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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

A High-Fidelity Modeling Tool to Support the Design of Oxy-Combustors for Direct-Fired Supercritical CO2 Cycles

The challenge in the design of oxy-combustors for direct-fired supercritical CO 2 (sCO 2 ) cycles is in addressing disparate performance metrics and objectives. Key design parameters to consider include, among others, injector design for mixing and flame stability, split of recycled CO 2 diluent between injectors and cooling films, target flame temperatures to control noncondensable products, and strategies to inject the diluent CO 2 for film cooling and thermal control. In order to support novel oxy-combustor designs, a high-fidelity yet numerically efficient modeling framework based on the CRUNCH CFD® flow solver is presented, featuring key physics-based submodels relevant in this regime. For computational efficiency in modeling large kinetic sets, a flamelet/progress variable (FPV) based tabulated-chemistry approach is utilized featuring a three-stream extension to allow for the simulation of the CO 2 film cooling stream in addition to the fuel and oxidizer streams. Finite rate chemistry effects are modeled in terms of multiple progress variables for the primary flame as well as for slower-evolving chemical species such as NO x and SO x contaminants. Real fluid effects are modeled using advanced equations of states. The predictive capabilities of this computationally tractable design support tool are demonstrated on a conceptual injector design for an oxy-combustor operating near 30 MPa. Simulations results provide quantitative feedback on the effectiveness of the film cooling as well as the level of contaminants (CO, NO, and N) in the exhaust due to impurities entering from the injectors. These results indicate that this framework would be a useful tool for refining and optimizing the oxy-combustor designs as well as risk mitigation analyses.

Engineering↗
NASA NTRS2015

Human Factors and Habitability Challenges for Mars Missions

As NASA is planning to send humans deeper into space than ever before, adequate crew health and performance will be critical for mission success. Within the NASA Human Research Program (HRP), the Space Human Factors and Habitability (SHFH) team is responsible for characterizing the risks associated with human capabilities and limitations with respect to long-duration spaceflight, and for providing mitigations (e.g., guidelines, technologies, and tools) to promote safe, reliable and productive missions. SHFH research includes three domains: Advanced Environmental Health (AEH), Advanced Food Technology (AFT), and Space Human Factors Engineering (SHFE). The AEH portfolio focuses on understanding the risk of microbial contamination of the spacecraft and on the development of standards for exposure to potential toxins such as chemicals, bacteria, fungus, and lunar/Martian dust. The two risks that the environmental health project focuses on are adverse health effects due to changes in host-microbe interactions, and risks associated with exposure to dust in planetary surface habitats. This portfolio also proposes countermeasures to these risks by making recommendations that relate to requirements for environmental quality, foods, and crew health on spacecraft and space missions. The AFT portfolio focuses on reducing the mass, volume, and waste of the entire integrated food system to be used in exploration missions, and investigating processing methods to extend the shelf life of food items up to five years, while assuring that exploration crews will have nutritious and palatable foods. The portfolio also delivers improvements in both the food itself and the technologies for storing and preparing it. SHFE sponsors research to establish human factors and habitability standards and guidelines in five risk areas, and provides improved design concepts for advanced crew interfaces and habitability systems. These risk areas include: Incompatible vehicle/habitat design, inadequate human-computer interaction, inadequate critical task design, inadequate human-automation/robotic interaction, and performance errors due to training deficiencies. To address the identified research gaps within each risk, SHFH's research plan includes studies in the laboratory, in analogs, and on International Space Station (ISS). In addition to establishing and maintaining the risk-based research portfolio, SHFH is also implementing a qualitative approach to determine how we at NASA evaluate human performance. Via interviews with experts, such as trainers, flight controllers, and flight surgeons, we are collecting the metrics by which they assess human performance, evidence of performance issues, and potential or actual consequences. The Human Performance Data Project will determine what human performance data have been collected in the past at NASA, and what data should be collected in the future in order to complete our knowledgebase and reduce risks related to human factors and habitability.

Whitmore, Mihriban↗
DOE OSTI2021

Demethylation or Sorption? The Fate of Methylmercury in the Presence of Manganese Dioxide

Manganese oxide (MnO 2 ) amendments to mercury (Hg)-contaminated sediment have been shown to decrease methylmercury (MeHg) concentrations in sediment porewater. In the absence of solid-phase MeHg measurements, it is unclear whether the decreased porewater concentrations are due to inhibition of methylation, adsorption of the MeHg to the MnO 2 , demethylation of MeHg catalyzed by the MnO 2 , or some combination of these mechanisms. We conducted controlled laboratory experiments to determine whether MeHg losses from solution in the presence of amorphous MnO 2 are due to sorption or demethylation. In this work, we quantified MeHg in the dissolved phase and solid phase and found that no demethylation occurred. We used batch and isotherm experiments to determine MeHg sorption efficiency to MnO 2 in a variety of solutions with varying ionic strength and dissolved organic matter (DOM) concentration. Isotherms over an initial concentration range of 5–500 ng/L of MeHg showed no saturation effects. Increasing ionic strength from 0.012 M to 0.1 M produced relatively minor decreases in MeHg sorption. Increasing DOM concentrations from 0.64 to 16.4 mg C/L yielded substantial decreases in MeHg sorption. Under the experimental conditions, MnO2 is a less efficient MeHg sorbent compared to other sorbent materials, such as Thiol-SAMMS®, activated carbon, and biochar.

42 ENGINEERING↗
NASA NTRSDate not supplied

EVA Swab Kit: Tools and Techniques for Collecting Aseptic Samples from Crewed Space Missions

Introduction: When we send humans to search for life on other planets, we'll need to know what we brought with us versus what may already be there. To ensure our crewed spacecraft meet planetary protection requirements—and to protect our science from human contamination—we'll need to assess and verify whether micro-organisms may be leaking/venting from our spacesuits. This requires collecting samples under Extravehicular Activity (EVA) conditions. Detailed, systematic research on forward contamination from robotic spacecraft has been steadily progressing since the Viking missions, but systematic studies of contamination from space suits has not been conducted in many years. The modern EMU (Extravehicular Mobility Unit) suit used by NASA is designed to leak at rates as high as 100 cc/min. Before humans land on Mars there is a critical need to understand the types and quantities of microbes that could be introduced via space suits. The Human Forward Contamination Assessment team at NASA’s Johnson Space Center (JSC) has developed a prototype EVA swab tool [1,2,3,4] designed for use in space to sample cleaned and uncleaned space suits to determine the present day microbial load and eventually the rate of leakage. The ability to assess microbial leakage early in advanced space suit and life support system design cycles will help avoid costly hardware redesign later. Test Objectives: The primary objective of EMU testing was to characterize the type of micro-organisms typically found on or near selected suit pressure joints under suit differential pressure conditions. Most human-borne microbes can fit through a 0.5 to 1.0 µm gap. Knowing which joints are more likely to leak will inform hardware design decisions. Knowing which types of micro-organisms may leak from EVA suits provides a basis for subsequent studies to characterize the viability of those organisms under destination conditions, as well as how far they might spread through natural or human-influenced processes. That data, in turn, will inform exploration mission operations and hardware design. The secondary objective of testing was to evaluate the interface between a fully suited test subject and the EVA swab tool at vacuum. Bulky EVA suits can restrict movement and limit visibility through the helmet visor. Fully suited testing is important for identifying tool design issues prior to flight. At exploration destinations, such as Mars, suited crew may be required to periodically sample their suits as part of an environmental monitoring protocol. Suit Microbial Sampling Results: This report details results of microbial swabs collected from current flight suit configurations worn by crew members assigned to upcoming ISS expedition missions as well as swabs collected from prototype suits intended for use on the Orion spacecraft. These tests were intended to characterize the types of contaminants found on flight suits under current, typical handling conditions. No attempt was made to change suit handling procedures, provide additional sterilization, or to limit typical potential contaminant sources. Using culture based techniques, we cultivated 235 CFU (colony forming units) comprised of 26 bacterial species and one fungal species on the outside of the suits. The fungal species and 14 of the bacterial species were unique to the suit surfaces and were not detected in any of the background samples collected within the chambers. We sequenced 755,434 ribosomal fragments on all of the suit surfaces from swab samples. 557,016 of these sequences represent DNA that survived at least 4 hours at vacuum. These sequences formed 2,464 OTU's (Operational Taxonomic Units, 97% similarity) showing low diversity in the samples. The most abundant sequences that survived vacuum belong to the genera Staphyloccocus, Ralstona, Bacillus and Rhodobacter all of which are common to the human microbiome. [5] See Danko et al., (2021) for more complete details of these first analyses. Further analysis of EVA suit materials with respect to the efficacy of various cleaning protocols and engineered containment solutions is planned to inform suit design for NASA’s Artemis Moon to Mars program crew testing. Swab Tool Function Results: The kit was demonstrated for fit and function in suited subject vacuum tests to determine how well the tool worked as an aseptic microbial sampling device as well as to identify any design elements that could be upgraded for EVA task specific improvement. It was found that sample acquisition efficacy could be enhanced by redesign of the sample canister to end-effector interface. Several modifications of the sample caddy assemblies to optimize EVA safety and functionality were also identified. Consequently, fabrication of the redesigned sample canister to end-effector assembly interfaces and and the sample caddy assemblies are required. Fabrication of sixteen flight sample canister assemblies (8 per each of two EVA Swab Kits) and two sample caddy assemblies are in process to be followed by hardware testing and certification to produce two flight-certified EVA Swab Kits for transport to ISS no earlier than summer of 2022. Sampling Strategy: The International Space Station is an ideal testbed for systematic studies of contamination from crewed vehicles since it has been continuously occupied for 20 years and exposed to non-terrestrial conditions. We will sample the exterior of the ISS during EVA using a purpose-built swab tool capable of maintaining sterility while undergoing temperature changes from -151 to +121°C under hard vacuum. Prior to each EVA, the project team will work with ISS mission managers to identify precise sampling locations, which will vary by EVA based on the translation paths and worksites scheduled for that particular EVA. Ideally, translation path handrails and areas near ECLSS (Environmental Control and Life Support System) external vent openings on a spacecraft would be assessed. There are currently more than a dozen ECLSS external vents on the ISS. Some are connected to systems that vent waste products, while others are intended to equalize cabin pressure. As EVA opportunity allows, microbial samples from any of these external vents would provide a valuable data point, though some will be more useful than others. Four criteria have been identified to help prioritize sampling sites near vents: • EVA Accessibility: To minimize cost, it is desired to piggy-back onto a planned EVA. Therefore, the sampling location must be readily accessible by an EVA crew • Type of Vented Products: Vent products that have been in direct contact with crew, such as cabin air, are more likely to contain microorganisms than vent products associated with isolated systems, such as experiment module combustion products. • Mass of Vented Products: Higher-flow vents are more likely to contain detectible levels of microbial contaminants than lower-flow vents. • Local Environment: Sample locations with relatively benign local conditions, such as warm surfaces shielded from direct ultraviolet (UV) radiation exposure, may be more likely to support microbial growth than locations with harsher local environmental conditions. Because EVA accessibility is the most important criteria, the proposal team worked with an astronaut and flight controllers using the Dynamic Onboard Ubiquitous Graphics (DOUG) tool. The DOUG virtual environment allows an operator to “fly” around the current ISS vehicle configuration to assess EVA translation paths, attach points, and keep-out zones. While analysis on station or rapid return to Earth would be preferable, samples collected from the exterior of the ISS have already been exposed to temperature variations between -157 and +121 °C as well as hard vacuum. Therefore, they should be fairly stable and robust. We hypothesize that samples collected from the ISS exterior could be stored for up to 6 months at -80°C without degradation. Sample canisters will be returned to Earth while frozen at -80°C for analysis, and sterilized canisters can be re-flown back to ISS to support additional sampling opportunities Relevance to NASA Exploration Objectives: These data will allow us to identify new or improved methods, technologies, and procedures for spacecraft sterilization and leakage mitigation to minimize the amount of contamination introduced to the environment by human explorers. This work is funded by NASA research grant: NNH18ZDA001N-PPR References: [1] Bell, M.S. et al. (2015) LPS XLVI, Abst. #1832 [2] Rucker et al. (2018) 42nd COSPAR (PPP.3) [3] Bell, M.S. et al. (2019) Mars Extant Life Conference, Abst. #5096.[4] Bell, M.S. et al., (2020) 43rd COSPAR (BO.2).[5] Danko D, et.al.,(2021)Front.Microbiol.12:608478.

Mary Suzanne Bell↗
NASA NTRS2014

NASA Wearable Technology CLUSTER 2013-2014 Report

Wearable technology has the potential to revolutionize the way humans interact with one another, with information, and with the electronic systems that surround them. This change can already be seen in the dramatic increase in the availability and use of wearable health and activity monitors. These devices continuously monitor the wearer using on-­‐body sensors and wireless communication. They provide feedback that can be used to improve physical health and performance. Smart watches and head mounted displays are also receiving a great deal of commercial attention, providing immediate access to information via graphical displays, as well as additional sensing features. For the purposes of the Wearable Technology CLUSTER, wearable technology is broadly defined as any electronic sensing, human interfaces, computing, or communication that is mounted on the body. Current commercially available wearable devices primarily house electronics in rigid packaging to provide protection from flexing, moisture, and other contaminants. NASA mentors are interested in this approach, but are also interested in direct integration of electronics into clothing to enable more comfortable systems. For human spaceflight, wearable technology holds a great deal of promise for significantly improving safety, efficiency, autonomy, and research capacity for the crew in space and support personnel on the ground. Specific capabilities of interest include: Continuous biomedical monitoring for research and detection of health problems. Environmental monitoring for individual exposure assessments and alarms. Activity monitoring for responsive robotics and environments. Multi-modal caution and warning using tactile, auditory, and visual alarms. Wireless, hands-free, on-demand voice communication. Mobile, on-demand access to space vehicle and robotic displays and controls. Many technical challenges must be overcome to realize these wearable technology applications. For example, to make a wearable device that is both functional and comfortable for long duration wear, developers must strive to reduce electronic mass and volume while also addressing constraints imposed by the body attachment method. Depending on the application, the device must be placed in a location that the user can see and reach, and that provides the appropriate access to air and the wearer's skin. Limited power is available from body-­‐worn batteries and heat must be managed to prevent discomfort. If the clothing is to be washed, there are additional durability and washability hurdles that traditional electronics are not designed to address. Finally, each specific capability has unique technical challenges that will likely require unique solutions. In addition to the technical challenges, development of wearable devices is made more difficult by the diversity of skills required and the historic lack of collaboration across domains. Wearable technology development requires expertise in textiles engineering, apparel design, software and computer engineering, electronic design and manufacturing, human factors engineering, and application-­‐specific fields such as acoustics, medical devices, and sensing. Knowledge from each of these domains must be integrated to create functional and comfortable devices. For this reason, the diversity of knowledge and experience represented in the Wearable Technology is critical to overcoming the fundamental challenges in the field.

Simon, Cory↗
DOE OSTI2023

Defining a compact dry cooler design to reduce LCOE contribution in a CSP facility

Concentrating solar power (CSP), when coupled with a supercritical carbon dioxide (sCO 2 ) power cycle and sensible heat storage, presents a renewable and clean alternative for utility-scale power generation. However, in order to be competitive in the current and future markets, CSP facilities must limit their levelized cost of electricity (LCOE) by minimizing capital costs and reducing operating costs over the lifetime of the plant. Targeting this goal, this study investigates the LCOE impact of the power cycle pre-cooler. This study considers a compact dry cooler with micro-channel technology on the CO 2 side and formed fin geometry on the air side, using directly-coupled centrifugal fans and a transition duct to improve air distribution across the fins as well as protect the fins from contaminants which may cause blockage, soiling, fouling, and damage. In an effort to better understand the dry cooler impact on LCOE, a sensitivity study was conducted using various combinations of end-to-end approach temperatures, air-side pressure drop values, CO 2 -side pressure drop values, fan types, cooler turndown control schemes, cooler module sizes, and design-point ambient temperatures. Furthemore, off-design cycle performance data was calculated for each dry cooler design using NPSS simulation software; cycle performance data were then input to System Advisor Model (SAM) along with the associated capital costs for LCOE prediction of a 100 MW system over a 30 year plant lifetime. Results of this study show the LCOE is most sensitive to air-side performance, followed by heat transfer effectiveness and capital cost. It was found that a power cycle with a mid- to high-performance dry cooler will produce the most competitive power-production costs. Designing at the extreme ends for approach temperature (or effectiveness), design-point ambient temperature, and compactness (footprint) produce higher LCOE values; mid-range values for these parameters balance performance, operating costs, and associated capital cost to optimize LCOE.

14 SOLAR ENERGY↗
DOE OSTI2018

Contamination control and assay results for the Majorana Demonstrator ultra clean components

The Majorana Demonstrator is a neutrinoless double beta decay experiment utilizing enriched Ge-76 detectors in 2 separate modules inside of a common solid shield at the Sanford Underground Research Facility. The Demonstrator has utilized world leading assay sensitivities to develop clean materials and processes for producing ultra-pure copper and plastic components. This experiment is now operating, and initial data provide new insights into the success of cleaning and processing. Post production copper assays after the completion of Module 1 showed an increase in U and Th contamination in finished parts compared to starting bulk material. A revised cleaning method and additional round of surface contamination studies prior to Module 2 construction have provided evidence that more rigorous process control can reduce surface contamination. In conclusion, this article describes the assay results and discuss further studies to take advantage of assay capabilities for the purpose of maintaining ultra clean fabrication and process design.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Use of Separator with Regular Granular Filling in Extraction Processes - 12209

The separator with a regular granular filling has been developed to be used for the operations of the removal of carbon-black impurities from the aqueous flow; the intra-cycle regeneration of back-extractants; and the concentrating back-extraction of plutonium in the extraction SNF reprocessing technology. The process conditions for those operations have been experimentally tested using this separator. Thus, the separator for operations of concentrating reextraction of plutonium and regeneration recycling extractant allows to: - derive plutonium from the organic stream into an extremely concentrated form, reducing the amount of liquid radioactive waste (raffinate, decantate) plutonium branches to a minimum; - controlling the processes of concentration of uranium and plutonium, get uranium-plutonium product with required concentration and the amount of metal with required ratio; - eliminate contamination of the emulsion flows; - simplify the purification of uranium from the extract plutonium; - test results showed that when working on a solution 'hydrazine-DTPA' in the separator it is achieved the extraction of plutonium re-extract - 82% TC - at 56-65%. With the transition to the reextraction by solution 'U (IV)-hydrazine', of plutonium into re-extract increases to 95%, technetium - up to 83%; - regenerate the extractant recycling minimizing the amount of liquid radioactive waste generated as a technology used as well as alternative 'salt-free' systems; - it is found that the regeneration of the extractant solution of soda and EDA in the separator at a load of 3.2 m{sup 3} / (m{sup 2}.h) it can be achieved almost complete phase separation. Residual carryover of 0,005-0,006% emulsion is on the verge of analytical detection. - It is shown that in the depth of separation phase a separation of the extractant regeneration of quality superior is more than 5-7 times to the extraction. (authors)

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

Approaches for effective negative pressure isolation space control to minimize airborne transmission of contaminants in residential homes

Controlling airborne transmission of contaminants including respired viruses such as SARS-CoV-2 is necessary to protect occupants living in the same house with a contagious person. The effectiveness of interventions requiring minor efforts that create a negative pressure isolation zone (IZ) for a contagious person has yet to be systematically tested for residential homes. In this study, ASHRAE Standard 170, which offers guidance for negative pressure isolation space control in healthcare facilities, was used in developing practical and attainable recommendations for residential single-family homes. The relative effectiveness of several control strategies was evaluated through experimentally conducting 17 different test cases in a manufactured single-family house laboratory. These cases were designed based on various heating, ventilation and air-conditioning (HVAC) operating scenarios, intervention measures including closing the IZ door and/or sealing over supply and return air grilles in the IZ, and utilization of bathroom exhaust or portable window fans for pressure control. Four out of 17 test cases were identified as having the potential for strong containment with adequate depressurization in the IZ. The most effective IZ depressurization was achieved through continuously operating the exhaust fan in the bathroom attached to the IZ, by installing a portable window fan that extracted air out of the IZ, and a portable room air conditioner with the AC unit exhaust duct installed in one of the IZ windows.

Construction & Building Technology↗
DOE OSTI2018

EPA and Idaho National Laboratory create first of its scale

Advancing the science and engineering of decontaminating water distribution systems and safely disposing of high-volumes of contaminated water are high priorities for the EPA. To help address these science gaps, EPA homeland security researchers have developed the first-of-its-scale Water Security Test Bed (WSTB). Water is an important component of everyday life. We rely on safe, clean water for our health and the health of the environment. Protecting this vital resource is critical to living safely and securely. The U.S. Environmental Protection Agency is responsible for working with water utilities to protect water systems from contamination and to clean up systems that become contaminated. Purposeful or inadvertent distribution system contamination can result in large amounts of infrastructure and water that must be cleaned. Water distribution systems contamination can be caused by, for example, natural disasters such as Superstorm Sandy or by individuals hoping to cause harm. The WSTB, constructed at the Department of Energy’s (DOE) Idaho National Laboratory, replicates a section of a typical municipal drinking water system including a piping system with roughly 445 feet of pipe and two fire hydrants laid out in an “L” shape using 40-year-old, eight-inch cement mortar lined, ductile iron pipes, excavated after twenty years of use for water conveyance. Researchers built the WSTB above ground for easy access during experiments, and to facilitate fast leak detection. Over the next several years, EPA and partner researchers will conduct experiments using simulants of various biological, chemical, and radioactive materials that simulate high toxic versions of these agents. At this “full” sized system, researchers will demonstrate approaches to contamination detection, sensor and model testing, infrastructure decontamination, water treatment and cyber testing developed at lab and pilot scale. Researchers are also able to verify if laboratory results that were effective in controlled conditions are as effective in full-scale testing. Having the ability to conduct bench scale studies in a real world setting can help address specific research gaps, and help water researchers understand conditions in which real world drinking water systems operate.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Probing unintentional Fe impurity incorporation in MOCVD homoepitaxy GaN: Toward GaN vertical power devices

Unintentional impurity incorporation in GaN drift layers represents a challenging issue that can limit their potential performance in vertical power devices. In this paper, we focus on studying the origins of Fe impurity incorporation in metal-organic chemical vapor deposition (MOCVD) grown GaN materials. Acting as a compensator in n-type GaN drift layers, Fe impurities can reduce the electron mobility in GaN and limit the lowest controllable doping level. Two sources, the sample cleaning process and growth susceptor, were identified as the main mechanisms of Fe incorporation in the MOCVD GaN growth process. It was found that solvent cleaning of the wafer can introduce significant Fe contamination at the growth interface, which would slowly be incorporated into the GaN epilayer, thus causing background Fe impurity as high as 10 17 cm -3 level. Moreover, the Fe impurity in the coating material on the susceptor can introduce additional Fe impurity during the growth process. Our studies revealed that the Fe impurity level could be significantly suppressed by more than two orders when an alternative cleaning process was used and the susceptor surface was fully covered by substrates. Characterization of the Fe impurity concentrations was performed via secondary ion mass spectrometry. The trap level (E C - 0.57) eV from deep-level transient spectroscopy that had previously been attributed to Fe confirmed the carrier compensation effect from Fe. Room temperature Hall mobility as high as 1007 cm 2 /V s was achieved on the MOCVD grown low-Fe GaN. Results from this work will provide guidance for achieving high purity GaN toward high performance GaN vertical power devices.

42 ENGINEERING↗
NASA NTRS2011

External Tank Program - Legacy of Success

The largest single element of Space Shuttle is the External Tank (ET), which serves as the structural backbone of the vehicle during ascent and provides liquid propellants to the Orbiter s three Main Engines. The ET absorbs most of the seven million pounds of thrust exerted by the Solid Rocket Boosters and Main Engines. The design evolved through several block changes, reducing weight each time. Because the tank flies to orbital velocity with the Space Shuttle Orbiter, minimization of weight is mandatory, to maximize payload performance. The initial configuration, the standard weight tank, weighed 76,000 pounds and was an aluminum 2219 structure. The light weight tank weighed 66,000 pounds and flew 86 missions. The super light weight tank weighed 58,500 pounds and was primarily an aluminum-lithium structure. The final configuration and low weight enabled system level performance sufficient for assembly of the International Space Station in a high inclination orbit, vital for international cooperation. Another significant challenge was the minimization of ice formation on the cryogenic tanks. This was essential due to the system configuration and the choice of ceramic thermal protection system materials on the Orbiter. Ice would have been a major debris hazard. Spray on foam insulation materials served multiple functions including thermal insulation, conditioning of cryogenic propellants, and thermal protection for the tank structure during ascent and entry. The tank is large, and unique manufacturing facilities, tooling, and handling, and transportation operations were developed. Weld processes and tooling evolved with the design as it matured through several block changes. Non Destructive Evaluation methods were used to assure integrity of welds and thermal protection system materials. The aluminum-lithium alloy was used near the end of the program and weld processes and weld repair techniques had to be refined. Development and implementation of friction stir welding was a substantial technology development incorporated during the Program. Automated thermal protection system application processes were developed for the majority of the tank surface. Material obsolescence was an issue throughout the multi-decade program. Process controls were implemented to assure cleanliness in the production environment, to control contaminants, and to preclude corrosion. Each tank was accepted via rigorous inspections, including non-destructive evaluation techniques, proof testing, and all systems testing. In the post STS-107 era, the project focused on ascent debris risk reduction. This was accomplished via stringent process controls, post flight assessment using substantially improved imagery, and selective redesigns. These efforts were supported with a number of test programs to simulate combined environments. The debris risk was reduced by two orders of magnitude. During this time a major natural disaster was overcome when hurricane Katrina damaged the manufacturing facility. Numerous lessons from these efforts, the manufacturing and material processing issues, the key design features, and evolution of the design will be discussed.

Pilet, Jeffery C.↗
DOE OSTI2022

Smart Ventilation Controls for Occupancy and Auxiliary Fan Use Across U.S. Climates

Smart Ventilation has been developed as a way to reduce the energy associated with ventilation by changing when ventilation happens and how much ventilation occurs at any given time. In high performance buildings with low envelope and appliance related loads, ventilation is becoming a bigger part of the total building energy use and needs to be addressed if performance targets are to be met. This work explores the development and performance of smart ventilation controls based on occupancy and auxiliary fan operation that provide annual dwelling unit ventilation equivalence to ASHRAE Standard 62.2-2016. A prototype high performance home compliant with U.S. DOE Building America Zero Energy Ready program requirements was simulated using the REGCAP tool with and without smart controls across 15 U.S. DOE climate zones. Balanced and unbalanced IAQ fans were independently simulated, and all smart controlled fans had airflows double the reference 62.2-2016 airflow. Three idealized occupancy patterns were examined: 1st shift (a typical daily work/school absence), an extended 1st shift with more time spent out of the home evenings and weekends and 3rd shift (night work). The Occupancy controller turns the IAQ fan off during unoccupied periods, and it resumes ventilation upon their return. While unoccupied, contaminants are allowed to accumulate in the space, because occupants are not exposed to these contaminants. When occupants return home, they are exposed to these higher contaminant concentrations, and the controller increases the ventilation rate sufficiently to ensure equivalence with a continuous IAQ fan. Accounting for pollutant emissions that occur during unoccupied periods (as required by ASHRAE 62.2-2016), sharply distinguishes our occupancy controls from past Demand Controlled Ventilation systems. This new accounting method results in equivalent contaminant exposure, as well as lower reductions in average ventilation rates and lower energy savings. Smart controls were demonstrated that saved HVAC energy (i.e., avoided heating/cooling load, as well as fan energy)—averaging between 6 and 46% of ventilation-related energy use depending on the control strategy and occupancy pattern assumptions. The greatest savings were in the combined Auxiliary Fan + Occupancy control. Energy savings increased with climate heating demand and longer unoccupied time periods. The 3rd shift occupancy pattern had better performance, due to the thermal benefit of reducing the ventilation rate during the cold nighttime hours. This same effect provided a cooling energy benefit in hotter locations for the 1st shift. Overall, savings from occupancy-based smart controls were low, because of the recovery period required after occupants return home, during which the airflow is double the 62.2 reference. This recovery is required to maintain equivalence with the ASHRAE standard. Occupancy-based control performance was improved when combined with sensing auxiliary fans and when providing a pre-occupancy flush out of one- or two-hours. Performance was similarly improved if the ASHRAE Standard were to recognize that pollutant emissions are lower during unoccupied periods, iii allowing a lower target ventilation rate during unoccupied periods (not currently in the standard) (see Full vs. Half AEQ in this report). Finally, over-sized unbalanced fans that are cycled on-and-off by a smart controller (or timer) were found to substantially increase annual average air exchange and energy use relative to a continuous unbalanced fan due to the effects of superposition with natural infiltration.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Vertical Extraction Process Implemented at the 118-K-1 Burial Ground for Removal of Irradiated Reactor Debris from Silo Structures - 12431

The primary objective of a remediation project is the safe extraction and disposition of diverse waste forms and materials. Remediation of a solid waste burial ground containing reactor hardware and irradiated debris involves handling waste with the potential to expose workers to significantly elevated dose rates. Therefore, a major challenge confronted by any remediation project is developing work processes that facilitate compliant waste management practices while at the same time implementing controls to protect personnel. Traditional burial ground remediation is accomplished using standard excavators to remove materials from trenches and other excavation configurations often times with minimal knowledge of waste that will be encountered at a specific location. In the case of the 118-K-1 burial ground the isotopic activity postulated in historic documents to be contained in vertical cylindrical silos was sufficient to create the potential for a significant radiation hazard to project personnel. Additionally, certain reported waste forms posed an unacceptably high potential to contaminate the surrounding environment and/or workers. Based on process knowledge, waste management requirements, historic document review, and a lack of characterization data it was determined that traditional excavation techniques applied to remediation of vertical silos would expose workers to unacceptable risk. The challenging task for the 118-K-1 burial ground remediation project team then became defining an acceptable replacement technology or modification of an existing technology to complete the silo remediation. Early characterization data provided a good tool for evaluating the location of potential high exposure rate items in the silos. Quantitative characterization was a different case and proved difficult because of the large diameter of the silos and the potential for variable density of attenuating soils and waste forms in the silo. Consequently, the most relevant information supporting job planning and understanding of the conditions was the data obtained from the gross gamma meter that was inserted into each casing to provide a rough estimate of dose rates in the tubes. No added value was realized in attempting to quantify the source term and/or associate the isotopic activity with a particular actual waste form (e.g., sludge). Implementing the WRM system allowed monitoring of worker and boundary exposure rates from a distance, maintaining compliance with ALARA principles. This system also provided the project team early knowledge of items being removed that had high exposure rates associated with them, thus creating an efficient method of acknowledging an issue and arriving at a solution prior to having an upset condition. An electronic dosimeter with telemetry capability replaced the excavator mounted AMP-100 system approximately half way through remediation of the silos. Much higher connectivity efficiency was derived from this configuration. Increasing the data feed efficiency additionally led to less interruption of the remediation effort. Early in system testing process a process handicap on the excavator operator was acknowledged. A loss of depth perception resulted when maneuvering the excavator and bucket using the camera feed to an in-cab monitor. Considerable practice and mock-up testing allowed this handicap to be overcome. The most significant equipment failures involved the cable connection to the camera mounted between the clamshell bucket jaws and the video splitter in the excavator cab. Rotation of the clamshell bucket was identified as the cause of cable connection failures because of the cyclic twisting motion and continuous mechanical jarring of the connection. In-cab vibration was identified as the culprit in causing connection failures of the video splitter. While these failures were repaired, substantial production time was lost. Ultimately, the decision was made to purchase a second cable and higher quality video splitter eliminate the down time. An engineering improvement for future operations would be inserting cable pig tails at more stressed cable connection points to facilitate rapid change out of the cable should that be required. Overall, the system performed better than expected in a safe and efficient manner. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Waste Management 2016 300-296 Soil Remediation Project. Developing Innovative Solutions to Overcome Design Challenges - 16229

The 324 Building is a non-reactor, Hazard Category 2, Nuclear Facility located in the 300 Area of the U.S. Department of Energy (DOE) Hanford Site, located near Richland, Washington. The building is undergoing deactivation, decommissioning, decontamination, and demolition by Washington Closure Hanford (WCH) under the River Corridor Closure Contract. During the Cold War Era, the facility was used for chemical and radionuclide processing associated with nuclear weapons production. Historical records indicate that in October 1986, approximately 516 L of a concentrated liquid waste stream containing cesium-137 and strontium-90 was spilled onto the floor of B-Cell. B-Cell is located in the Radiochemical Engineering Complex (REC) of the 324 Building. It is estimated that this spill contained approximately 1.3 million curies of radioactivity. Some fraction of the spill was recovered; however, an unknown quantity was released into the soil beneath the 324 Building through an undetected breach in the B-Cell floor sump. Unknown quantities of water were used after the spill to wash items contained in B-Cell. When B-Cell was taken out of service, wastes being removed from B-Cell were placed in Grout Containers (GCs) and stabilized using a particulate grout. In the course of grouting activities, grout was spilled on the floor of B-Cell, eventually filling the sump. The primary scope of this project is to design, test, and implement a process capable of removing and isolating contaminated soil below B-Cell. This remediation effort has been divided into two removal zones identified as the primary and secondary removal zones. Based on current assumptions and estimates, the primary phase of this cleanup effort will remove roughly 156.45 m{sup 3} of highly contaminated materials. B-Cell debris, particulate grout, and the floor slab and liner comprise about 21.24 m{sup 3} of the total. The remaining 135.21 m3 will be contaminated soil. All of this material must be disposed of within the existing 324 Facility or packaged for disposal at the Hanford site. The objective of this project is to remove the B-Cell floor and highly contaminated underlying soils from beneath B-Cell using remote equipment to reduce the radiation levels and allow open-air excavation for the remaining contaminated soil. The challenges and subsequent technological solutions encountered from the Conceptual Design phase to the 100% Design Issued For Fabrication/Issued For Construction (IFF/IFC) consisted in part of the following: Design an efficient remote cleanup strategy for highly contaminated Low Level Waste (LLW) given the unknowns. Maintain contamination control down to 18 feet below B-Cell in a highly radioactive environment (12,870 R/Hr Cs-137 and Sr-90). Perform facility upgrades to enable remediation process implementation while maintaining integrity of pre-existing facility structure and license. Designing first-of-a-kind remote equipment for use in high radiation areas. Developing first-of-a-kind operations sequences for remote equipment while minimizing usage of original facility equipment (i.e. cranes, manipulators, etc.). Conducting time-motion studies of operations sequences to maximize efficiency while keeping dose As Low As Reasonably Achievable (ALARA) in a high dose environment. Construction of a full scale mockup to conduct performance testing in a clean environment and train the work force to operate the equipment. Overcoming scope, budget and schedule constraints associated with a fast-track DOE project. (authors)

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

Benefits of digitalizing and employing simulation to increase plant system performance and ensure compliance with technical specifications - 109

The essential services water system in a BWR nuclear power plant was affected by corrosion, soiling and blockages due to ageing. Those episodes affected safety margins hindering the Technical Specifications compliance during periodic system testing. Tecnatom designed, implemented and tested a design modification for the on-line monitoring of this system by integrating it in the existing Digital Control System (DCS). Key system parameters were acquired in real time to be displayed in the Human System Interface, used in performing calculations and stored their historical evolution. The objective was to optimize monitoring and surveillance of the essential service water system. Furthermore, Tecnatom developed an engineering simulator ('What if' simulator) consisting of a hydraulic model of the system. This simulator takes as inputs each heat exchanger performance parameters from the plant DCS, allows the user to change the essential services water system configuration (valves position, UHS level...) and calculates theoretical process values predicting the system real behavior. In a second stage, more system instruments were wired to the DCS for Technical Specifications compliance automatic surveillance regarding opening and closing times of system valves. Operating experience shows important benefits after the digitalization. It enhances on-line information of system operation and automates calculation of load loss factor of each heat exchanger. It eases the evaluation of blockages and soiling in the system allowing optimization of cleaning proceedings. System Surveillance Requirements and Test Requirements reports have been automated optimizing the operation workload. The simulator use enables to identify optimal system configuration increasing safety margins of the system and ensuring Technical Specifications fulfillment. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2012

Radiation Impact of Very Low Level Radioactive Steel Reused in Building Industry with Emphasis on External Exposure Pathway - 12569

Considerable quantities of various materials are accumulated during the decommissioning process of nuclear installations. Some of arising materials are activated or contaminated. However, many of them continue to have an economic value and exist in a form that can be recycled or reused for special purposes. Furthermore much of the material generated during decommissioning process will contain only small amounts of radionuclides. For these materials there exist environmental and economic incentives to maximize the use of the concept of clearance from further regulatory control. This impact analysis is devoted to mentioned incentives. The aim is to conditionally clear maximum amount of the scrap steel and consequently recycle and reuse it in form of reinforcing components in tunnel and bridge building scenarios. Recent calculations relevant for external exposure pathway indicate that concept of conditional clearance represent a feasible option for the management of radioactive materials. Even in chosen specific industrial applications it is possible to justify new, approximately one order of magnitude higher, clearance levels. However analysis of other possible exposure pathways relevant for particular scenario of reuse of conditionally cleared materials has to be performed in order to confirm indications from partially obtained results. Basically, the concept of conditional clearance can bring two basic benefits. Firstly it is saving of considerable funds, which would be otherwise used for treatment, conditioning and disposal of materials at appropriate radioactive waste repository. Moreover materials with intrinsic value (particularly metals) can be recycled and reused in industrial applications instead of investing resources on mining and production process in order to obtain new, 'fresh' materials. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Porous Iron Electrodes Reduce Energy Consumption During Electrocoagulation of a Virus Surrogate: Insights into Performance Enhancements Using Three-Dimensional Neutron Computed Tomography

Electrocoagulation has attracted significant attention as an alternative to conventional chemical coagulation because it is capable of removing a wide range of contaminants and has several potential advantages. In contrast to most electrocoagulation research that has been performed with nonporous electrodes, in this study, we demonstrate energy-efficient iron electrocoagulation using porous electrodes. In batch operation, investigation of the external pore structures through optical microscopy suggested that a low porosity electrode with sparse connection between pores may lead to mechanical failure of the pore network during electrolysis, whereas a high porosity electrode is vulnerable to pore clogging. Electrodes with intermediate porosity, instead, only suffered a moderate surface deposition, leading to electrical energy savings of 21% and 36% in terms of electrocoagulant delivery and unit log virus reduction, respectively. Neutron computed tomography revealed the critical role of electrode porosity in utilizing the electrode’s internal surface for electrodissolution and effective delivery of electrocoagulant to the bulk. Energy savings of up to 88% in short-term operation were obtained with porous electrodes in a continuous flow-through system. Further investigation on the impact of current density and porosity in long-term operation is desired as well as the capital cost of porous electrodes.

42 ENGINEERING↗