Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Processing”

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

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
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 OSTI2016

THE DIVERSE ORIGINS OF NEUTRON-CAPTURE ELEMENTS IN THE METAL-POOR STAR HD 94028: POSSIBLE DETECTION OF PRODUCTS OF i-PROCESS NUCLEOSYNTHESIS

We present a detailed analysis of the composition and nucleosynthetic origins of the heavy elements in the metal-poor ([Fe/H] = −1.62 ± 0.09) star HD 94028. Previous studies revealed that this star is mildly enhanced in elements produced by the slow neutron-capture process (s process; e.g., [Pb/Fe] = +0.79 ± 0.32) and rapid neutron-capture process (r process; e.g., [Eu/Fe] = +0.22 ± 0.12), including unusually large molybdenum ([Mo/Fe] = +0.97 ± 0.16) and ruthenium ([Ru/Fe] = +0.69 ± 0.17) enhancements. However, this star is not enhanced in carbon ([C/Fe] = −0.06 ± 0.19). We analyze an archival near-ultraviolet spectrum of HD 94028, collected using the Space Telescope Imaging Spectrograph on board the Hubble Space Telescope, and other archival optical spectra collected from ground-based telescopes. We report abundances or upper limits derived from 64 species of 56 elements. We compare these observations with s-process yields from low-metallicity AGB evolution and nucleosynthesis models. No combination of s- and r-process patterns can adequately reproduce the observed abundances, including the super-solar [As/Ge] ratio (+0.99 ± 0.23) and the enhanced [Mo/Fe] and [Ru/Fe] ratios. We can fit these features when including an additional contribution from the intermediate neutron-capture process (i process), which perhaps operated through the ingestion of H in He-burning convective regions in massive stars, super-AGB stars, or low-mass AGB stars. Currently, only the i process appears capable of consistently producing the super-solar [As/Ge] ratios and ratios among neighboring heavy elements found in HD 94028. Other metal-poor stars also show enhanced [As/Ge] ratios, hinting that operation of the i process may have been common in the early Galaxy.

79 ASTRONOMY AND ASTROPHYSICS↗
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 OSTI2014

Evaluation of a recycling process for printed circuit board by physical separation and heat treatment

Highlights: • The parts mounted on printed circuit board (PCB) were liberated by underwater explosion and mechanical crushing. • The crushed PCB without surface-mounted parts was carbonized under inert atmosphere at 873 K to recover copper. • The multi-layered ceramic capacitors including nickel was carbonized at 873 K to recover nickel by the magnetic separation. • The tantalum powders were recovered from the molded resins by heat treatment at 723 and 823 K in air atmosphere and screening. • Energy and treatment cost of new process increased, however, the environmental burden decreased comparing conventional one. - Abstract: Printed circuit boards (PCBs) from discarded personal computer (PC) and hard disk drive were crushed by explosion in water or mechanical comminution in order to disintegrate the attached parts. More parts were stripped from PCB of PC, composed of epoxy resin; than from PCB of household appliance, composed of phenol resin. In an attempt to raise the copper grade of PCB by removing other components, a carbonization treatment was investigated. The crushed PCB without surface-mounted parts was carbonized under a nitrogen atmosphere at 873–1073 K. After screening, the char was classified by size into oversized pieces, undersized pieces and powder. The copper foil and glass fiber pieces were liberated and collected in undersized fraction. The copper foil was liberated easily from glass fiber by stamping treatment. As one of the mounted parts, the multi-layered ceramic capacitors (MLCCs), which contain nickel, were carbonized at 873 K. The magnetic separation is carried out at a lower magnetic field strength of 0.1 T and then at 0.8 T. In the +0.5 mm size fraction the nickel grade in magnetic product was increased from 0.16% to 6.7% and the nickel recovery is 74%. The other useful mounted parts are tantalum capacitors. The tantalum capacitors were collected from mounted parts. The tantalum-sintered bodies were separated from molded resins by heat treatment at 723–773 K in air atmosphere and screening of 0.5 mm. Silica was removed and 70% of tantalum grade was obtained after more than 823 K heating and separation. Next, the evaluation of Cu recycling in PCB is estimated. Energy consumption of new process increased and the treatment cost becomes 3 times higher comparing the conventional process, while the environmental burden of new process decreased comparing conventional process. The nickel recovery process in fine ground particles increased energy and energy cost comparing those of the conventional process. However, the environmental burden decreased than the conventional one. The process for recovering tantalum used more heat for the treatment and therefore the energy consumption increased by 50%, when comparing with conventional process. However, the market price for tantalum is very large; the profit for tantalum recovery is added. Also the environmental burden decreased by the recycling of tantalum recovery. Therefore, the tantalum recovery is very important step in the PCB recycling. If there is no tantalum, the consumed energy and treatment cost increase in the new process, though the environmental burden decreases.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Study of the element abundances in HD 140283: The abundance robustness of the weak r- and main r-process stars

Many works have attempted to investigate the astrophysical origin of the neutron-capture elements in the metal-poor star HD 140283. However, no definite conclusions have been drawn. In this work, using the abundance-decomposed approach, we find that the metal-poor star HD 140283 is a weak r-process star. Although this star is a weak r-process star, its Ba abundance mainly originates from the main r-process. This is the reason that the ratio [Ba/Eu]= −0.58±0.15 for HD 140283 is close to the ratio of the main r-process. Based on the comparison of the abundances in the six-weak r-process stars, we find that their element abundances possess a robust nature. On the other hand, we find that the robust nature of the abundance of the extreme main r-process stars ([r/Fe] ⩾ 1.5) can be extended to the lighter neutron-capture elements. Furthermore, the abundance characteristics of the weak r-process and main r-process are investigated. The abundance robustness of the two category r-process stars could be used as the constraint of the r-process theory and could be used to investigate the astrophysical origins of the elements in the metal-poor stars and population I stars.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2013

Processing liquid organic wastes at the NNL Preston laboratory

Organic compounds of various kinds have been used in the nuclear industry for numerous duties in uranium chemical, metal and ceramic processing plants. In the course of the various operations undertaken, these organic compounds have become contaminated with uranic material, either accidentally or as an inevitable part of the process. Typically, the chemical/physical form and/or concentration of the uranic content of the organics has prevented disposal. In order to address the issue of contaminated liquid organic wastes, the National Nuclear Laboratory (NNL) has developed a suite of treatments designed to recover uranium and to render the waste suitable for disposal. The developed processes are operated at industrial scale via the NNL Preston Laboratory Residue Processing Plant. The Oil Waste Leaching (OWL) Process is a fully industrialised process used for the treatment of contaminated oils with approximately 200 tonnes of uranium contaminated oil being treated to date. The process was originally developed for the treatment of contaminated tributyl phosphate and odourless kerosene which had been adsorbed onto sawdust. However, over the years, the OWL process has been refined for a range of oils including 'water emulsifiable' cutting oils, lubricating oils, hydraulic oils/fluids and 'Fomblin' (fully fluorinated) oils. Chemically, the OWL process has proved capable of treating solvents as well as oils but the highly volatile/flammable nature of many solvents has required additional precautions compared with those required for oil treatment. These additional precautions led to the development of the Solvent Treatment Advanced Rig (STAR), an installation operated under an inert atmosphere. STAR is a small 'module' (100 dm{sup 3} volume) which allows the treatment of both water miscible and immiscible solvents. This paper discusses the challenges associated with the treatment of liquid organic wastes and the process developments which have allowed a wide range of materials to be successfully treated. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
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 OSTI2017

Chemical evolution of {sup 244}Pu in the solar vicinity and its implications for the properties of r-process production

Meteoritic abundances of r-process elements are analyzed to deduce the history of chemical enrichment by the r-process, from the beginning of disk formation to the present time in the solar vicinity. Our analysis combines the abundance information from short-lived radioactive nuclei such as {sup 244}Pu with the abundance information from stable r-process nuclei such as Eu. These two types of nuclei can be associated with one r-process event and an accumulation of events until the formation of the solar system, respectively. With the help of the observed local star formation (SF) history, we deduce the chemical evolution of {sup 244}Pu and obtain three main results: (i) the last r-process event occurred 130–140 Myr before the formation of the solar system; (ii) the present-day low {sup 244}Pu abundance as measured in deep-sea reservoirs results from the low recent SF rate compared to ∼4.5−5 Gyr ago; and (iii) there were ∼15 r-process events in the solar vicinity from the formation of the Galaxy to the time of solar system’s formation and ∼30 r-process events to the present time. Then, adopting the hypothesis that a neutron star (NS) merger is the r-process production site, we find that the ejected r-process elements are extensively spread out and mixed with interstellar matter, with a mass of ∼3.5×10{sup 6} M{sub ⊙}, which is about 100 times larger than that for supernova ejecta. In addition, the event frequency of r-process production is estimated to be 1 per ∼1400 core-collapse supernovae, which is identical to the frequency of NS mergers estimated from the analysis of stellar abundances.

79 ASTRONOMY AND ASTROPHYSICS↗
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 OSTI2013

Hanford Low-Activity Waste Processing: Demonstration of the Off-Gas Recycle Flowsheet - 13443

Vitrification of Hanford Low-Activity Waste (LAW) is nominally the thermal conversion and incorporation of sodium salts and radionuclides into borosilicate glass. One key radionuclide present in LAW is technetium-99. Technetium-99 is a low energy, long-lived beta emitting radionuclide present in the waste feed in concentrations on the order of 1-10 ppm. The long half-life combined with a high solubility in groundwater results in technetium-99 having considerable impact on performance modeling (as potential release to the environment) of both the waste glass and associated secondary waste products. The current Hanford Tank Waste Treatment and Immobilization Plant (WTP) process flowsheet calls for the recycle of vitrification process off-gas condensates to maximize the portion of technetium ultimately immobilized in the waste glass. This is required as technetium acts as a semi-volatile specie, i.e. considerable loss of the radionuclide to the process off-gas stream can occur during the vitrification process. To test the process flowsheet assumptions, a prototypic off-gas system with recycle capability was added to a laboratory melter (on the order of 1/200 scale) and testing performed. Key test goals included determination of the process mass balance for technetium, a non-radioactive surrogate (rhenium), and other soluble species (sulfate, halides, etc.) which are concentrated by recycling off-gas condensates. The studies performed are the initial demonstrations of process recycle for this type of liquid-fed melter system. This paper describes the process recycle system, the waste feeds processed, and experimental results. Comparisons between data gathered using process recycle and previous single pass melter testing as well as mathematical modeling simulations are also provided. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Development of a Performance and Processing Property Acceptance Region for Cementitious Low-Level Waste Forms at Savannah River Site - 13174

The Saltstone Production and Disposal Facilities (SPF and SDF) at the Savannah River Site (SRS) have been treating decontaminated salt solution, a low-level aqueous waste stream (LLW) since facility commissioning in 1990. In 2012, the Saltstone Facilities implemented a new Performance Assessment (PA) that incorporates an alternate design for the disposal facility to ensure that the performance objectives of DOE Order 435.1 and the National Defense Authorization Act (NDAA) of Fiscal Year 2005 Section 3116 are met. The PA performs long term modeling of the waste form, disposal facility, and disposal site hydrogeology to determine the transport history of radionuclides disposed in the LLW. Saltstone has been successfully used to dispose of LLW in a grout waste form for 15 years. Numerous waste form property assumptions directly impact the fate and transport modeling performed in the PA. The extent of process variability and consequence on performance properties are critical to meeting the assumptions of the PA. The SPF has ensured performance property acceptability by way of implementing control strategies that ensure the process operates within the analyzed limits of variability, but efforts continue to improve the understanding of facility performance in relation to the PA analysis. A similar understanding of the impact of variability on processing parameters is important from the standpoint of the operability of the production facility. The fresh grout slurry properties (particularly slurry rheology and the rate of hydration and structure formation) of the waste form directly impact the pressure and flow rates that can be reliably processed. It is thus equally important to quantify the impact of variability on processing parameters to ensure that the design basis assumptions for the production facility are maintained. Savannah River Remediation (SRR) has been pursuing a process that will ultimately establish a property acceptance region (PAR) to incorporate elements important to both processability and long-term performance properties. This process involves characterization of both emplaced product samples from the disposal facility and laboratory-simulated samples to demonstrate the effectiveness of the lab simulation. With that basis confirmed, a comprehensive variability study using non-radioactive simulants will define the acceptable PAR, or 'operating window' for Saltstone production and disposal. This same process will be used in the future to evaluate new waste streams for disposal or changes to the existing process flowsheet. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Facility Improvements and Modifications to Extend the Operational Life of the Modular Caustic-Side Solvent Extraction Process - 16082

Savannah River Remediation, LLC (SRR) is working to remove, stabilize, and dispose of approximately 36.7 million gallons (138.9 million liters) of liquid radioactive waste currently stored in 43 underground waste tanks, and ultimately close waste tanks. In 2008, as an interim salt treatment system to remove cesium from high level waste salt solutions prior to the Salt Waste Processing Facility start up, the Modular Caustic-Side Solvent Extraction Unit (MCU) initiated the removal of cesium from liquid radioactive salt waste prior to disposal. The MCU was designed and built for an expected three-year operational life and five-year design life. The first MCU cold runs began in June 2007 and hot startup was completed in April 2008. MCU remains in hot operation to this day, aiding in multiple, high-level tank closures. In an effort to continue liquid waste disposition at the Savannah River Site (SRS), equipment upgrades and operational improvements have been made to extend the life of the MCU beyond the original three years. Several pieces of fixed equipment have been converted into removable equipment which reduces the downtime associated with equipment change-outs and thereby reduces the dose to workers and processing impacts. Multiple pumps and filters have been upgraded to more robust designs. Process monitoring and controls have been upgraded to improve process performance. Redundant centrifugal contactor vibration equipment has been installed on each contactor in order to better assess the reliability, processing performance, and lifetime of the contactors. A new Solvent Hold Tank (SHT) Sampler has been installed to minimize the organic cross-contamination within the sampler, dose to workers, and sample analysis time. To increase processing availability and aid in visually obtained data, camera port has been added to the Salt Solution Feed Tank (SSFT). In order to decrease the overall background dose to the workers, the Process Vessel Ventilation (PVV) duct work now has the capability to be flushed to remove contamination. The caustic wash addition system has been modified to be a once-through system to improve equipment reliability, decrease downtime, and decrease dose to workers. In addition, the solvent that MCU utilizes to extract Cesium out of salt waste has been upgraded to Next Generation Solvent (NGS) which is based on MaxCalix extractant instead of a BobCalix extractant. Further, these upgrades and improvements have allowed MCU to be able to process at higher flow rates (up to 8.5 GPM) and with increased throughput (as high as 1.3 million gallons in FY13 and 5.3 million gallons since hot operations initiated) that have allowed SRR to continue the disposition of nuclear salt waste. The continued operation of MCU ensures more curies are stabilized into a glass matrix at SRS's Defense Waste Processing Facility (DWPF) and less curies are retained within South Carolina at SRS's Saltstone Disposal Facility (SDF). Unique challenges associated with modifying and improving a demonstration plant that is in hot operations and was designed to be temporary with a limited plant footprint have been successfully overcome. Further, creative strategies for removing old equipment have been utilized given the limited decontamination agents available for use that will not interfere with the organic solvent. This paper presents and discusses the deployment of these upgrades and operational improvements to MCU in order to allow continued, increased salt waste processing beyond the initial design life. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Filtration Improvements in Support of Increased Salt Waste Processing Throughput at the Savannah River Site - 16173

Crossflow Filtration is currently used at the U.S. Department of Energy (DOE) Savannah River Site (SRS) for the removal of actinides, strontium and sludge solids from the high-level salt waste stored in underground tanks. At SRS, crossflow filtration is deployed in the Actinide Removal Process (ARP). Salt waste is transferred from an underground waste tank to one of two strike tanks where it is struck with Monosodium Titanate (MST), which adsorbs uranium, plutonium and strontium. The MST laden salt waste is then transferred to the ARP filtration facility, which contains the crossflow filter. The filtrate, which is called Clarified Salt Solution (CSS), is sent to a downstream facility for cesium removal, while the MST and sludge solids are concentrated at the filtration facility and eventually sent to the Defense Waste Processing Facility (DWPF) for vitrification. ARP and the downstream cesium removal facility, the Modular Caustic Side Solvent Extraction Unit (MCU), were both developed as an interim salt waste processing technology and as smaller scale radioactive demonstration plants for the Salt Waste Processing Facility (SWPF), which is currently under construction. Since the beginning of ARP in 2008, there have been challenges with achieving desired filtration rates through the crossflow filter system. Historically the crossflow filter system has been the flow limiter in salt waste processing and many changes have been made and are planned to achieve desired throughput, especially as MCU increases its processing capacity. Some of these changes include the design of a new crossflow filter, the implementation of a new process chemistry flowsheet and several operational changes. The modifications to the ARP crossflow filter have helped contribute to periods of record throughput in salt waste processing in FY 2015. This paper will discuss the technical challenges and system limitations of retrofitting an older facility as well as past, present and future modifications to the ARP filtration process in order to achieve salt waste processing goals at SRS. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
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↗