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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

The importance of cycle-by-cycle data in performing rapid battery technology development and validation

Lithium-ion battery (LiB) technology is playing a crucial role in transforming the predominantly fossil fuel-based transportation and stationary storage sectors to achieve a low-carbon economy. Rapid innovation in the LiB materials to electrode to cell design is happening to satisfy the performance, life, and safety metrics required by those myriads of applications. Lately, advanced analytics, such as machine-learning or artificial intelligence (ML/AI) techniques, are being used more frequently to aid in expedited LiB technology development, performance validation, and life prediction. The success of these techniques often relies on a large volume of well-defined and high-quality battery test data. On the other hand, most battery developers and research and development (R&D) communities are still following a classical approach to develop batteries, which is running calendar- and/or cycle-aging tests, performing reference performance tests (RPTs), and conducting post-mortem analyses periodically without paying attention to the wealth of data often not collected during the calendar or cycle life aging tests. This sparse data collection approach is time- and resource-intensive, requiring data capture and evaluation of months to years of RPT data to diagnose accurate battery state of performance, health, and safety. Even so, the underlying aging modes and mechanisms can be missed. If collected properly, battery test data during cycling or calendaring can be efficiently combined with ML/AI techniques to create powerful tools in the rapid diagnosis of battery state of performance, health, and safety along with insights into underlying aging modes and mechanisms. In this report, we discuss the importance of effective cycle-by-cycle (CBC) data collection with example case studies. Within a reasonable timeframe, RPT data are often inadequate in capturing many of the crucial battery aging dynamics, which often predominantly show up in CBC test data. Finally, we also show examples of ML/AI techniques that use CBC data in rapid diagnosis and projection of LiB state of health (SOH) to motivate the scientific community in collecting and using CBC data to facilitate expeditious technology development and validation.

25 ENERGY STORAGE↗
DOE OSTI2025

Future Intensity‐Duration‐Frequency Curves of Extreme Precipitation in the Midwest United States From Convection‐Permitting Modeling

Abstract During the last four decades, global warming has statistically significant intensified extreme precipitation events in the Midwestern United States (defined here as the region covering Illinois, Indiana, Ohio, and Kentucky), leading to increased risks to human life, property, and infrastructure. To enable climate change adaptation and resilience across various economic and social sectors in this region, updated information about future climate changes, specifically at finer spatial scales, is essential. Leveraging a new 150‐year dynamical downscaling data set at convection‐permitting resolution, this study introduces a framework to construct the projected future intensity‐duration‐frequency (IDF) curves of heavy precipitation, which are prominent tools for infrastructure design and water resources management. This framework generates IDF curves at both sub‐daily and multi‐day duration utilizing hourly in situ observations as well as quantile‐based statistical techniques in bias‐correction and return levels selection. The assumption of non‐stationarity in the distribution parameter fitting process is also implemented in this workflow. Compared to historical IDF curves for 1980–2022, future projected IDF curves for 2058–2100 under Representative Concentration Pathway (RCP) 4.5 and RCP 8.5 scenarios indicate an average intensity increase of approximately 15% and 25%, respectively, across 74 stations, considering both annual and seasonal timescales. Future projections suggest that extreme precipitation events may become more severe across six investigated return periods, with longer return periods showing a greater increase. The frequency of future extreme precipitation events in the Midwest region is also projected to double. Furthermore, current results reveal spatial heterogeneity of future trends across stations owing to the high‐resolution input data set. Plain Language Summary This study investigates the evolving nature of extreme precipitation events in the Midwestern United States under a changing climate. By leveraging a high‐resolution dynamical downscaling data set, we construct projected intensity‐duration‐frequency (IDF) curves for future extreme rainfall events. These curves serve as vital tools for infrastructure planning and water resource management. Our analysis reveals a significant increase in both the intensity and frequency of extreme precipitation events in the region. Future projected IDF curves for the late century indicate an average intensity increase of approximately 15%–25% compared to historical values. Moreover, the frequency of such events is expected to double. Spatial heterogeneity in future trends is observed across different stations within the Midwest, highlighting the importance of high‐resolution modeling in capturing localized climate variability. These findings underscore the urgent need for climate adaptation strategies to mitigate the increasing risks associated with extreme precipitation events in the region. Key Points This study introduces a workflow to construct future intensity‐duration‐frequency (IDF) curves over the Midwest United States using a new convection‐permitting modeling data set The current IDF construction workflow reproduces well the historical observed IDF 30 curves in summer months with median relative errors of 2.4% among 74 stations and 6 investigated durations The projected IDF curves show diverse future trends of extreme precipitation across stations, with intensity increases of approximately 15% and 25% under RCP4.5 and RCP8.5 climate scenarios, respectively, and a doubling of frequency on average

Nguyen, Trung↗
DOE OSTI2023

Phase Field Modeling of Corrosion for Design of Next-Generation Magnesium-Aluminum Vehicle Joints

In this study, WPI and its partners sought to understand galvanic corrosion in Mg-Al friction stir weld (FSW) joints. Unlike fusion welds, FSW is done in the solid state. This limits (but does not eliminate) the formation of brittle Al-Mg intermetallics, resulting in better joint strength and corrosion resistance. This study aimed to understand corrosion behavior of Mg-Al FSW joints by using a Cahn-Hilliard phase field electrochemistry model based on the work of Pongsaksawad et al. Its context challenge problem was an ultra-light door designed by Magna with 6061-Al sheet outer and ZEK100-Mg sheet inner panels, joined by an adhesive and FSW. Unlike most FSW joints, which weld through the softer material into the harder one, the Al sheet’s hem joint around Mg required the FSW tool to through the harder Al into the softer Mg, which was itself a challenge. Despite this challenge, PNNL succeeded in consistently making very strong FSW lap joints, by using a triflute tool and power control. Characterization showed mostly separate Al and Mg regions in the weld, usually with a hook protruding from Al into Mg, which likely contributed to high joint strength. Nanohardness mapping showed higher hardness in thin Mg swirls into the Al nugget, likely due to the intermetallics. The study used the industry standard SAE J2334 Cyclic Corrosion Test (CCT) to simulate corrosion conditions over the life of a vehicle, as well as linear polarization testing and ASTM G71 pitting corrosion testing. Corrosion reactions were: H 2 O + ½O 2 + 2e - → 2OH - at the Al cathode, and either Mg → Mg 2+ + 2e - or Mg + 2OH - → Mg(OH) 2 + 2e - at the Mg anode, with electron transfer through the joint. Mass loss increased with Al section length, supporting the hypothesis that galvanic corrosion in Al-Mg joints is limited by the cathodic reaction. Both pitting corrosion (first anode reaction) and hydroxide film formation (second reaction) were observed. The J2334 CCT test method was slightly modified, adding a chromium solution cleaning step after each week of corrosion testing, in order to remove Mg oxides and hydroxides and accurately measure mass loss over time. That said, FSW joints treated in this way did not did not exhibit significant reduction in lap shear strength of the joints vs. newly welded samples which had not undergone corrosion. Corrosion appeared to consist mainly of pitting in Mg in a way which did not directly affect the bond between the materials where the joints failed. A Cahn-Hilliard phase field model coupled with electrical potential described the electronically mediated galvanic corrosion electrochemical reactions described above in the four-component Al-Mg-H 2 O-(H 2 O+½O 2 ) system. This 2-D model successfully predicted Mg(OH)₂ formation at the anode in some circumstances, and Mg pitting corrosion in others, and showed the correct electric field directions in both cases. The model predicted Mg pit corrosion depth within a factor of two of measured pits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Ceramic–Metal (Cermet) Composites: A Review of Key Properties and Synthesis Methods Focused on Nuclear Waste Immobilization

Here this paper reviews key properties, applications, and examples of ceramic-metal composites (cermets), and metal matrix composites (MMC) with emphasis on their applicability as waste forms for immobilizing nuclear waste. While the literature is mature for vitrified and cementitious radioactive waste forms, cermet materials have not received adequate attention as potential candidates for immobilizing nuclear waste. To promulgate this effort, this review connects cermet and MMC design, such as hardened tools, with the chemistry of radioactive waste streams. A discussion on certification and qualification standards for cermet waste forms, literature gaps, and “how-to” sections on cermet processing techniques. Key parameters discussed include thermal conductivity, chemical durability, and waste loading, as well as examples for metal-containing waste forms. As cermet waste forms gain momentum within the community, this review paper aims ensure the end-of-life nuclear fuel cycle is addressed from a materials and waste disposition perspective.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Influence of helium bubbles on the bulk equation of state of gold under static compression

Nuclear materials often evolve into two-phase systems comprising a bulk matrix with dispersed inert-gas bubbles. The presence of these bubbles can have consequences to the thermomechanical response of materials and is a key life-limiting factor in some nuclear fuel forms. Understanding the behavior of these two-phase, bubble-matrix systems is, thus, important to improved predictive models and frameworks for many nuclear materials applications. While temperature excursions of these two-phase systems have been characterized, fewer studies have focused on the evolution of inert-gas bubbles under pressure. Here, in this paper, we use x-ray tools to interrogate a He-implanted gold foil to determine the pressure-dependent evolution of the individual components (Au matrix + bubbles), and we compare that total pressure dependence to theoretical equation-of-state descriptions based on mixing rules.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Friction stir processing: A thermomechanical processing tool for high pressure die cast Al-alloys for vehicle light-weighting

This study uses friction stir processing (FSP) for thermomechanical processing of high-pressure die-casting (HPDC) to modify microstructure and improve mechanical properties. FSP is carried out on two different HPDC aluminum alloys: (a) general-purpose, high-iron, HPDC A380 alloy and (b) premium quality, low-iron HPDC Aural-5 alloy in thin wall, flat plate geometry. Subsequent mechanical testing shows ~30 % and ~65 % enhancement in yield strength and tensile ductility. In addition, FSP leads to ~10 times improvement in fatigue life for A380 alloy and ~70 % improvement in fracture toughness for Aural-5 alloy. These findings emphasize the capability of FSP to modify the microstructure of HPDC Al-alloys-based structural components so that they can demonstrate a good combination of strength, ductility, fracture toughness, and high fatigue properties for long-term durability and reliability.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Targeting Mycobacterium tuberculosis Persistence through Inhibition of the Trehalose Catalytic Shift

Tuberculosis (TB), caused by Mycobacterium tuberculosis (Mtb), is the leading cause of death worldwide by infectious disease. Treatment of Mtb infection requires a six-month course of multiple antibiotics, an extremely challenging regimen necessitated by Mtb’s ability to form drug-tolerant persister cells. Mtb persister formation is dependent on the trehalose catalytic shift, a stress-responsive metabolic remodeling mechanism in which the disaccharide trehalose is liberated from cell surface glycolipids and repurposed as an internal carbon source to meet energy and redox demands. Here, using a biofilm-persister model, metabolomics, and cryo-electron microscopy (EM), we found that azidodeoxy- and aminodeoxy-d-trehalose analogues block the Mtb trehalose catalytic shift through inhibition of trehalose synthase TreS (Rv0126), which catalyzes the isomerization of trehalose to maltose. Out of a focused eight-member compound panel constructed by chemoenzymatic synthesis, the natural product 2-trehalosamine exhibited the highest potency and significantly potentiated first- and second-line TB drugs in broth culture and macrophage infection assays. We also report the first structure of TreS bound to a substrate analogue inhibitor, obtained via cryo-EM, which revealed conformational changes likely essential for catalysis and inhibitor binding that can potentially be exploited for future therapeutic development. Our results demonstrate that inhibition of the trehalose catalytic shift is a viable strategy to target Mtb persisters and advance trehalose analogues as tools and potential adjunctive therapeutics for investigating and targeting mycobacterial persistence.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Development of Employee Health Services Scorecards and Dashboards for Sandia National Laboratories (SAND2020-2243 J)

The mission of Employee Health Services (EHS) at Sandia National Laboratories is to positively and efficiently impact the health of Sandia through patient-centered, cost-effective, community-connected care in support of its mission and people. We strive to continuously improve the delivery of health and wellness services. For the past few years, we have modeled our health programs around findings from the 2010 World Economics Forum (WEF): there are 8 top health risks and behaviors that drive 15 chronic conditions which account for 80% of the total health-care costs for all chronic illness worldwide. The WEF goes on to state that information and innovation are the keys to prevention, and EHS has decided to take a strong stand in both categories by utilizing health scorecards and department dashboards to visualize and share metrics with Sandia Leadership to foster improvements in employee wellness and optimize wellness offerings. Finally, these 2 types of information-sharing tools allow us to track the dollars spent and saved on our wellness programs, and show leadership where there is risk, where there is progress, and where there is need by providing current data that gives monthly, quarterly, and yearly feedback.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Learning curves for drug response prediction in cancer cell lines

Motivated by the size and availability of cell line drug sensitivity data, researchers have been developing machine learning (ML) models for predicting drug response to advance cancer treatment. As drug sensitivity studies continue generating drug response data, a common question is whether the generalization performance of existing prediction models can be further improved with more training data. We utilize empirical learning curves for evaluating and comparing the data scaling properties of two neural networks (NNs) and two gradient boosting decision tree (GBDT) models trained on four cell line drug screening datasets. The learning curves are accurately fitted to a power law model, providing a framework for assessing the data scaling behavior of these models. The curves demonstrate that no single model dominates in terms of prediction performance across all datasets and training sizes, thus suggesting that the actual shape of these curves depends on the unique pair of an ML model and a dataset. The multi-input NN (mNN), in which gene expressions of cancer cells and molecular drug descriptors are input into separate subnetworks, outperforms a single-input NN (sNN), where the cell and drug features are concatenated for the input layer. In contrast, a GBDT with hyperparameter tuning exhibits superior performance as compared with both NNs at the lower range of training set sizes for two of the tested datasets, whereas the mNN consistently performs better at the higher range of training sizes. Moreover, the trajectory of the curves suggests that increasing the sample size is expected to further improve prediction scores of both NNs. These observations demonstrate the benefit of using learning curves to evaluate prediction models, providing a broader perspective on the overall data scaling characteristics. A fitted power law learning curve provides a forward-looking metric for analyzing prediction performance and can serve as a co-design tool to guide experimental biologists and computational scientists in the design of future experiments in prospective research studies.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

CyclusJS: A Distributed Web-based Fuel Cycle Visual Analytics. Research Performance (Final Report)

The overall aim of the CyclusJS project has been to design novel approaches that support fuel cycle simulations and empower decision-makers and researchers with better tools to compare and contrast results from multiple simulations to understand the landscape of potential outcomes better. In particular, nuclear fuel cycle simulations focus on modeling the nuclear industry and ecosystem at a macroscopic level, and the analysis tools connect such simulations with decision support systems. As a demonstration of the novelty and effectiveness of the proposed approach, we study scenarios for transitioning from one technology, Light Water Reactors (LWR), to a newer Sodium-cooled Fast breeder Reactor (SFR) technology.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Final Report: Enhanced Algal Production of CA for Improved Atmospheric Delivery of CO2 To Ponds

Technologies that enable direct-air-capture (DAC) of CO2 and eliminate the need for a CO2 capture, storage, and distribution system would significantly reduce the cost of algal production, and greatly increase the volume of algae biomass that can be produced by enabling algae farms to be located anywhere. Such technologies include cultivation under high alkalinity/high pH conditions, which increase the driving force for CO2 absorption, and development of genetic tools and genetically engineered strains to decorate the surface of the algae with carbonic anhydrase (CA), enable secretion of CA by the algae, or more generally boost the performance of the carbon concentrating mechanism (CCM).

09 BIOMASS FUELS↗
DOE OSTI2023

Analysis Program 2022 Annual Progress Report

The VTO Analysis Program supports mission-critical technological, economic, and interdisciplinary analyses to assist in prioritizing VTO technology investments and to inform research portfolio planning. These efforts provide essential vehicle and market data, modeling and simulation, and integrated and applied analyses, using the unique capabilities, analytical tools, and expertise resident in the DOE’s national laboratory system. VTO Analysis projects also demonstrate additional capabilities and expertise provided by research partnerships that may include academia, the private sector, and non-profit organizations.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Ptychography at all wavelengths

Ptychography is a computational imaging technique that operates across multiple wavelength regimes, from electron (picometres) to X-ray (~0.1 nm), extreme ultraviolet (~10 nm) and visible light (micrometres). By reconstructing both amplitude and phase from diffraction patterns, ptychography enables high-resolution, quantitative imaging without conventional limitations imposed by lens-based optics. Ptychography has enabled advances across a range of scales: achieving deep-sub-angstrom resolution with electron microscopy, becoming an indispensable tool at X-ray synchrotron facilities worldwide and overcoming the trade-offs between resolution and field-of-view in optical imaging. This Primer provides a unified treatment of ptychography across these wavelength regimes. First, we discuss theoretical foundations, reconstruction algorithms, experimental considerations and wavelength-specific challenges. We then give examples of raw and processed data from various configurations and wavelengths. Next, we highlight key applications of ptychography in life sciences, materials science and industry. We also discuss data standards, open-source software implementations and best practices for ensuring reproducibility across different wavelength regimes. Finally, we consider limitations and future opportunities for ptychography. Together with accompanying datasets and code implementations, this Primer aims to serve newcomers and experienced practitioners in the field, facilitating broader adoption of ptychography across different disciplines.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Computational prediction of the effect of amino acid changes on the binding affinity between SARS-CoV-2 spike RBD and human ACE2

The association of the receptor binding domain (RBD) of severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2) spike protein with human angiotensin-converting enzyme 2 (hACE2) represents the first required step for cellular entry. SARS-CoV-2 has continued to evolve with the emergence of several novel variants, and amino acid changes in the RBD have been implicated with increased fitness and potential for immune evasion. Reliably predicting the effect of amino acid changes on the ability of the RBD to interact more strongly with the hACE2 can help assess the implications for public health and the potential for spillover and adaptation into other animals. Here, we introduce a two-step framework that first relies on 48 independent 4-ns molecular dynamics (MD) trajectories of RBD-hACE2 variants to collect binding energy terms decomposed into Coulombic, covalent, van der Waals, lipophilic, generalized Born solvation, hydrogen bonding, π-π packing, and self-contact correction terms. The second step implements a neural network to classify and quantitatively predict binding affinity changes using the decomposed energy terms as descriptors. The computational base achieves a validation accuracy of 82.8% for classifying single–amino acid substitution variants of the RBD as worsening or improving binding affinity for hACE2 and a correlation coefficient of 0.73 between predicted and experimentally calculated changes in binding affinities. Both metrics are calculated using a fivefold cross-validation test. Our method thus sets up a framework for screening binding affinity changes caused by unknown single– and multiple–amino acid changes offering a valuable tool to predict host adaptation of SARS-CoV-2 variants toward tighter hACE2 binding.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Bamboo Bio-composite Truck/Trailer Decking

Bamboo is one of the fastest growing plants in the world. Massively productive, bamboo will maintain that productivity with limited inputs and minimal management resulting in predictable volume and operating margins and with low overhead. The goal of this project was to develop a bamboo bio-composite trailer decking product that replaces apitong, is lighter weight, stronger and luminescent. The collaboration partners, Fontaine, Resource Fiber and IACMI, worked closely to develop the bamboo bio-composite decking to Fontaine Trailer’s (end-user) specifications. The various technological objectives were (a) To conduct a comprehensive Design of Experiments study for bamboo composites to understand the structure-property relationships for different resin composites and bamboo forms (strips, woven, bulk etc); (b) To establish the nail pull out characteristics of trailer deck geometry bamboo composite form. The nail pull out is a critical test in trailer decks; (c) To design, process and prototype select number of trailer decking planks for Fontaine evaluation; and (d) To conduct life cycle analysis to conduct energy calculations from the various conversion steps of the bamboo from crop to product. The project meets DOE/IACMI metrics of reduced embodied energy, lightweighting and lowering the cost of the end product. It also offers a green solution to a value-added application, i.e. trailer decking. The development goals and benefits of bamboo composite decking included: A. Decreased weight when compared to Apitong and Gen 1, thereby reducing operating costs and petroleum usage due to increased miles per gallon. B. Flexibility to allow camber design into trailers. C. Luminescence to increase safety during low light and dark conditions. D. Composite material to maximize use of bamboo bio-composites as substitute for petroleum-based composites. E. Embedded layer(s) of conditioned bamboo for added strength and stability. F. Improved safety over Apitong by temporary cargo indentation in planks for better stability. G. Cradle-to-cradle design so end-of-life becomes beginning-of-life for other products. Resource Fiber’s bamboo biocomposite trailer decking passed nail pullout tests as compared to apitong (incumbent), was lighter weight than apitong, and used less embodied energy particularly when bamboo is sourced domestically. The planks were optimized in the lab setting to the extent possible and successfully installed on the trailer at Fontaine for field testing. Despite the process not being fully optimized due to through-heat and tooling limitations within the budget constraints, the prototype decking withstood 400 cycles of reverse fatigue loading of a 107,000 lb Caterpillar 349F which was extreme conditions of field testing by Fontaine Trailer. Resource Fiber plans to outsource production of a next round of planks with a commercial pultrusion processor, then to do a re-test with Fontaine Trailers. Tooling specific to the part is required. Long-term commercial plans are to continue outsourcing production while supplying bamboo fiber and mats. Commercial markets include heavy haul trailers, military trailers, and decking for marine, industrial and residential use.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Integrated Dynamic Facade Control with an Agent-based Architecture for Commercial Buildings

Dynamic façades have significant technical potential to minimize heating, cooling, and lighting energy use and peak electric demand in the perimeter zone of commercial buildings, but the performance of these systems is reliant on being able to balance complex trade-offs between solar control, daylight admission, comfort, and view over the life of the installation. As the context for controllable energy-efficiency technologies grows more complex with the increased use of intermittent renewable energy resources on the grid, it has become increasingly important to look ahead towards more advanced approaches to integrated systems control in order to achieve optimum life-cycle performance at a lower cost. This study examines the feasibility of a model predictive control system for low-cost autonomous dynamic façades. A system architecture designed around lightweight, simple agents is proposed. The architecture accommodates whole building and grid level demands through its modular, hierarchical approach. Automatically-generated models for computing window heat gains, daylight illuminance, and discomfort glare are described. The open source Modelica and JModelica software tools were used to determine the optimum state of control given inputs of window heat gains and lighting loads for a 24-hour optimization horizon. Penalty functions for glare and view/ daylight quality were implemented as constraints. The control system was tested on a low-power controller (1.4 GHz single core with 2 GB of RAM) to evaluate feasibility. The target platform is a low-cost ($35/unit) embedded controller with 1.2 GHz dual-core cpu and 1 GB of RAM. Configuration and commissioning of the curtainwall unit was designed to be largely plug and play with minimal inputs required by the manufacturer through a web-based user interface. An example application was used to demonstrate optimal control of a three-zone electrochromic window for a south-facing zone. The overall approach was deemed to be promising. Further engineering is required to enable scalable, turnkey solutions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

High-performance computing leadership to enable advances in artificial intelligence and a thriving compute ecosystem

The past three decades have witnessed the widespread adoption of high-performance computing (HPC) as an essential tool in the advancement of science. From accelerating critical research in the wake of a global pandemic to climate modelling and national security, HPC has become integral to the most cutting-edge scientific research around the world and across application domains. The global competition to debut the next fastest supercomputer keeps pushing the field forward. Meanwhile, increasing capabilities are bringing hallmarks of science fiction, such as artificial intelligence (AI), into daily life. However, the tremendous power of new computing systems comes with an increased concern about equitable access to these resources and their impact on supporting a thriving workforce.

Tourassi, Georgia↗
DOE OSTI2020

Challenges and Solutions in Operation and Lay-Up of the Modular Caustic- Side Solvent Extraction Unit - 20078

The Modular Caustic-Side Solvent Extraction (CSSX) Unit (MCU) was designed and constructed to provide interim salt waste processing so that the Liquid Waste Disposition Program (LWDP) could continue waste removal and tank closure until start-up of the Salt Waste Processing Facility (SWPF). MCU processes Clarified Salt Solution (CSS), or salt solution (SS) that has undergone actinide removal/filtration, to produce two waste streams: the cesium laden Strip Effluent (SE), which is incorporated into glass at the Defense Waste Processing Facility (DWPF), and the cesium depleted Decontaminated SS (DSS), which is incorporated into grout at the Saltstone Production Facility (SPF). MCU completed start-up in 2008 with an initial operating life of 3 years and design life of 5 years. Prior to reaching the end of the design life, multiple critical components were upgraded and/or replaced to mitigate risks associated with any delays in SWPF start-up. During the remainder of operation (until June 2019), MCU was challenged to maximize processing with minimal additional modifications to repair/improve aging infrastructure, while maintaining low levels of risk to workers and the environment. Notable challenges during the extended operating life of the facility involved both mechanical and operational issues. Two of the most significant issues were the increased frequency of Process Vessel Ventilation (PVV) High Efficiency Particulate Air (HEPA) filter change-outs and the biofouling of the SE coalescer (SEC). The major impacts of both issues were that replacement of these components 1) resulted in high exposure to workers, and 2) required substantial downtime, thus hindering achievement of processing goals. PVV HEPA filter replacements are required based on dose rate and differential pressure (dP) limits. After introducing a higher-curie feed to MCU, the operating time between change outs was reduced by approximately half. SEC replacements are required based on dP limits. After restarting from an extended outage, the operating life of the SEC was significantly reduced by more than half due to biofouling. As a result of extensive troubleshooting and process improvements, the facility was able to recover performance and extend the operating life of the PVV HEPA filters and the SEC media. Through troubleshooting both of these issues, the facility was also able to learn from prior experience and adapt in order to minimize down time and maintain throughput. Although the facility took advantage of short periods of downtime to perform nonintrusive troubleshooting and minor corrective/preventative maintenance activities, longer outages were periodically required for corrective maintenance involving process cell entry. During these outages, remote tools and specialized shield plates were employed to minimize dose to workers. Mock-ups of non-routine maintenance activities were critical to early identification of potential issues and improvements, which shortened outage duration. Consistent with the facility's operational strategy, evolutions needed for MCU layup were identified and sequenced to ensure safe conditions within the facility, meet pre-defined criteria for lay-up configuration, and protect workers, while minimizing the impact to SWPF integration. De-inventory and flushing of process areas was prioritized so that the total residual inventory was reduced as efficiently as possible. This paper discusses lessons learned and best practices from troubleshooting unique issues, performing complex maintenance activities, and implementing a layup strategy that best supports the overall system mission. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗