Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Contamination Control Engineering”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

241 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Final Demolition and Disposition of 209-E Critical Mass Laboratory - 12267

The 209-E Critical Mass Laboratory was constructed in 1960 to provide a heavy shielded reactor room where quantities of plutonium or uranium in solution could be brought to near-critical configurations under carefully controlled and monitored conditions. In the late 1980's, the responsible contractor, Pacific Northwest National Laboratory (PNNL), was directed by the Department of Energy (DOE) to prepare the facility for unoccupied status. The facility was demolished under a Removal Action Work Plan pursuant to the Comprehensive Environmental Response, Compensation, and Liability Act of 1980 (CERCLA). The funding for this project was provided by the American Recovery and Reinvestment Act (ARRA). The primary rooms of concern with regards to contamination in 209-E facility, which is over 9,000 square feet, are the criticality assembly room (CAR), the mix room, and the change room. The CAR contained two reactor hoods (HO-140 and HO-170), which each had a high efficiency particulate air (HEPA) filter system. The CAR contained 13 tanks ranging from 38 L (10 gal) to 401 L (106 gal). Tanks TK-109 and TK-110 are below grade, and were removed as part of this demolition and disposition remedy. Nonradiological and radiological hazardous substances were removed, decontaminated, or fixed in place, prior to demolition. Except for the removal of below grade tanks TK-109 and TK-110, the facility was demolished to slab-on-grade. PNNL performed stabilization and deactivation activities that included removal of bulk fissile material and chemicals, flushing tanks, stabilizing contamination within gloveboxes and hoods, and packaging and removing waste. The removal of the contaminated plutonium equipment and materials from the 209E facility presented a number of challenges similar in nature to those associated with the inventory reduction and cleanup activities at the Plutonium Finishing Plant. Although there were no bulk fissile materials or chemicals within the facility, there were residual radiological materials (isotopes of plutonium and americium) in the tanks and hoods. The complexity of the remedy was present because of the various configurations of the tanks and hoods, combined with the residual contaminants. Because of the weight and dimensional configuration, size reduction of the slab tanks, as well as removal and disposal of the different material used for moderation and absorption, were two examples of challenges that were resolved to complete the remedy. One of the key methods developed and implemented at the facility was the design and construction of a shroud to allow the cutting of the Pu contaminated tanks. The shroud design, development and implementation at the 209E Project was an example of enhanced work planning and task hazards analysis with worker involvement. This paper will present the lessons learned from the 209E facility inventory reduction activities including the shroud and other methodologies used. The initial Lessons Learned discussion for this project was scheduled for late January 2012. This facility is the first open-air demolition of a highly contaminated plutonium-contaminated facility accomplished by CH2M Hill under the Plateau Remediation Contract. The demolition was completed without spread of contamination to the workers and the surrounding area. As with any project of this complexity, there are significant accomplishments, as well as experience that can be applied to future demolition of plutonium-contaminated facilities on the Hanford Site. These experiences will be documented at a later date. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Remote Technology to Retrieve Waste Below the 324 Building at the Hanford Site - 19622

The Waste Technology Engineering Laboratory (324 Building) is a Category 2 Nuclear Facility at Hanford. The 324 Building Disposition Project is responsible for the removal and remedial actions under CERCLA. Additionally, there are RCRA Dangerous Waste Management Units which the CERCLA actions are presumed to satisfy. The Radiochemical Engineering Complex (REC) is a group of four hot cells (A, B, C and D Cells) with an interconnecting airlock inside of the 324 Building. Underneath the REC B-Cell are contaminated soils that have an estimated 12,793 R/Hr dose rate and remediation is under CERCLA 300-FF-2 Operable Unit. The current action consists of debris removal from the floor of B-Cell, B-Cell floor removal, and excavation of the soils beneath the floor to a depth of up to twelve feet with four Remote Excavator Arms (REA). This paper provides insight into the preparation and performance of high tolerance core drilling into a hot cell complex. Installation of the REA Through Support (REA TS) mechanism through the 4'-6' concrete shield walls is a complex series of tasks with demanding tolerances at each of four locations around the perimeter of B-Cell. The use of training mock ups was included in the completion of this work. The REA TS is two 11 inch diameter high strength steel sleeves that have expandable collars at each end allowing the interstitial space between the outside of the sleeve and inside of the core drill to be grouted to form a substantial structural connection, and a 10 inch pipe with hydraulic hoses to power the REA. There are three cores required for each REA location. The REAs themselves are customized excavator arms, mounted on support columns to be used in the excavation and transfer of the contaminated soil into storage facilities. The tasks for the installation of the REA TSs are: 1) Characterization of B-Cell Cubicles. 2) Embedded Pipe Fill. 3) Interference Removal. a. Internal Walls, b. External Walls. 4) Core Drilling. 5) Go/No-Go gauge, and video inspection. 6) Installation of REA Through Support Assembly. The 324 Building REC Hot Cells have internal, external, and embedded utilities throughout the shield walls in conflict with the REA TS locations. Some of the embedded utilities have connection points inside of the B-Cell Cubicles. There were two separate issues at the conflicted locations. The first issue was the core drill cooling water would flow along the embedded utility potentially spreading legacy chemical and radiological contamination to areas of the facility that was unwanted. The second issue was that the REA TS required a substantial structural connection to the B-Cell wall, the cored diameter is larger than the REA TS and these interstitial areas required a full grouted connection. The embedded utilities posed a hazard that if unfilled, the interstitial grout would flow into the embedded utility and destabilize the required grouted structural connection. The B-Cell Cubicles had not been opened in over 10 years. A mockup was completed to install a glovebag over the cubicle opening and then to verify functionality and port requirements. The embedded utility pipe connections in the cubicles were then opened inside a glovebag to verify the correct connection points, connection method for future embedded pipe fill material delivery system, radiological characterization, and air flow to show that the embedded utility pipes were not blocked and would not pressurize. The embedded pipe fill material and grout system was mocked up and run several times to verify methodology and functionality. The B-Cell Cubicles were then reentered and the embedded utility pipe fill was completed using a hand pump. External interferences at the core drill locations were removed using standard interference removal techniques. Internal interferences at the core drill locations were removed using a remote cutting tool that was controlled through the use of the B-Cell crane, remote cameras and remote lighting. The core drilling was mocked up two separate times, the project's purpose built 'Mock Up Facility' was core drilled to verify tolerances and methodology prior to subcontract award, the core drill subcontractor built a 'dummy wall' to train and practice on achieving the demanding tolerances, coordinated alignments between the cores, short term and long term dose shielding techniques, and contamination control techniques. A core drill template, and additional anchoring techniques were used to maximize accuracy and precision of the REA TS core drills. A 'Go/No-Go' gauge was built and installed at each of the four REA TS locations to verify that the core drill met tolerances. The core drill locations were visually inspected using a boroscope. The REA TS installation was mocked up at the projects 'Mock Up Facility' beginning with basic hazard controls, then with intermediate hazard controls, and finally with full occupational safety, industrial hygiene, and radiological controls. The REA TSs were installed and grouted into place. (authors)

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

Adsorption Equilibrium and Kinetics at Goethite-Water and Related Interfaces

This research study is an important component of a broader comprehensive project, “Geochemistry of Interfaces: From Surfaces to Interlayers to Clusters,” which sought to identify and evaluate the critical molecular phenomena at metal-oxide interfaces that control many geochemical and environmental processes. The primary goal of this research study was to better understand and predict adsorption of metal ions at mineral/water surfaces. Macroscopic data in traditional batch experiments was used to develop predictive models that characterize sorption in complex systems containing a wide range of background solution compositions. Our studies focused on systems involving alkaline earth metal (Mg 2+ , Ca 2+ , Sr 2+ , Ba 2+ ) and heavy metal (Hg 2+ , Co 2+ , Cd 2+ , Cu 2+ , Zn 2+ , Pb 2+ ) cations. The anions we selected for study included Cl - , NO 3 - , ClO 4 - , SO 4 2- , CO 3 2- and SeO 3 2- and the background electrolyte cations we examined included (Na + , K + , Rb + and Cs + ) because these represent a range of ion sizes and have varying potentials for forming ion-pairs or ternary complexes with the metal ions studied. The research led to the development of a modified titration congruency approach for estimating site densities for mineral oxides such as goethite. The CD-MUSIC version of the surface complexation modeling approach was applied to potentiometric titration data and macroscopic adsorption data for single-solute heavy metals, oxyanions, alkaline earth metals and background electrolytes over a range of pH and ionic strength. The model was capable of predicting sorption in bi-solute systems containing multiple cations, cations and oxyanions, and transition metal cations and alkaline earth metal ions. Incorporation of ternary complexes was required for modeling Pb(II)-Se(IV) and Cd(II)-Se(IV) systems. -Both crystal face contributions and capacitance values were shown to be sensitive to varying specific surface area but were successfully accounted for in the modeling strategy. The insights gained from the macroscopic, spectroscopic and CD-MUSIC modeling developed in this study can be used to guide the implementation of less complex models which may be more applicable to field conditions. The findings of this research suggest that surface complexation models can be used as a predictive tool for fate and transport modeling of metal ions and oxyanions in fresh and saline systems typical of energy production waters and wastewaters.

42 ENGINEERING↗
DOE OSTI2021

Pilot-Scale Testing of an Integrated Circuit for the Extraction of Rare Earth Minerals and Elements from Coal and Coal Byproducts Using Advanced Separation Technologies

The primary objective of this project was to develop and demonstrate an integrated pilot-scale circuitry for recovering high-value rare earth elements (REEs) from coal and coal byproducts. The target performance was to produce a mixed REE product with content of at least two percent by weight on a dry mass basis in a cost-effective and environmentally benign manner. During the first nine months of the project period (Phase 2 Budget Period 2), pilot plant construction was completed including all field site startup activities such as permitting, engineering design, procurement/bidding, unit fabrication, site construction, equipment installation, module assembly, safety training, and circuit shakedown. During the remaining 21 months of project period (Phase 2 Budget Period 3), detailed field-testing activities were performed including feedstock sample collection and preparation, exploratory testing, circuit modification, detailed parametric study, and performance optimization. A detailed techno-economic analysis was performed based on the pilot plant testing findings which provided various scenarios for REE production. The project successfully accomplished the proposed target performance by producing mixed rare earth oxide (REO) with greater than 90% purity by weight in a continuous pilot scale operation from two distinctly different coarse refuse materials (i.e., West Kentucky No. 13 and Fire Clay coal seams), and at least three secondary sources (i.e., heap leach process and naturally formed acid mine drainage system). Project partners included the University of Kentucky, Virginia Tech, West Virginia University, Alliance Coal, Blackhawk Mining, Mineral Refining Company, and Mineral Separation Technologies. The pilot scale test facility was constructed at a former mining complex owned by Alliance Natural Resource Partners (Alliance Coal). The site was rehabilitated to accommodate the equipment installation, construction and fabrication, electrical power requirement, water line management and containment. The process units constructed and installed included X-ray sorting unit, crushing and grinding unit, physical separation unit, acid leaching unit, solvent extraction unit, and wastewater management unit. A rare earth mineral concentration unit was constructed as a standalone unit for flexible operation. A detailed environmental assessment and control plan was carried out to identify and quantify any potential impacts of the pilot-scale processing circuitry on the human and eco-system health and well-being. Corresponding mitigation strategies and control measures were provided. A conceptual flowsheet was developed to effectively remove thorium and uranium from high purity rare earth oxide mix or any potential radionuclide enriched stream. The two distinct feedstock materials were secured from the Blackhawk Mining Complex in eastern Kentucky where the Fire Clay (Hazard No. 4) seam is processed. The West Kentucky No. 13 (Baker) coarse refuse material was collected from an active process stream at an Alliance coal preparation plant located in western Kentucky. Characterization analysis indicated that both of feed materials generated from the two sources contained >300 ppm of TREEs on a dry whole mass basis which met the requirements for a qualified feed stock. The two feedstocks were further upgraded using a dual x-ray sorter to prepare the feed material for hydrometallurgical circuit. Thermal treatment on feed material prior to leaching was found to: 1) improve the leaching recovery of REEs, 2) increase the leaching kinetics, and 3) allow the leaching reaction to occur at lower acidity. Roasting at 600°C was selected as the pre-treatment condition for both West Kentucky No. 13 and Fire Clay coarse refuse material. Over 40% of leaching recovery was achieved by roasting West Kentucky No. 13 material having a top particle size of 3 mm in the pilot scale operation using 1.2M sulfuric acid leaching at 75OC. Initial pilot scale testing involved continuous operation of the pilot plant for 94 hours. The leaching unit was operated at solid-to-liquid ratio of 1 to 10 (w/v) using 0.5M sulfuric acid solution at a temperature of 75°C. The continuous solvent extraction circuit utilized rougher and cleaner units with DEHPA and TBP as the extractants. An innovative stripping circuit was developed to accumulate the REE concentration in the stripping solution to a level above 600 ppm. A bleed stream from the recycled strip solution was treated using oxalic acid precipitation which produced a high grade rare earth oxalate. The oxalate product was roasted to remove the oxalate which produced a rare earth oxide product having a purity greater 90%. Due to high concentrations of contaminant ions in the pregnant leach solution (PLS), a modified flowsheet was developed that involved pre-concentration of the REEs using multiple stages of precipitation and redissolution. The advantage of this process was improved removal of contamination before the downstream purification process and a significant cost reduction relative to the circuit that utilized the solvent extraction process. The modified circuitry included processes involving leaching, multistage precipitation, redissolution, and oxalate precipitation followed by roasting of the oxalate product. The circuit produced a mixed REO that was 92.96% pure from the initial test. A detailed parametric test plan was carried out which involved varying key parameters including solids feed rate, acid flowrate, acid concentration, multistage precipitation pH, redissolution pH, oxalate precipitation dosage and pH. The response variables included REE recovery, contaminant recovery, REO product grade and overall chemical consumption. Test results indicated that the acid-to-solid ratio is the key parameter to leaching efficiency as performance deteriorated with an increase in solids concentration. The optimal pH determined for REE precipitation and redissolution was 6.5 and 2.5, respectively. Additional tests were conducted to further improve the flowsheet. Recirculating a portion of the PLS to the feed of the leach tanks improved the leaching performance by lowering the pH of the leaching system and reducing the contamination recovery by shortening the residence time. Moreover, the removal of Al prior to REE precipitation significantly reduced the oxalic acid consumption in the oxalate precipitation circuit. The modified circuit produced over 90% grade REO by weight from both West Kentucky No. 13 and Fire Clay coarse refuse material in pilot scale continuous test programs. A case analysis model was developed to project the REE and major contaminants concentration in each PLS stream based on the leaching condition, pH cut point, and oxalic acid dosage. A correlation was established using empirical and semi-empirical models. Using the models, chemical consumption required for each stage was predicted based on the projected performance of the hydrometallurgy circuit. After identifying the optimum conditions, validation tests were carried out for the treatment of both West Kentucky No. 13 and Fire Clay coarse refuse materials in the pilot plant. The actual circuit performance and chemical consumptions were very close to the model predictions. Other than the two coarse refuse sources, several secondary feedstocks were also tested in the pilot plant facility. A “heap leach” system was constructed using the coarse refuse material generated from cleaning the West Kentucky No. 13 seam coal. Using the two stage SX rougher and cleaner circuit, a concentrate with a grade >90% REO was produced while recovering >97% of the REEs from the heap leach PLS. Naturally generated acid mine drainage (AMD) from West Kentucky No.13 mine was processed using the multistage precipitation circuit in the pilot plant in a test conducted for a period of 32 hours. The final grade of the mix RE oxide produced from the AMD was 90.84% with an overall circuit recovery of 64%. The primary source of REE was the selective precipitation steps involving iron and aluminum rejection. The hydrophobic-hydrophilic separation (HHS) process was proven to effectively recover coal from fine waste materials. For REM recovery, the HHS process was able to produce concentrates at grades of approximately 1.8% REE on an ash basis; however, recovery values were typically low, <10%, under the optimal conditions determined in the laboratory-scale testing. Staged testing of the pilot-scale HHS process for coal recovery and semi-continuous laboratory testing for REM testing showed that a total concentration ratio of more than 15x was observed for the REM recovery process. A circuit simulation package was developed for REE extraction and purification using a spreadsheet-based platform (Microsoft Excel). The REESim circuit simulation package is configured to track the mass and volume flows of components passing through a series of unit operations specified and configured by the user. The mass rates can then be utilized by the user to determine important performance indicators such as product mass yields, concentrate purity levels, element-by-element recoveries, and so forth. The techno-economic analysis showed that the roasting and leaching operations were the most expensive capital items, each contributing approximately 30% to the total capital cost. One notable contributor to the high production costs was the low REE recovery observed in the pilot scale trials. The product basket price was shown to have a strong influence on the economic viability of the scenarios, with the scandium price being the most significant influencer. Operating cost was shown to be extremely sensitive to REE recovery, REE feed grade, and leaching acid consumption. An analysis of ten different scenarios for a 500 t/h commercial operation revealed that three were economically favorable, producing internal rates of return varying from 27.7% to 33.1% and payback periods of 4 to 5 years. The project successfully developed and demonstrated a process to recover REEs from coal and coal byproducts in a pilot-plant operation which consistently produced over 90% grade REO mix from varies types of feedstocks. Commercialization analysis showed that the technology readiness level successfully achieved TRL 6 at the end of the project and demonstrated the need and the potential for scaling the process to further advance the technologies toward the goal of providing a domestic supply of REEs at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Co-Firing Switchgrass and Waste Coal in A Power Plant: A Techno-Economic and Life Cycle Evaluation for The Ohio River Valley (SWITCH) (Final Technical Report for Ohio State/FE0032204)

Abandoned coal mine lands (AMLs) represent one of the most persistent environmental challenges in the United States. Prior to the enactment of the Surface Mining Control and Reclamation Act (SMCRA) in 1977, coal mining operations were not legally required to reclaim disturbed lands, leaving behind approximately 500,000 AML sites nationwide. These sites pose severe environmental and health risks, including acid mine drainage, soil and water contamination, and spontaneous combustion of waste coal piles. Millions of Americans live within one mile of these AMLs, underscoring the urgency of remediation. Traditional reclamation practices, such as planting cool-season grasses, often fail to fully restore ecological function or leverage the economic potential of these lands. This project addressed these challenges by developing integrated strategies for resource recovery, land reclamation, and sustainable energy production. This project evaluated an integrated strategy to convert this liability into an opportunity by recovering waste coal and co-firing it with switchgrass (Panicum virgatum L.) cultivated on reclaimed or marginal AML areas in existing coal-fired power plants. Switchgrass not only provides a renewable feedstock but also aids in land reclamation and carbon sequestration. 1) Remote Sensing and Machine Learning for Waste Coal Identification Using Sentinel-2 satellite imagery and supervised classification, we applied four machine learning models to detect historical waste coal piles. Random Forest achieved the highest accuracy (precision: 86%, recall: 77%). Time-series analysis revealed gradual vegetation recovery since 1986, indicating natural reclamation processes in historical sites, while active mining areas showed ongoing disturbance. This workflow enables scalable monitoring and prioritization of reclamation efforts. 2) UAS-Based Stockpile Volume Estimation To quantify recoverable waste coal, we evaluated Unmanned Aerial Systems (UAS) equipped with Light Detection and Ranging (LiDAR) and multispectral sensors. Structure-from-Motion (SfM) photogrammetry combined with interpolated Digital Terrain Models (DTMs) achieved strong agreement with LiDAR reference volumes (Root Mean Square Error (RMSE) ≈147 m 3 , Mean Absolute Percentage Error (MAPE) ≈2%). Sensitivity analysis confirmed that spatial resolution significantly influences accuracy, emphasizing the need for high-resolution data for precise volume estimation. This approach offers a scalable, cost-effective, and accurate alternative to conventional ground-based surveys. 3) Switchgrass Cultivation for Bioenergy and Water Quality Improvement We assessed the hydrological and water quality impacts of converting AMLs to switchgrass production areas using the Soil and Water Assessment Tool (SWAT). Results showed that converting 10% of the watershed area into the switchgrass production zone reduced streamflow by 3.1%, total suspended solids by 18.1%, total nitrogen by 7.6%, and total phosphorus by 6.2%, while achieving biomass yields of 8.6–9.2 metric tons per hectare. These findings highlight switchgrass as a dual-benefit strategy for land reclamation and bioenergy feedstock production. 4) Integrated Co-Firing and CCS for Carbon-Negative Power Generation We modeled co-firing scenarios using the Power Plant Flexible Model (PPFM) to evaluate plant efficiency, greenhouse gas (GHG) emissions, and levelized cost of electricity (LCOE). Without carbon capture and storage (CCS), increasing switchgrass co-firing ratios reduced LCOE from $\$$150/MWh at 0% biomass to $\$$110/MWh at full substitution. Under CCS, costs remained higher (~$\$$250/MWh at 0% biomass) but decreased to $\$$200/MWh at 100% biomass, while enabling net-zero or carbon-negative electricity due to switchgrass sequestration benefits. Although CCS introduced efficiency penalties, pairing it with biomass co-firing offset these impacts and maximized climate benefits. Overall, optimizing co-firing ratios between 60-100%, supported by reliable logistics and storage strategies, emerged as a practical pathway to balance affordability, sustainability, and net-zero or negative GHG emissions while promoting productive reuse of AMLs.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2019

Commercial Building Technology Demonstration (Final Scientific/Technical Report)

The background for this project was a unique and innovative concept that had been proposed and demonstrated by enVerid Systems, reducing the energy consumption in HVAC systems in commercial and public buildings by up to 50% at peak loads. The concept involves selective scrubbing of gas contaminants from indoor air as a practical substitute for outside air ventilation, the latter being the conventional practice today. This scrubbing enables recycling of most of the indoor air and significantly decreasing the amount of outside air, resulting in a reduced HVAC load and commensurate energy savings for the facility. Key to our approach is low cost scrubbing of all gas contaminants from indoor air using novel, efficient and regenerable sorbent materials. The total solution, labeled HLR (HVAC Load Reduction) is implemented by means of compact modules that can be retrofitted onto virtually any building, and utilizes novel sorbents that have been developed and brought to scale production by enVerid. Although the technology had been deployed and demonstrated, the US commercial building and HVAC markets, famously conservative with respect to innovation and new technologies, had yet to embrace the idea or the product. The overarching goal of the project was to help overcome market hesitancy and enable widespread adoption, by creating a critical mass of success stories across different regions and building types, all under oversight and verification of the DOE and NREL, to ensure credibility and accuracy. The project, overall, was a resounding success. Several installations were deployed and tested comprehensively for the impact on both energy consumption and indoor air quality, and results were not only excellent, but quantitatively in line with expectations. A total number of eight (8) installations were attempted, with 2 aborted due to building issues. Of the six successful installations, however, complete M&V was performed by NREL on 2 (Miami and NYC) and partial analysis on a third site (ArcBest), and these three, along with their results, were therefore presented from a financial and reporting standpoint. Although the number of case studies fell short of the original target of 10, we nevertheless had excellent demonstrations in vastly different climate zones: Southeast, Northeast and Midwest, and in very different building types. This included a modern high-rise office building in New York City and a University Campus health center in Miami, and a mid-rise high-density office in Arkansas. The cooling load reduction was shown to be significant, averaging 37% during the final cooling season in the Miami site. In the NYC site, the cooling energy savings were generally less, at around 12%, as expected. While this is a lower number for average/total savings, two comments are important to note: (i) the outside airflow (OA) reduction was not consistent during the data collection period, at least in part understating the attainable savings through incorrect measurement of the “high energy” reference state; and (ii) the peak impact in NYC is almost certainly as high as Miami, with critical ramifications for peak load reduction and equipment downsizing ability. Importantly, the measured energy savings in all locations were related to the outdoor climate conditions and the actual achievable reduction in outside air, very much in line with models and calculations; this leaves us with increased confidence in our understanding of the interaction between the technology and the building, and our ability to project the impact of this innovation in the future, through broad adoption. Simply put: the energy savings and load reduction impact of the HLR solution has been confirmed quantitatively. The results also confirmed the air quality objective. This may be even more significant, in that air quality is more complex and harder to measure and quantify, and the performance of the HLR as an air scrubber is the linchpin of the entire solution. In all sites, indoor air quality met or exceeded the required parameters, in terms of achieving the target (low) levels of indoor pollutants. Furthermore, the concentrations of outdoor sourced pollutants were markedly lower, as expected, mostly due to the reduction in outside air intake although in part also due to the scrubbing. The success was not immediate nor easy, and early challenges with the systems, especially (but not only) around controls and communication, caused delays in commissioning and undermined some of our M&V schedules. The good news is no fundamental issues were encountered and the number of such glitches was declining quickly by the end of the project. Other challenges had to do with coordinating the control of the building OA dampers, which the HLR needs to have in order to deliver the load reduction, but which the facility manager controls regularly and independently. This is not necessarily a problem for normal HLR operation but interferes with accurate M&V, where switching OA settings back and forth on a precise timetable is essential for clean data. The project provided valuable experience in retrofitting buildings that had been originally designed to operate with less recirculation and more outside air, and some key learnings related to the cyclical regeneration of the sorbents in the operational environment of the building. Some of these learnings gave already been incorporated into ongoing improvements in the design of the HLR module as well as the software that is used to control its operation. The cost and time of retrofit installations is much better understood; so is the test and balance procedure of the building that determines the available range of outside air reduction, which in turn determines the amount of load reduced. We had also implemented at least one annual cycle of sorbent cartridge replacement in the field, after which we tested the used sorbent to assess the rate of degradation of sorbent potency – an important factor affecting the long-term economics of HLR deployments. A notable shortfall of the project, other than the fact that the number of sites was below target, was that we had not (yet) completed testing to measure and verify (M&V) the winter energy savings. This is primarily due to late start on the NYC sites (Miami does not portend any heating savings associated with reduced outside air), combined with the issues of OA damper control. It is by no means suggested that such savings cannot be captured, only that the M&V with respect to winter in NYC has been incomplete. The value of this project and its interest to the general public are hard to overstate. The case studies created from Miami and especially from NYC have, without a doubt, opened up the interest of the broad HVAC industry to HLR in the past year. Major manufacturer reps have signed up to represent and promote the product, and dozens of top tier engineering consultants have introduced HLR as a base of design in upcoming construction and renovation projects – precisely the overarching goal of this project. These would not have happened without the highly visible installation in NYC and its ultimately satisfied customer. Furthermore, the DOE itself issued a report in late 2017 analyzing hundreds of candidate technologies for reducing energy consumption in HVAC; remarkably, the budding HLR solution ranked among the top 3(!); no doubt, its status as a viable and significant contender on this list is informed by the success of these demonstrations. And furthermore, in the wake of these demos, several major energy utilities, led by ConEdison in NYC, have endorsed the HLR solution and now routinely provide substantial cash rebates for customers choosing to incorporate the HLR in their buildings and reap the benefit of the reduced peak load as well as reduced cumulative energy demand. Last but not least, in January of 2019, as this report was being written, the HLR module won the AHR Expo Innovation Award for Green Buildings and, remarkably, the prestigious and only Product of the Year 2019, being selected by an independent professional panel of judges from AHR and ASHRAE. Given the confirmation of the enormous energy saving potential of HLR in widescale deployment, as well as ancillary but significant benefits in terms of equipment downsizing and indoor air quality, the benefit of this effort to the public speaks for itself. Accelerating adoption of HLR, without dependence on subsidies and driven by the private sector, is well under way. There is still much work to be done in terms of educating the HVAC and construction ecosystems and improving the product’s robustness and simplicity, to further facilitate the adoption of this technology and the capture of its potential value. But the American public will greatly benefit both directly and indirectly in the immediate future and beyond.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2016

Evaluating Age Effects on HEPA Filter Performance

Nuclear grade high efficiency particulate air (HEPA) filters are routinely employed as the final control element in confinement ventilation systems. The traditional HEPA filter utilizes a pleated filter medium of fibrous glass that has been produced in a manner analogous to manufacturing paper. These filters are the physically weakest element in a containment ventilation system. Containment ventilation systems are designed to condition the air-stream (temperature, relative humidity, moisture, particle size distribution of aerosols, and aerosol concentration) to levels/conditions that fibrous glass HEPA filters can handle. Approximately 6000 nuclear grade HEPA filters are purchased each year for use in the DOE/NNSA complex. Additional filters are purchased for use in commercial nuclear power generation and ventilation systems of other nuclear applications. These filters are designed and tested in accordance with the American Society of Mechanical Engineers (ASME) AG-1 Code Nuclear Air and Gas Treatment. This code establishes design requirements and qualification procedures. Qualification testing of axial flow filters is described in paragraphs 5000 and following of AG-1. The series of qualification tests are intended to describe the operating envelope of HEPA filters and verify the reliability of a filter design. AG-1 qualification also confirms the pedigree of components used in manufacture for that filter design. The collective set of qualification tests establishes the assumed operating envelope for AG-1 filters. The effects of age on HEPA filter performance have been a concern for at least two decades. A combination of physical evaluation of aged filter media and a review of filter failure records resulted in Appendix C of the Nuclear Air Cleaning Handbook (NACH), Determination of HEPA Filter Life. This states that HEPA filters are not to be used beyond 10 years from the date of manufacture. Additionally, filters put into service in locations where they may become wet are to be taken out of service five years from date of manufacture. Filters that have become wet are to be taken out of service immediately. Finally, it should also be pointed out that filters held in Level B storage are subject to the same 10-year service life. Very limited bench-scale testing in the 1990's raised concern that aging HEPA filters do not have the strength to withstand an accident scenario. In May of 1999, the DNFSB released a Technical Report 23 entitled HEPA Filters Used in the Department of Energy's Hazardous Facilities. This report expressed concerns for the potential vulnerability of HEPA filters in vital safety systems. Concerns and uncertainty associated with degradation of HEPA filter performance over time led the DOE sites to limit HEPA filter service life to 10 years from the date of manufacture or five years in cases where filters may become wet. Establishment of a conservative service life needs to be based on data from a structured series of tests comparing the performance envelope of new and aged full-scale filters. A service life that is insufficiently conservative endangers workers and the public. One that is excessively conservative costs can cause hundreds of otherwise unnecessary filter changes. This increases exposure of employees, disrupts facility operations, and increase disposal costs by millions of dollars annually. Conclusive data are needed to resolve uncertainty associated with the damaging effects of aging on durability of HEPA filters. Therefore, this study needs to provide a sufficient body of evidence to allow DOE and site professionals to make prudent decisions. An updated version of ASME AG-1 Section FC included a non-mandatory appendix that would include the DOE guidance for service life of HEPA filters. Balloting of this revision generated significant resistance to inclusion of any kind of service life language citing the lack of supporting experimental data. Efforts to resolve negative votes failed and resistance to acceptance of the language increased. The result has been to not include service language in Section FC and requests to remove it from sections that already include such language. The recent activity of the ASME AG-1 Committee on Nuclear Air and Gas Treatment effectively de-emphasizes following DoE's service life guidelines. The DOE Office of Nuclear Safety under its NSR and D program provided the Mississippi State University Institute for Clean Energy Technology (ICET) finding to initiate a study to determine the effects of aging on AG-1 axial flow filters just prior to actions taken within the AG-1 committee regarding service life. The NSR and D funding facilitated timely development of a national technical working group comprised of members from the regulatory community, DOE complex, and commercial power to resolve uncertainty associated with effects of aging. The Department of Energy Office of Environmental Management (DOE-EM) has been funding the ICET to evaluate the performance envelope for AG-1 HEPA filters. ICET is one of DOE-EM's qualified suppliers. Synergy has been achieved by associating the NSR and D aged filter activities to testing activities evaluating the performance envelopes of separator and separator-less AG-1 HEPA filters funded by DOE-EM. The DOE-EM funded activities establish baseline data for the aged filter study and future EM funding will provide long term support for testing additional aged filters. EM funding of new filters includes analytical evaluation of media tensile strength by thermal analysis to establish baseline values and determine mass loss of moisture resistance and acrylic binders due to use. All of these values can be used for comparison of test results for aged filters. (authors)

07 ISOTOPE AND RADIATION SOURCES↗