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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Metal Additive Manufacturing Process Selection and Development Lifecycle for Propulsion Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication processes. Each of these manufacturing process has unique advantages and challenges for use in aerospace propulsion applications. The most commonly used AM processes include Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and solid-state processes as in Cold Spray, Ultrasonic Additive Manufacturing, and Additive Friction Stir Deposition. While detailed research has been conducted among many of the AM processes to mature processing parameters and material properties, navigating which processes are best to select is difficult as it is based on specific component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various key attributes. These key attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) certification approaches. This presentation summarizes these results and is meant to introduce specific examples which show what to consider when designing a metal AM component for aerospace propulsion applications.

Paul Gradl↗
NASA NTRS2023

Leveraging Automated Fiber Placement Computer Aided Process Planning Framework for Defect Validation and Dynamic Layup Strategies

Process planning represents an essential stage of the Automated Fiber Placement (AFP) workflow. It develops useful and efficient machine processes based upon the working material, composite design, and manufacturing resources. The current state of process planning requires a high degree of interaction from the process planner and could greatly benefit from increased automation. Therefore, a list of key steps and functions are created to identify the more difficult and time-consuming phases of process planning. Additionally, a set of metrics must exist by which to evaluate the effectiveness of the manufactured laminate from the machine code created during the Process Planning stage. Layup strategies, in addition to dog ears, stagger shifts, steering constraints, and starting points, represented the group of functions labeled as process optimization and ranked the highest in terms of priority for automation. The laminates resulting from the selected parameters are evaluated through the occurrences of principal defect metrics such as fiber gaps, overlaps, angle deviation and steering violations. This document presents an automated software solution to the layup strategy and starting point selection phase of process planning. A series of ply scenarios are generated with variations of these ply parameters and evaluated according to a set of metrics entered by the Process Planner. These metrics are generated through use of the Analytical Hierarchy Process (AHP), where relative importance between each of the fiber features are defined. The ply scenarios are selected which reduce the overall fiber feature scores based on the defects the Process Planner wishes to minimize.

HiCAM↗
NASA NTRS2024

Moon to Mars (M2M) Cross Program Utilization Payload Safety Process

It is the goal of Moon to Mars (M2M) to establish a single consolidated set of safety requirements and a safety review process for utilization payloads that will cross program vehicle hatches or operate externally on multiple program vehicles during transport or operation that satisfies Exploration Ground Systems (EGS), Orion, EVA, and Human Surface Mobility Program (EHP), Gateway (GW), and Human Landing System (HLS) programs. This document defines the Cross Program Utilization Payload (xPUP) safety review process for mission effectivity of Artemis III and beyond. This review process will help ensure protection of the overall Moon to Mars integrated system from potential hazards created by cross program payloads that either cross a program vehicle hatch or can interface with more than one M2M lunar exploration program vehicle. The process will identify payload hazards and controls that will protect ground personnel, flight crew, the integrated vehicle, ground equipment, or facilities. This process is also applicable to samples that cross hatches between vehicles including for return to Earth. The xPUP safety review process will be led by one of the M2M programs' integration safety panels, chosen on a per-payload basis. After the lead integration safety panel is determined, the common safety process is established, based on pre-determined criteria, which includes ad-hoc members from other stakeholder programs. Stakeholder programs are those that interface with the utilization payload in any way (e.g., operating on a lunar exploration vehicle or crossing program vehicle hatches). The xPUP will execute this safety review process for flight and ground utilization payload hardware design, its ground support equipment, and landing and recovery in accordance with the applicable safety requirements as specified in M2M-30043: Moon to Mars Cross Program Utilization Payload Safety Requirements. The xPUP safety process will follow the lead integration safety panel’s safety process requirements. Formal agreements will be communicated with the payload developer using the payload integration processes documented in M2M-30037, Artemis Payload Integration Implementation Plan.

payloads↗
DOE OSTI2018

Power management across heterogeneous processing units

A method includes controlling active frequency states of a plurality of heterogeneous processing units based on frequency sensitivity metrics indicating performance coupling between different types of processing units in the plurality of heterogeneous processing units. A processor includes a plurality of heterogeneous processing units and a performance controller to control active frequency states of the plurality of heterogeneous processing units based on frequency sensitivity metrics indicating performance coupling between different types of processing units in the plurality of heterogeneous processing units. The active frequency state of a first type of processing unit in the plurality of heterogeneous processing units is controlled based on a first activity metric associated with a first type of processing unit and a second activity metric associated with a second type of processing unit.

Paul, Indrani↗
DOE OSTI2018

Pseudo-dynamic Aspen Plus{sup R} Model of the Defense Waste Processing Facility - 18475

The Defense Waste Processing Facility (DWPF) at the Savannah River Site converts legacy high-level waste from the Cold War into borosilicate glass for permanent disposal in a geological repository. The waste sludge is chemically adjusted by the addition of acid, mixed with frit, and concentrated in the DWPF Chemical Process Cell (CPC) to ensure that the final glass has the desired properties. The resulting mixture is fed into the melter where the waste is melted and poured into stainless steel storage canisters. We present an Aspen Plus{sup R} model of the DWPF CPC, which is being developed to aid chemical processing decisions pertaining to the current flowsheet and to aid decisions regarding optimizing future processing. Given a waste feed composition with acid and frit additions, the model will predict the sludge and off-gas compositions throughout the processing, as well as the final melter feed composition. This allows different processing scenarios to be investigated easily, reducing the reliance on experimental testing, and hence saving time and money. The model has multiple potential applications, including calculating the acid and frit additions required to give acceptable glass properties, off-gas permitting, tracking mercury steam-stripped from the waste in the off-gas system, tracking flammable gases in the offgas system, investigating the effect of reducing air purges in the condensers, and general process optimization. The waste is processed in the CPC in batches, requiring dynamic simulation to track the time-dependent operations. Accurate modeling of the processing also requires calculations of phase and electrolyte chemical equilibria and parallel rate-dependent reactions. Due to existing technical limitations with dynamic simulation of the complex chemical system, we have adopted a pseudo-dynamic approach in which time intervals are treated as consecutive steady-state operations in Aspen Plus{sup R}. Thus, the model consists of ∼100 replicas of the processing vessel and its off-gas system, with the sludge output by one replica (representing one time interval) becoming the feed to the next (representing the next time interval). By examining the results from these replicas in sequence, one can see the time evolution of the model. This general approach can be used wherever simultaneous calculation of phase and electrolyte chemical equilibria in a dynamically evolving system is needed. In addition to describing the general structure and chemistry of the model, we present results from tests of the model against experimental data. These data are from laboratory-scale process simulations of the CPC with a nonradioactive waste sludge simulant. These tests include the model's predictions of the offgas composition, the sludge pH, and the final sludge composition. We will also discuss planned future developments of the model. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

The Production of Low Ash Coals Using the Hydrophobic-Hydrophilic Separation Process with Novel Developments

Froth flotation is a common mineral processing method in coal preparation. This process becomes less efficient, however, as particle size is reduced, and ultrafine particles are often discarded prior to froth flotation, contributing to a substantial amount of coal waste in impoundments. Because of the land-use and risk of an impoundment failure, these impoundments pose an environmental liability. To address ultrafine coal rejection, researchers at Virginia Tech developed the hydrophobic-hydrophilic separation (HHS) process. Unlike in froth flotation, HHS uses an organic solvent to separate and dewater hydrophobic particles from hydrophilic minerals. Past work on the HHS process yielded promising results. In particular, the HHS process has produced a low-ash (<2%) and low moisture (<8%) product, which is a viable feed stock for carbon products. In this work, an investigation of the effects of auxiliary processes on the HHS process was conducted. The auxiliary processes included grinding, pre-concentration, and reagent conditioning. This work also contains an investigation on the interaction between two primary unit operations in the HHS process: oil agglomeration and de-emulsification. Lastly, to make the HHS process more viable for commercial scale-up, a novel unit operation was developed and tested that performs comparably to the current HHS process.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Radiopaque particle processing additive

A radiopaque processing medium comprising a plurality of radiopaque particles and a non-radiopaque processing medium. The plurality of radiopaque particles is added to the non-radiopaque processing medium to increase a bulk density of the processing medium thereby forming the radiopaque processing medium. The radiopaque processing medium allows excess process media to be located and characterized during X-ray inspection of an electronic device on which the radiopaque processing medium was used. The radiopaque processing medium may also be used to locate and identify flaws/defects of the electronic device based on the location of excess radiopaque processing medium. The radiopaque processing medium may also be used as an underfill material to reinforce electronic chips soldered to the electronic device.

Diamond, Louis↗
DOE OSTI2019

Computer–aided process intensification: Challenges, trends and opportunities

Chemicals based products and the processes that manufacture them play important roles in sustaining our society. Chemical, biochemical, petrochemical and related processes are characterized by either conversion of specific raw materials to desired chemicals or extraction of desired chemicals from specific raw materials. Well–known examples in the first category are the conversion of methanol and acetic acid to form methyl acetate and water, and, carbon dioxide hydrogenation to methanol via the reverse water gas shift reaction. In the second category, the use of de–methanizer, de–ethanizer, de–propanizer, and so on, separation steps in gas processing plants are well–known. In the conversion–based processes, as the conversions of raw materials are usually not 100% complete, energy intensive downstream separation techniques need to be employed to separate the desired products and recycle the unreacted raw materials. Note that the conversion process itself may also be energy intensive. In the extraction–based processes where product chemicals do not usually represent 100% of the raw material, energy intensive separation techniques are commonly employed to achieve the desired separations. This means that for both categories of processes, energy in different forms need to be supplied and the processes during operation have the potential to produce waste that may lead to negative environmental impacts and cause supply chain issues. Furthermore, planet earth is facing challenges with respect to energy, water, food, and environment, and significant improvements in process efficiencies of new and/or existing processes are needed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Characterization of Hot Workability of 5052 Aluminum Alloy Based on Activation Energy-Processing Map

In the design of hot forming processes for aluminum alloys, hot processing maps are usually used as a powerful tool for processing parameters optimizations. Although the stability of deformation is considered in conventional hot processing (CHP) maps, the difficulty of deformation, i.e., whether deformation is easy to occur, is not taken into account. Therefore, it is difficult for CHP maps to efficiently and accurately obtain the optimal processing parameters and achieve satisfying hot workability. Hence, in this study, thermal compression tests were performed to investigate the hot forming behavior of 5052 aluminum alloy in the deformation temperature range of 553-733 K and strain rate range of 0.001-1 s{sup −1}. We proposed an activation energy-processing (AEP) map by coupling the CHP map and the activation energy value, and thereby applied it to evaluate the hot workability of 5052 aluminum alloy. In CHP maps, the region with the highest power dissipation efficiency is generally considered to be the best processing region. However, the AEP map shows that materials with satisfying hot workability not only depends on high power dissipation efficiency, but also on low activation energy values. At the strain of 0.7, the optimal hot processing region predicted by the CHP map lies in the temperature range of 583-673 K and strain rate range of 0.001-0.1 s{sup −1}, but that predicted by AEP map locates in the temperature range of 643-733 K and strain rate range of 0.001-0.1 s{sup −1}. Microstructure characterization implies that the optimal processing region predicted by the CHP map presents necklace-like structures, which are non-uniform and unbeneficial for deformation, while that predicted by the AEP map consists of fine, uniform and equiaxed grains. Thus, it is implied that the processing regions predicted by the AEP map are more suitable for forming, i.e., the reasonability of the AEP map is verified.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Process mining for healthcare: Characteristics and challenges

Process mining techniques can be used to analyse business processes using the data logged during their execution. These techniques are leveraged in a wide range of domains, including healthcare, where it focuses mainly on the analysis of diagnostic, treatment, and organisational processes. Despite the huge amount of data generated in hospitals by staff and machinery involved in healthcare processes, there is no evidence of a systematic uptake of process mining beyond targeted case studies in a research context. When developing and using process mining in healthcare, distinguishing characteristics of healthcare processes such as their variability and patient-centred focus require targeted attention. Against this background, the Process-Oriented Data Science in Healthcare Alliance has been established to propagate the research and application of techniques targeting the data-driven improvement of healthcare processes. This paper, an initiative of the alliance, presents the distinguishing characteristics of the healthcare domain that need to be considered to successfully use process mining, as well as open challenges that need to be addressed by the community in the future.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Optimization of edge bead removal (EBR) process to enhance defect reduction in optical lithography

Defect reduction remains a critical objective in the integrated circuit manufacturing process, particularly within the highly re-entrant lithography modules where minimizing defects is crucial. Defects at the wafer edge can contaminate lithography modules and downstream processing equipment, leading to redistribution onto the wafer surface and adversely affecting overall device yield. A persistent challenge in the resist coating process is the formation of resist edge beads, driven by the strong Van der Waals attraction of excess photoresist (PR) to itself and the underlying substrate. The edge bead removal (EBR) process is a standard cleaning step designed to eliminate these edge beads and prevent potential contamination. Here, in this study, we identify the sources of EBR induced defects and additional EBR process encroachment toward edge patterning during the EBR cleaning process. This study provides a comprehensive study aimed at optimizing the EBR cleaning process to effectively eliminate EBR-induced defects, thereby enhancing overall device yield. Specifically, we identify three primary defects induced by the EBR cleaning process: rainbow-type, finger-shaped, and teardrop-type defects. Our experimental study reveals that in addition to EBR rinse time, PR cast time is crucial parameters contributing to the formation of these defects. By properly optimizing the PR cast time and EBR rinse time, we were able to remove nearly 100 % of dense clusters of defects that were easily visible even at low magnification optical microscopy throughout the wafer edge. We observed that shorter PR casting times shows edge defects caused by inefficient EBR process because of insufficient time for PR to fully settle causing superfluous PR to continue flowing toward wafer edge during EBR clearing step, leading to partial removal of PR at the wafer edge and the formation of rainbow defects. Proper optimization of both PR casting time and EBR chemistries dispense time is essential to resolve these defects, ensuring efficient EBR cleaning process and improved overall device yield.

42 ENGINEERING↗
DOE OSTI2021

Comparative Assessment of Data-driven Process Models in Health Information Technology

Process mining for conformance analysis consists of comparing a reference process model against a data-driven process model generated via log files from information technology systems. However, in the absence of a complete reference process model, we found no suggested approaches in the literature to address the need for evaluating process conformance among different healthcare facilities to assess standardization of care. Our goal is to find similarities and dissimilarities in data-driven process models among US Veterans Health Administration (VHA) facilities that can be indicative of patient safety issues. Our hypothesis was that the analysis would not produce statistically significant differences in outcome. We present a unique implementation of conformance analysis in process mining that consists of combining process mining, process mapping and statistical metrics. We illustrate our approach by applying it to the analysis of two clinical radiology order process models generated from healthcare data provided by two similar facilities in the VHA. The comparative assessment showed that about 70% of the orders completed successfully and 30% were not completed due to policy and duplications. Our analysis found a good statistical correlation between both facilities, as the Spearman’s correlation coefficient between facilities for the frequency of cases per total hours was 0.87879, for the frequency of cases by state transition was 0.79702 and for the throughput time per state transition was 0.63582. Additional statistical analyses using the Mann-Whitney U test and the root mean square error both produced values that were not significant. The foregoing approach validated our hypothesis by demonstrating a good statistical correlation of data describing the flow of clinical radiology orders absent a credible reference model. Finding good agreement between both facilities was important in confirming that the clinical orders flow in a similar manner, suggesting standardization of care.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Air Pollutant Emissions and Regulatory Implications of Co-Processing Raw Bio-Oil in U.S. Petroleum Refineries

Pyrolysis oil, often referred as bio-oil or biocrude, has attracted considerable attention because it has higher energy density and carbon content compared to the raw biomass. Using pyrolysis oil derived from low cost and underutilized biomass to produce renewable hydrocarbon fuels provides a viable link between the agriculture/forestry and (petro-) chemical industry. Co-processing bio-oil with vacuum gas oil (VGO) in petroleum refinery is appealing due to the relatively low capital requirement to retrofit refinery and the compatibility of fuel products with existing infrastructure. In order to implement co-processing, a petroleum refinery would need to consider several process modifications and therefore could be subject to varying levels of air permitting requirements based on bio-oil co-processing ratio, co-processing capacity in existing units, the amount of regulated pollutants expected to be emitted, among other factors. This analysis considers co-processing 5% (by weight) of raw bio-oil with VGO in the fluidized catalytic cracking (FCC) unit(s) in a petroleum refinery. We estimate the potential increase in emissions of regulated air pollutants resulting from the modifications required to implement bio-oil co-processing and evaluate the regulatory and permitting implications for three FCC size categories in the U.S. refineries, which could co-processes raw bio-oil to produce partially renewable transportation fuels. We also assess technically feasible emission control options petroleum refineries could adopt to avoid being subject to major source permitting requirements if the estimated increase in regulated air pollutant emission exceeds the applicable threshold for major modifications. Insights from our analysis can help overcome challenges and risks associated with timely obtaining air permits required to implement bio-oil co-processing in existing refineries. Our analysis also provides needed information for decision makers (e.g., local air quality agencies) to understand the potential air quality implications for retrofitting refineries to co-process bio-oil, particularly in areas with high concentration of petroleum refineries.

09 BIOMASS FUELS↗
DOE OSTI2018

Process Control Approach to Implement High Waste Loading Glass Formulations for Hanford Low Activity Waste Vitrification - 18435

Acceptable glass formulations for vitrification of Hanford low activity waste (LAW) at The Hanford Tank Waste Treatment and Immobilization Plant (WTP) must meet a variety of product quality, processability, and waste loading requirements. The glass formulation development work underpinning the WTP baseline LAW glasses was captured in a vitrification process control approach developed by the Vitreous State Laboratory (VSL) and Atkins Energy Federal EPC, Inc. that permits the calculation of the glass formulation required for each particular batch of LAW delivered to the LAW vitrification facility. Since that time, we have developed a wide range of glass formulations that achieve considerably higher waste loadings and which therefore are more economically attractive in terms of reduced amounts of glass produced and decreased time for treatment. That work was done in support of the Department of Energy's Office of River Protection program that is examining options to optimize the LAW facility and LAW glass waste form. Implementation of these high waste loading formulations at the WTP requires the development of a new LAW vitrification process control algorithm, which is the subject of this paper. Waste loadings in LAW glasses are typically limited by either the alkali loading for LAW with low sulfate content or the SO{sub 3} loading for LAW with high sulfate content. In the former case, waste loadings are limited by refractory corrosion and glass corrosion on the vapor hydration test (VHT) and product consistency test (PCT), all of which tend to increase with higher alkali concentrations. In the latter case, waste loadings are limited by the formation of a molten sulfate phase in the melter, which has deleterious effects. The LAW vitrification process control strategy must mitigate these effects while optimizing waste loadings. Given the composition of any LAW stream, the new LAW vitrification process control algorithm permits the calculation of a suitable high waste loading glass composition and the required glass forming additives such that all processing, waste loading, and product quality requirements are met. This algorithm was developed from data for a large number of glasses that were formulated, and characterized with respect to a variety of properties affecting processability and product quality; many of these formulations were also subjected to melter testing to verify acceptable processing characteristics, processing rates, and the absence of secondary sulfate phase formation. This paper describes the development of the present algorithm, comparisons to the present lower waste loading baseline WTP process control approach, and plans for further development and testing. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Implementation of Increased Salt and Decreased Sludge Volumes in the Defense Waste Processing Facility - 19597

The Savannah River Site (SRS) Liquid Waste System (LWS) safely stores and treats high-level radioactive waste. The LWS consists of 51 waste storage tanks (eight of which are operationally closed and filled with grout), waste evaporators, treatment facilities, and solidification facilities such as the Defense Waste Processing Facility (DWPF) and Saltstone Production Facility (SPF). The disposition of high-level waste (HLW) into a glass waste form poured into canisters at the DWPF began in 1996. DWPF processed a sludge only flowsheet until 2008 when the Actinide Removal Process (ARP) and Modular Caustic Side Solvent Extraction Unit (MCU) began treating the salt waste from the underground liquid storage tanks by striking with monosodium titanate (MST) to remove actinides, when necessary to meet downstream acceptance criteria, and removing the MST and entrained sludge solids (SS) by filtration before using an organic solvent to strip the cesium from the salt, creating two new concentrated HLW streams. This change caused the DWPF to begin processing under both a sludge-only and a coupled operations flowsheet where salt streams would only be added when available. This strategy allows for continuous glass canister production at DWPF. Recently, DWPF completed a 10-month melter replacement in December 2017 and the Concentrate, Storage, and Transfer Facility (CSTF) has completed repairs to the 3H Evaporator system. These facility outages have caused delays in preparing the next batch of sludge feed for DWPF. Concurrent with these facility outages, the Salt Waste Processing Facility (SWPF) has been undergoing system testing and commissioning, working toward startup. SWPF is designed to process salt waste in the same manner as ARP/MCU, but with much higher throughput volumes produced per unit time. In order to process the SWPF salt streams efficiently, DWPF will implement a coupled operation only flowsheet. Based on the facility outages mentioned above, efforts have been made to identify strategies to minimize sludge volumes and maximize salt volumes in the DWPF until the next sludge batch is ready for processing in DWPF. Savannah River Remediation (SRR) recently performed an evaluation that examines the effects of reducing the volume of sludge and maximizing the addition of the cesium-rich concentrated salt solution in each Sludge Receipt and Adjustment Tank (SRAT) batch in order to extend the existing sludge batch as long as possible until the next sludge batch is ready. These effects include a reduction of weight percent solids in the DWPF processing vessels, an increase in cycle time, a new canister heat generation value that remains within regulatory limits, and higher gamma source that remains within bulk facility gamma shielding. Balancing the above parameters resulted in a small reduction of sludge volume per SRAT batch under SWPF operation and maximizing the salt volumes for both ARP/MCU and SWPF operation. This slight reduction in sludge volume and increase in salt volumes allows SRR to mitigate some of the schedule impact incurred by the facility outages. This strategy was evaluated for both ARP/MCU and SWPF operation. This strategy has been successfully implemented under ARP/MCU operation using small step changes in the current process. This paper provides an overview of the evaluation performed for DWPF with ARP/MCU and DWPF with SWPF operations. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Novel Foaming Solutions for High Level Waste (HLW) Processing - 20195

Foaming occurs during treatment of high level waste (HLW) at Savannah River Site's Defense Waste Processing Facility (DWPF) in the Chemical Process Cell (CPC) due to high gas generation from process steam and chemical offgas products [1]. The presence of amphiphilic particles in the waste slurry stabilizes the foam [2], [3]. Efficient processing of HLW requires foam control, as foam-overs lead to lower productivity and potential radioactive contamination of condensate streams. DWPF currently employs Siovation Antifoam 747, a surfactant produced by Momentive Performance Materials, as an antifoaming agent during waste treatment. Despite its ability to control foam generation, processing issues have arisen from its use [4]. During DWPF chemical processing, a chemical antifoam agent must be effective at temperatures up to 103 deg. C between pH 3-13. Antifoam 747 is effective at pH 7 but degrades as pH deviates [5]. Antifoam 747 is 90% by weight Momentive{sup TM} L77 and 10% by weight Momentive{sup TM} Y-17580. These ingredients are trisiloxane products, which are especially vulnerable to attack in acidic and caustic environments. Since Antifoam 747 readily degrades, periodic addition is required. Several processing concerns related to Antifoam 747 have affected DWPF operation. Its overuse warranted concern of potential flammable melter offgas under upset conditions due to the generation of carbon dioxide and hydrogen. As a result, a Potential Inadequacy in the Safety Analysis (PISA) was declared [6]. Antifoam contribution has been included in the melter offgas flammability strategy and the quantity of antifoam is monitored to ensure limits are not exceeded. Testing at Savannah River National Laboratory (SRNL) determined that propanal, tri-methylsilanol, and hexamethyldisiloxane are generated as Antifoam 747 degrades, leading to a second PISA [7]. The formation of these byproducts poses additional flammability risks. Furthermore, the methyl and ethyl groups of these compounds may be responsible for the formation of the methyl and ethyl mercury discovered in DWPF [8], [9]. The formation of organomercury has specifically been called out by DOE as a need for increased research. The effectiveness of non-chemical methods for foam control and the efficiency of alternative antifoam agents were evaluated as part of an effort to improve HLW treatment operations at DWPF and to reduce, or eliminate, the flammability hazards associated with Antifoam 747 currently in use. Foaming of high-level waste (HLW) slurries is an issue at the Defense Waste Processing Facility (DWPF) Chemical Process Cell (CPC) which is currently mitigated with a chemical antifoam agent. The effectiveness of non-chemical methods for foam control and the efficiency of alternative antifoams were examined to improve HLW treatment at DWPF and to eliminate the flammability hazards associated with Siovation Antifoam 747 currently in use. Non-chemical foam control methods were deemed unviable for chemical processing at DWPF, as the spray/mist technique requires too much water and space limitations make installation and implementation of headspace agitators unfeasible. The use of ultrasonic energy thickened and further stabilized the foam. Two suitable alternative defoaming agents, Momentive{sup TM} Y- 17112 and Evonik Surfynol{sup R} MD-20, were identified. Both defoamers control foam over a pH range of 4- 13 at boiling, with no flammable degradation products, and only minimal quantities (100-200 mg/kg) are required under glycolic acid conditions. In order to validate the effectiveness of these defoaming agents, SRNL recommends irradiation testing and laboratory scale SRAT/SME experiments with actual radioactive waste. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

ProCAFD: Computer-aided Tool for Sustainable Process Synthesis, Intensification and Hybrid solutions

Process industry is always in quest for innovative designs which are both efficient, safe and sustainable. The feasible search space of all unit operations that can be combined to generate process flowsheet alternatives for a given synthesis problem can be large and difficult to manually navigate in order to determine the best processing route. Therefore, it is helpful to utilize computer-aided methods and tools to enumerate, analyze and determine within the design space, the more sustainable processes. In this study, an integrated computer-aided method and corresponding software-tool that’s capable of generating and searching the entire design space for more sustainable process options is presented. In this work a comprehensive analysis method consisting of economic, life cycle, sustainability and process safety indicators is used to identify process bottlenecks on the selected alternative which are translated to design targets. Matching of these design targets minimizes/eliminates the process hot-spots and, thereby generating non-trade-off innovative process designs.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Current challenges and potential directions towards precision microscale additive manufacturing – Part III: Energy induced deposition and hybrid electrochemical processes

The Part III of the four-part series of articles discusses the challenges and opportunities in microscale additive manufacturing processes, specifically focusing on energy-induced deposition and electrochemical processes. Compared to the direct ink write (DIW) and laser-based processes, the energy-induced deposition methods can fabricate high-resolution, high aspect ratio and complex parts, while the hybrid electrochemical process can be used to fabricate complex parts using a wide range of conductive and photoactive materials. However, the volumetric throughput of these processes is lower than their DIW and laser-based counterparts. The processes that have been explored in this process are Focused-ion Beam Induced Deposition (FIBID), Laser Chemical Vapor Deposition (LCVD), Menicus-confined Electrodeposition (MCED) and Laser-Enabled Electrochemical Printing (LECP). The range of processable materials, feature-size resolution, geometry and volumetric throughput are used as factors to evaluate the current state-of-the-art for these processes. Finally, novel approaches have been proposed in the article to address these challenges associated with microscale AM processes.

42 ENGINEERING↗