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DOE OSTI2015

Scaling Effects of Cr(VI) Reduction Kinetics. The Role of Geochemical Heterogeneity

The natural subsurface is highly heterogeneous with minerals distributed in different spatial patterns. Fundamental understanding of how mineral spatial distribution patterns regulate sorption process is important for predicting the transport and fate of chemicals. Existing studies about the sorption was carried out in well-mixed batch reactors or uniformly packed columns, with few data available on the effects of spatial heterogeneities. As a result, there is a lack of data and understanding on how spatial heterogeneities control sorption processes. In this project, we aim to understand and develop modeling capabilities to predict the sorption of Cr(VI), an omnipresent contaminant in natural systems due to its natural occurrence and industrial utilization. We systematically examine the role of spatial patterns of illite, a common clay, in determining the extent of transport limitation and scaling effects associated with Cr(VI) sorption capacity and kinetics using column experiments and reactive transport modeling. Our results showed that the sorbed mass and rates can differ by an order of magnitude due to of the illite spatial heterogeneities and transport limitation. With constraints from data, we also developed the capabilities of modeling Cr(VI) in heterogeneous media. The developed model is then utilized to understand the general principles that govern the relationship between sorption and connectivity, a key measure of the spatial pattern characteristics. This correlation can be used to estimate Cr(VI) sorption characteristics in heterogeneous porous media. Insights gained here bridge gaps between laboratory and field application in hydrogeology and geochemical field, and advance predictive understanding of reactive transport processes in the natural heterogeneous subsurface. We believe that these findings will be of interest to a large number of environmental geochemists and engineers, hydrogeologists, and those interested in contaminant fate and transport, water quality and water composition, and natural attenuation processes in natural systems.

58 GEOSCIENCES↗

DOE OSTI2012

Field Test Report: NETL Portable Raman Gas Composition Monitor Initial Industrial tests at NETL and General Electric (GE)

NETL has developed new technology which enables the use of Raman spectroscopy in the real-time measurement of gas mixtures. This technology uses a hollow reflective metal-lined capillary waveguide as a gas sampling cell which contains the sample gas, and efficiently collects optical Raman scattering from the gas sample, for measurement with a miniature spectrometer. The result is an optical Raman “fingerprint” for each gas which is tens or hundreds of times larger than that which can be collected with conventional free-space optics. In this manner, the new technology exhibits a combination of measurement speed and accuracy which is unprecedented for spontaneous Raman measurements of gases. This makes the system especially well-suited to gas turbine engine control based on a-priori measurement of incoming fuel composition. The system has been developed to produce a measurement of all of the common components of natural gas, including the lesser nitrogen, oxygen, carbon-dioxide, and carbon monoxide diluents to better than 1% concentration accuracy each second. The objective of this task under CRADA 10-N100 was to evaluate the capability of a laser Raman capillary gas sensor for combustion fuels. A portable version of the Raman gas sensor, constructed at NETL, was used for field-trials conducted in a cooperative research effort at a GE facility. Testing under the CRADA was performed in 5 parts. Parts 1-4 were successful in testing of the Raman Gas Composition Monitor with bottled calibration gases, and in continuous monitoring of several gas streams at low pressure, in comparison with an online mass spectrometer. In part 5, the Raman Gas Composition Monitor was moved outdoors for testing with high pressure gas supplies. Some difficulties were encountered during industrial testing including the condensation of heavy hydrocarbons inside the sample cell (in part 5), communication with the GE data collection system, as well as some drift in the optical noise background. The difficulties with liquid contaminants will be overcome through the use of prodigious sample-cell heating and additional line filtration including liquid ingress-protection. The communication problem was resolved through site-specific troubleshooting of the MODBUS data tags.

25 ENERGY STORAGE↗

DOE OSTI2012

Field Test Report: NETL Portable Raman Gas Composition Monitor - Initial Industrial tests at NETL and General Electric (GE)

25 ENERGY STORAGE↗

DOE OSTI2013

Evaluation of Uranium Measurements in Water by Various Methods - 13571

In December 2000, EPA amended its drinking water regulations for radionuclides by adding a Maximum Contaminant Level (MCL) for uranium (so called MCL Rule)[1] of 30 micrograms per liter (μg/L). The MCL Rule also included MCL goals of zero for uranium and other radionuclides. Many radioactively contaminated sites must test uranium in wastewater and groundwater to comply with the MCL rule as well as local publicly owned treatment works discharge limitations. This paper addresses the relative sensitivity, accuracy, precision, cost and comparability of two EPA-approved methods for detection of total uranium: inductively plasma/mass spectrometry (ICP-MS) and alpha spectrometry. Both methods are capable of measuring the individual uranium isotopes U-234, U- 235, and U-238 and both methods have been deemed acceptable by EPA. However, the U-238 is by far the primary contributor to the mass-based ICP-MS measurement, especially for naturally-occurring uranium, which contains 99.2745% U-238. An evaluation shall be performed relative to the regulatory requirement promulgated by EPA in December 2000. Data will be garnered from various client sample results measured by ALS Laboratory in Fort Collins, CO. Data shall include method detection limits (MDL), minimum detectable activities (MDA), means and trends in laboratory control sample results, performance evaluation data for all methods, and replicate results. In addition, a comparison will be made of sample analyses results obtained from both alpha spectrometry and the screening method Kinetic Phosphorescence Analysis (KPA) performed at the U.S. Army Corps of Engineers (USACE) FUSRAP Maywood Laboratory (UFML). Many uranium measurements occur in laboratories that only perform radiological analysis. This work is important because it shows that uranium can be measured in radiological as well as stable chemistry laboratories and it provides several criteria as a basis for comparison of two uranium test methods. This data will indicate which test method is the most accurate and most cost effective. This paper provides a benefit to Formerly Utilized Sites Remedial Action Program (FUSRAP) and other Department of Defense (DOD) programs that may be performing uranium measurements. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

Conventional and Next Generation Treatment Technologies for PFAS - 20067

In 2016, the United States Environmental Protection Agency (USEPA) established a Health Advisory Limit (HAL) for perfluorooctanoic acid (PFOA) and perfluorooctane sulfonic acid (PFOS) (individually and the summation) of 70 nanograms per liter (ng/L) based on developing toxicological information. These two compounds are among several thousand per- and polyfluoroalkyl substances (PFAS). Due to a multitude of commercially beneficial physical and chemical properties, the availability of PFAS-relevant and practical water treatment technologies is limited. The use of conventional adsorbents, such as activated carbon (AC) and anion exchange (AIX) resins, have become a 'de facto' interim measure to immediately address drinking water above this criterion. However, these adsorbents can have marginal long-term efficiency and are relatively unproven against the diversity of polyfluorinated compounds. Additionally, geochemical and/or co-contaminant competition can significantly impede adsorption based PFAS removal. These challenges may be addressed using engineered filtration, such as reverse osmosis or nanofiltration (RO/NF); however, for larger flow systems RO/NF may have unacceptable reject ratios as high as 35% and the capital cost may preclude these technologies. Extending these technologies to natural waters, which have various degrees of geochemical and co-contaminant competition, often requires a treatment train, combining conventional adsorbents or engineered filtration with pretreatment and more innovative and emerging remediation solutions for PFAS. Conventional and Next Generation water treatment technologies for PFAS generally employ one of three mechanisms (adsorption, separation, or destruction). These mechanisms include many types of technologies for both municipal drinking water and extracted natural water applications. The previously mentioned AC, AIX, and RO/NF are commercially available technologies that are actively being deployed for PFAS treatment. Research and development around these technologies is focused on optimization, and ultimate destruction of PFAS is achieved through incineration. Next Generation water treatment technologies include PFAS-specific flocculants, foam fractionation, novel AIX resins, new engineered adsorptive media, electrochemical treatment, sonolysis, and photolysis, radiation, and plasma (forms of advanced reductive processes [ARP]). Research and development around these technologies is focused on proof of concept and assimilation to real world applications. As the PFAS-relevant destructive technologies (such as incineration, electrochemical treatment, sonolysis, and ARP) are energy intensive, the state of the practice for PFAS water treatment is to focus adsorption/separation based technologies on reducing and concentrating the volume of water requiring destructive treatment. This enables more flexibility with respect to circulation frequency, residence time, and more control over energy usage. Water treatment for PFAS presently requires multiple technologies (i.e. a treatment train) to protect human health in a cost-conscious manner. An investment in research and development to explore new technologies is part of a key initiative for efficient protection of human health. This presentation attempts to review PFAS-relevant water treatment technologies and provide perspective as to their status with respect to applicability and commercial relevance. (authors)

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2017

Biocatalytic membranes prepared by inkjet printing functionalized yeast cells onto microfiltration substrates

Biocatalytic cells displaying functional enzymes on their surface have the ability to catalyze the degradation of persistent micropollutants with high enzyme accessibility and stability. However, the high migration and limited processing capability of suspended biocatalytic cells remain major challenges for practical applications in water treatment. Here, in this study, we fabricated biocatalytic membranes (BCMs) by immobilizing biocatalytic cells, i.e., Baker's yeast with cell surface display laccase (SDL), on microporous membranes via inkjet printing and chemical crosslinking. The incorporation of SDL biocatalytic cells on the surface of the membranes was confirmed by microscopy, elemental analysis, and enzyme assay tests. Moreover, it was demonstrated that the number of SDL cells incorporated and therefore, the enzyme activity of the BCMs, could be systematically controlled by altering the printing parameters. The viability, regeneration, and high storage stability of SDL cells were maintained in the BCM platform. Furthermore, the BCMs could be reused with high stability as they retained 76% of their initial activity after ten repeated reaction cycles. In comparison, the activity of freely-suspended SDL cells declined to 42% of their initial activity after ten reaction cycles. Finally, the effectiveness of BCMs in treating emerging contaminants was confirmed using bisphenol A and acetaminophen as substrates in proof-of-concept experiments. The results of this study establish that BCMs can address concerns related to the utilization of suspended biocatalytic cells by fixing them on a microporous substrate. With further study and optimization, BCMs have the potential to be incorporated into membrane-based separation and pollutant degradation processes.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2017

Particle and chemical control using tunnel flow

An apparatus for contaminant control, having: a first optical assembly including: a first light homogenizer tunnel with: a first end connected to an extreme ultra-violet light source, a second end in communication with a destination chamber, a first enclosed space, and, a first gas input arranged to introduce a first gas such that the first gas flows in a first direction toward the first end and in a second direction toward the second end. The apparatus alternately having: a second optical assembly including: a second light homogenizer tunnel with: a third end connected to an extreme ultra-violet light source, a fourth end in communication with a destination chamber, a second enclosed space, a diffusion barrier tube including: a fifth end facing the fourth end and a sixth end in communication with a destination chamber, and a second gas input between the second light homogenizer tunnel and the diffusion tube.

42 ENGINEERING↗

DOE OSTI2018

On-board Radiation Sensor and Low-Altitude Contour Mapping of Radiation Fields using UAS Swarm - 18239

This paper addresses the design of light weight radiation sensors for the small-scale unmanned aerial system (UAS), and its implementation for low-altitude radiation source localization and contour mapping. The compact, high-resolution gamma-ray CZT sensors were integrated to UAS platforms as plug-and-play components using Robot Operation System (ROS). In this work, the UAS swarm consists of three platforms positioned in circular formation. The onboard data analysis provides time and position stamped intensities of gamma-ray peaks for each UAS-based sensor that are used as the input data for the swarm flight control algorithm. Each UAS measures radiation simultaneously for estimating gradient of radiation to compute a bulk heading angle of the swarm for contour mapping, which can provide relatively precise boundary of the safe area for potential human exploration. The UAS radiation sensors allow measurements from just few meters up to hundreds of meters thus filling the gap between land- and helicopter- based platforms. The swarm of UAS has advantages over a single agent based approach in detecting radiative sources and effectively mapping the area. The proposed method can locate sources of radiation as well as mapping the contaminated area for enhancing situation awareness capabilities for first responders. Computer simulation is presented for UAS swarm based source localization and contour mapping in the simulated radiation fields created by the MCNP code. Selected key gradient estimation and contour mapping algorithms are validated experimentally with small scale multicopter UAS in the indoor flight test bed. (authors)

42 ENGINEERING↗

DOE OSTI2024

IMAGINE BioSecurity: Mesocosm-Based Methods to Evaluate Biocontainment Strategies and Impact of Industrial Microbes Upon Native Ecosystems

Project Goals: The Integrative Modeling and Genome-scale Engineering for Biosystems Security (IMAGINE BioSecurity) SFA project seeks to establish an understanding of the behavior of engineered microbes in controlled versus environmental conditions to predictively devise new strategies for responding to biological escape. To this end, the IMAGINE Team has established a plant-soil mesocosm platform to track and quantify the fate of industrial microbes in environmental systems and assess the efficacy of biocontainment constraints upon genetically engineered microbe escape frequency and the impact of industrial microbes upon native ecological microbiomes. Abstract Text: Genetically modified industrial production microbes and their associated bioproducts have emerged as an integral component of a sustainable bioeconomy. However, the rapid development of these innovative technologies raises biosecurity concerns, namely, the risk of environmental escape. Thus, the realization of a bioeconomy hinges not only on the development and deployment of microbial production hosts, but also on the development of secure biosystems and biocontainment designs. Current laboratory-based biocontainment testing systems do not accurately reflect complexities found in natural environments, necessitating an environmentally relevant analysis pipeline that allows for the detection of rare escapees, the effect of associated bio-products, and the impact on native ecologies. To this end, we have developed an approach that utilizes soil mesocosms and integrated systems analyses to evaluate the efficacy of novel biocontainment strategies and to assess the impact of production systems upon terrestrial microbiome dynamics. We demonstrate the utility of this approach by modeling a contamination with industrial microbial chasses versus their biocontained counterparts. Here we demonstrate the broad utility of this system by highlighting findings from both strains of Saccharomyces cerevisiae that are contained with an inducible toxin anti-toxin system, and stains of Escherichia coli that are contained via genomic recoding. The resultant data demonstrate that this system has broad utility across diverse microbial chassis and biocontainment strategies, enables us to track the fate of our contaminating microbe with high sensitivity in the soil, as well as monitor broader impacts of the perturbation on the underlying soil system. The findings presented here support the use of this mesocosm-based approach to assess the environmental impact of industrial microbes and to validate biocontainment strategies.

BASIC BIOLOGICAL SCIENCES,INORGANIC, ORGANIC, PHYS↗

DOE OSTI2023

Robotic Systems integration for cleanroom SRF assembly at Fermilab

Superconducting Radio Frequency (SRF) cryomodule assembly is a critical process that demands the highest levels of contamination control in a cleanroom to ensure product quality and reliability. Within the cleanroom environment, human-driven activities remain the major source of uncontrolled particulate. Moreover, the precise manual alignment of components often exceeds expected timeframes, increasing the risk of particulate migration into the critical inner space of the SRF resonant cavity, and causing extended discomfort for workers. Automation comes as a natural solution to address these challenges. The goal of this activity is to set up and integrate a robotic system to support cavity coupler installation in the cleanroom environment. Initially, remote control of a 6-axis collaborative robot arm will be implemented as an introductory step towards automation in the cleanroom. Subsequently, the system will be further enhanced by integrating manipulation capabilities through an appropriate end-effector, and computer vision technology to enable accurate pose estimation. This comprehensive approach aims to achieve a fully automated and adaptable assembly process in the partially structured cleanroom environment, thereby enhancing efficiency and mitigating existing challenges for better product quality and workers safety.

42 ENGINEERING↗

DOE OSTI2018

Challenges of Remote Handling in Windowless Hot Cells - 18341

Facilities such as nuclear power stations and neutron sources produce radioactive waste, which must be handled in shielded containment chambers [hot cells]. Traditionally these hot cells are built with lead glass windows to allow direct observation by operators, however, as the complexity and size of handling operations increases, the restrictions imposed by such windows becomes problematic. For the International Thermonuclear Experimental Reactor [ITER] under construction in the South of France and the European Spallation Source [ESS] under construction in Lund, Sweden the hot cell must be capable of processing large, activated and contaminated components, requiring the dexterous tele-manipulation of high dose payloads in the cell. Using lead glass windows would severely restrict the operational envelope within the cell to the volumes directly in front of the windows. This places unreasonable constraints on the types of handling operations that can be carried out. Conversely, a windowless configuration is much more flexible and maximises the operational space for robotic manipulators. Windowless hot cells do however introduce their own challenges. This paper examines the difficulties introduced by lack of direct sight and describes solutions to overcome them. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2012

Diffusion Dominant Solute Transport Modelling in Fractured Media Under Deep Geological Environment - 12211

Deep geologic disposal of high activity and long-lived radioactive waste is gaining increasing support in many countries, where suitable low permeability geological formation in combination with engineered barriers are used to provide long term waste contaminant and minimise the impacts to the environment and risk to the biosphere. This modelling study examines the solute transport in fractured media under low flow velocities that are relevant to a deep geological environment. In particular, reactive solute transport through fractured media is studied using a 2-D model, that considers advection and diffusion, to explore the coupled effects of kinetic and equilibrium chemical processes. The effects of water velocity in the fracture, matrix porosity and diffusion on solute transport are investigated and discussed. Some illustrative modelled results are presented to demonstrate the use of the model to examine the effects of media degradation on solute transport, under the influences of hydrogeological (diffusion dominant) and microbially mediated chemical processes. The challenges facing the prediction of long term degradation such as cracks evolution, interaction and coalescence are highlighted. The potential of a novel microstructure informed modelling approach to account for these effects is discussed, particularly with respect to investigating multiple phenomena impact on material performance. The GRM code is used to examine the effects of media degradation for a geological waste disposal package, under the combined hydrogeological (diffusion dominant) and chemical effects in low groundwater flow conditions that are typical of deep geological disposal systems. An illustrative reactive transport modelling application demonstrates the use of the code to examine the interplay of kinetic controlled biogeochemical reactive processes with advective and diffusive transport, under the influence of media degradation. The initial model results are encouraging which show the disposal system to evolve in a physically realistic manner. In the example presented the reactive-transport coupling develops chemically reducing zones, which limit the transport of uranium. This illustrates the potential significance of media degradation and chemical effect on the transport of radionuclides which would need to be taken into account when examining the long-term behaviour and containment properties of the geological disposal system. Microstructure-informed modelling and its potential linkage with continuum flow modelling is a subject of ongoing studies. The approach of microstructure-informed modelling is discussed to provide insight and a mechanistic understanding of macroscopic parameters and their evolution. The proposed theoretical and methodological basis for microstructure-informed modelling of porous quasi-brittle media has the potential to develop into an explanatory and predictive tool for deriving mechanism-based, as opposed to phenomenological, evolution laws for macroscopic properties. These concepts in micro-scale modelling are likely to be applicable to the diffusion process, in addition to advective transport illustrated here for porous media. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Testing and Deployment of Remote Systems to Remove Highly Radioactive Soil at Hanford's 324 Building - 18043

U.S. Department of Energy (DOE) contractor CH2M HILL Plateau Remediation Company (CHPRC) is in the process of procuring, testing and deploying remotely operated tools to safely remove highly contaminated soil from beneath the 324 Building on the Hanford Site in southeastern Washington State. The 324 Building operated for more than 40 years, completing a variety of high-dose engineering development and demonstration activities inside six hot cells that shielded the workers from the highly radioactive materials. Activities to decommission, decontaminate and demolish the facility began in 2008. In 2010, soil contamination was found in the soil under one of the hot cells, and building deactivation was paused to evaluate the soil contamination. Sampling efforts, using borehole technology, revealed significant under-building contamination with dose rates measuring has high as 130 Sv/hr (13,000 R/hr). The highly-contaminated soil has to be removed before traditional open air deactivation activities can continue. CHPRC completed proof of concept testing and built a full-scale test facility to demonstrate the effectiveness of three primary tools that will accomplish the floor and soil removal. The tools include a commercially available concrete saw, and a commercially available excavator arm that have been modified to operate remotely in the high-radiation environment within the hot-cell. In order to reduce the wear on the hot-cell overhead cranes, a remote operated rail and cart system has been designed to transport soil and debris out of the hot-cell to an airlock area where the waste will be separated, according to its level of radioactivity. A camera and light system has been designed to provide visual and audio coverage of the hot-cell area that will allow the operations to proceed from remote control stations. This paper will describe the primary remote operated equipment designed for the project and the challenges and processes for developing, testing and deploying the equipment necessary to excavate the soil from below the 324 Building. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2013

Ventilation Control of Volatile Organic Compounds in New U.S. Homes: Results of a Controlled Field Study in Nine Residential Units

In order to optimize strategies to remove airborne contaminants in residences, it is necessary to determine how contaminant concentrations respond to changes in the air exchange rate. The impact of air exchange rate on the indoor concentrations of 39 target volatile organic compounds (VOCs) was assessed by measuring air exchange rates and VOC concentrations at three ventilation settings in nine residences. Active sampling methods were used for VOC concentration measurements, and passive perfluorocarbon tracer gas emitters with active sampling were used to determine the overall air exchange rate corresponding to the VOC measurements at each ventilation setting. The concentration levels and emission rates of the target VOCs varied by as much as two orders of magnitude across sites. Aldehyde and terpene compounds were typically the chemical classes with highest concentrations, followed by alkanes, aromatics, and siloxanes. For each home, VOC concentrations tended to decrease as the air exchange rate was increased, however, measurement uncertainty was significant. The indoor concentration was inversely proportional to air exchange rate for most compounds. For a subset of compounds including formaldehyde, however, the indoor concentration exhibited a non-linear dependence on the timescale for air exchange

42 ENGINEERING↗

DOE OSTI2021

Near-complete depolymerization of polyesters with nano-dispersed enzymes

Successfully interfacing enzymes and biomachinery with polymers affords on-demand modification and/or programmable degradation during the manufacture, utilization and disposal of plastics, but requires controlled biocatalysis in solid matrices with macromolecular substrates. Embedding enzyme microparticles speeds up polyester degradation, but compromises host properties and unintentionally accelerates the formation of microplastics with partial polymer degradation. Here we show that by nanoscopically dispersing enzymes with deep active sites, semi-crystalline polyesters can be degraded primarily via chain-end-mediated processive depolymerization with programmable latency and material integrity, akin to polyadenylation-induced messenger RNA decay. It is also feasible to achieve processivity with enzymes that have surface-exposed active sites by engineering enzyme-protectant-polymer complexes. Poly(caprolactone) and poly(lactic acid) containing less than 2 weight per cent enzymes are depolymerized in days, with up to 98 per cent polymer-to-small-molecule conversion in standard soil composts and household tap water, completely eliminating current needs to separate and landfill their products in compost facilities. Furthermore, oxidases embedded in polyolefins retain their activities. However, hydrocarbon polymers do not closely associate with enzymes, as their polyester counterparts do, and the reactive radicals that are generated cannot chemically modify the macromolecular host. This study provides molecular guidance towards enzyme-polymer pairing and the selection of enzyme protectants to modulate substrate selectivity and optimize biocatalytic pathways. Furthermore, the results also highlight the need for in-depth research in solid-state enzymology, especially in multi-step enzymatic cascades, to tackle chemically dormant substrates without creating secondary environmental contamination and/or biosafety concerns.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2013

Rapid Characterization of Vegetation Structure with a Microsoft Kinect Sensor

The importance of vegetation structure and biomass in controlling land-atmosphere exchange is widely recognized, but measurements of canopy structure are challenging, time consuming, and often rely on destructive methods. The Microsoft Kinect is an infrared sensor designed for video gaming that outputs synchronized color and depth images and that has the potential to allow rapid characterization of vegetation structure. We compared depth images from a Kinect sensor with manual measurements of plant structure and size for two species growing in a California grassland. The depth images agreed well with the horizontal and vertical measurements of plant size made manually. Similarly, the plant volumes calculated with a three-dimensional convex hulls approach was well related to plant biomass. The Kinect showed some limitations for ecological observation associated with a short measurement range and daytime light contamination. Nonetheless, the Kinect’s light weight, fast acquisition time, low power requirement, and cost make it a promising tool for rapid field surveys of canopy structure, especially in small-statured vegetation.

Microsoft Kinect↗

DOE OSTI2019

Embedded Sensor Development in Metallic Structures for the Transformational Challenge Reactor

The ability to make minimally intrusive measurements of process conditions has tremendous potential for improving system performance and control in applications such as nuclear power generation. Towards this end, emerging and evolving advanced manufacturing methods, such as additive manufacturing, present new opportunities for more seamlessly integrating sensing with structure. This technical report summarizes the progress of work performed to assess the feasibility of embedding commercial off-the-shelf (COTS) sensors in a metallic reactor core using advanced manufacturing methods. The progress of four research and development tasks are documented: 1) A survey of COTS sensors for nuclear applications that are candidates for embedded fabrication, 2) Development of a conceptual framework for investigating the feasibility of sensor embedment, 3) Definition of structural geometries and other characteristics that will represent compelling proof-of-concept, and 4) Preliminary prototyping of embedded sensors. For the purposes of this initial study, nuclear grade K-type thermocouples were selected for investigation of embedment methodologies. This sensor was selected as an initial candidate because it represents one of the simplest sensor configurations that can provide useful process information. A selective laser melting (SLM) additive manufacturing process was used to fabricate structures with complexity representative of the core design of the transformational challenge reactor (TCR) and methods were developed to embed a thermocouple with a complex two-dimensional routing path. There are many challenges associated with embedding sensors during the additive manufacturing process including securing the sensor in the structure, relocating the part in the additive machine if using a “pick and place” sensor placement method, mitigating the potential for powder contamination, optimizing energy deposition parameters to build as closely as possible around the sensor path and improve structural integrity of the part, and tuning energy deposition to mitigate thermally induced warpage of the sensor and part as well as potential for damaging the sensing device. Preliminary results indicate that it is feasible to integrate the sensor while minimally compromising the structural integrity of the part and preserving sensor performance. This first phase of this work focused on developing a workflow for embedding sensors and controlling energy deposition during the additive manufacturing process to better understand the build characteristics around the sensor. Future work will perform more in-depth characterization of prototype parts using X-ray computed tomography and scanning electron microscopy to better understand fabricated structures, performance testing of embedded sensors in high temperature environments, adding new embedded measurement modalities, embedding devices with dissimilar materials in contact with additive powders, and the development of methods for embedding sensors with three-dimensional routing paths.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

Quo vadis? Microbial profiling revealed strong effects of cleanroom maintenance and routes of contamination in indoor environments

Space agencies maintain highly controlled cleanrooms to ensure the demands of planetary protection. To study potential effects of microbiome control, we analyzed microbial communities in two particulate-controlled cleanrooms (ISO 5 and ISO 8) and two vicinal uncontrolled areas (office, changing room) by cultivation and 16S rRNA gene amplicon analysis (cloning, pyrotagsequencing, and PhyloChip G3 analysis). Maintenance procedures affected the microbiome on total abundance and microbial community structure concerning richness, diversity and relative abundance of certain taxa. Cleanroom areas were found to be mainly predominated by potentially human-associated bacteria; archaeal signatures were detected in every area. Results indicate that microorganisms were mainly spread from the changing room (68%) into the cleanrooms, potentially carried along with human activity. The numbers of colony forming units were reduced by up to ~400 fold from the uncontrolled areas towards the ISO 5 cleanroom, accompanied with a reduction of the living portion of microorganisms from 45% (changing area) to 1% of total 16S rRNA gene signatures as revealed via propidium monoazide treatment of the samples. Our results demonstrate the strong effects of cleanroom maintenance on microbial communities in indoor environments and can be used to improve the design and operation of biologically controlled cleanrooms.

42 ENGINEERING↗