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NASA NTRS2019

Ozonesonde Quality Assurance: JOSIE-SHADOZ (2017) and SHALLOTS (2018)

Ozonesonde data constitute a mainstay of satellite calibration and are used for climatologies and analysis of trends, especially in the lower stratosphere where satellites are most uncertain. The electrochemical-concentration cell (ECC) ozonesonde has been deployed at ~100 stations worldwide since the 1960s, with changes over time in manufacture and procedures, including details of the cell chemical solution and data processing. As a consequence, there are biases among different stations and discontinuities in profile timeseries from individual site records. Since 1996 the Jülich [Germany] Ozone Sonde Intercomparison Experiment (JOSIE) has periodically tested ozonesondes in a simulation chamber designated the World Calibration Centre for Ozonesondes by WMO. In October- November 2017 a JOSIE campaign evaluated the sondes and procedures used in SHADOZ (Southern Hemisphere Additional Ozonesondes), a 14-station tropical and subtropical network. A distinctive feature of the 2017 JOSIE was that the tests were conducted by operators from eight SHADOZ stations; Nairobi, Natal, Irene, Costa Rica, Paramaribo, Reunion, Hanoi, Kuala Lumpur. Experimental protocols and preliminary results for the SHADOZ sonde configurations, which represent most of those in use today, are described. SHADOZ stations that follow WMO-recommended protocols record total ozone within 3% of the JOSIE reference instrument. Instrument biases noted in prior JOSIE and field tests like BESOS (2004) were noted in JOSIE-2017, with maximum effect in the stratosphere. In June 2018 we organized a series of dual launches during the OWLETS II campaign in the Maryland and Chesapeake Bay area (SHALLOTS = SHADOZ-OWLETS ParaLLel Ozonesonde Test Study). Instrument and solution types were varied as in JOSIE-2017 and three radiosonde-ozonesonde variants were tested. An example of a parallel sampling in SHALLOTS, from a Greenbelt EnSCI-iMet sonde combination flown with the Wallops SPCLMS package, is illustrated in the Figure. The result was a range of biases but in general the instrument combination (EnSCI-iMet) deployed at 11 SHADOZ stations recorded ~5-10% less ozone in the stratosphere than the SPC ECC sonde flown with a Vaisala or LMS system. These 2017 and 2018 results and prior JOSIEs demonstrate that regular testing is essential to maintain best practices in ozonesonde operations and to ensure high-quality data for the ozone assessment communities.

Quality assurance↗

DOE OSTI2020

Evaluation of Engineered Barrier Systems (FY19 Report)

This report describes research and development (R&D) activities conducted during fiscal year 2019 (FY19) specifically related to the Engineered Barrier System (EBS) R&D Work Package in the Spent Fuel and Waste Science and Technology (SFWST) Campaign supported by the United States (U.S.) Department of Eneregy (DOE). The R&D activities focus on understanding EBS component evolution and interactions within the EBS, as well as interactions between the host media and the EBS. A primary goal is to advance the development of process models that can be implemented directly within the Genreric Disposal System Analysis (GDSA) platform or that can contribute to the safety case in some manner such as building confidence, providing further insight into the processes being modeled, establishing better constraints on barrier performance, etc.The FY19 EBS activities involved not only modeling and analysis work, but experimental work as well. The report documents the FY19 progress made in seven different research areas as follows: (1) thermal analysis for the disposal of dual purpose canisters (DPCs) in sedimentary host rock using the semianalytical method, (2) tetravalent uranium solubility and speciation, (3) modeling of high temperature, thermal-hydrologic-mechanical-chemical (THMC) coupled processes, (4) integration of coupled thermalhydrologic- chemical (THC) model with GDSA using a Reduced-Order Model, (5) studying chemical controls on montmorillonite structure and swelling pressure, (6) transmission x-ray microscope for in-situ nanotomography of bentonite and shale, and (7) in-situ electrochemical testing of uranium dioxide under anoxic conditions. The R&D team consisted of subject matter experts from Sandia National Laboratories, Lawrence Berkeley National Laboratory (LBNL), Los Alamos National Laboratory (LANL), Pacific Northwest National Laboratory (PNNL), the Bureau de Recherches Géologiques et Minières (BRGM), the University of California Berkeley, and Mississippi State University. In addition, the EBS R&D work leverages international collaborations to ensure that the DOE program is active and abreast of the latest advances in nuclear waste disposal. For example, the FY19 work on modeling coupled THMC processes at high temperatures relied on the bentonite properties from the Full-scale Engineered Barrier EXperiment (FEBEX) Field Test conducted at the Grimsel Test Site in Switzerland. Overall, significant progress has been made in FY19 towards developing the modeling tools and experimental capabilities needed to investigate the performance of EBS materials and the associated interactions in the drift and the surrounding near-field environment under a variety of conditions including high temperature regimes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Design, Development and Testing Plan for Energy Efficiency Algorithms Related to Building-Integrated Cooling, Heating, and Power Systems

Building-integrated cooling, heating and power (CHP) systems are more efficient than conventional systems at providing local power and thermal energy, and favorable fuel prices are bound to spur their increased adoption. It is estimated that the total CHP technical potential in the commercial building sector is approximately 76 GW, but only a small fraction of it is actually deployed. Advanced control and monitoring systems that realize the full potential of these CHP systems can transform this capacity into an asset for both the owner and the grid and also accelerate the adoption of these systems in the building sector. However, to realize the full benefit of the CHP systems, we must ensure persistence of energy efficient operations. It has been demonstrated by several studies that as much as 30% of building energy use is wasted. Much of the waste results from the inability to anticipate load variations (design day vs. non-design day operations; diurnal variation of loads), identify improper operation, and efficiently operate, control and maintain building systems. Moreover, many buildings, even those with adequate control infrastructure, lack knowledgeable staff to operate and maintain energy systems. Operators of buildings with CHP systems will constantly need to make tradeoffs (economic dispatch) between onsite power generation and purchasing power, between onsite heat production from distributed generation versus heating/cooling from conventional systems, and different passive and active load management measures. Much of the inefficiency in the current building operations can be eliminated by use of automated performance monitoring (PM), real-time commissioning verification (CxV) and automated fault detection and diagnostic (AFDD) tools. Automation can help system operators make intelligent decisions. Remote and continuous monitoring of system conditions and performance will enable better management and integration of CHP with existing building systems. Continuous PM, real-time CxV and AFDD could alleviate burdens for operations staff, enhance operations and maintenance (O&M), and improve reliability of building and CHP systems. To address the O&M challenges and to provide a means to maximize the rate-of-return of building-integrated CHP systems, the Building Technologies Office (BTO) within the U.S. Department of Energy’s (DOE’s) Office of Energy Efficiency and Renewable Energy (EERE) initiated a project to design, develop, and field test a VOLTTRON™-based supervisory controller and associated open-source algorithms. These algorithms will ensure real-time optimal operation of a building-integrated CHP system, support electric grid reliability, and lead to achieving the goal of a clean, efficient, reliable and affordable next-generation integrated energy systems. This report lists the components for which PM, real-time CxV and AFDD algorithms will be developed, how the algorithms will be tested, and metrics that will be used to validate the algorithms and easy of deployment. Deployment of these algorithms in the field will result in savings reduction in energy consumption of between 10% and 20%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1988

A vision system for a Mars rover

A Mars rover must be able to sense its local environment with sufficient resolution and accuracy to avoid local obstacles and hazards while moving a significant distance each day. Power efficiency and reliability are extremely important considerations, making stereo correlation an attractive method of range sensing compared to laser scanning, if the computational load and correspondence errors can be handled. Techniques for treatment of these problems, including the use of more than two cameras to reduce correspondence errors and possibly to limit the computational burden of stereo processing, have been tested at JPL. Once a reliable range map is obtained, it must be transformed to a plan view and compared to a stored terrain database, in order to refine the estimated position of the rover and to improve the database. The slope and roughness of each terrain region are computed, which form the basis for a traversability map allowing local path planning. Ongoing research and field testing of such a system is described.

Wilcox, Brian H.↗

NASA NTRS1994

Linear quadratic Gaussian and feedforward controllers for the DSS-13 antenna

The controller development and the tracking performance evaluation for the DSS-13 antenna are presented. A trajectory preprocessor, linear quadratic Gaussian (LQG) controller, feedforward controller, and their combination were designed, built, analyzed, and tested. The antenna exhibits nonlinear behavior when the input to the antenna and/or the derivative of this input exceeds the imposed limits; for slewing and acquisition commands, these limits are typically violated. A trajectory preprocessor was designed to ensure that the antenna behaves linearly, just to prevent nonlinear limit cycling. The estimator model for the LQG controller was identified from the data obtained from the field test. Based on an LQG balanced representation, a reduced-order LQG controller was obtained. The feedforward controller and the combination of the LQG and feedforward controller were also investigated. The performance of the controllers was evaluated with the tracking errors (due to following a trajectory) and the disturbance errors (due to the disturbances acting on the antenna). The LQG controller has good disturbance rejection properties and satisfactory tracking errors. The feedforward controller has small tracking errors but poor disturbance rejection properties. The combined LQG and feedforward controller exhibits small tracking errors as well as good disturbance rejection properties. However, the cost for this performance is the complexity of the controller.

Gawronski, W. K.↗

DOE OSTI2022

A novel approach to build algal consortia for sustainable biomass production

In the last decade, microalgae have reemerged as a feedstock for biofuels and a diverse suite of bioproducts. Yet, considerable challenges must be overcome before algal biofuels and bioproducts become technoeconomically viable. At present, single algal strain selected for particular phenotypic traits, such as maximum specific growth rate or lipid content, are commonly scaled for cultivation in open, outdoor raceway ponds due to the low capital costs of these systems. Although this monoculture approach may maximize the production of end products, monocultures are particularly susceptible to crashes associated with environmental and biological variability. An approach that has been proposed to generate more productive and stable microalgal crops is the use of eco-engineered communities, or consortia. Yet, attempts to construct productive consortia have not been consistently successful. We argue that failures stem from the lack of an eco-engineering approach to design species combinations. Here, we used an in silico method to build consortia before testing their performance against monocultures. Focusing on consortia of Nannochloropsis and Microchloropsis, we measured growth of strains along gradients of light, temperature, and salinity and used a functional dispersion approach to generate over 8000 functionally-diverse consortia combinations. We tested the 50 most functionally diverse consortia in a laboratory experiment and found that consortia overwhelmingly outperformed monocultures. Indeed, overyielding (OY) and a positive net biodiversity effect (NBE) was found respetively in 8%-86% and 88-92% of consortia combinations over the different experimental phases. To our knowledge, this is the first application of an in silico approach to design functionally diverse consortia before laboratory and field testing. Furthermore, our results highlight the importance of employing a functional diversity approach for consortia design.

09 BIOMASS FUELS↗

NASA NTRS1971

SSA-A spacecraft magnetic tests

In the initial magnetic tests the spacecraft perm moment as received was 43 milliampere-meter squared (pole-cm), which was reduced by deperm treatment to milliampere-meter squared. Facility fluxgate probe bias results indicated Z axis bias at the SSS-A fluxgate magnetometer position to be about one half nanotesla (gamma) after Z axis deperm. The ASCS magnetometers, 01 and 02, were successfully aligned and proper operation of the ASCS system were verified. The spacecraft fluxgate magnetometer was calibrated in both the high and low sensitivity modes after a defective 01 electronics card was replaced. Problems were encountered in the Z axis search coil during calibration and the test was re-scheduled. Final test results indicated that the total perm moment could not be reduced any lower than 35 milliampere-meter squared by deperm treatment. However, the Z axis moment decreased from 22 milliampere-meter squared to 6 milliampere-meter squared after deperm. Correct operation and calibration was verified for all three axes of the spacecraft fluxgate magnetometer and no significant bias was observed during stray field testing. Null and spot calibration of the ASCS magnetometer was completed and the measured spin and attitude coil moments were: 2535 and 9820 milliampere-meter squared respectively.

Roy, T. N.↗

NASA NTRS2018

An Improved UAV-Based Fog Collector for Local-Scale Aerobiological Sampling

The use of unmanned air vehicles (UAVs) to passively collect fog for microbiological analysis is being investigated at NASA Ames, contributing to our understanding of the dynamics and limits of the biosphere. Current improvements to a preliminary payload design include physically modifying the mesh of the passive impactor collection unit (PICU) to increase fog-capture efficiency and a quick- mounting system to improve sample turnaround and contamination control. Increasing the water-capture efficiency of the PICU involved changing the surface roughness of the polypropylene mesh by abrasive sanding. Four scale models of the PICU were created, with three of those models sanded with 80-, 150-, and 240-grit sand paper for a minimum of thirty seconds on each side. Each mesh was individually tested in a fog-simulation chamber to measure collection efficiency. Tests showed that sanding the mesh will increase the water-capture efficiency by at least 3-fold for the 150- and 240-grit. Next steps are to determine the scaling laws and minimum amount of exposure time as a function of the fog density, to acquire enough microorganisms for analysis; a light-weight ground module for the PICU has been developed to allow rapid, easy field testing. Developing a mounting system that will ensure sterile deployment, as well as prompt changes of PICUs, for collection of fog water, utilized computational fluid dynamics (CFD) for the UAV to ensure that the location of the impactors will not be contaminated by particulates in the UAV downwash. The original design allowed the impactors to remain within sterile packaging until mounted on the UAV but did not address the concerns of contamination from aerodynamic ground effects and particulate lofting during takeoff. Design for a raised launch pad would allow for the sterile PICU to be attached to UAV and launched from outside the region of projected particulate lofting. California coastal sites have been scouted for appropriate testing locations. The improvements to the PICU design and operations will allow for multiple sampling points within a single fog event. The returned fog samples will undergo ion chromatography, qPCR, ATP quantification, and other tests to characterize microbial species and relevant biochemistry.

Wong, Amber↗

DOE OSTI2020

Grimsel Test Site - A Successful International Underground Research Laboratory for Many Decades - 20429

For more than 35 years, Nagra and its partners from around the world have been conducting underground research projects at the Grimsel Test Site (GTS, www.grimsel.com) to contribute to the development and confirmation of safe geological disposal concepts and for the characterization of suitable host rock formations. Over the years, the results of this internationally recognized research program have been, and continue to be, incorporated directly into exploration programs, modelling, safety, and engineering feasibility studies on options for deep geological repositories. Each project of the GTS program involves field-testing, laboratory studies, design and modelling tasks, and integrates all scientific and technical aspects. Each project phase is planned with a duration of three to five years to facilitate practical and administrative aspects and allow flexibility for updating the overall project plans with the latest findings. Scientific and engineering interaction among the different projects is ensured via an international steering committee meeting. Hosting an IAEA level C radiation- controlled zone, which allows use of radionuclides, including actinides such as thorium, uranium, neptunium, plutonium and americium, in in-situ experiments is one of the reasons why GTS also developed as a center of excellence for work with radioactive tracers under realistic in-situ boundary conditions. Last year, a new five-year program (2019 to 2023) started which includes projects with a planning horizon of decades. The new five-year program includes a new phase of in-situ experiments using radionuclides such as migration experiments in the Colloid Formation and Migration project (CFM), the Long-Term Diffusion experiment (LTD) and the newly established C-14 and I-129 Migration in cement project (CIM). The 'High Temperature effects on Bentonite' (HotBENT) project is starting in the current phase and is studying the effects of elevated temperatures (>175 deg. C) on bentonite materials. As a generic underground research laboratory (URL) it is expected that the GTS will provide in the coming years a platform for international collaboration, knowledge development and knowledge transfer for the next generation of scientists and engineers in the area of radioactive waste disposal and geosciences. A key role regarding knowledge transfer and training is provided by the well-established Grimsel Training Center (GTC), which (beside many URL related issues) also covers many general aspects of radioactive waste management. In this paper we provide an overview of the current program at the GTS, focusing on the experiments that study the migration of radionuclides through engineered barrier materials and the geosphere. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2005

Diagnostics Adapted for Heat-Treating Furnace Environment

Diagnostics developed for the in situ monitoring of rocket combustion environments were adapted for use in heat-treating furnaces. Simultaneous, in situ monitoring of the carbon monoxide, carbon dioxide, methane, water, and hydrogen concentrations in the endothermic gas of a heat-treating furnace were demonstrated under a Space Act Agreement between the NASA Lewis Research Center, the Heat Treating Network, and Akron Steel Treating Company. This endothermic gas, or "endogas," is produced in a catalytic process, where natural gas is "cracked" in the presence of air. Variations in the composition of the natural gas supplied lead to variations in the composition of the endothermic gas. These variations could lead to an unacceptable quality of steel products that are hardened through the carborization process that uses this gas. Conventional methods of monitoring the endogas include measuring the dew point of the gas and the oxygen concentration. From these data, the carbon monoxide content of the gas can be calculated. This carbon monoxide concentration creates the carbon potential needed for carburization. Several weak links are present in this approach. The oxygen monitor deteriorates over time, and the measurement might be inaccurate by 50 percent. Also, the chemistry equations, which are based on several assumptions, such as secondary species concentrations, provide only an approximate estimate of the carbon monoxide concentration. To address these weaknesses, we investigated a new method based on ordinary Raman spectroscopy, in which the carbon monoxide concentration is measured directly and in situ. This method measures the laser light scattered from the molecules. Each species interacts with the light and scatters the light at a different frequency. Spectral monitoring of the scattered light intensity at each molecular frequency of interest provides the species concentrations. One advantage over the conventional method is that several species can be monitored simultaneously. A second advantage is that the measurement is direct; there is no need to make assumptions, to filter the gas, or to calibrate the instrument. An instrument was designed consisting of a laser and a detection system within an enclosure, connected to an optical probe by fibers. For determining carbon monoxide concentration, the probe is mounted on the endothermic gas line, close to the generator. Optical fibers with a length of 150 ft have been used to transmit laser light from the instrument to the probe. There, the light is focused into the gas, and the scattered light is collected and transmitted back to the instrument where it is analyzed with a photomultiplier and lock-in amplifier. Laboratory tests have shown that with the current system the concentration of carbon monoxide, water, nitrogen, oxygen, and hydrogen in the air can be monitored with an accuracy of 1 percent. The concentration of carbon dioxide in the air can be monitored with an accuracy of 0.5 percent, and the concentration of methane with an accuracy of 0.2 percent. This instrument was taken to the Akron Steel Treating Plant, where field tests are in progress to verify the system capabilities. Planned developments are improving the accuracy, monitoring multiple locations, and reducing instrument size and cost.

Source record↗

NASA NTRS2015

Integrated Ultra-Wideband Tracking and Carbon Dioxide Sensing System Design for International Space Station Applications

A three-dimensional (3D) Ultra-Wideband (UWB) Time-of-Arrival (TOA) tracking system has been studied at NASA Johnson Space Center (JSC) to provide the tracking capability inside the International Space Station (ISS) modules for various applications. One of applications is to locate and report the location where crew experienced possible high level of carbon-dioxide (CO2) and felt upset. Recent findings indicate that frequent, short-term crew exposure to elevated CO2 levels combined with other physiological impacts of microgravity may lead to a number of detrimental effects, including loss of vision. To evaluate the risks associated with transient elevated CO2 levels and design effective countermeasures, doctors must have access to frequent CO2 measurements in the immediate vicinity of individual crew members along with simultaneous measurements of their location in the space environment. To achieve this goal, a small, low-power, wearable system that integrates an accurate CO2 sensor with an ultra-wideband (UWB) radio capable of real-time location estimation and data communication is proposed. This system would be worn by crew members or mounted on a free-flyer and would automatically gather and transmit sampled sensor data tagged with real-time, high-resolution location information. Under the current proposed effort, a breadboard prototype of such a system has been developed. Although the initial effort is targeted to CO2 monitoring, the concept is applicable to other types of sensors. For the initial effort, a micro-controller is leveraged to integrate a low-power CO2 sensor with a commercially available UWB radio system with ranging capability. In order to accurately locate those places in a multipath intensive environment like ISS modules, it requires a robust real-time location system (RTLS) which can provide the required accuracy and update rate. A 3D UWB TOA tracking system with two-way ranging has been proposed and studied. The designed system will be tested in the Wireless Habitat Testbed which simulates the ISS module environment. This report describes the research and development effort for this prototype integrated UWB tracking and CO2 sensing system. The remainder of the report is organized as follows. In Section II, the TOA tracking methodology is introduced and the 3D tracking algorithm is derived. The simulation results are discussed in Section III. In Section VI, prototype system design and field tests are discussed. Some concluding remarks and future works are presented in Section V.

Ni, Jianjun (David)↗

NASA NTRS2012

Progress Made in Lunar In-Situ Resource Utilization Under NASA's Exploration Technology and Development Program

Incorporation of In-Situ Resource Utilization (ISRU) and the production of mission critical consumables for 9 propulsion, power, and life support into mission architectures can greatly reduce the mass, cost, and risk of missions 10 leading to a sustainable and affordable approach to human exploration beyond Earth. ISRU and its products can 11 also greatly affect how other exploration systems are developed, including determining which technologies are 12 important or enabling. While the concept of lunar ISRU has existed for over 40 years, the technologies and systems 13 had not progressed much past simple laboratory proof-of-concept tests. With the release of the Vision for Space 14 Exploration in 2004 with the goal of harnessing the Moon.s resources, NASA initiated the ISRU Project in the 15 Exploration Technology Development Program (ETDP) to develop the technologies and systems needed to meet 16 this goal. In the five years of work in the ISRU Project, significant advancements and accomplishments occurred in 17 several important areas of lunar ISRU. Also, two analog field tests held in Hawaii in 2008 and 2010 demonstrated 18 all the steps in ISRU capabilities required along with the integration of ISRU products and hardware with 19 propulsion, power, and cryogenic storage systems. This paper will review the scope of the ISRU Project in the 20 ETDP, ISRU incorporation and development strategies utilized by the ISRU Project, and ISRU development and 21 test accomplishments over the five years of funded project activity.

Sanders, Gerald B.↗

NASA NTRS1981

A comprehensive analysis of the performance characteristics of the Mount Laguna solar photovoltaic installation

This paper represents the first comprehensive survey of the Mount Laguna Photovoltaic Installation. The novel techniques used for performing the field tests have been effective in locating and characterizing defective modules. A comparative analysis on the two types of modules used in the array indicates that they have significantly different failure rates, different distributions in degradational space and very different failure modes. A life cycle model is presented to explain a multimodal distribution observed for one module type. A statistical model is constructed and it is shown to be in good agreement with the field data.

Shumka, A.↗

NASA NTRS2010

Use of a Microphone Phased Array to Determine Noise Sources in a Rocket Plume

A 70-element microphone phased array was used to identify noise sources in the plume of a solid rocket motor. An environment chamber was built and other precautions were taken to protect the sensitive condenser microphones from rain, thunderstorms and other environmental elements during prolonged stay in the outdoor test stand. A camera mounted at the center of the array was used to photograph the plume. In the first phase of the study the array was placed in an anechoic chamber for calibration, and validation of the indigenous Matlab(R) based beamform software. It was found that the "advanced" beamform methods, such as CLEAN-SC was partially successful in identifying speaker sources placed closer than the Rayleigh criteria. To participate in the field test all equipments were shipped to NASA Marshal Space Flight Center, where the elements of the array hardware were rebuilt around the test stand. The sensitive amplifiers and the data acquisition hardware were placed in a safe basement, and 100m long cables were used to connect the microphones, Kulites and the camera. The array chamber and the microphones were found to withstand the environmental elements as well as the shaking from the rocket plume generated noise. The beamform map was superimposed on a photo of the rocket plume to readily identify the source distribution. It was found that the plume made an exceptionally long, >30 diameter, noise source over a large frequency range. The shock pattern created spatial modulation of the noise source. Interestingly, the concrete pad of the horizontal test stand was found to be a good acoustic reflector: the beamform map showed two distinct source distributions- the plume and its reflection on the pad. The array was found to be most effective in the frequency range of 2kHz to 10kHz. As expected, the classical beamform method excessively smeared the noise sources at lower frequencies and produced excessive side-lobes at higher frequencies. The "advanced" beamform routine CLEAN-SC created a series of lumped sources which may be unphysical. We believe that the present effort is the first-ever attempt to directly measure noise source distribution in a rocket plume.

Panda, J.↗

DOE OSTI2021

Pilot-Scale Testing of an Integrated Circuit for the Extraction of Rare Earth Minerals and Elements from Coal and Coal Byproducts Using Advanced Separation Technologies

The primary objective of this project was to develop and demonstrate an integrated pilot-scale circuitry for recovering high-value rare earth elements (REEs) from coal and coal byproducts. The target performance was to produce a mixed REE product with content of at least two percent by weight on a dry mass basis in a cost-effective and environmentally benign manner. During the first nine months of the project period (Phase 2 Budget Period 2), pilot plant construction was completed including all field site startup activities such as permitting, engineering design, procurement/bidding, unit fabrication, site construction, equipment installation, module assembly, safety training, and circuit shakedown. During the remaining 21 months of project period (Phase 2 Budget Period 3), detailed field-testing activities were performed including feedstock sample collection and preparation, exploratory testing, circuit modification, detailed parametric study, and performance optimization. A detailed techno-economic analysis was performed based on the pilot plant testing findings which provided various scenarios for REE production. The project successfully accomplished the proposed target performance by producing mixed rare earth oxide (REO) with greater than 90% purity by weight in a continuous pilot scale operation from two distinctly different coarse refuse materials (i.e., West Kentucky No. 13 and Fire Clay coal seams), and at least three secondary sources (i.e., heap leach process and naturally formed acid mine drainage system). Project partners included the University of Kentucky, Virginia Tech, West Virginia University, Alliance Coal, Blackhawk Mining, Mineral Refining Company, and Mineral Separation Technologies. The pilot scale test facility was constructed at a former mining complex owned by Alliance Natural Resource Partners (Alliance Coal). The site was rehabilitated to accommodate the equipment installation, construction and fabrication, electrical power requirement, water line management and containment. The process units constructed and installed included X-ray sorting unit, crushing and grinding unit, physical separation unit, acid leaching unit, solvent extraction unit, and wastewater management unit. A rare earth mineral concentration unit was constructed as a standalone unit for flexible operation. A detailed environmental assessment and control plan was carried out to identify and quantify any potential impacts of the pilot-scale processing circuitry on the human and eco-system health and well-being. Corresponding mitigation strategies and control measures were provided. A conceptual flowsheet was developed to effectively remove thorium and uranium from high purity rare earth oxide mix or any potential radionuclide enriched stream. The two distinct feedstock materials were secured from the Blackhawk Mining Complex in eastern Kentucky where the Fire Clay (Hazard No. 4) seam is processed. The West Kentucky No. 13 (Baker) coarse refuse material was collected from an active process stream at an Alliance coal preparation plant located in western Kentucky. Characterization analysis indicated that both of feed materials generated from the two sources contained >300 ppm of TREEs on a dry whole mass basis which met the requirements for a qualified feed stock. The two feedstocks were further upgraded using a dual x-ray sorter to prepare the feed material for hydrometallurgical circuit. Thermal treatment on feed material prior to leaching was found to: 1) improve the leaching recovery of REEs, 2) increase the leaching kinetics, and 3) allow the leaching reaction to occur at lower acidity. Roasting at 600°C was selected as the pre-treatment condition for both West Kentucky No. 13 and Fire Clay coarse refuse material. Over 40% of leaching recovery was achieved by roasting West Kentucky No. 13 material having a top particle size of 3 mm in the pilot scale operation using 1.2M sulfuric acid leaching at 75OC. Initial pilot scale testing involved continuous operation of the pilot plant for 94 hours. The leaching unit was operated at solid-to-liquid ratio of 1 to 10 (w/v) using 0.5M sulfuric acid solution at a temperature of 75°C. The continuous solvent extraction circuit utilized rougher and cleaner units with DEHPA and TBP as the extractants. An innovative stripping circuit was developed to accumulate the REE concentration in the stripping solution to a level above 600 ppm. A bleed stream from the recycled strip solution was treated using oxalic acid precipitation which produced a high grade rare earth oxalate. The oxalate product was roasted to remove the oxalate which produced a rare earth oxide product having a purity greater 90%. Due to high concentrations of contaminant ions in the pregnant leach solution (PLS), a modified flowsheet was developed that involved pre-concentration of the REEs using multiple stages of precipitation and redissolution. The advantage of this process was improved removal of contamination before the downstream purification process and a significant cost reduction relative to the circuit that utilized the solvent extraction process. The modified circuitry included processes involving leaching, multistage precipitation, redissolution, and oxalate precipitation followed by roasting of the oxalate product. The circuit produced a mixed REO that was 92.96% pure from the initial test. A detailed parametric test plan was carried out which involved varying key parameters including solids feed rate, acid flowrate, acid concentration, multistage precipitation pH, redissolution pH, oxalate precipitation dosage and pH. The response variables included REE recovery, contaminant recovery, REO product grade and overall chemical consumption. Test results indicated that the acid-to-solid ratio is the key parameter to leaching efficiency as performance deteriorated with an increase in solids concentration. The optimal pH determined for REE precipitation and redissolution was 6.5 and 2.5, respectively. Additional tests were conducted to further improve the flowsheet. Recirculating a portion of the PLS to the feed of the leach tanks improved the leaching performance by lowering the pH of the leaching system and reducing the contamination recovery by shortening the residence time. Moreover, the removal of Al prior to REE precipitation significantly reduced the oxalic acid consumption in the oxalate precipitation circuit. The modified circuit produced over 90% grade REO by weight from both West Kentucky No. 13 and Fire Clay coarse refuse material in pilot scale continuous test programs. A case analysis model was developed to project the REE and major contaminants concentration in each PLS stream based on the leaching condition, pH cut point, and oxalic acid dosage. A correlation was established using empirical and semi-empirical models. Using the models, chemical consumption required for each stage was predicted based on the projected performance of the hydrometallurgy circuit. After identifying the optimum conditions, validation tests were carried out for the treatment of both West Kentucky No. 13 and Fire Clay coarse refuse materials in the pilot plant. The actual circuit performance and chemical consumptions were very close to the model predictions. Other than the two coarse refuse sources, several secondary feedstocks were also tested in the pilot plant facility. A “heap leach” system was constructed using the coarse refuse material generated from cleaning the West Kentucky No. 13 seam coal. Using the two stage SX rougher and cleaner circuit, a concentrate with a grade >90% REO was produced while recovering >97% of the REEs from the heap leach PLS. Naturally generated acid mine drainage (AMD) from West Kentucky No.13 mine was processed using the multistage precipitation circuit in the pilot plant in a test conducted for a period of 32 hours. The final grade of the mix RE oxide produced from the AMD was 90.84% with an overall circuit recovery of 64%. The primary source of REE was the selective precipitation steps involving iron and aluminum rejection. The hydrophobic-hydrophilic separation (HHS) process was proven to effectively recover coal from fine waste materials. For REM recovery, the HHS process was able to produce concentrates at grades of approximately 1.8% REE on an ash basis; however, recovery values were typically low, <10%, under the optimal conditions determined in the laboratory-scale testing. Staged testing of the pilot-scale HHS process for coal recovery and semi-continuous laboratory testing for REM testing showed that a total concentration ratio of more than 15x was observed for the REM recovery process. A circuit simulation package was developed for REE extraction and purification using a spreadsheet-based platform (Microsoft Excel). The REESim circuit simulation package is configured to track the mass and volume flows of components passing through a series of unit operations specified and configured by the user. The mass rates can then be utilized by the user to determine important performance indicators such as product mass yields, concentrate purity levels, element-by-element recoveries, and so forth. The techno-economic analysis showed that the roasting and leaching operations were the most expensive capital items, each contributing approximately 30% to the total capital cost. One notable contributor to the high production costs was the low REE recovery observed in the pilot scale trials. The product basket price was shown to have a strong influence on the economic viability of the scenarios, with the scandium price being the most significant influencer. Operating cost was shown to be extremely sensitive to REE recovery, REE feed grade, and leaching acid consumption. An analysis of ten different scenarios for a 500 t/h commercial operation revealed that three were economically favorable, producing internal rates of return varying from 27.7% to 33.1% and payback periods of 4 to 5 years. The project successfully developed and demonstrated a process to recover REEs from coal and coal byproducts in a pilot-plant operation which consistently produced over 90% grade REO mix from varies types of feedstocks. Commercialization analysis showed that the technology readiness level successfully achieved TRL 6 at the end of the project and demonstrated the need and the potential for scaling the process to further advance the technologies toward the goal of providing a domestic supply of REEs at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1971

Theory of the unmagnetized plasma.

The Vlasov mathematical model of a plasma, which has come to be thought more useful than any other in describing the dynamical behavior of the majority of plasmas of interest, is first examined. Macroscopic variables and moment equations; linear electrostatics solutions; plasma oscillations, ion acoustic waves, and linear instabilities are treated, as well as external fields, 'test' charges, and nonlinear Vlasov phenomena. Plasmas are statistically described, and attention is given to the kinetic theory of the stable, uniform plasma and the Balescu-Lenard equation; two-time ensemble averages and fluctuation spectra in stable plasmas; the kinetic theory of the unstable plasma; and ensembles of Vlasov plasmas. Some illustrative experiments are described. Four appendixes deal with the electrostatic approximation and transverse waves; solution of the linearized Vlasov equation in a magnetic field; estimates of correlation functions from thermal equilibrium; and equivalence of spatially uniform BBGKY and Klimontovich correlations.

Montgomery, D. C.↗

DOE OSTI2021

Accelerated reliability tests of n + and p + poly-Si passivated contacts

We report on the stability of encapsulated, low-pressure chemical vapor-deposited phosphorus (n + poly-Si) doped and boron (p + poly-Si) doped poly-Si/SiO x passivated contacts by exposing the samples to three different accelerated tests: damp heat test, thermal cycling and ultraviolet exposure, adhering closely to the IEC 61215 standard. Outdoor testing was also performed by exposing the samples in the outdoor testing field at the National Renewable Energy Laboratory, and preliminary data accumulated for 1000 h from February to April of 2021 is reported. We studied non-metallized, thermally-metallized, and screen-printed n + and p + poly-Si by monitoring the effective minority carrier lifetime at the implied maximum power point using a Sinton lifetime tester, and recorded photoluminescence images before and after the exposure. Furthermore, the samples were found to be stable under all test conditions, which is encouraging for incorporation of these contacts in next-generation industrial silicon solar cells.

14 SOLAR ENERGY↗

DOE OSTI2023

HFTS-1 (Final Report)

Despite the long history of hydraulic fracturing, the optimal number of fracturing stages during multi-stage fracture stimulation in horizontal wells can be a complex subject. In addition to the increased expense of multistage fracturing in horizontal wells, increasing the number of fracturing stages does not always correlate with a commensurate increase in production. The problem is the application of a uniform fracture stimulation design to all stages with no consideration for geological variations along the wellbore. The result is an inefficient use and costly waste of energy and water. Optimization of the fracturing process requires an understanding of the cause-and-effect relationship between fracturing parameters and local geological properties at a given location along the wellbore. Realizing that the generalized rock mechanics theories and hypotheses are not truly applicable to fractured and laminated shales, quantifiable impacts of a shale’s geomechanical and depositional features are a prerequisite for design and implementation of optimized hydraulic fractures. The overarching goal of this project is to understand and define the relationships of shale geology and fracture dynamics using detailed field data that includes coring of the fracture domain. Finally, resource recovery from shale formations is estimated to be less than fifteen percent. Research proposed in this project will establish the foundations for investigating enhanced recovery techniques for increased resource recovery in existing fracture treated wells. Natural gas as an EOR fluid is in the initial stages of being used broadly in the oil and gas industry and as such, many aspects of the process need to be researched and addressed prior to widespread acceptance. In addition, re-fracturing techniques, particularly using cemented liners also need to be further investigated. This project explores several of these EOR techniques in greater detail, not just at the theoretical level, but through actual field test sites. This report delves into the research program, identified tasks, several studies, observations, results, and conclusions under the Hydraulic Fracturing Test Site (HFTS) project. This test project is subdivided into three distinct phases and each phase is discussed in detail under separate sections. The original test site for Phase 1 as well as the Phase 2 site are in Midland Basin in Texas and operated by Laredo Petroleum. In the first two phases, the program targeted the Wolfcamp formation in Midland Basin. Phase 3 of the study targeted the EagleFord play in South Texas with Devon Energy as the operator. Significant conclusions from this study include: 1) lateral and vertical fracture growth mapping as well as proppant transport behavior, 2) Use of field gas and its applicability for huff n puff EOR injection in the Midland Basin, 3) Development and validation of proppant log, both at core scale as well as in-fill well implementation by analyzing drilling mud return samples, 4) Applicability of liner refracturing including best practices for enhanced unit level productivity. This report will detail all these studies as well as technical results and conclusions from said studies. These include general subsurface characterization work, completion designs as implemented, studies looking at fracture geometry, high resolution microseismic study, advanced crosswell strain mapping studies including drainage characterization, core characterization results, proppant analysis (core and observation wells), geochemistry, etc. to name a few.

02 PETROLEUM↗