Results for “process loads” — Page 15

DOE OSTI2023

Isotope Exchange of ND 3 on Pt Catalyst–Loaded 5A Molecular Sieve

Recollecting and purifying unburned tritium is a preferred process for D-T fusion operations. However, tritium containing byproducts act as a potential holdup for the material, requiring additional processing to liberate the tritium. Furthermore, using deuterium as a surrogate for tritium, this work demonstrates the capture and isotope exchange of deuterated ammonia using a Pt catalyst–loaded 5A molecular sieve, performed at ambient temperatures, verified by the analysis of the effluent gas streams and desorbed ammonia isotopologues post exchange.

5A↗

DOE OSTI2023

Comparison of Heterogeneous Langmuirian Models for Mixed-Gas Adsorption Equilibria

Mixed-gas adsorption remains a very active area of research, where newly proposed adsorption equilibrium models need to be compared to standards in the field. The generalized Langmuir (gL) isotherm, proposed by Hamid et al. to address adsorption of different size molecules on heterogeneous adsorbents without requiring evaluation of the Gibbs isotherm, has thus far been tested mainly against the adsorbed solution theory (AST). The gL isotherm was shown to be thermodynamically consistent and gave either better or similar representation than AST models. Here, the gL isotherm is contrasted with the Dual-Process Langmuir isotherm popularized by Ritter and his co-workers and the Loading Ratio Correlation popularized for simple mixtures, both of which are considered the “standard” models for process simulation. Furthermore, the comparison is based on their theoretical roots, interpretations, and representation of the equilibrium loading and the isosteric enthalpy of adsorption of unary, binary, and ternary mixtures of various gaseous adsorbates on different adsorbents over a range of experimental pressures and temperatures.

42 ENGINEERING↗

DOE OSTI2021

A high solids field-to-fuel research pipeline to identify interactions between feedstocks and biofuel production

Abstract Background Environmental factors, such as weather extremes, have the potential to cause adverse effects on plant biomass quality and quantity. Beyond adversely affecting feedstock yield and composition, which have been extensively studied, environmental factors can have detrimental effects on saccharification and fermentation processes in biofuel production. Only a few studies have evaluated the effect of these factors on biomass deconstruction into biofuel and resulting fuel yields. This field-to-fuel evaluation of various feedstocks requires rigorous coordination of pretreatment, enzymatic hydrolysis, and fermentation experiments. A large number of biomass samples, often in limited quantity, are needed to thoroughly understand the effect of environmental conditions on biofuel production. This requires greater processing and analytical throughput of industrially relevant, high solids loading hydrolysates for fermentation, and led to the need for a laboratory-scale high solids experimentation platform. Results A field-to-fuel platform was developed to provide sufficient volumes of high solids loading enzymatic hydrolysate for fermentation. AFEX pretreatment was conducted in custom pretreatment reactors, followed by high solids enzymatic hydrolysis. To accommodate enzymatic hydrolysis of multiple samples, roller bottles were used to overcome the bottlenecks of mixing and reduced sugar yields at high solids loading, while allowing greater sample throughput than possible in bioreactors. The roller bottle method provided 42–47% greater liquefaction compared to the batch shake flask method for the same solids loading. In fermentation experiments, hydrolysates from roller bottles were fermented more rapidly, with greater xylose consumption, but lower final ethanol yields and CO 2 production than hydrolysates generated with shake flasks. The entire platform was tested and was able to replicate patterns of fermentation inhibition previously observed for experiments conducted in larger-scale reactors and bioreactors, showing divergent fermentation patterns for drought and normal year switchgrass hydrolysates. Conclusion A pipeline of small-scale AFEX pretreatment and roller bottle enzymatic hydrolysis was able to provide adequate quantities of hydrolysate for respirometer fermentation experiments and was able to overcome hydrolysis bottlenecks at high solids loading by obtaining greater liquefaction compared to batch shake flask hydrolysis. Thus, the roller bottle method can be effectively utilized to compare divergent feedstocks and diverse process conditions.

09 BIOMASS FUELS↗

DOE OSTI2022

A novel post-processing method for progressive failure analysis of brittle composite compression

Finite element analysis of brittle materials in axial compression typically uses element deletion to allow continued global deformation post-element-failure. However, element deletion produces cyclic load-displacement curves that underestimate energy absorption and are not representative of a continuum system. Two key observations support the conclusion that results from an appropriately discretized model can be an adequate representation of a continuum system. Specifically, the frequency of the oscillations in the load-displacement curve is directly dependent upon element length in the loading direction, and the peak amplitudes of oscillations are mesh size independent. A method of post-processing the analysis results, by connecting the peak amplitudes of oscillations, is proposed and applied to a series of continuous carbon fiber composite crush tubes. The load-displacement curve, stable crushing load, and specific energy absorption of the post-processed results compare well to an experimental study of crush tubes with similar layups.

Materials Science↗

DOE OSTI2024

Development of transparent, particle‐loaded photoresins for volumetric additive manufacturing of silica glass

Abstract Additive manufacturing of glass aims to change the paradigm of glass manufacturing by allowing for improved customization coupled with lower energy and post‐processing needs. Fabrication of glass via volumetric additive manufacturing (VAM) involves printing in a silica‐loaded photopolymer resin with subsequent thermal processing and adds additional advantages by allowing for rapid printing of parts with smooth surfaces and no supports. Previous work in glass VAM has demonstrated fabrication of optical quality microoptics with overall dimensions on the scale of tens of cubic millimeters. For applications requiring glass printed on the scale of cubic centimeters the rheology, scattering, and green part strength must be controlled via resin formulation. Here, we present insight into a novel glass photopolymer resin suitable for VAM and in the effect of tuning formulation on the ability to produce dense glass parts with volumes on the scale of cubic centimeters.

Myers, Luke A.↗

DOE OSTI2022

Cosmogenic nuclide and solute flux data from central Cuban rivers emphasize the importance of both physical and chemical mass loss from tropical landscapes

We use 25 new measurements of in situ produced cosmogenic 26 Al and 10 Be in river sand, paired with estimates of dissolved load flux in river water, to characterize the processes and pace of landscape change in central Cuba. Long-term erosion rates inferred from 10 Be concentrations in quartz extracted from central Cuban river sand range from 3.4–189 Mg km –2 yr –1 (mean 59, median 45). Dissolved loads (10–176 Mg km –2 yr –1 ; mean 92, median 97), calculated from stream solute concentrations and modeled runoff, exceed measured cosmogenic- 10 Be-derived erosion rates in 18 of 23 basins. This disparity mandates that in this environment landscape-scale mass loss is not fully represented by the cosmogenic nuclide measurements. The 26 Al / 10 Be ratios are lower than expected for steadystate exposure or erosion in 16 of 24 samples. Depressed 26 Al/ 10 Be ratios occur in many of the basins that have the greatest disparity between dissolved loads (high) and erosion rates inferred from cosmogenic nuclide concentrations (low). Depressed 26 Al/ 10 Be ratios are consistent with the presence of a deep, mixed, regolith layer providing extended storage times on slopes and/or burial and extended storage during fluvial transport. River water chemical analyses indicate that many basins with lower 26 Al/ 10 Be ratios and high 10 Be concentrations are underlain at least in part by evaporitic rocks that rapidly dissolve. Our data show that when assessing mass loss in humid tropical landscapes, accounting for the contribution of rock dissolution at depth is particularly important. In such warm, wet climates, mineral dissolution can occur many meters below the surface, beyond the penetration depth of most cosmic rays and thus the production of most cosmogenic nuclides. Our data suggest the importance of estimating solute fluxes and measuring paired cosmogenic nuclides to better understand the processes and rates of mass transfer at a basin scale.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Structure, properties, and applications of polyacrylonitrile/carbon nanotube ( CNT ) fibers at low CNT loading

Abstract Bi‐component, polyacrylonitrile (PAN)/carbon nanotube (CNT) fibers were processed, at different core‐sheath area ratios, by gel spinning. A percolated CNT network at 10 wt% CNT in the sheath enhanced electrical conductivity as compared to the neat PAN fiber, while PAN polymer in the core contributed to the good mechanical properties. Fibers with relatively thin sheath allowed overall CNT loading as low as 3.7 wt% to be made with good electrical conductivity, and PAN stabilization by Joule heating was demonstrated. Such fibers with combined good mechanical properties and electrical conductivity can also potentially be used for electrical heating of fabrics, for making smart textiles, and for electromagnetic interference shielding.

Lu, Mingxuan↗

DOE OSTI2021

Hybrid Chemo-Mechanical Plastics Recycling: Solvent-free, High-speed Reactive Extrusion of Low-Density Polyethylene

Low-Density Polyethylene (LDPE) is ubiquitous in the packaging industry due to its flexibility, toughness, and low cost. However, it is typically contaminated with other materials, seriously limiting options for mechanical recycling. Interest in chemical recycling techniques such as pyrolysis and hydrothermal liquefaction is growing, but most of these processes face technoeconomic challenges that have limited commercial deployment. We present a hybrid chemo-mechanical approach using reactive twin-screw extrusion (TSE) for tailoring the molecular weight and chain structure of reclaimed LDPE. Two types of zeolite catalysts at several loading levels were evaluated over a range of processing conditions. Structural, thermal, and rheological properties of the extruded samples were investigated and compared to virgin LDPE and LDPE extruded without the catalyst. A nuclear magnetic resonance spectroscopic technique was used to investigate changes in the structure of the polymer. LDPE extruded with microporous y-zeolite showed lower degradation temperature and increased short chain branching. Mesoporous MCM-41 also induced increased branching but had no effect on degradation temperature. The theoretical mechanical energy input for the chemical modification was calculated using process modeling. The demonstrated hybrid reactive extrusion process provides a potential low-cost, simple approach for repurposing LDPE-based flexible packaging as coatings and adhesives.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Aerosol-boundary layer interaction modulated entrainment process

Abstract Aerosol-boundary layer interactions play an important role in affecting atmospheric thermodynamics and air pollution. As a key factor in dictating the development of the boundary layer, the entrainment process in the context of aerosol-boundary layer interactions is still poorly understood. Using comprehensive field observations made at a superstation in Beijing, we gain insight into the response of the entrainment process to aerosols. We found that high aerosol loading can significantly suppress the entrainment rate, breaking the conventional linear relationship between sensible heat fluxes and entrainment fluxes. Related to aerosol vertical distributions, aerosol heating effects can alter vertical heat fluxes, leading to a strong interaction between aerosols and the entrainment process in the upper boundary layer. Such aerosol-entrainment coupling can inhibit boundary layer development and explains the great sensitivity of observed entrainment rates to aerosols than can traditional calculations. The notable impact of aerosols on the entrainment process raises holistic thinking about the dynamic framework of the boundary layer in a polluted atmosphere, which may have a significant bearing on the dispersion of air pollutants and the land-atmosphere coupling.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

An In-Depth Exploration of the Electrochemical Oxygen Reduction Reaction (ORR) Phenomenon on Carbon-Based Catalysts in Alkaline and Acidic Mediums

Detailed studies of the electrochemical oxygen reduction reaction (ORR) on catalyst materials are crucial to improving the performance of different electrochemical energy conversion and storage systems (e.g., fuel cells and batteries), as well as numerous chemical synthesis processes. In the effort to reduce the loading of expensive platinum group metal (PGM)-based catalysts for ORR in the electrochemical systems, many carbon-based catalysts have already shown promising results and numerous investigations on those catalysts are in progress. Most of these studies show the catalyst materials’ ORR performance as current density data obtained through the rotating disk electrode (RDE), rotating ring-disk electrode (RRDE) experiments taking cyclic voltammograms (CV) or linear sweep voltammograms (LSV) approaches. However, the provided descriptions or interpretations of those data curves are often ambiguous and recondite which can lead to an erroneous understanding of the ORR phenomenon in those specific systems and inaccurate characterization of the catalyst materials. In this paper, we presented a study of ORR on a newly developed carbon-based catalyst, the nitrogen-doped graphene/metal-organic framework (N-G/MOF), through RDE and RRDE experiments in both alkaline and acidic mediums, taking the LSV approach. The functions and crucial considerations for the different parts of the RDE/RRDE experiment such as the working electrode, reference electrode, counter electrode, electrolyte, and overall RDE/RRDE process are delineated which can serve as guidelines for the new researchers in this field. Experimentally obtained LSV curves’ shapes and their correlations with the possible ORR reaction pathways within the applied potential range are discussed in depth. We also demonstrated how the presence of hydrogen peroxide (H2O2), a possible intermediate of ORR, in the alkaline electrolyte and the concentration of acid in the acidic electrolyte can maneuver the ORR current density output in compliance with the possible ORR pathways.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Recent Developments in Hydrogeologic Applications for Strain Tensor Analyses

Changes in fluid pressure deform porous media and this effect occurs in a variety of hydrogeologic processes, from the change in storage during pumping or injection to fluctuations in water levels caused by barometric pressure. We have developed instruments for measuring small strains in porous media, and we have used the resulting strain data to evaluate well testing, hydraulic fracturing, manual loading at the ground surface, and ambient hydrologic processes, like rainfall and evaporation. A particularly important application is the use of strain tensor data measured at shallow depths to analyze well tests or hydraulic fractures conducted at much greater depths. An early demonstration of this technique was conducted at the North Avant Field north of Tulsa, Oklahoma, where Pennsylvanian sandstone creates a confined aquifer and oil reservoir at a depth of 530m. We have showed that the strains caused by injecting into the aquifer could be measured at a depth of 30m and used to evaluate the properties of the aquifer. We recently expanded the array of strainmeters at the North Avant Field by deploying three more instruments at shallow depth (30m) along with a deep instrument at 520m depth in the winter, 2021. The deep instrument is deployed in shale caprock slightly above the aquifer. To our knowledge, the deep strainmeter at the North Avant Field is the deepest strainmeter ever deployed and this required refining methods originally developed for shallow deployments. The instrument was lowered to depth on oil field tubing and cemented in place using techniques and materials developed for use in oil wells. Optical fiber used to communicate with the instrument was cemented in the annulus on the outside of tubing. This is significant because the techniques we used could readily be extended to greater depth, suggesting that strainmeters can be deployed over a wide range of depths for monitoring critical subsurface processes. For example, it suggests that strainmeters could be deployed through the caprock to monitor for leaks from underlying CO2 storage reservoirs. The strainmeter array at the North Avant Field has been used to characterize deformation during a series of injection tests in the spring and summer, 2021. All the new strainmeters respond to pumping, and the strainmeters we installed earlier also responded. To our knowledge, this is the first application of well testing in a deep aquifer that was monitored by an array of strainmeters—our earlier work used strainmeters at a single location. We are currently analyzing the strain data using an analytical solution, a proxy-based Bayesian inversion algorithm, and other methods. Strainmeter data has also been used to characterize periodic pumping tests by us and Riley Blais. A periodically varying pumping rate causes both hydraulic head and strain signals that vary with the same period as the pumping. The peaks and troughs of the head in monitoring wells lag behind the peaks and troughs of the head in the pumping well, and this lag time increases with distance from the pumping well. The lag time of the pressure and the distance to the monitoring well can be used in a simple analysis to estimate the hydraulic diffusivity of the aquifer. The lag time determined from strain data can be used to estimate aquifer properties using the same analysis that works for the pressure only for strain data measured at particular locations. That is because the strain field in a confining unit advances upward, laterally and then downward even though the pressure in the underlying aquifer only advances laterally, according to our recent simulations. We have field data showing that a small periodic signal superimposed on an injection rate at the North Avant Field will create a periodic strain signal at shallow strainmeters. The field data and the recent simulations suggest that including a periodic component to injection or pumping and then monitoring the resulting strain signal could be a way to monitor the subsurface.

Murdoch, Larry↗

DOE OSTI2023

Recent Developments in Hydrogeologic Applications for Strain Tensor Analyses

Changes in fluid pressure deform porous media and this effect occurs in a variety of hydrogeologic processes, from the change in storage during pumping or injection to fluctuations in water levels caused by barometric pressure. We have developed instruments for measuring small strains in porous media, and we have used the resulting strain data to evaluate well testing, hydraulic fracturing, manual loading at the ground surface, and ambient hydrologic processes, like rainfall and evaporation. A particularly important application is the use of strain tensor data measured at shallow depths to analyze well tests or hydraulic fractures conducted at much greater depths. An early demonstration of this technique was conducted at the North Avant Field north of Tulsa, Oklahoma, where Pennsylvanian sandstone creates a confined aquifer and oil reservoir at a depth of 530m. We have showed that the strains caused by injecting into the aquifer could be measured at a depth of 30m and used to evaluate the properties of the aquifer. We recently expanded the array of strainmeters at the North Avant Field by deploying three more instruments at shallow depth (30m) along with a deep instrument at 520m depth in the winter, 2021. The deep instrument is deployed in shale caprock slightly above the aquifer. To our knowledge, the deep strainmeter at the North Avant Field is the deepest strainmeter ever deployed and this required refining methods originally developed for shallow deployments. The instrument was lowered to depth on oil field tubing and cemented in place using techniques and materials developed for use in oil wells. Optical fiber used to communicate with the instrument was cemented in the annulus on the outside of tubing. This is significant because the techniques we used could readily be extended to greater depth, suggesting that strainmeters can be deployed over a wide range of depths for monitoring critical subsurface processes. For example, it suggests that strainmeters could be deployed through the caprock to monitor for leaks from underlying CO2 storage reservoirs. The strainmeter array at the North Avant Field has been used to characterize deformation during a series of injection tests in the spring and summer, 2021. All the new strainmeters respond to pumping, and the strainmeters we installed earlier also responded. To our knowledge, this is the first application of well testing in a deep aquifer that was monitored by an array of strainmeters—our earlier work used strainmeters at a single location. We are currently analyzing the strain data using an analytical solution, a proxy-based Bayesian inversion algorithm, and other methods. Strainmeter data has also been used to characterize periodic pumping tests by us and Riley Blais. A periodically varying pumping rate causes both hydraulic head and strain signals that vary with the same period as the pumping. The peaks and troughs of the head in monitoring wells lag behind the peaks and troughs of the head in the pumping well, and this lag time increases with distance from the pumping well. The lag time of the pressure and the distance to the monitoring well can be used in a simple analysis to estimate the hydraulic diffusivity of the aquifer. The lag time determined from strain data can be used to estimate aquifer properties using the same analysis that works for the pressure only for strain data measured at particular locations. That is because the strain field in a confining unit advances upward, laterally and then downward even though the pressure in the underlying aquifer only advances laterally, according to our recent simulations. We have field data showing that a small periodic signal superimposed on an injection rate at the North Avant Field will create a periodic strain signal at shallow strainmeters. The field data and the recent simulations suggest that including a periodic component to injection or pumping and then monitoring the resulting strain signal could be a way to monitor the subsurface.

Murdoch, Larry↗

DOE OSTI2021

Power System Event Identification Based on Deep Neural Network With Information Loading

Online power system event identification and classification are crucial to enhancing the reliability of transmission systems. In this study, we develop a deep neural network (DNN) based approach to identify and classify power system events by leveraging real-world measurements from hundreds of phasor measurement units (PMUs) and labels from thousands of events. Two innovative designs are embedded into the baseline model built on convolutional neural networks (CNNs) to improve the event classification accuracy. First, we propose a graph signal processing based PMU sorting algorithm to improve the learning efficiency of CNNs. Second, we deploy information loading based regularization to strike the right balance between memorization and generalization for the DNN. Numerical results based on real-world dataset from the Eastern Interconnection of the U.S power transmission grid show that the combination of PMU based sorting and the information loading based regularization techniques help the proposed DNN approach achieve highly accurate event identification and classification results.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Interactions between molecular-scale processes and hyporheic exchange for understanding Fe-S-C cycling in riparian wetlands (Final Report)

Wetlands represent some of the most productive ecosystems on the planet and critically influence global environmental health. Specifically, wetlands promote water quality by transforming nutrients and organic compounds and sequestering metals and contaminants. Riparian wetland hyporheic zones, where toxic surface water and anoxic groundwater mix, exhibit dynamic conditions that drive steep redox gradients and promote hotspots of diverse and fluctuating microbial activity. Changes in climate, water quality, and water quantity can disturb hydrologic flow and biogeochemical processing in these environments. Understanding how sulfate loading, impacted by hydrologic flux and anthropogenic inputs, influences iron and carbon cycling in wetlands will be crucial for predicting water quality issues driven by iron mineral precipitation and sorption, such as the release of heavy metals and other toxic elements. We used a fully integrated multi-scale and multi-method approach to develop a mechanistic understanding of how hydrologic flow influences coupled iron and sulfur cycles in riparian wetlands. This entailed hydrological, geochemical, and microbial observations at two locations: an anthropogenic sulfate-impacted riparian wetland in northern Minnesota, and a low-sulfate Fe-rich riparian wetland in Tims Branch at the Savannah River Site (SRS). These sites were characterized by hydrologically dynamic conditions where the stream and wetland systems oscillated between gaining (upward flow) and losing (downward flow) conditions that recharged the system occasionally with oxidants that fueled a variety of biogeochemical reactions. Aqueous geochemical measurements of surface water, groundwater, and porewater samples were made alongside solid-phase geochemical analyses of sediment gravity cores. Bulk X-ray absorption spectroscopy at the Advanced Photon Source (APS; Argonne) interrogated the speciation and distribution of Fe and S mineral phases of the sediments. Interestingly, it was discovered that, despite strongly reducing conditions, Fe(III) compounds and a variety of intermediate valence S compounds were stable in the subsurface. Indeed, compounds like thiosulfate, S(0), and intermediate valence organosulfur compounds were more prevalent than FeS and pyrite. The composition of the sediments did change with changes in hydrologic flow, showing their reactivity in changing redox conditions. The abundance of these intermediate S compounds was likely formed as a result of anaerobic oxidation by aqueous and solid-phase Fe(III) compounds, fueling a cryptic S cycle that is driving the breakdown of organic matter in the hyporheic zone. Microbiome surveys showed a core community that seemed stable across the landscape, but changed with increasing depth into the sediment. The community composition did not seem to change dramatically with changes in season or hydrologic flow, except for some organisms that have the potential to contribute to S cycling. More work is needed to confirm their functional activity. These fine process-scale analyses were placed within a dynamic field context using physical flow parameters from surface water and groundwater level measurements. These data helped shed light on sulfur-driven biogeochemical processes in hydrologically dynamic riparian wetlands, addressing a gap in our understanding about the impacts of pollution and other anthropogenic changes on ecologically sensitive environments.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

A Custom Machine to Convey Radiologically Impacted Cohesive Soils to the Orion ScanSortSM System - 20382

An established method to reduce the volume of material required to be disposed of as radioactive waste is conveyor-based sorting of potentially radiologically impacted soils. With the Orion ScanSortSM system, potentially impacted soils are conveyed beneath radiation detectors and sorted into above and below criteria bins based on the detectors' response. Confident measurements can only be efficiently achieved when the soil column being conveyed has a reasonably consistent geometry. Highly cohesive soils present a very significant challenge as they tend to clump and adhere to the conveyor hopper, strike-off bar, and belt skirting. This causes voids and valleys in the soil column that affect the measurement geometry and reduce the confidence in the measurement. The reduction in confidence necessitates a longer residence time (i.e. reduction in conveyor belt speed and processing rates) or that the soils in highly unfavorable geometries be dispositioned as impacted or segregated for resurvey (should site logistics support that option). These outcomes may increase the volume of material required to be dispositioned as radiological waste and have a negative impact on project cost and schedule. To minimize impact to sorting operations, Wood designed and built a customized Extruder, to optimize the soil column prior to assay. The design was developed and refined to minimize the volume of highly cohesive soils presented in highly unfavorable geometries in the soil column in order to confidently assess and disposition such soils in a high-production environment. The Extruder is a customized 90 cm wide flat conveyor that has an oversized hopper with a pair of motor-driven rollers that force the soils in the hopper through an opening of adjustable height. The soils are extruded through the opening to produce a soil column that is ∼75 cm wide and ∼8-18 cm deep with a design rate of 225 metric tons/hr. The Extruder was recently deployed with the Orion ScanSort{sup SM} System to a site in northeast Ohio. The site has highly cohesive soils that result from the weathering of glacial sediments and consist of clay and clay loam, resulting in poor drainage and high moisture content. The project infrastructure only supported two bins of material (above and below criteria), which necessitated that soils with unfavorable geometries be discharged into the above criteria bin, along with material determined to have been contaminated. The Extruder was extremely successful in producing a stable soil column with favorable geometries for radiological assay. During production, less than 0.5% (by mass) of the soils processed were presented in unsatisfactory geometries requiring disposition as radioactive waste. The Extruder did not get clogged due to the cohesive soils (as is typical with conventional conveyors) and required very little maintenance, again minimizing impacts to sorting operations. The conveyor belt speed was operated at 14 cm/s with a typical belt loading of ∼109 kg/m resulting in a mean process rate of ∼49 metric tons/hr. The process rate was constrained by other project logistics, rather than by the capabilities of the Extruder, which was operated at less than 20% of the maximum design speed (75 cm/s). It is concluded that the Extruder is highly likely to produce a stable highly cohesive soil column suitable for efficient and confident radiological assay in production environments of 250 short tons/hr or more. The Extruder has the capability to drastically reduce the duration and costs of projects with radiologically impacted highly cohesive soils. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Critical statistical assessment of data in metal additive manufacturing

Obtaining high quality data reflecting the relationships between the additive manufacturing (AM) process parameters, material microstructure and mechanical properties is crucial for the use of machine learning in AM. A database of over 4,000 data entries of metal AM was created thanks to a large number of literature studies on key process parameters and indicators of build quality. Meta-analysis reveals critical biases in the literature. Firstly, majority of studies report only high quality builds, these imbalances in reporting result in weak correlation between process parameters, properties and consolidation, limiting the ability of machine learning models to generalize beyond optimized conditions. Nevertheless, the trained models accurately predict yield strength ($R^2 = 0.85$), suggesting that certain process–property relationships are effectively captured within these models. Secondly, quantitative microstructural data are largely absent, limiting the learning of the microstructure-mechanical properties relationships. Finally, current process window identification is based largely on the consolidation, despite significant uncertainty in its measurement. It is important to identify the process map on the basis of not only the consolidation, but also mechanical behaviour under loading. Such a identification shows that 316 L and Inconel have much larger process map (i.e. highly printable) in comparison to the AlSi10Mg and Ti6Al4V.

Additive manufacturing↗

DOE OSTI2020

Automotive fuel cell stack and system efficiency and fuel consumption based on vehicle testing on a chassis dynamometer at minus 18 °C to positive 35 °C temperatures

In this work we present an in-depth laboratory technology assessment of a 2016 Toyota Mirai Fuel Cell (FC) vehicle based on chassis dynamometer testing. The 114.6 kW FC stack has a high dynamic response, which makes this powertrain a FC-dominant hybrid electric vehicle. The measured peak efficiency is 66.0% FC stack and 63.7% FC system with an idle hydrogen flow rate of 4.39 g/hr. The high FC system efficiencies at low loads match typical vehicle power spectrums, resulting in a high average vehicle efficiency of 62% compared to 45% and 23% for a hybrid electric vehicle and a conventional vehicle, respectively. An energy breakdown accounts for the FC stack losses, FC system losses, air compressor loads, and heater loads for different drive cycles and different thermal conditions. The cold-start North American city drive cycle (UDDS) energy consumption values are, respectively, 758, 581, 226, and 321 Wh/km at ambient conditions of -18 degrees C, -7 degrees C, -25 degrees C and 35 degrees C with 850 W/m 2 of solar loading. The FC system shutdown and startup processes at temperatures below the freezing point contribute to the increased hydrogen consumption. Additionally, the raw test data files are available for download, thus providing the research community with a public reference data on a modern production automotive FC system.

08 HYDROGEN↗

DOE OSTI2021

Polyacrylonitrile Composites of Ag–Al–Si–O Aerogels and Xerogels as Iodine and Iodide Sorbents

Mechanically robust engineered sorbents were constructed by embedding Ag-loaded aerogels or xerogels in a polyacrylonitrile (PAN) matrix at 30 or 50 mass% loadings of gel in PAN. Here, the process for making the base gels as well as the composite materials is described herein, a technology that is very flexible for making hybrid sorbents using various inorganic or organic active sorbents. The PAN-gel composite materials were evaluated for iodine uptake in the form of gaseous iodine [I 2(g) ] at room temperature and at 150°C as well as iodide (I – ) at room temperature from simulated liquid nuclear wastes. The composites show high I 2(g) uptake and high I – uptake (= 93 mass%) in simulated liquid secondary waste spiked with 5 mg L -1 I – . These results demonstrate the utility of such a composite form for iodine removal from contaminated gas and liquid streams.

36 MATERIALS SCIENCE↗