Energy (DOE) needs to safely and efficiently treat its 'legacy' transuranic (TRU) waste and mixed low-level waste (LLW) from past research and defense activities at the Oak Ridge National Laboratory (ORNL) so that the waste is prepared for safe and secure disposal. The TWPC operates an Environmental Management (EM) waste processing facility on the Oak Ridge Reservation (ORR). The TWPC is classified as a Hazard Category 2, non-reactor nuclear facility. This facility receives, treats, and packages low-level waste and TRU waste stored at various facilities on the ORR for eventual off-site disposal at various DOE sites and commercial facilities. The Remote Handled TRU Waste Sludge held in the Melton Valley Storage Tanks (MVSTs) was produced as a result of the collection, treatment, and storage of liquid radioactive waste originating from the ORNL radiochemical processing and radioisotope production programs. The MVSTs contain most of the associated waste from the Gunite and Associated Tanks (GAAT) in the ORNL's Tank Farms in Bethel Valley and the sludge (SL) and associated waste from the Old Hydro-fracture Facility tanks and other Federal Facility Agreement (FFA) tanks. The SL Processing Facility Build-outs (SL-PFB) Project is integral to the EM cleanup mission at ORNL and is being accelerated by DOE to meet updated regulatory commitments in the Site Treatment Plan. To meet these commitments a Baseline (BL) Change Proposal (BCP) is being submitted to provide continued spending authority as the project re-initiation extends across fiscal year 2012 (FY2012) into fiscal year 2013. Future waste from the ORNL Building 3019 U-233 Disposition project, in the form of U-233 dissolved in nitric acid and water, down-blended with depleted uranyl nitrate solution is also expected to be transferred to the 7856 MVST Annex Facility (formally the Capacity Increase Project (CIP) Tanks) for co-processing with the SL. The SL-PFB project will construct and install the necessary integrated systems to process the accumulated MVST Facilities SL inventory at the TWPC thus enabling safe and effective disposal of the waste. This BCP does not include work to support current MVST Facility Surveillance and Maintenance programs or the ORNL Building 3019 U-233 Disposition project, since they are not currently part of the TWPC prime contract. The purpose of the environmental compliance strategy is to identify the environmental permits and other required regulatory documents necessary for the construction and operation of the SL- PFB at the TWPC, Oak Ridge, TN. The permits and other regulatory documents identified are necessary to comply with the environmental laws and regulations of DOE Orders, and other requirements documented in the SL-PFB, Safety Design Strategy (SDS), SL-A-AD-002, R0 draft, and the Systems, Function and Requirements Document (SFRD), SL-X-AD-002, R1 draft. This compliance strategy is considered a 'living strategy' and it is anticipated that it will be revised as design progresses and more detail is known. The design basis on which this environmental permitting and compliance strategy is based is the Wastren Advantage, Inc., (WAI), TWPC, SL-PFB (WAI-BL-B.01.06) baseline. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Computer-aided process intensification of natural gas to methanol process

The recent revolution in shale gas has presented opportunities for distributed manufacturing of key commodity chemicals, such as methanol, from methane. However, the conventional methane-to-methanol process is energy intensive which negatively affects the profitability and sustainability. Here an intensified process configuration that is both economically attractive and environmentally sustainable. This flowsheet is systematically discovered using the building block-based representation and optimization methodology. The new process configuration utilizes membrane-assisted reactive separations and can have as much as 190% higher total annual profit compared to a conventional configuration. Additionally, it has 57% less CO 2 -equivalent greenhouse gas emission. Such drastic improvement highlights the advantages of building block-based computer-aided process intensification method.

42 ENGINEERING↗
DOE OSTI2017

Process evaluation and flowsheet development for the recovery of rare earth elements from coal and associated byproducts

Coal and coal byproducts produced annually contain enough rare earth elements (REEs) to meet current U.S. demand. Here, the REEs exist in the form of minerals, ion-exchanged elements associated with clays and chemically bonded elements within the organic coal matrix. Researchers at three universities have collaborated to evaluate the effectiveness of existing physical and chemical concentration processes for the recovery of the REEs. The efforts have found that physical separation processes can increase the total REE content in the thickener underflow material collected from a Central Appalachian coal cleaning facility from around 300 ppm to values greater than 17,500 ppm on an ash basis. Leaching followed by solvent extraction was found to be the most effective to recover the REEs from coarse middlings materials collected from multiple coal basins as indicated by recovery values exceeding 80%. Based on material characterization data and process evaluations conducted for several potential feed coal sources, economic recovery of the REEs will require byproduct production of both clean coal and REE concentrate using a process flowsheet that is unique for each source.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

A graph signal processing‐based multiple model Kalman filter ( GSP‐MMKF ) tool for predictive analytics: An air separation unit process application

Abstract The industrial Air Separations Unit (ASU) is a complicated and tightly operated process. The use of dynamic process analytics is also a key element of safe and economic operation of these processes, with increasing focus on predictive analytics to take preemptive actions. With the availability of real‐time data from hundreds of sensors, the data analysis process should also consider the topology of the data, as seen in sensor networks. In this paper, a novel tool is presented that considers the complex connectivity patterns in the sensor network and uses local adaptive disturbance estimations to predict global network‐scale trends. The paper introduces the emerging field of Graph Signal Processing (GSP) and presents a rigorous derivation of the tool starting from the extraction of the sensor‐network (in a graph theoretical sense) from the data. This network, which is in the form of a matrix, is then used to derive a Kalman‐filter type of state‐space model driven by input disturbances. Multiple disturbance models (e.g., step, ramp, periodic) are included to allow the model to have different kinds of disturbance propagation. Each graph node (representing the sensors used) dynamically adapts to the most recent detected disturbance individually. These estimated disturbances are propagated to the global network using the graph. Modifications to ensure stability are also discussed. The fidelity of the tool is tested on certain downtime events and the paper concludes by discussing the advantages of the method and planned future improvements.

Ghosh, Sambit↗
DOE OSTI2025

Comprehensive Analysis of the Relative Dispersion of Droplet-Size Distributions and Their Relationships to Key Physical Fog Processes Under Different Aerosol Conditions and Evolutionary Stages

The relative dispersion of cloud and fog droplets has significant impacts on aerosol indirect effects, radiative transfer, and microphysical processes. However, previous studies have been mostly concerned with clouds, with limited studies on fog, particularly those that examine the combined influences of all key physical processes and their roles during fog evolution. As such, this study aims to conduct a comprehensive investigation by examining the relationships between relative dispersion and other microphysical variables, as well as the underlying microphysical and dynamic processes, based on field fog campaigns in polluted and clean conditions. In polluted fog, droplet concentrations are higher, leading to smaller droplets and increased dispersion. The correlation between dispersion and droplet volume-mean radius is positive in the polluted fog, but shifts to negative in clean fog. Here, we attribute the difference to various microphysical processes like aerosol activation, condensation, collision-coalescence, and entrainment-mixing. In polluted fog, high aerosol concentrations, low supersaturations, and strong turbulence (entrainment-mixing) provide suitable conditions for the simultaneous occurrence of droplet condensation and aerosol activation, resulting in a positive correlation between dispersion and volume-mean radius, especially during the fog formation stage. In contrast, during the mature stage in clean fog, condensation is dominant with weak aerosol activation leading to a negative correlation between relative dispersion and volume-mean radius. The collision-coalescence process is more active in the mature stage, increasing radii and leading to the negative correlation between dispersion and volume-mean radius. This result sheds new light on understanding the relative dispersion and mechanisms in fog under different aerosol backgrounds.

54 ENVIRONMENTAL SCIENCES↗