SEARCH · Engineering Papers
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
The Defense Waste Processing Facility (DWPF) began processing Sludge Batch 7b (SB7b), also referred to as Macrobatch 9 (MB9), in January 2012. SB7b is a blend of the heel of Tank 40 from Sludge Batch 7a (SB7a) and the SB7b material that was transferred to Tank 40 from Tank 51. SB7b was processed using Frit 418.
Alternatives to conventional diesel electric propulsion are currently of interest to rail operators. In the U.S., smaller railroads have implemented natural gas and other railroads are exploring hydrogen technology as a cleaner alternative to diesel. Diesel, battery, hydrogen fuel cell, or track electrification all have trade-offs for operations, economics, safety, and public acceptability. A framework to compare different technologies for specific applications is useful to optimize the desired results. Standards from the Association of American Railroads (AAR) and other industry best practices were reviewed for applicability with hydrogen fuel cell technology. Some technical gaps relate to the physical properties of hydrogen, such as embrittlement of metals, invisible flames, and low liquid temperatures. A reassessment of material selection, leak/flame detection, and thermal insulation methods is required. Hydrogen is less dense and diffuses more easily than natural gas, and liquid hydrogen is colder than liquefied natural gas. Different densities between natural gas and hydrogen require modifications to tank designs and flow rates. Leaked hydrogen will rise rather than pool on the ground like diesel, requiring a modification to the location of hydrogen tanks on rolling stock. Finally, the vibration and shock experienced in the rail environment is higher than light-duty vehicles and stationary applications for which current fuel cell technology has been developed, requiring a modification in tank design requirements and testing.
At Savannah River Site, High-Level Waste is stored in below-grade carbon steel tanks. This waste in part consists of sludge, salt cake, and/or supernate. Preparation of this waste for future processing involves dissolution of the salt cake layer. The salt dissolution process can create conditions that leave the carbon steel tanks susceptible to localized corrosion. The salt to be dissolved contains high concentrations of nitrate, that once released, create an environment that may be conducive to pitting corrosion or stress corrosion cracking (SCC) of carbon steel. The salt dissolution process also liberates interstitial liquid trapped between the salt crystals. This liquid is initially high in nitrite and hydroxide concentration. High pH and greater ratios of nitrite to nitrate act as inhibitors to minimize corrosion of carbon steel in high nitrate environments. However, as dissolution proceeds, the concentration of nitrate increases while the hydroxide and nitrite concentration of the interstitial liquid depletes and becomes insufficient to prevent the onset of corrosion attack. While tank blending and the addition of inhibitors are used to ensure adequate concentrations of hydroxide and nitrite during normal operation, this is not desirable during salt dissolution as it can reduce process efficiency and increase the amount of waste that needs processed.
Energy storage technologies offer a promising solution to electric grid stability issues associated with the integration of variable renewable generators. The capability to match the electrical power output to instantaneous fluctuations in grid demand is crucial to ensure continuity of service. Including energy storage capability in an integrated energy system (IES) can provide the flexibility needed to meet variable electric demand and reduce the load following demands place on the reactor. In this report, economic data collected for energy storage (ES) technologies are described to support the objective of assessing the profitability of ES integration within the IES framework. In particular, there is a growing interest in thermal energy storage (TES) given its unique capability for long-duration storage for improving electricity reliability at a low levelized cost. It is common practice to evaluate the total lifetime cost and profitability before commercializing new technologies. In this report we identify and examine the models needed to better understand the economics of thermal energy storage. We extend the TES cost model in RAVEN in the context of a balance of plant (BOP) that incorporates thermal storage. To focus the discussion, following a general overview of the most promising TES technologies, we consider a use case that involves a sensible heat, two-tank, molten-salt system. Structural and operational details are reported to identify the source of construction capital expenditure and operation and maintenance cost. A detailed description of the different cost items is provided as well as the cost scaling with different storage capacity and power ratings for capacity optimization purpose. In addition, the capital expenditure and the recurring cost of representative two-tank, molten salt coupled with concentrated solar plants are provided for readers’ reference. The ES use case is noteworthy as it is in the pilot stage of commercialization. We identify those areas that would benefit from an increased economic focus to obtain a more complete compilation of cost data. We also describe the thermal coupling issues that arise from integration of the two-tank molten salt thermal energy storage system with a BOP, which is the subject of our current research. Some components of costs will need to be evaluated through dedicated technoeconomic analysis in future modeling activities using modeling procedures proposed in this report. With the data presented and the procedures described in this report, sufficiently accurate models can be implemented for the solution of both the power dispatch and the capacity expansion problems within the RAVEN-based HYBRID framework.
About 50 million gallons of high-level mixed waste is currently stored in underground tanks at The United States Department of Energy’s (DOE’s) Hanford site in the State of Washington. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) will provide DOE’s Office of River Protection (ORP) with a means of treating this waste by vitrification for subsequent disposal. The tank waste will be separated into low- and high-activity waste fractions, which will then be vitrified respectively into Immobilized Low Activity Waste (ILAW) and Immobilized High Level Waste (IHLW) products. The ILAW product will be disposed in a near-surface engineered facility – the Integrated Disposal Facility (IDF) – on the Hanford site, while the IHLW product is designed for deep geological disposal in a national facility for high-level nuclear waste. The ILAW and IHLW products must meet a variety of requirements with respect to protection of the environment before they can be accepted for disposal. The objective of the work described in this report is to perform testing, data collection, and analyses for the ILAW glass product for subsequent use in the performance assessment (PA) of the IDF to assess potential environmental risks associated with long-term storage.
About 50 million gallons of high-level mixed waste is currently stored in underground tanks at The United States Department of Energy’s (DOE’s) Hanford site in the State of Washington. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) will provide DOE’s Office of River Protection (ORP) with a means of treating this waste by vitrification for subsequent disposal. The tank waste will be separated into low- and high-activity waste fractions, which will then be vitrified respectively into Immobilized Low Activity Waste (ILAW) and Immobilized High-Level Waste (IHLW) products. The ILAW product will be disposed of in an engineered facility – the Integrated Disposal Facility (IDF) – on the Hanford site, while the IHLW product will be directed to the national deep geological disposal facility for high-level nuclear waste. The ILAW and IHLW products must meet a variety of requirements with respect to protection of the environment before they can be accepted for disposal.
The U.S. Department of Energy (DOE) is responsible for building the Hanford Tank Waste Treatment and Immobilization Plant (WTP) at the Hanford Site in Washington to remediate 55 million gallons of radioactive waste that is temporarily stored in 177 underground tanks. The Office of River Protection (ORP) has requested that the Savannah River National Laboratory (SRNL) contribute to current glass studies to support successful startup of the WTP, due to SRNL’s recognized capabilities and expertise for glass waste form development. As part of this effort, the Pacific Northwest National Laboratory (PNNL) is developing, batching, and fabricating simulated high-level waste (HLW) glasses to generate the associated property data needed to validate or identify areas of potential characterization improvements in the current glass property/ composition models. Currently, the models cover only a small fraction of the waste compositions projected in the Hanford tank farm; therefore, the models must be expanded to include high fluoride compositions to successfully complete the WTP mission. SRNL support of this work is defined in the Task Technical and Quality Assurance Plan (TTQAP). This report provides results from the chemical analyses of a series of sulfur-saturated melt (SSM) versions of simulated nuclear waste glasses fabricated at PNNL. The glasses were selected as part of a broader study of the influence of glass composition on chemical durability, sulfur retention, and other properties. The glasses were designated the High Fluoride Glasses-1 (HLG1).
Concentrated Solar Power plants using nitrate salts used cantilevered pump designs to avoid use of bearings in the 565°C salt; however, this necessitated the use of a sump that added additional cost, complexity, and thermal losses. Sump systems had their own complications, including risk of flooding the sump due to control issues either with level indicators or failures in the control valve responsible for filling the sump. Long-shafted pumps were developed and tested, and they outline the need to develop journal sleeves and bearings for new salt systems. Based on reports, pumps will need to be a vertical single- or multi-stage type, mounted to the roof of the molten salt tanks. Design and service for molten salt pumps above 550°C is relatively limited, and at temperatures up to 750°C there is no available design or service experience. Long-shaft pumps that extend to the bottom of the thermal energy storage tank will require bearing materials that are suitable to the given salt chemistry. Lubricity of proposed salts is unclear and need to be determined, especially for cold-tank pumps that require multi-stages for lifting the salt to the top of the tower. Materials, design, and maintenance are all major unknowns.
The Saltstone Production and Disposal Facility is designed and permitted by the state of South Carolina Department of Health and Environmental Control (SCDHEC) to treat and dispose of low-level radioactive and hazardous liquid waste (salt solution) remaining from the processing of radioactive material at the Savannah River Site (SRS). Low-level waste (LEW) aqueous streams from the Effluent Treatment Project (ETP) and decontaminated solutions from the Tank Closure Cesium Removal Unit (TCCR) and the Salt Waste Processing Facility (SWPF) are stored in Tank 50 until the LEW can be transferred to the Saltstone Facility for treatment and disposal. In the past, decontaminated solution from the Modular Caustic Side Solvent Extraction Unit (MCU) was stored in Tank 50 until the LEW could be transferred to the Saltstone Facility for treatment and disposal. MCU is currently in a suspended operations state. LEW that meets the Waste Acceptance Criteria (WAC) can be transferred, stored, and treated in the Saltstone Production Facility (SPF) for subsequent disposal as saltstone grout in the Saltstone Disposal Facility (SDF). Sampling will be conducted as new waste streams are identified for treatment and disposal at the Saltstone Industrial Wastewater Treatment Facility (IWTF) and Z-Area Industrial Solid Waste Landfill (ISWLF), Facility ID# 025500-1603, General Condition B.9 or every six years in accordance with South Carolina (SC) Regulation 61-107.19 Parti C, “Solid Waste Management: Solid Waste Landfills and Structural Fill - General Requirements.”
Savannah River National Laboratory (SRNL) was requested by Savannah River Remediation (SRR) to conduct testing via Technical Task Request (HR) to determine the thermolytic HGR of Mobil SHC™ 630, a lubrication oil. Currently, 35 gallons of contaminated Mobil SHC 630 is proposed for release into the recycle stream from the Defense Waste Processing Facility (DWPF) to Tank 22 and then to the 242-16H (2H) Evaporator system. Inhibited recycle waste in the Recycle Collection Tank (RCT) is transferred to Recycle Pump Tank (RPT) in the Low Point Pump Pit (LPPP) and then to the Concentration, Storage and Transfer Facilities (CSTF) H-area. The lubrication oil would be added directly to the RPT, bypassing the RCT. The current DWPF waste compliance plan for liquid transfers from the RCT to the CSTF limits the concentration of Mobil SHC 630 to <1,100 ppm which is equal to <9.3 gallons of Mobil SHC 630 when considering a 7,500 gal RCT batch with an initial Mobil SHC 630 concentration of 42 mg/L. Mobil SHC 630 is expected to be largely immiscible in the caustic aqueous waste stream. It is a blend of base oils including polyalphaolefin (PAO) base oil and additives such as triphenylphosphate and cresyl diphenyl phosphate at various concentrations (<0.25 wt%). While the base oils are expected to be largely unreactive in CSTF waste, the triarylphosphates additives would be expected to hydrolyze in the caustic waste, forming diarylphosphates and phenol. The tests described herein were governed by a single Run Plan and will determine thermolytic HGR from the caustic aqueous solution, as well as from any organic phases present.
The U.S. Department of Energy (DOE) is responsible for building the Hanford Tank Waste Treatment and Immobilization Plant (WTP) at the Hanford site in Washington to remediate 55 million gallons of radioactive waste that is temporarily stored in 177 underground tanks. The Office of River Protection (ORP) has requested that the Savannah River National Laboratory (SRNL) contribute in areas of recognized capabilities and expertise for glass waste form development to support successful startup of the WTP. As part of this effort, the Pacific Northwest National Laboratory (PNNL) is developing, batching, and fabricating simulated high-level waste (HLW) glasses to generate the associated property data needed to validate or identify areas of potential characterization improvement in the current glass property/composition models. Currently, the models cover only a small fraction of the waste compositions projected in the Hanford tank farm; therefore, the models must be expanded to include high fluoride compositions to successfully complete the WTP mission. SRNL support of this work is defined in the Task Technical and Quality Assurance Plan (TTQAP). This report provides the results of the Product Consistency Test (PCT) leachates from the High Fluoride Glasses-1 (HFG1), a series of simulated nuclear waste glasses fabricated at PNNL. The series included quenched (Q) and canister-centerline cooled (CCC) versions of the glasses. The glasses were selected as part of a broader study of the influence of glass composition on chemical durability, sulfur retention, and other properties. These data will be used to validate or identify areas of potential characterization improvements in the current glass property/composition models.
The Savannah River Site (SRS) Defense Waste Processing Facility (DWPF) processes radioactive High Level Waste (HLW) sludge solids from the Concentration, Storage, and Transfer Facilities (CSTF); which includes the SRS Tank Farm and Evaporator facilities, and a concentrated Cs-137 laden stream and a Monosodium Titanate (MST) and sludge solids stream from the SRS Salt Waste Processing Facility (SWPF). The waste is chemically adjusted with acids and reductant (currently with 50 wt.% nitric acid and ~90 wt.% formic acid, but eventually formic acid will be substituted with ~70 wt.% glycolic acid), and frit is added so that a durable, borosilicate glass waste form can be produced when the material is vitrified in the melter. As a result of the evaporation of water during both the melter feed preparation and the melter feed vitrification steps in DWPF, a recycle waste stream is generated, neutralized, and sent back to the CSTF. The recycle waste is a dilute aqueous stream originating from the collection of condensate liquids containing some minor sludge, MST, and frit solids and other waste components resulting from melter feed entrainment during foamover events and transfer of volatile species into the condensate. The recycle stream volume is significant and is expected to approach 3 million gallons per year once SWPF reaches full operation, requiring the use of multiple large CSTF tanks for storage. The recycle waste is currently collected in the SRS Tank Farm and periodically evaporated in the 242-16H (2H) Evaporator to conserve storage space.
At Savannah River Site (SRS), High-Level Waste is stored in below-grade carbon steel tanks. This waste in part consists of sludge, salt cake, and/or supernate. Preparation of this waste for future processing involves dissolution of the salt cake layer. The salt dissolution process can create conditions that leave the carbon steel tanks susceptible to localized corrosion. The salt to be dissolved contains high concentrations of nitrate, that once released, create an environment that may be conducive to pitting corrosion and/or stress corrosion cracking (SCC) of carbon steel. The salt dissolution process also liberates interstitial liquid trapped between the salt crystals. This liquid is initially high in nitrite and hydroxide concentration. High pH and greater ratios of nitrite to nitrate act as inhibitors to minimize corrosion of carbon steel in high nitrate environments. However, as dissolution proceeds, the concentration of nitrate will increase, while the hydroxide and nitrite concentration of the interstitial liquid will deplete and become insufficient to prevent the onset of corrosion attack. Tank blending and addition of inhibitors are used to ensure adequate concentrations of hydroxide and nitrite. However, this is not desirable during salt dissolution as it can reduce process efficiency and increase the amount of waste that needs processing. It has been proposed that these corrosion control limits be revisited to evaluate the corrosion susceptibility of carbon steel in environments that more closely resemble current operating conditions at SRS. An experimental matrix was designed to evaluate the use of the pitting factor for supernate chemistries characteristic to SRS, particularly during the salt dissolution process. Two electrochemical methods were identified to determine the susceptibility of A537 and A285 low-carbon steels to pitting corrosion with this chemistry envelope at temperatures up to 75 °C. The predominant electrochemical test method was Cyclic Potentiodynamic Polarization (CPP) studies. Through CPP, the pitting factor was used, based on Hanford Site corrosion studies, to accurately identify pitting susceptibility within the compositional range studied with some conservatism. Additionally, sulfate was determined to have no statistically significant influence, at concentrations up to 0.6 M, on pitting behavior in more concentrated solutions where other aggressive species govern pitting susceptibility. Where CPP was inconclusive, Modified ASTM G192 was successfully used to evaluate pitting susceptibility conditions and allowed for a pass/fail result to be determined. In all cases, the pitting factor was determined to be applicable to the simulants tested, with this metric accurately predicting incidences in which pitting occurred. Based upon the findings in this work, a pitting factor of 1.2 is being proposed to build in a safety factor and remain consistent with the Hanford Site approach. Additionally, a minimum pH limit of 12 is proposed to ensure carbon steel passivity and localized corrosion the primary degradation mechanism. Susceptibility to SCC was evaluated using a reduced matrix of tests at 75 °C. No failures due SCC were observed at open circuit. In addition, tests polarized anodically by 200 mV only resulted in failures for trials with pitting factors less than 0.86. However, a test with a passing condition based upon the pitting factor metric (pitting factor = 1.40) did exhibit a failure with an applied potential of +300 mV vs. OCP. This result is contrary to the prediction based upon the pitting factor, however, a polarization of 300 mV, or even 200 mV, from open circuit is substantial. The relationship between these testing parameters and service environment/conditions and the desired level of conservatism in the metric should be further evaluated in the determination of the significance of this result. While the pitting factor accurately predicted susceptibility to SCC at temperatures up to 75 °C and with positive overpotentials up to 200 mV, the relatively small sample matrix and failure of a passing pitting factor with a 300 mV polarization resulted in an inconclusive determination of whether the pitting factor may be used for predicting susceptibility to SCC at temperatures between 50 °C and 75 °C. As such, additional testing is recommended to evaluate the validity of the pitting factor for SCC susceptibility prediction at temperatures between 50 °C and 75 °C.
Fourteen Chemical Processing Cell (CPC) simulations were performed with nonradioactive sludge simulants at the Aiken County Technology Laboratory in Aiken, SC. Four of these experiments were performed with Tank 51 sludge simulant. The remaining ten were performed with Tank 40 sludge simulant. The purpose of these experiments was to elucidate the chemistry and characteristics of Sludge Batch (SB) 10 as anticipated in the Defense Waste Processing Facility (DWPF). Experiments were performed at acid stoichiometries between 76% and 138% of the Koopman Minimum Acid requirement (85% - 144% of the Hsu acid requirement) and at REDuction/OXidation (REDOX) targets between 0.1 and 0.3. Testing examined the impact of coupled operations and sludge-only operations during Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME) processing at both design basis and nominal boilup rates. This report shares conclusions made as a result of this testing.
The presence of regulated organic species in Hanford nuclear tank waste is assessed in this report, along with fate of the organics and possible evaporative treatment. A narrowed list of regulated organic species of concern is developed based upon published analyses, chemical properties like aqueous solubility, and chemical reactivity under alkaline conditions. Published analyses include tank headspace and liquid samples, review of chemical reagents formerly used at Hanford, and the Tank Waste Information Network System (TWINS). This work supports possible stabilization of Hanford Supplemental Low Activity Waste (SLAW) by grouting.
The Defense Waste Processing Facility (DWPF) is currently preparing to initiate processing of Sludge Batch 10 (SB10), which is comprised of material from Tanks 11H, 13H, 15H, and 26F, Alternate Feed Stock-2 (AFS-2) and Sodium Reactor Experiment (SRE) material from H-Canyon. In support of SB10 qualification, frit development using 2020 Tank 40 blend projections and experimental work for the glass variability study were previously conducted. Frit 473 and Frit 209 were identified as candidate frits and both were included in the development of the variability study test matrix; however, a final frit recommendation was postponed until more information could be determined about the composition of SB10 after washing. In May 2021, Savannah River Remediation (SRR) reprojected SB10 based on the analytical results from the Tank 51 qualification sample that was washed in the Savannah River National Laboratory (SRNL) Shielded Cells Facility.
The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.
The presence of regulated organic species in Hanford nuclear tank waste is assessed in this report, along with fate of the organics and possible evaporative treatment. A narrowed list of regulated organic species of concern is developed based upon published analyses, chemical properties like aqueous solubility, and chemical reactivity under alkaline conditions. Published analyses include tank headspace and liquid samples, review of chemical reagents formerly used at Hanford, and the Tank Waste Information Network System (TWINS). This work supports possible stabilization of Hanford Supplemental Low Activity Waste (SLAW) by grouting.