Results for “Quality by Design” — Page 2

DOE OSTI2020

Fabrication Lessons Learned of Transportation Packaging from the Perspective of a Design Authority - 20322

This paper presents lessons learned regarding fabricating packaging systems from the perspective of a design authority (DA). Capturing and implementing lessons learned is critical for an organization to reduce systematic project risk and thereby promote the likelihood of project success. This paper defines the design authority as the organization responsible for technical design, resolving technical design issues, quality assurance program, and maintenance of the packaging system license. A package system is defined as the packaging, its contents, and auxiliary equipment. Packages are certified by the NRC under 10 CFR 71[1] for transportation by ground. The following lessons learned subjects are presented in the paper: quality assurance, interpretation of drawing dimensional requirements, execution of manufacturing processes, hardware dimensional inspection, and leakage rate testing. All discrepancies presented in this paper have been resolved as described in the appropriate final data package. All described package systems are in compliance with their Safety Analysis Report (SAR) and certificate of conformance requirements. The intent of this paper is to identify opportunities for improving the outcome of future projects and to mitigate fabrication challenges proactively. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Fuel Property-Informed Process Design for the Direct Catalytic Conversion of Cellulosics

The direct catalytic conversion of cellulosics (DC3) with supercritical methanol presents a promising pathway to completely solubilize woody biomass and produce >60% mass yield of C2-C6 oxygenates for light duty vehicle applications. Although the oxygenate composition can be tuned by modifying catalyst and process conditions, limited efforts to date have examined DC3 fuel properties for light duty fuel applications to iteratively inform conversion process design. In this work, we designed and evaluated multi-component surrogate bioblendstocks that represent major DC3 light oxygenates and refined catalyst formulations and distillation parameters to improve the resulting light duty fuel quality. Surrogate design for this novel fuel production pathway was based on a preliminary product slate that was systematically adjusted to determine impacts on fuel properties of interest including heating value, oxidative stability, and heat of vaporization, among others. The resulting predictions and measurements of these surrogates were then used to inform improvement of conversion process, and specifically, reformulation of the catalyst which resulted in production of a higher energy density fuel product primarily comprised of saturated alcohols. Fuel testing outcomes also informed downstream oxygenate separations requirements. This resulted in the production of a promising DC3 light-duty fuel blendstock with >15% greater energy density relative to ethanol, while maintaining high octane number and octane sensitivity.

BIOMASS FUELS↗

DOE OSTI2020

Nitrate loading projection is sensitive to freeze-thaw cycle representation

Climate change can have substantial impacts on nitrogen runoff, which is a major cause of eutrophication, harmful algal blooms, and hypoxia in freshwaters and coastal regions. We examined responses of nitrate loading to climate change in the Upper Mississippi River Basin (UMRB) with an enhanced Soil and Water Assessment Tool with physically based Freeze-Thaw cycle representation (SWAT-FT), as compared with the original SWAT model that employs an empirical equation. Driven by future climate projections from five General Circulation Models (GCMs) from 1960 to 2099 under the Representative Concentrations Pathways (RCP) 8.5 scenario, we analyzed changes in riverine nitrate loadings, as well as terrestrial surface and subsurface contributions of the UMRB in the 21st century relative to the baseline period of 1960–1999. By the end of the 21st century, the original SWAT model predicted about a 50% increase in riverine nitrate loadings which is nearly twice as much as that estimated by SWAT-FT (ca. 25%). Such a large difference in projected nitrate changes can potentially mislead mitigation strategies that aim to reduce nitrogen runoff from the UMRB. Further analysis shows that the difference between the original SWAT model and SWAT-FT led to substantial discrepancies in the spatial distribution of surface and subsurface nitrate loadings in the UMRB. In general, SWAT-FT predicted more nitrate leaching for northwestern parts of the UMRB which are more sensitive to freeze-thaw cycle, mainly because SWAT-FT simulated less frequent frozen soils. This study highlights the importance of using physically based freeze-thaw cycle representation in water quality modeling. Design of future nitrogen runoff reduction strategies should include careful assessment of effects that land management has on the freeze-thaw cycles to provide reliable projection of water quality under climate change.

Wang, Qianfeng↗

DOE OSTI2023

Exploration of superconducting multi-mode cavity architectures for quantum computing

Superconducting radio-frequency (SRF) cavities coupled to transmon circuits have proven to be a promising platform for building high-coherence quantum information processors. An essential aspect of this realization involves designing high quality factor three-dimensional superconducting cavities to extend the lifetime of quantum systems. To increase the computational capability of this architecture, we are exploring a multimode approach. This paper presents the design optimization process of a multi-cell SRF cavity to perform quantum computation based on an existing design developed in the scope of particle accelerator technology. We perform parametric electromagnetic simulations to evaluate and optimize the design. In particular, we focus on the analysis of the interaction between a nonlinear superconducting circuit known as the transmon and the cavity. This parametric design optimization is structured to serve as a blueprint for future studies on similar systems.

Reineri, Alessandro↗

DOE OSTI2022

Summary: SEE4GEO

The seismoelectric effects technique (SEE) is a new and innovative approach for geothermal subsurface imaging and monitoring at reservoir scale. The objective of this project is to assess SEE in terms of data acquisition, cost and quality, and to determine its capability in comparison with classical imaging and monitoring techniques, particularly decoupled seismic and electromagnetic methods. This will be achieved by (1) development of a fast, true 3D numerical package, handling SEE imaging and subsurface properties characterization, including resistivity and permeability, (2) laboratory experiments performed in a controlled environment to define optimal deployment design, data quality, and inform field deployment, and (3) field surveys to ultimately test and draw lessons for practical use of SEE technology. There is a relatively extensive body of work in the literature on SEE, and members of this consortium have been involved in theoretical and numerical development of SEE modeling as well as laboratory experiments. Nevertheless, to our knowledge few, if any, documented efforts have been specifically targeting the use of SEE for geothermal subsurface imaging and monitoring. The strength and originality of our proposal rely on an integrated approach leveraging numerical, laboratory and field experiments, to properly document the practical use of SEE. Through this process, SEE in-hand technology for the geothermal industry will be able to progress from a TRL 1 to TRL 3.

58 GEOSCIENCES↗

DOE OSTI2022

Seismoelectric Effects for Geothermal Resources Assessment and Monitoring (SEE4GEO)

The seismoelectric effects technique (SEE) is a new and innovative approach for geothermal subsurface imaging and monitoring at reservoir scale. The objective of this project is to assess SEE in terms of data acquisition, cost and quality, and to determine its capability in comparison with classical imaging and monitoring techniques, particularly decoupled seismic and electromagnetic methods. This will be achieved by (1) development of a fast, true 3D numerical package, handling SEE imaging and subsurface properties characterization, including resistivity and permeability, (2) laboratory experiments performed in a controlled environment to define optimal deployment design, data quality, and inform field deployment, and (3) field surveys to ultimately test and draw lessons for practical use of SEE technology. There is a relatively extensive body of work in the literature on SEE, and members of this consortium have been involved in theoretical and numerical development of SEE modeling as well as laboratory experiments. Nevertheless, to our knowledge few, if any, documented efforts have been specifically targeting the use of SEE for geothermal subsurface imaging and monitoring. The strength and originality of our proposal rely on an integrated approach leveraging numerical, laboratory and field experiments, to properly document the practical use of SEE. Through this process, SEE in-hand technology for the geothermal industry will be able to progress from a TRL 1 to TRL 3.

58 GEOSCIENCES↗

DOE OSTI2023

Failure Modes and Effects Analysis of Biorefinery Pathways

This talk provides an overview of failure modes and effects analysis (FMEA) development and implementation as a systematic criticality and risk assessment tool for biorefinery pathways within the FCIC. This supports a quality by design (QbD) approach, and this talk provides a high-level overview of the results for the FMEA evaluation focused on the generation of pine residue materials for high-temperature pyrolysis conversion. the FMEA interviews included two approaches. The first approach was based around the entire system of unit operations giving a wholistic system level view. The second approach used detailed interviews from individual unit operation within the system allowing for specific failures for individual system components. These two approaches provide different resolutions of information about the reliability and risk. The FMEA results focused on failures associated with meeting critical quality attributes (CQAs) identified for the high temperature conversion of loblolly pine residues and were supplemented with experimental data supporting process upsets and reliability also collected within the consortium. Estimations of risk scores for meeting each given CQA specification, identification of the impacts for not meeting a CQA specification, capturing causes associated with material attributes and process parameters for each failure, identification of current detection methods, and speculation of potential mitigation strategies for decreasing a failure’s risk score were gathered through the FMEA interviews, and were combined to understand the overall process risk metrics and where technology, process, and knowledge improvements are needed in order to de-risk emerging biorefineries.

09 BIOMASS FUELS↗

DOE OSTI2020

GBCGE Subsurface Database Explorer and APIs

This submission defines a DOI for the Great Basin Center for Geothermal Energy's (GBCGE) Subsurface Database Explorer web application and underlying data services, and acknowledges the INGENIOUS project as a major source of funding for data compilation and quality assurance. The GBCGE Subsurface Database Explorer is an interactive web mapping application that provides public access to the GBCGE Subsurface Database, and its collection of datasets pertinent to geothermal exploration, oil and gas exploration, critical mineral exploration, and other subsurface characterization for the Great Basin Region, western US. This is a living database, and will be continuously updated with new data and datasets as funding and motivations allow. The underlying database views that populate the web application are on an automated refresh schedule. Data sources and acknowledgements: We thank our partners with the Nevada Division of Minerals (NDOM), the Southern Methodist University (SMU), and Great Basin State Geological Surveys for their active efforts in data curation, schema design, and quality assurance. We also thank contributors among the USGS, Oregon Institute of Technology, State Divisions of Water Resources, State Divisions of Oil, Gas, and Minerals, and State Geological Surveys for open data availability and direct contributions made under the National Geothermal Data System (NGDS).

15 GEOTHERMAL ENERGY↗

DOE OSTI2026

High-quality Acinetobacter genomes recovered from combat wounds via metagenomic sequencing resemble cultured isolate genomes

The ability to accurately characterize wound pathogens is critical to informing clinical decisions for wound infections with complex treatment requirements. Acinetobacter baumannii is an impactful nosocomial pathogen in combat wounds and civilian hospital-acquired infections. An informed understanding of the phylogenetics and epidemiology of A. baumannii infections in military and civilian environments could guide approaches that improve antibiotic treatment regimens for both military and civilian patients. Whole-genome data for bacterial strains can be difficult to obtain due to challenges in culturing isolates from preserved military specimens. Metagenomic sequencing and assembly create opportunities for genomic analysis of pathogens directly from clinical specimens. The ability to perform comparative analyses between metagenome-derived genomes and culture-derived genomes would support a range of comparative bacterial genomic studies. Wound tissue biopsy and effluent samples from combat injuries were subjected to metagenomic sequencing and assembly. In total, 42 microbial metagenome-assembled genomes (MAGs) were obtained directly from metagenomic sequence data, 36 of which were designated “high” quality. Thirty of these genomes corresponded to Acinetobacter, with 29 mapping specifically to A. baumannii. Other observed genera included Bordetella, Citrobacter, Escherichia, and Pseudomonas. Single-copy and multi-copy orthologs were identified across Acinetobacter MAGs and publicly available isolate genomes derived from military and civilian sources. Both MAG and military isolate genomes were annotated with antimicrobial resistance data, and MAG genomes were statistically comparable to genomes obtained from isolates. Our results highlight the potential of de novo metagenome assembly for enabling high-resolution characterization directly from clinical specimens, thereby improving diagnostic precision, guiding antimicrobial stewardship, and enhancing understanding of pathogen evolution across diverse healthcare and battlefield environments.

Acinetobacter baumannii↗

DOE OSTI2022

Feedstock-Conversion Interface Consortium: Failure Mode and Effects Analysis Summary Report (FY2022)

This report provides an overview of the development of failure modes and effects analysis (FMEA) and its implementation as a systematic criticality and risk assessment tool supporting a quality by design (QbD) approach for FCIC research. This report also provides a high-level overview of the results for the FMEA evaluation of two feedstock preprocessing system configurations: (1) generation of pine residue materials for high-temperature pyrolysis conversion and (2) generation of corn stover materials for low-temperature conversion using deacetylation and disc mechanical refining pretreatment for fermentation to hydrocarbons. For the results presented in this report, our FMEA interviews included two approaches. The first approach was to perform FMEA interviews for the entire system of unit operations giving a wholistic system level view. The second approach consisted of detailed interviews for each individual unit operation within the system allowing for a “deep dive” into the specific failures for the individual components within the configuration. These two approaches provide different resolutions of information. The FMEA results of this report were focused on failures associated with meeting critical quality attributes (CQAs) identified for the target conversion processes for each processed feedstock type. The information gathered through the FMEA interviews include estimations of risk scores for meeting each given CQA specification, identification of the impacts for not meeting a CQA specification, capturing causes associated with material attributes and process parameters for each failure, identification of current detection methods, and speculation of potential mitigation strategies for decreasing a failure’s risk score. The complete results of all FMEA interviews are provided in the Appendices of this report.

09 BIOMASS FUELS↗

DOE OSTI2023

Failure Mode and Effects Analysis Summary Report

This report provides an overview of the development of failure modes and effects analysis (FMEA) and its implementation as a systematic criticality and risk assessment tool supporting a quality by design (QbD) approach for FCIC research. This report also provides a high-level overview of the results for the FMEA evaluation of two feedstock preprocessing system configurations: (1) generation of pine residue materials for high-temperature pyrolysis conversion and (2) generation of corn stover materials for low-temperature conversion using deacetylation and disc mechanical refining pretreatment for fermentation to hydrocarbons. For the results presented in this report, our FMEA interviews included two approaches. The first approach was to perform FMEA interviews for the entire system of unit operations giving a wholistic system level view. The second approach consisted of detailed interviews for each individual unit operation within the system allowing for a “deep dive” into the specific failures for the individual components within the configuration. These two approaches provide different resolutions of information. The FMEA results of this report were focused on failures associated with meeting critical quality attributes (CQAs) identified for the target conversion processes for each processed feedstock type. The information gathered through the FMEA interviews include estimations of risk scores for meeting each given CQA specification, identification of the impacts for not meeting a CQA specification, capturing causes associated with material attributes and process parameters for each failure, identification of current detection methods, and speculation of potential mitigation strategies for decreasing a failure’s risk score. The complete results of all FMEA interviews are provided in the Appendices of this report.

conversion↗

DOE OSTI2025

Credible Criticality Safety Margin in the 30B Package with LEU+ UF 6 and Hypothetical Water Ingress

The commercial nuclear industry is pursuing advancements in fuel and reactor design that increase the uranium enrichment above 5 wt. % 235 U. These advancements will necessitate the ability to transport bulk quantities of UF 6 at increased enrichments. Currently, the 30B cylinder is the primary container used by the industry for UF6 storage and transportation and has a long history of successful shipments. This container can transport up to 2,277 kg of UF 6 at a maximum enrichment of 5 wt. % 235 U. Previous evaluations have assessed the potential impact of criticality safety for 30B transport at higher enrichments but assumed moderator intrusion would not require evaluation. Although current regulations allow for the exception of moderator intrusion for UF6 packages through the design and quality control of the package content, this exception is limited to enrichments up to 5 wt. % 235 U. Thus, an investigation of moderator intrusion into a 30B cylinder should be performed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Assessing the Impacts of Recent Crop Expansion on Water Quality in the Missouri River Basin Using the Soil and Water Assessment Tool

The Missouri River Basin (MORB) has experienced a resurgence of grassland conversion to crop production, which raised concerns on water quality. We applied the Soil and Water Assessment Tool (SWAT) to address how this conversion would impact water quality. We designed three crop production scenarios representing conversion of grassland to: (a) continuous corn; (b) corn/soybean rotation; and (c) corn/wheat rotation to assess the impact. The SWAT model results showed: (a) the lower MORB produced high total nitrogen (TN) and total phosphorus (TP) load before conversion (baseline) due mainly to high precipitation and high agricultural activity; (b) the greatest percentage increases of TN and TP occurred in the North and South Dakotas, coinciding with the highest amount of grassland conversion to cropland; and (c) grassland conversion to continuous corn resulted in the greatest increase in TN and TP loads, followed by conversion to corn/soybean and then conversion to corn/wheat. Although the greatest percentage increases of TN and TP occurred in the North and South Dakotas, these areas still contributed relatively low TN and TP to total basin loads after conversion. However, watersheds, predominantly in the lower MORB continued to be “hotspots” that contributed the greatest amounts of TN and TP to the total basin loads—driven by a combination of grassland conversion, high precipitation, and loading from pre-existing cropland. At the watershed outlet, the TN and TP loads were increased by 6.4% (13,800 t/yr) and 8.7% (3,400 t/yr), respectively, during the 2008–2016 period for the conversion to continuous corn scenario.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Chapter 4: "Waste"-to-Energy for Decarbonization - Transforming Nut Shells Into Carbon-Negative Electricity

This chapter presents a study demonstrating waste pistachio nut shells as a renewable feedstock for climate-friendly electricity generation via industrial gasification technology. The study includes biomass feedstock characterization (i.e., pistachio waste critical material attributes), process variability (i.e., bulk material handling), and overall operational reliability and conversion performance through extended testing. Additionally, techno-economic analysis (TEA) and life cycle assessment (LCA) were performed to assess the economic feasibility and environmental impact of the technology to transform agricultural waste to biopower. For processing pistachio waste material, among critical material attributes, fines content in the biomass (<1/4") had the largest potential to reduce the operating time of the gasifiers due to plugging. Pelletizing fines and co-feeding them with the mixed pistachio waste increased the average feed density, feed rate, and biochar production. Compared to pine wood chips, mixed pistachio waste yielded higher biochar quantity but slightly reduced quality. In general, a systematic Quality by Design methodology is the preferred approach for designing preprocessing and material conveyance systems, where a downstream technology (end user) for the produced intermediate is specified at the outset. TEA results show that the biochar production rate and selling price had an overwhelming impact on the modeled Minimum Electricity Selling Price (MESP), which ranged from 35.5 to 39.9 cents/kWh for the cases studied (16 h/day operational basis). Moreover, LCA results show that the valorization of pistachio shells for biopower generation is a "carbon negative" process that can help decarbonize the U.S. electricity grid. The specific carbon intensity was -0.29 to -0.71 kg CO2e/kWh, compared to 0.45 kg CO2e/kWh for the average U.S. electricity mix. Biochar production from pistachio waste as a potential means for carbon sequestration was a significant driver for the LCA. The highly stable biochar permanently sequesters a considerable fraction of biochar carbon in the ground, more than enough to offset the life cycle emissions, and can be a complementary climate change mitigation strategy.

bio-char↗

DOE OSTI2024

Anti-reflection coating with mullite and Duroid for large-diameter cryogenic sapphire and alumina optics

We developed a broadband two-layer anti-reflection (AR) coating for use on a sapphire half-wave plate (HWP) and an alumina infrared (IR) filter for the cosmic microwave background (CMB) polarimetry. Measuring the faint CMB B-mode signals requires maximizing the number of photons reaching the detectors and minimizing spurious polarization due to reflection with an off-axis incident angle. Sapphire and alumina have high refractive indices of 3.1 and are highly reflective without an AR coating. This paper presents the design, fabrication, quality control, and measured performance of an AR coating using thermally sprayed mullite and Duroid 5880LZ. This technology enables large optical elements with diameters of 600 mm. We also present a thermography-based nondestructive quality control technique, which is key to assuring good adhesion and preventing delamination when thermal cycling. We demonstrate the average reflectance of about 2.6% (0.9%) for two observing bands centered at 90/150 (220/280) GHz. At room temperature, the average transmittance of a 105 mm square test sample at 220/280 GHz is 83%, and it will increase to 90% at 100 K, attributed to reduced absorption losses. Therefore, our developed layering technique has proved effective for 220/280 GHz applications, particularly in addressing dielectric loss concerns. This AR coating technology has been deployed in the cryogenic HWP and IR filters of the Simons Array and the Simons observatory experiments and applies to future experiments such as CMB-S4.

Sakaguri, Kana (ORCID:0000000156678118)↗

DOE OSTI2020

Development of Anti- Yersinia pestis Human Antibodies with Features Required for Diagnostic and Therapeutic Applications

Yersinia pestis is a category A infective agent that causes bubonic, septicemic, and pneumonic plague. Notably, the acquisition of antimicrobial or multidrug resistance through natural or purposed means qualifies Y. pestis as a potential biothreat agent. Therefore, high-quality antibodies designed for accurate and sensitive Y. pestis diagnostics, and therapeutics potentiating or replacing traditional antibiotics are of utmost need for national security and public health preparedness. Here, we describe a set of human monoclonal immunoglobulins (IgG1s) targeting Y. pestis fraction 1 (F1) antigen, previously derived from in vitro evolution of a phage-display library of single-chain antibodies (scFv). We extensively characterized these antibodies and their effect on bacterial and mammalian cells via: ELISA, flow cytometry, mass spectrometry, spectroscopy, and various metabolic assays. Two of our anti-F1 IgG (αF1Ig 2 and αF1Ig 8) stood out for high production yield, specificity, and stability. These two antibodies were additionally attractive in that they displayed picomolar affinity, did not compete when binding Y. pestis, and retained immunoreactivity upon chemical derivatization. Most importantly, these antibodies detected < 1,000 Y. pestis cells in sandwich ELISA, did not harm respiratory epithelial cells, induced Y. pestis agglutination at low concentration (350 nM), and caused apparent reduction in cell growth when radiolabeled at a nonagglutinating concentration (34 nM). These antibodies are amenable to the development of accurate and sensitive diagnostics and immuno/radioimmunotherapeutics.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

An Analytical Model of Erosive Wear of BioMass Comminution Components

An analytical erosion model that relates critical process parameters (speed and impingement angle) to critical material attributes of inorganic mineral species in feedstock (density, size, aspect ratio) and substrate (hardness, toughness, and fatigue ductility) was applied to model wear in pretreatment milling operations. Results of the model were compared to experimental measurements of wear produced using the Accelerated Wear Test (AWT) rig at Idaho National Laboratory (INL). Results showed that there is good agreement between predicted and measured performance, and that a quality-by-design (QbD) tool can be developed to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches.

09 BIOMASS FUELS↗

DOE OSTI2020

Application of an Erosion Wear Model to Predict Wear of Hammer Milling Components

A workable analytical erosion model that relates critical hammermill process parameters (hammermill geometry and rotational speed) to critical material attributes of inorganic mineral species in feedstock (density, size, and aspect ratio) and substrate (hardness, toughness, and fatigue ductility) was applied to model wear (more specifically, change in the shape of hammers) in hammer milling operations. Results of the model were compared to experimental observations of the shape of hammers used in the INL Stage 1 Vermeer hammermill. Results showed good agreement between predicted and measured shape of the hammer, and that a quality-by-design (QbD) approach can be developed to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches.

36 MATERIALS SCIENCE↗