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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Dual Material System for Polymer Large Scale Additive Manufacturing

Big Area Additive Manufacturing (BAAM) technology allows for manufacturing of large-scale objects with a potential to reduce energy embedded in products, reduce or eliminate energy necessary for transportation of goods along with reducing the lead time and cost in some cases. Over the last few years, Oak Ridge National Laboratory (ORNL) has been focusing on large-scale printing of single material systems, typically un-reinforced or short fiber reinforced polymers, in order to address needs in stiffness-limited applications. This paper describes the development of a multi-material large-scale AM system through a collaboration with Cincinnati Inc. and Performance Feed Screw Inc. Modifications to the Big Area Additive Manufacturing (BAAM) system includes a new extruder design to accommodate a dual feed system, an expanded two-dryer system with a capacity of 273 kg/dryer, and a system that is capable of mixing pelletized materials up to 60Kg/hr. This article highlights the advantages and limitations of the multi-material system as well as potential applications.

Smith, Tyler↗
DOE OSTI2025

Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints

A single-class joining process known as “friction self-piercing riveting (F-SPR)” has been developed for joining various low-ductility lightweight materials on a laboratory scale. The frictional heat generated during the F-SPR process improved local ductility, resulting in crack-free joints and robust mechanical performance. This innovative joining technology was further advanced through the scale-up of the process using a new system with several key features (e.g., automatic rivet feeding and clamping system, vacuum system) toward industry readiness. The new integrated F-SPR systems were effectively demonstrated for joining different material combinations (e.g., carbon fiber composite to 7075 Al alloy, 7075 Al alloy to 7075 Al alloy, and 7075 Al alloy to casting Al Aural 5) with a unified technique. Crack-free joint with adequate mechanical interlocking resulted in good mechanical joint strength for each material combination. Then, the process was successfully scaled up by producing multiple joints without any cracks on larger CFC-Al and Al-Al components by the new integrated system, bringing it closer to industrial application.

Lim, Yong Chae [ORNL] (ORCID:0000000321773988)↗
DOE OSTI2021

Fiscal Year 2021 Filtration of Hanford Tank 241-AP-107 Supernatant Samples Obtained at Prototypic Tank Level and Filtered at 16 °C

Bench-scale filtration testing of 8.5 liters of supernatant from Hanford waste tank 241-AP-107, chilled to 16 °C, was conducted using a backpulse dead-end filter (BDEF) filtration system equipped with a feed vessel and a Mott inline filter Model 6610 (Media Grade 5) in the hot cells of the Radiochemical Processing Laboratory at Pacific Northwest National Laboratory. This was done to assess the impact of a lower sampling location within the tank as well the lowered filtration temperature on supernatant stability and fouling. The as-received samples were transferred to 1.5-liter poly bottles and held at 16 °C for approximately 1 week prior to filtration. The feed was filtered through the BDEF system at a targeted flux of 0.065 gpm/ft 2 to match the prototypic operation of the TSCR system. During the initial period of filtration, the differential pressure required to effect filtration at 0.065 gpm/ft 2 increased until it reached 2 psid [the Tank Side Cesium Removal (TSCR) action limit] at 26 hours. After this, the filter was backpulsed to dislodge accumulated solids and reduce this pressure differential. An additional eight backpulses were conducted during the initial filtration period; each time, the target pressure was reached sooner than during the previous interval. Volume filtered decreased from 0.9 to 0.03 m 3 /m 2 over the course of 14 processing hours. After the ninth backpulse, the backpulse frequency had become unsustainable, and it was decided to perform an extensive filter cleaning. The filter was cleaned by draining the chilled AP-107 feed into chilled holding containers, introducing 0.1 M NaOH into the feed vessel, and recirculating the NaOH through the system for 20 minutes before allowing the system to soak for 2 hours without temperature control. A measurable decrease in filter resistance during this recirculation indicated that the 0.1 M NaOH was likely dissolving some of the solids that had deposited on the filter. Post cleaning, the filter resistance was effectively restored to initial conditions as the initial transmembrane pressure was restored to original levels. However, resumed processing of the AP-107 feed at 16 °C continued to result in an increased rate of filter resistance. An additional five backpulses were conducted (four during feed processing, one during subsequent cleaning) before the conclusion of the test. Solids concentrated from the backpulse solutions displayed sodium oxalate-type phases, Al-oxides and sodium Al-oxides/carbonates, iron oxides, and Ca-bearing phases (calcite). The scanning electron microscopy analyses also revealed a large distribution of particles, with some particles, notably sodium phosphate dodecahydrate, having diameters close to 0.5 mm.

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

Fiscal Year 2022. Filtration of Hanford Tank 241-AP-101 Supernatant at 16 °C

Bench-scale filtration testing of ~9 liters of supernatant from Hanford waste tank 241-AP-101, chilled to 16 °C, was conducted using a backpulse dead-end filter (BDEF) filtration system equipped with a feed vessel and a Mott inline filter Model 6610 (Media Grade 5) in the hot cells of the Radiochemical Processing Laboratory at Pacific Northwest National Laboratory. This was done to assess the performance of the anticipated third feed to the Tank Side Cesium Removal (TSCR) system. The as-received samples were diluted to the target sodium concentration and transferred to 1.5-liter polyethylene bottles and held at 16 °C for approximately 1 week prior to filtration. The feed was filtered through the BDEF system at a targeted flux of 0.065 gpm/ft 2 to match the prototypic operation of the TSCR system. During filtration, the differential pressure required to effect filtration at 0.065 gpm/ft 2 increased little over the filtration campaign and never reached 2 psid (the TSCR action limit). This indicates that the TSCR filter should perform well when processing AP-101 supernatant. After completing filtration of the AP-101 feed, the filter was cleaned. Solids concentrated from the backpulse solutions displayed sodium nitrate-type phases, aluminum and silicon phases reported as cancrinite or nitrate-cancrinite, a mixed chromium-aluminum oxide, iron oxides, and Ca-bearing phases (calcite). Scanning electron microscopy analyses showed that the average particle size was 0.5 micron.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

A rotor-based multileaf collimator for beam shaping

We introduce a new style of multileaf collimator which employs rotors with angularly dependent radius to control the masking aperture: a rotor-based multileaf collimator (RMLC). Using a padlock-inspired mechanism, a single motor can set dozens of rotors, i.e. leaves, independently. This is especially important for an ultra-high vacuum (UHV) compatible MLC, since this reduces the number of actuators and vacuum feedthroughs required by more than an order of magnitude. This new RMLC will complement previous work employing a UHV compatible MLC with an emittance exchange beamline to create arbitrarily shaped beams on demand. A feed-forward control system which abstracts away the complexity of the RMLC operation, and is adaptable to real beamline conditions, is discussed and demonstrated in simulation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Pilot Plant Reliability Metrics for Grinding and Fast Pyrolysis of Woody Residues

The reliability of biomass size reduction, feeding, and conversion processes remains a critical technical hurdle and important cost driver for biomass conversion systems. While Biorefinery projects have typically focused on scaling up conversion technologies that maximize yield of desired products, e.g. fuels and chemicals, solids handling and reactor feeding systems are often considered secondarily. These are frequently scaled down or adapted from other industries, without a full appreciation of how biomass heterogeneity and variability impact process reliability. Here we present the effects of feedstock variability on relative throughput, mass loss, plant uptime, operator intervention, product yield, and product quality for grinding and fast pyrolysis operations at the pilot scale. Loblolly pine residues were sourced and collected using commercial harvesting techniques. Grinding and pyrolysis experiments were performed at INL's Biomass Feedstock National User Facility and NREL's Thermal and Catalytic Process Development Unit, respectively. Preprocessing throughput using a hammer mill varied between 31-48% of nameplate capacity (5 tons/hr), and fast pyrolysis throughput varied between 57-72% of nameplate capacity (20 kg/hr) for an overall system throughput of 18-35% of nameplate capacity across biomass preprocessing and conversion to pyrolysis oil. Pyrolysis oil yields varied between 46-53% (feedstock carbon to oil, dry basis). Grinder overloads in the size reduction step were more prevalent for lower ash and higher moisture materials. During fast pyrolysis operations, downtime was caused by bridging in the feed and char removal systems and plugging in the condensation system, and significant variation in the type and frequency of operator intervention was observed between feedstocks. Cohesion of solids (feedstock and char) leading to system plugging appeared less problematic for higher ash feedstocks, and differences in condenser plugging behavior between high and low ash feedstocks indicates the composition and physical nature of the deposited material is important for process reliability and is feedstock dependent.

09 BIOMASS FUELS↗
DOE OSTI2022

sCO2 Primary Power Large-Scale Pilot Plant FEED Summary

Echogen Power Systems and its project partners the Electric Power Research Institute, CDM Smith, Riley Power Inc. (a Babcock Power Inc. company), and the University of Missouri completed the Front-End Engineering Design (FEED) study of a nominal 10 MWe supercritical carbon dioxide (sCO2) large-scale pilot plant based on Recompression Brayton Cycle (RCBC) architecture. The FEED study was completed under Phase II of the U.S. Department of Energy Fossil Fuel Large-Scale Pilots program. The FEED study scope included the preliminary design of the combustion and environmental control systems, the primary heater, the sCO2 power cycle and its associated turbomachinery, and the balance of plant equipment to determine accurate cost and schedule requirements for fabrication and installation of the system at the University of Missouri’s Combined Cooling, Heat, and Power Plant, located in Columbia, Missouri. The RCBC sCO2 cycle presents superior thermodynamic efficiency compared to steam-Rankine cycles and is adaptable to a broad range of heat sources. The risk aversion of the power generation industry requires a successful large-scale pilot plant demonstration to enable financing and deployment of commercial-scale plants. Therefore, successful construction and demonstration of a 10 MWe RCBC sCO2 power plant would empower a transformational step forward for the efficiency of the next generation of utility power plants. This paper provides details on the primary heater, environmental control systems, and sCO2 power cycle design and performance.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Performance of reverse osmosis membrane with large feed pressure fluctuations from a wave-driven desalination system

Wave-driven desalination systems are proposed water treatment systems that involve reverse osmosis of seawater powered directly by wave motion. Such a configuration would result in drastic feed pressure fluctuations. For a technology conventionally operated with a constant feed condition, the effect of these variable pressures on membrane integrity and performance is unknown. Here, experiments were conducted with spiral wound membranes coupled to a system capable of producing feed pressure fluctuations of more than 400 psi. Feed composition included 5, 20, and 35 g/L NaCl, and a synthetic seawater at normal and 1.5x concentration. The variable feed conditions included sine-like pressure waves swings of 200-500 and 500-900 psi with frequencies of 1.25, 7.5, and 12 waves/min, and a model-generated random waveform. Between each wave experiment we performed membrane integrity tests at 650 psi and 25 g/L NaCl feed, which showed a 7.4% drop in the membrane's water permeability coefficient, an 18.4% flux decline, and more than 99% salt rejection over 1770 h of cumulative experimental time. Analysis of permeate samples showed high salt rejection. In general, variable feed pressure had no significant deleterious effect on membrane integrity or performance.

16 TIDAL AND WAVE POWER↗
DOE OSTI2020

MRDIS Case Study

The Mobile Radiation Detection and Identification System (MRDIS) is a large mobile scanner that inspects containers in transit from cargo ships for radiological materials. The MRDIS platform operates as a two-part system with one MRDIS using a plastic Polyvinyl Toleune (synthetic polymer) for primary detection and another MRDIS that uses spectroscopic detectors for secondary isotopic identification. MRDIS can operate either independently or as part of a team, depending on the needs of the port. MRDIS is controlled by a human operator, who searches the computer monitor for any traces of radiological materials when the containers pass through the center of the system. Each MRDIS can also feed data into a central system or collect data on its own for additional material analysis. The system integrates radiation detection, radioisotope identification, an optical character recognition system, occupancy/speed sensors, wireless communications, and data processing capabilities to discern what specific radiological materials are of particular interest. In addition, Sandia engineers created a detailed set of requirements for subsequent models, allowing for faster implementation of additional detection systems.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

NREL CITIES Support (CRADA CRD-14-00558 Final Report)

The Technical University of Denmark has received a Grant from the Danish Council for Strategic Research for the project "CITIES - Centre for IT-Intelligent Energy Systems in Cities", a strategic research centre, which involves industrial partners and universities. The Alliance for Sustainable Energy, LLC will participate with DTU as an industrial partner in "CITIES" under this Cooperative Research and Development Agreement (CRADA). The Centre for IT based Intelligent Energy Systems in Cities (CITIES) Project is a Danish national research center focused on work in building short-term operational integrated energy system models that feed longer term plam1ing models, considering the spatio-temporal variations, interactions, dynamics and stochastics in the energy system, from production to consumption. CITIES will harness the extensive expertise and experience of its industrial and academic partners to conduct meaningful research with tangible outputs, including a roadmap to a fossil free future. Decision support tools will be developed to inform stakeholders of the impact of investment, control and policy measures and to identify further opportunities for energy system efficiency. Dissemination and transferring knowledge is a key value to this CRADA, and the use of results by Danish policymakers, industry and society is vital. All participants in the Centre for IT based Intelligent Energy Systems in Cities (CITIES) Project are therefore encouraged to use all means to communicate their findings to society. Wherever possible, and compatible with applicable intellectual property regulations, publications should be produced and disseminated under Open Science, Data, Source and Access principles.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Exploring New Resin Systems for Nb3Sn Accelerator Magnets

Epoxy resins have long been a focus of magnet design. They provide strength and stability to the superconductor, to allow coil fabrication and consistent magnet performance. They are often cited as a main contributor to magnet performance, often as a limiting factor, from epoxy cracking and energy release. New resin systems are being designed to improve magnet quench and training performance through several means. Baseline candidate resin systems are evaluated for neat resin mechanical properties as well as behavior in Nb 3 Sn subscale composites. Furthermore, this data feeds additional resin system tuning to meet the goals stated above.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Optimal Control of Biomass Feedstock Processing System Under Uncertainty in Biomass Quality

Planning of biorefinery operations is complicated by the stochastic nature of physical and chemical characteristics of biomass feedstock, such as, moisture level and carbohydrate content. Biomass characteristics affect the performance of the equipment which feed the reactor and the efficiency of the conversion process in a biorefinery. We propose a stochastic optimization model to identify a blend of feedstocks, inventory levels, and operating conditions of equipment to ensure a continuous flowing of biomass to the reactor while meeting the requirements of the biochemical conversion process. We propose a sample average approximation (SAA) of the model, and develop an efficient algorithm to solve the SAA model. A feedstock preprocessing process consists of two-stage grinding and pelleting is used to develop a case study. Extensive numerical analysis are conducted which lead to a number of observations. Our main observation is that sequencing bales based on moisture level and carbohydrate content leads to robust solutions that improve processing time and processing rate of the reactor. We provide a number of managerial insights that facilitate the implementation of the model proposed. Note to Practitioners—This paper is motivated by the challenges faced in the bioenergy industry. The focus of this paper is on plants which use the biochemical conversion process to generate liquid fuels. It has been observed that variations in biomass characteristics, such as moisture content, cause variations in feeding of the system which lead to under-utilization of equipment. A requirement of biochemical conversion process is to maintain the carbohydrate content of biomass processed by the reactor, larger than a threshold. We propose a model that identifies the inventory levels and operating conditions of equipment to ensure a continuous flowing of biomass to the reactor. The goal is to improve equipment utilization while satisfying the requirements of the conversion process. The model is tested using real-life data. We found out that by sequencing bales based on moisture level and carbohydrate content, a plant can reduce variability in the system leading to improved system reliability, higher processing rates of the reactor, and higher throughput.

09 BIOMASS FUELS↗
DOE OSTI2021

Adaptive resource allocation for surrogate modeling of systems comprised of multiple disciplines with varying fidelity

We present an adaptive algorithm for constructing surrogate models for integrated systems composed of a set of coupled components. With this goal we introduce ‘coupling’ variables with a priori unknown distributions that allow approximations of each component to be built independently. Once built, the surrogates of the components are combined and used to predict system-level quantities of interest (QoI) at a fraction of the cost of interrogating the full system model. We use a greedy experimental design procedure, based upon a modification of Multi-Index Stochastic Collocation (MISC), to minimize the error of the combined surrogate. This is achieved by refining each component surrogate in accordance with its relative contribution to error in the approximation of the system-level QoI. Our adaptation of MISC is a multi-fidelity procedure that can leverage ensembles of models of varying cost and accuracy, for one or more components, to produce estimates of system-level QoI. Several numerical examples demonstrate the efficacy of the proposed approach on systems involving feed-forward and feedback coupling. For a fixed computational budget, the proposed algorithm is able to produce approximations that are orders of magnitude more accurate than approximations that treat the integrated system as a black-box.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Filtration Performance of Simulated 200 West Area Waste Feeds

This report describes the scaled experimental system and approach used to examine dead-end filtration performance of representative 200W waste feeds. The scaled system, which was originally designed and assembled to test Tank Side Cesium Removal (TSCR) system performance with higher-than-expected solid loadings in 2021 (Schonewill et al. 2021), was repurposed to conduct the current experiments at ~1/145 of full scale (based on throughput). Six experimental runs were conducted with five different 200W waste feed simulants: three using a DEF module scaled for TSCR and three using a DEF module scaled for the 200W process modules (based on the current design for the Advanced Modular Pretreatment System). Each experiment was run continuously for multiple days with an operating approach prototypic of the full-scale system. Staff performing the experimental runs monitored performance, obtained data from calibrated process instruments, and collected samples for observation and analysis. The measured data are presented with a focus on assessing DEF performance – specifically, the filters’ differential pressure response to the five waste simulants, frequency and efficacy of backwashing, and baseline recovery between experimental runs; data related to ion exchange column performance are also discussed in cases where the opportunity arose. The experimental campaign demonstrated that the DEFs satisfied their primary function of protecting the ion exchange column from solid intrusion for all the representative simulants used. The filters readily handled solids loadings of =500 ppm (and even greater), especially the modules scaled to the 200W process modules. Adjustments to the processing flow rate and reductions in feed temperature were observed to affect the rate of differential pressure increase on the filters, but neither adversely affected the ability of the DEFs to perform their primary function. Backflushing reliably recovered filter performance in all runs, although it did not prevent irreversible fouling for one simulant. The run that exhibited irreversible fouling established that both the quantity and the nature of the solids being filtered need to be considered when projecting filter performance.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Resilience Metrics and Framework for Distributed Wind Presentation

This presentation communicates information about the MIRACL project Resilience Metrics report and Resilience Framework report. It was created for the 2021 MIRACL advisory board meeting. We propose a three-tiered approach for the resilience framework. At the top level, we consider the time horizons on which resilience will be evaluated and executed. At the middle level, we consider the core functions of resilience, which span across the time horizons. At the lower level, we consider the process steps that correspond to implementing practices for resilience in each of the core functions. The framework considers three time horizons in order to enable organizations to assess and improve their system’s resilience throughout its lifecycle. We call these time horizons the planning, operational, and future stages. The planning stage uses organizational needs and current system evaluation to prepare for potential hazards. The operational stage seeks to execute responses to hazards as prudently and efficiently as possible to maintain system resilience. The future stage seeks to improve on current system resilience and feeds back into the planning stage to promote continuous improvement. While all three time horizons are important when considering a specific topic, the planning and evaluation phase (i.e., what is done in advance of the event) is critical in defining a system’s resilience characteristics and in outlining how a system responds to an event. This framework intentionally emphasizes the planning stage to highlight the overarching emphasis of this effort, not to imply that the other two time-related horizons (i.e., operational and change the future) are less important. The core functions in the framework are identify, prepare, detect, adapt, and recover. These five functions stem from a rigorous analysis of definitions used across the industry, and they represent the core capabilities that an organization must have to enable lifecycle resilience. Within each core function, process steps are described that help walk an organization through the information gathering, evaluation, decision-making, and implementation processes they will need to ensure their resilience goals are maintained throughout the system and the system lifecycle. Also highlighted in the figure is the concept that a resilience framework should be cyclical in nature. Because a system’s resilience is based on finite resources and time, it must continually evolve through this framework’s risk management and capital investment steps at an appropriate level of scope and pace.

17 WIND ENERGY↗
DOE OSTI2025

In anaerobic reactors the microbial community structure depends on feed type, with no “keystone” species tied to COD removal

Two-stage anaerobic digestion (AD) systems provide treatment for high strength wastewater with high stability and performance. Encapsulation technology can intensify AD to facilitate the separation of the solids retention time from the hydraulic retention time (HRT), offering lower HRTs, smaller reactors, and high effluent quality. To support successful deployment, however, the encapsulated community must contain all the needed microorganisms for successful treatment and be flexible enough to treat a variety of wastewaters. Here, a two-stage system was investigated in which microbial cultures were enriched on various high-strength wastewaters in suspended flow-through systems to determine how feed type influenced performance and microbial community structure. The hypothesis was that specific genera, or so-called “keystone species” would positively correlate to organic carbon degradation for a given feed, enabling construction of a well-functioning community for encapsulation. Results showed that the number of total bacteria (as 16S rRNA gene copies) did not correlate to soluble chemical oxygen demand (sCOD) removal, indicating that the community structure and/or members were important for good performance. Results also showed that feed type strongly influenced carbon removal and microbial community structure for 1st-stage fermenting communities, but not 2nd-stage methanogenic communities. In this study, the “core” community members were defined as organisms common to all of either the 1st- or 2nd-stage reactors irrespective of the feed they received and were present in at least 50% of the samples throughout the entire experiment. “Unique” community members were specific to a single feed, and hence, only present in either the 1st- or 2nd-stage reactors receiving that feed. In both 1st- and 2nd-stage communities, only one core genera and no unique genera were positively and significantly correlated to sCOD removal. Verification experiments performed with encapsulated communities showed that organisms identified in flow-through system and correlated with carbon degradation, though not significantly, seemed to be important for performance. Our results suggest that one cannot construct a community containing specific populations in lieu of enrichment. Nevertheless, a single diverse encapsulated anaerobic community should provide good (>80%) carbon removal when fed a variety of influents, if time is provided for enrichment after deployment.

54 ENVIRONMENTAL SCIENCES↗