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DOE OSTI2023

Modeling Tool Development and Validation for Solar Industry Process Heat Using Particle Thermal Energy Storage

U.S. industry sectors used 26.2 quadrillion Btu and accounted for 33% of total energy consumption in 2021 according to the Energy Information Agency. Industrial process heat accounts for 70% of industrial energy use with application temperatures ranging from 60 degrees -1100 degrees C. Industry processes, heavily relying on fossil fuels of cheap coal or natural gas, differ widely in operating conditions and load requirements which makes them difficult to standardize and imposes great challenges in decarbonization. Industry processes require reliable energy supply and vary widely in temperature ranges. Storing energy from renewable sources is necessary to improve reliability and to mitigate renewable intermittency when replacing carbon fuel-based heat supplies to achieve energy savings and reduce emissions. To this end, we have developed a particle-based thermal energy storage (TES) technology using low-cost and highly stable silica sand as a storage medium. The economic and performance-based analysis is key for renewable energy sources to reliably supply industry process heat and ultimately displace fossil fuels for decarbonization. The diversified industrial processes need case-by-case analysis and design. Therefore, an adaptive modeling tool is key for renewable power with energy storage to meet industry demands. Thus, a modeling tool to simulate a solar industry process heat system using the particle TES has been developed using the object-oriented equation-based language Modelica and the commercial platform of Modelon Impact. The Modelica-based software tool provides a general simulation environment for the design of reliable solar energy sources integrated with TES for various industrial process applications at different temperatures for economic competence with fossil fuels such as coal and natural gases. It uses both customized and standard component modeling modules in Modelon libraries for the flexibility to be adapted to a specific energy demand application. The particle TES system establishes a uniform energy supply platform with an efficient heat exchanger and particle thermal energy reservoir integrated with renewable powers. The particle TES system can provide a wide temperature range and can have a large storage temperature difference that increases storage energy density; therefore, it can be an adaptable energy storage system integrated with renewable power to supply 24/7 heat for industry decarbonization.

concentrated solar thermal↗

DOE OSTI2018

The Effect of Flocculent, Dispersants, and Binder on Wet-laid Process for Recycled Glass Fiber/PA6 Composite

The papermaking industry has been using the wet-laid process to suspend paper pulp-derived fibers in water and drain the solution through a forming mesh. This process has recently been adopted to produce non-woven, wet-laid fiber-reinforced polymer matrix composite mats. The mats can be postmolded into different complex shapes using compression molding or related processes. The objective of this study was to produce composite panels from wet-laid mats and observe the effect of chemicals used during the process on the mechanical and thermal characteristics of the resulting composite. Two sets of mats were processed using recycled glass fiber with Polyamide 6 (PA6). Flocculent, dispersant and binder (poly(vinyl alcohol) (PVOH)) were added to one of the mats, and the second mat was processed without these chemicals. The addition of these chemicals enhanced the fiber distribution and reduced processing defects in the mats. This was reflected in the mechanical properties of the final product. It was noticed that the flocculent, dispersant and binder volatilized during the compression molding step. Furthermore, the additives were found not to affect the thermal properties of the consolidated part.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Narrow-Band Least-Squares Infrasound Array Processing

Infrasound data from arrays can be used to detect, locate, and quantify a variety of natural and anthropogenic sources from local to remote distances. However, many array processing methods use a single broad frequency range to process the data, which can lead to signals of interest being missed due to the choice of frequency limits or simultaneous clutter sources. In this work, we introduce a new open-source Python code that processes infrasound array data in multiple sequential narrow frequency bands using the least-squares approach. We test our algorithm on a few examples of natural sources (volcanic eruptions, mass movements, and bolides) for a variety of array configurations. Our method reduces the need to choose frequency limits for processing, which may result in missed signals, and it is parallelized to decrease the computational burden. Improvements of our narrow-band least-squares algorithm over broad-band least-squares processing include the ability to distinguish between multiple simultaneous sources if distinct in their frequency content (e.g., microbarom or surf vs. volcanic eruption), the ability to track changes in frequency content of a signal through time, and a decreased need to fine-tune frequency limits for processing. We incorporate a measure of planarity of the wavefield across the array (sigma tau, στ) as well as the ability to utilize the robust least trimmed squares algorithm to improve signal processing and insight into array performance. Our implementation allows for more detailed characterization of infrasound signals recorded at arrays that can improve monitoring and enhance research capabilities.

58 GEOSCIENCES↗

DOE OSTI2020

Characterization and CST Batch Contact Equilibrium Testing of Modified Tank 9H Process Supernate Samples in Support of TCCR

The Tank Closure Cesium Removal (TCCR) system uses ion exchange columns filled with crystalline silicotitanate (CST) media to process radioactive waste solutions for the removal of ¹³⁷Cs. TCCR currently focuses on dissolving Savannah River Site (SRS) radioactive tank waste (primarily sodium saltcake solids) within Tank 10H followed by at-tank ion exchange column treatment. Two supernate batches from Tank 10H have been processed through the TCCR unit and processing of a third batch is expected soon. After processing of this supernate batch, plans are to replace the CST columns and process dissolved salt solution from Tank 9H through Tank 10H and then through the new CST columns installed in the TCCR unit. The new columns are expected to contain either a media similar to an archived CST batch (IE-911) or the R9120-B CST media used in the current TCCR columns (the two materials are fundamentally the same; just different specifications, product names, and preconditioning steps). Samples of Tank 9H dissolved saltcake were received at the Savannah River National Laboratory (SRNL) and characterized. The Tank 9H supernate contained a high sodium concentration (~9.6 M Na⁺) and will require dilution to near 6 M [Na⁺] prior to processing through the TCCR unit. The cesium concentration in Tank 9H is currently significantly higher than was observed with Tank 10H. Three dilutions of the Tank 9H supernate were conducted to mimic possible dilutions that could be conducted in the tank farm prior to TCCR processing using inhibited water, sodium hydroxide, and sodium nitrate solutions. Dilution #1 was prepared by diluting the Tank 9H supernate by a factor of 1.6 with inhibited water, Dilution #2 was prepared by diluting the Tank 9H supernate by a factor of 3.7 with a mixed sodium hydroxide/sodium nitrate diluent, and Dilution #3 was prepared by also diluting by a factor of 3.7 but with sodium hydroxide only. All three dilutions have similar Na⁺ concentrations (~6 M), but Dilutions #2 and #3 contain significantly less cesium. Major and key minor components of the diluted Tank 9H supernate samples are provided in Table ES-1. Batch contact equilibrium tests were conducted with the Tank 9H dilutions and the two different CST media batches being considered for use in the new TCCR columns. Results are summarized in Table ES-2 and compared to ZAM model predictions. The highest cesium distribution coefficient and percent removal were observed with Dilution #3. IE-911 CST (an archived CST media batch) was more effective at removing cesium than the more recently prepared R9120-B CST media, though both media samples removed >88% of the cesium and the differences may not be statistically different considering the overall uncertainty. Based on the results, maximum cesium loadings were calculated for each CST media type and Tank 9H dilution. In general, maximum cesium loadings from dilutions of this supernate batch are quite high (approaching 0.1 mmol total Cs⁺/g CST for Dilution #1). The highest calculated maximum ¹³⁷Cs loading for the Tank 9H dilutions using the ZAM model with input of the tank compositions and batch contact results was 207 Ci/kg CST (Dilution #1 with IE-911 CST). In all cases, higher maximum cesium loading values were predicted for IE-911 CST versus R9120-B, although the differences varied considerably between the dilutions. The maximum loading value for IE-911 CST with Tank 9H Dilution #1 was only 7% higher than the maximum loading for R9120-B. The maximum loading value for IE-911 CST with Dilution #3 was 24% higher than the maximum loading for R9120-B. Dilution #2 was intermediate between these values. Note that these maximum loading values are the theoretical calculated values, and actual operating conditions will cause differences. A CST binder dilution (correction) factor near 0.7 (relative to pure powder CST) was required for each batch contact test with IE-911 engineered CST using the three Tank 9H dilutions. Correction factors calculated for R9120-B CST ranged from 0.56 to 0.66 for the three dilutions. Following the batch contact tests, the CST samples were isolated from the Tank 9H solution, washed, dried, and digested in acid following established procedures. The analysis results are provided in Table ES-3. Total cesium loading values determined by CST digestion were similar to the calculated loading values based on solution analysis (Table ES-2) for all samples. In addition, the CST was observed to load calcium (R9120-B sample only), iron, strontium, lead, uranium, and plutonium after contact with the waste supernate, as has been observed previously.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Shear Assisted Processing and Extrusion (ShAPE) of Aluminum Alloy 7075, 2024, and Al-12.4TM

The most common aluminum alloys utilized in the aerospace industry are 7075 and 2024 due to their high strength-to-weight ratio compared to advanced high strength steels and other aluminum alloys. Despite excellent performance, these aluminum alloys have seen limited use outside of the aerospace industry due in part to high cost. If high-performance aluminum extrusions could be made more cost effectively by eliminating energy intensive process steps typical of conventional extrusion, then numerous opportunities exist for more widespread adoption. A key reason for the high cost of 7075 and 2024 extrusions (25-75% higher than 6061) is their slow extrusion speed. 7075 and 2024 are limited to 2 m/min and 3.5 m/min respectively, in contrast to 6061 which can be extruded at 20–80 m/min. In addition to slow speed, aluminum alloys require numerous thermal treatments throughout the extrusion process including homogenization and pre-heating prior to extrusion, and solution heat treating and artificial aging after extrusion. Each of these steps contribute to the total energy consumed during manufacturing of extruded components. This project investigates the use of ShAPE to improve extrusion speed and reduce, or even eliminate, the typical thermal treatments for high strength aluminum alloys, all while improving material performance. The overarching goal of this project was to demonstrate that Shear Assisted Processing and Extrusion (ShAPE) can manufacture high-performance aluminum alloy tubing with lower manufacturing energy and improved mechanical properties compared to conventional extrusion. Unlike conventional extrusion where the billet is rammed against a stationary die using a strictly linear motion, the ShAPE process superimposes a rotational shear force by spinning the die while the billet is plunged. Compared to conventional linear extrusion, the ShAPE process imparts significantly more strain into the feedstock material, which enables the formation of novel microstructures. These microstructures manifest an array of property and process improvements for extrusion of high-performance aluminum alloys. The following accomplishments were achieved for this project: Extrusion of 7075 at 12.2 meters/min compared to 2 meters/min for conventional extrusion; Elimination of 7075 billet homogenization (430 °C for 20 hours) which is required prior to conventional extrusion; Elimination of 7075 billet pre-heating (400 °C for 1 hour) in a separate furnace which is required prior to conventional extrusion; Achieved 7075-T6with yield strength = 595 MPa, ultimate tensile strength = 531MPa, and elongation = 17.4% for extrusions made from unhomogenized billets. Exceeds the ASTM and ASM standard, and typical industry values; Achieved 7075-T5 (i.e., no solution heat treatment) with yield strength = 588 MPa, ultimate tensile strength = 535 MPa, and elongation = 14.8% for extrusions made from homogenized billets; Extrusion of 2024 at 7.4 meters/min compared to 3.5 meters/min for conventional extrusion; Achieved 2024-T8510 yield strength = 522 MPa, ultimate strength = 510MPa, and elongation = 7.1% for extrusions made from wrought billets. Exceeds the ASTM and ASM standard, and typical industry values; Extrusion of Al-12.4TM high-performance aluminum powder directly into tubing, in a single step, which eliminates process steps typical of powder metallurgy extrusion.

36 MATERIALS SCIENCE↗

DOE OSTI2022

The Role of Process-Directing Agents on Enamel Lesion Remineralization: Fluoride Boosters

The aim of this study was to investigate the effects of two process-directing agents (polyaspartic acid and osteopontin) used in a polymer-induced liquid-precursor (PILP) process on the remineralization of bacteria-induced enamel demineralization. Enamel demineralization lesions (depths of about 180–200 µm) were created and exposed to Streptococcus mutans, cultured with a 10% sucrose solution for 21 days, and remineralized using a PILP process (pH = 7.4, 14 days) with a calcium phosphate solution containing either polyaspartic acid or osteopontin in the presence or absence of fluoride (0.5 ppm). The specimens were examined under scanning electron microscopy. The fluoride was successfully incorporated into the PILP remineralization process for both polyaspartic acid and osteopontin. When the fluoride was added to the PILP remineralization solution, there was more uniform remineralization throughout the lesion than with either polyaspartic acid or osteopontin alone. However, in the absence of these process-directing agents, fluoride alone showed less remineralization with the formation of a predominantly surface-only layer. The PILP remineralization process relies on the ability of process-directing agents to stabilize calcium phosphate ions and holds promise for enamel lesion remineralization, and these agents, in the presence of fluoride, seem to play an important role as a booster or supplement in the continuation of remineralization by reducing the mineral gains at the surface layer.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Selecting Post-Processing Schemes for Accurate Detection of Small Objects in Low-Resolution Wide-Area Aerial Imagery

In low-resolution wide-area aerial imagery, object detection algorithms are categorized as feature extraction and machine learning approaches, where the former often requires a post-processing scheme to reduce false detections and the latter demands multi-stage learning followed by post-processing. In this paper, we present an approach on how to select post-processing schemes for aerial object detection. We evaluated combinations of each of ten vehicle detection algorithms with any of seven post-processing schemes, where the best three schemes for each algorithm were determined using average F-score metric. The performance improvement is quantified using basic information retrieval metrics as well as the classification of events, activities and relationships (CLEAR) metrics. We also implemented a two-stage learning algorithm using a hundred-layer densely connected convolutional neural network for small object detection and evaluated its degree of improvement when combined with the various post-processing schemes. The highest average F-scores after post-processing are 0.902, 0.704 and 0.891 for the Tucson, Phoenix and online VEDAI datasets, respectively. The combined results prove that our enhanced three-stage post-processing scheme achieves a mean average precision (mAP) of 63.9% for feature extraction methods and 82.8% for the machine learning approach.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Gamma Rays as a Signature of r -process Producing Supernovae: Remnants and Future Galactic Explosions

We consider the question of whether core-collapse supernovae (CCSNe) can produce rapid neutron capture process (r-process) elements and how future MeV gamma-ray observations could address this. Rare types of CCSNe characterized by substantial magnetic fields and rotation, known as magnetorotational supernovae (MR-SNe), are theoretically predicted to produce these elements, although direct observational evidence is lacking. We suggest that this critical question be addressed through the study of some of the 11 CCSN remnants located within 10 kpc, as well as through the detection of gamma-ray emission from a future Galactic supernova. We use a two-dimensional MR-SN model to estimate the expected gamma flux stemming from nuclear decays in the range of a few tens of keV to a few MeV. Our results indicate that an observation of 126 Sn ( 126 Sb) in a remnant stands out as a signature of an r-process-producing supernova. Since the neutron-rich conditions that lead to the production of the r-process could also enhance the production of 60 Fe, the detection of substantial 60 Fe ( 60 Co) would be indicative of favorable conditions for the r-process. In the case of a future supernova explosion, when the evolution of the spectrum is studied over 10 days to a few years, a rich picture emerges. At various epochs, the second peak r-process isotopes such as 125 Sn, 131 I, 132 Te, 132 I, and 140 La produce signals that are not obscured by the gamma emission from explosive burning products and electron–positron annihilation. The weak r-process isotopes 95 Nb, 103 Ru, and 106 Rh also have periods of prominence.

Gamma-rays↗

NASA NTRSDate not supplied

High Temperature Material Property Data and Challenges to Thermal Process Model Predictions and In-Situ/Ex-Situ Measurements for Metallic Additive Manufacturing

Understanding and predicting performance properties of parts produced by metallic additive manufacturing has improved significantly over the past decade; however, difficult to measure material properties and process outcomes continue to be challenges. The qualification or certification of aerospace parts require extensive measures to quantify variable part properties in order to buy down the risk of component failure. The variability, inherent to the additive manufacturing, process adds unwanted uncertainty in the production of load critical structural components. Process modeling has proven valuable in providing predictions and context for understanding outcomes of the additive manufacturing process; however, these physically informed process models require material properties at temperatures that are difficult to measure and rarely available. Further, calibrating or validating such models is difficult because the process itself is challenging to measure. This talk will explore some of the challenges resulting from difficult to acquire input data by relating thermal process model predictions to in-situ and ex-situ optical microscopy measurements.

Process Model↗

NASA NTRSDate not supplied

Navigation Doppler Lidar Signal Processing Architecture and Algorithms

A coherent Doppler lidar has been developed to address the need for a high-performance, compact, and cost-effective velocity and altitude sensor onboard landing vehicles. One of the core subsystems within NDL is its signal processing architecture. The primary function of this subsystem is to digitize the analog output of the homodyned signal received from the photo-diode associated with each telescope, process this signal in the frequency domain, and then turn this information into velocity and range measurements. A secondary function of this subsystem is to setup and control the internal components within NDL and to enable the instrument to interface with external systems by receiving commands, sending telemetry, and synchronizing its measurements with external clocks and pulses. This paper will give an overview of the signal processing architecture within NDL. This will include a discussion on its fundamental processing components and the core signal processing algorithms. Command, telemetry and internal component controls will also be discussed as will how the signal processing architecture has also evolved over the years of development. We will discuss provisions for robust operation including Triple-Mode Redundancy (TMR) within NDL’s Field Programmable Gate Array (FPGA) and storage elements, a fault-tolerant boot process, and Error Detection and Correction (EDAC) on the Static Random-Access Memories (SRAMs). Finally, we conclude this paper with how this architecture could continue to evolve.

Doppler Lidar↗

DOE OSTI2018

Air Pollutant Emissions and Regulatory Implications of a Biorefinery Co-Processing Bio-Oil in a Petroleum Refinery: Preprint

Pyrolysis oil, often referred to as bio-oil when derived from biomass through a fast pyrolysis process, has attracted considerable attention because of the high carbonaceous matter and high heating value compared to the original biomass. Pyrolysis oil provides a viable link between the agriculture/forestry and (petro-) chemical industry. Utilizing existing fossil fuel infrastructure by introducing bio-oil in petroleum refineries to produce renewable hydrocarbon fuels (i.e., repurposing existing assets) is appealing due to its relatively low capital requirement. Our analysis examined the air pollutant emissions for a biorefinery utilizing an ex situ catalytic fast pyrolysis process to produce raw bio-oil, with a design capacity of 2,000 dry metric tons of biomass per day. Such a biorefinery is capable of providing sufficient bio-oil to a 4,200 barrels per day capacity of fluidized catalytic cracking unit if the bio-oil is co-processed at 5% (by volume) feed rate. This research is focused on understanding the potential air pollutant regulatory and permitting implications for a refinery co-processing 5% bio-oil with 95% vacuum gas oil in a fluidized catalytic cracking unit for two scenarios: the first case assumes that an ex situ biorefinery is collocated with a petroleum refinery, and the second one assumes that a petroleum refinery will receive bio-oil from a stand-alone biorefinery. We estimated the potential-to-emit values for 4 biorefinery and FCC sizes and assessed technically feasible emission control options that could help to avoid being subject to prevention of significant deterioration requirements due to petroleum refinery modifications to co-process bio-oil. This research fills gaps and overcomes barriers related to air permitting requirements for co-processing bio-oil in existing refineries for various stakeholders. The insights gained from this analysis can facilitate decision making and help expedite permitting processes for petroleum refineries, which seek opportunities to produce lower carbon fuels in their existing infrastructure.

09 BIOMASS FUELS↗

DOE OSTI2019

Air Pollutant Emissions and Regulatory Implications of a Biorefinery Co-Processing Bio-Oil in a Petroleum Refinery

09 BIOMASS FUELS↗

DOE OSTI2019

Development of New Antifoam for High Level Waste Processing in DWPF

During processing in the Defense Waste Processing Facility (DWPF), the evaporation of sludge leads to large amounts of foaming. This foaming can cause a foam-over, which contaminates other parts of the facility, most importantly the condensate. Currently, the antifoam being used is not sufficient at more extreme pH values and relatively high concentrations are required to minimize foaming. This means that a foam-over is more likely in parts of the process where the pH moves away from the neutral point and antifoam is needed in large quantities to prevent such occurrences. Adding this antifoam can also double processing time. The current antifoam also degrades into flammable byproducts, which creates a hazard in the processing. There are two main ideas proposed in order to solve the problems with the current antifoam: A new antifoam; A mechanical solution (sprays, agitator, etc). The focus of this summer was to develop a new antifoam that works across a broader range of pH values, can be added in lower concentrations, and does not degrade into flammable byproducts. This solution was pursued by obtaining different superspreaders and antifoams from companies across the country in order to perform a series of tests on them; these tests include superspreader testing, Foamscan testing, boiling testing, and Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME) process testing. To begin testing, four different superspreaders were tested on their ability to spread. The four superspreaders include: Y-17112, Y-17309, Antifoam 747 (the old antifoam), and Silwet L77 (the main component in Antifoam 747). These superspreaders were tested across a range of pH values and concentrations from 100 ppm to 5000 ppm. After completion of the tests, the results indicated that Y-17112 spread across a wider pH range than the others, even at lower concentrations. This is ideal for developing a new antifoam, as the pH throughout processing in DWPF varies and the lower the necessary concentration, the less antifoam that must be added per cycle. In order to test whether or not the superspreaders work as an antifoam, they have to be tested on real foam. In order to test this, a foamy simulant similar to the foaminess of the sludge in DWPF needed to be developed. This required testing many different sludges and designing our own simulant with different concentrations of insoluble solids. Eventually, a simulant similar enough to what is seen in DWPF was identified. Each superspreader will be tested on the simulant at different pH values and at different concentrations. The simulant will be allowed to foam and small amounts of the superspreader will be added while the Foamscan software tracks the height of the foam column; this allows us to know if the superspreader decreased the foam or not. Next, boiling testing in the Foamscan will be completed. This is testing identical to the Foamscan testing at room temperature, only at boiling conditions similar to DWPF. After boiling testing, the superspreader that is deemed most successful will be tested in a real, scaled-down SRAT/SME cycle. This will ensure it works with all the real chemicals that are added in DWPF and that it will remain successful in all the conditions that it may face. After the SRAT/SME testing, a decision will be made on whether or not the superspreader is successful and it may or may not be chosen as the new antifoam for DWPF.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Qualification of Processing Batches for Tank Closure Cesium Removal Through In-Tank Batch Contact Testing - 20470

The Tank Closure Cesium Removal (TCCR) process at the Savannah River Site (SRS) is currently processing waste from Tank 10H, generating decontaminated salt solution that is sent to Tank 11H. Transfers out of Tank 11H are then disposed of on site as a grout wasteform in the SRS Saltstone Processing Facility. This is a full-scale demonstration of the use of Crystalline Silicotitanate (CST) for the decontamination of aqueous nuclear waste supernate. CST primarily removes cesium from the high sodium alkaline feed, but also adsorbs strontium, actinides, and some other trace metals. The TCCR unit is an at-tank set of four ion exchange columns, with two typically being operated in series during waste processing. Tank 10H is serving a dual function as both the salt dissolution tank as well as the feed tank for the TCCR system. Prior to operation of TCCR, Tank 10H must undergo dissolution campaigns, dissolving the salt cake to form an aqueous salt solution (supernate). After each dissolution campaign, the supernate created must be qualified prior to processing through the TCCR system. Qualification includes detailed characterization of the supernate as well as in-tank batch contact tests to determine the equilibrium loading of Cs-137 on the CST ion exchange media (IONSIV{sup TM} R9120-Ba). In support of the in-tank batch contact testing, Savannah River National Laboratory (SRNL) developed a CST sample holder, also referred to as a 'tea-bag', to hold a measured amount (∼0.1 grams) of pretreated CST between stainless steel screens. The tea-bag fits within a standard stainless steel sample vial that has been modified to allow the flow of supernate to the CST. This sample holder is then immersed in the waste tank allowing free contact between the CST beads and the surrounding liquid, at an effectively infinite liquid-to-solid phase ratio. A pair of tea-bags are deployed in the tank for a period of 10 days for each batch, after which the CST is recovered, digested, and analyzed to determine the loading of cesium isotopes on the CST. This result then supports the TCCR column thermal loading limits for processing as part of the TCCR safety basis. This paper will discuss the design and testing of the CST sample holder, as well as results from the first few batches of waste qualified and subsequently processed through the TCCR system. In addition, results from analyses of Tank 11H samples, showing decontamination of the product will be included. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Impacts of processing decisions on TNSL cross sections and their applications

Thermal neutron scattering law (TNSL) data describe low-energy neutrons scattering off of bound materials, and can have a significant impact on modeling any system with slow neutrons, including nuclear reactors. Previous work to introduce TNSL data to neutron transport codes at LLNL focused on COG and TART, with the limitation that these codes require highly specialized data processing and formatting. We have recently increased efforts to process TNSL data with the LLNL nuclear data processing code FUDGE. FUDGE reads and writes the evaluated and processed files using the generalized nuclear database structure (GNDS). This process uncovered some significant difficulties in processing TNSL data, and unearthed assumptions made in current TNSL data processing that we have found inadequate. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Digitalization mapping and assessment process supporting ION strategic transformation activities

The existing fleet of commercial nuclear power plants (NPPs) are an important asset in the nation’s portfolio of electrical generating resources. Their continued safe and reliable operation are critical to providing a large source of carbon-free electricity to power the nation’s economy. The United States Department of Energy’s (DOE) Light Water Reactor Sustainability (LWRS) Program develops the scientific bases, methods, and tools, for the continued safe and economical operation of the nation's commercial NPPs. The Plant Modernization Pathway within LWRS Program focuses on providing guidance to industry on the full-scale implementation of modernization solutions for NPPs that significantly reduce the technical and financial risks associated with modernization. This research is focused on helping the nuclear industry understand how to digitize and digitalize their NPPs so that they can design their modernization solutions to be scalable, sustainable, and integrated both laterally and horizontally within their organization. That is, this research creates a digital transformation in NPPs by reshaping cultural mindsets and by identifying business efficiencies. In partnership with industry, and using four previously established guiding principles for digitalization, this research supported NPP modernization through assessing readiness for digitalization as a means to achieve integrated operations for nuclear. Specifically, this research created an assessment to review an entire organization’s work processes to gather information about the digitalization health of the plant. The assessment tools were administered to plant employees, and the results were used to develop a digitalization plan. The survey assessment identified the optimal candidate processes that would most benefit from a digitalization initiative which were revealed through analytical frameworks. One analysis calculated mean digitalization health indicator scores for all endorsed activities which allowed the researchers to rank and color code the results for easy identification. Individual health indicator scores are also provided, should our industry partner wish to understand these findings according to their own organizational priorities, business considerations and desired end-state. The results were also analyzed from the perspective that organizations are comprised of different types of innovators (e.g., generators, optimizers, conceptualizers, and implementers), which differentially affects the organization’s ability to comprehend and adapt to change (i.e., opportunities to innovate). Understanding the relative composition of innovator types at an NPP allows them to gather insights into the strengths and weaknesses they have in innovating how work is performed. For the utility that partnered with this research team, the results showed that implementers make up the largest portion of respondents and conceptualizers the smallest portion. Knowing the proportion of innovator types gave this organization insights on how they can effectively implement their innovation solutions. Additionally, the results were analyzed from a technical, economic, and risk perspective to identify and quantify work reduction opportunities (WROs). Recognizing that not all cost-saving opportunities are the same, a Technical, Economic and Risk Assessment (TERA) was performed to evaluate WROs to identify areas of greatest potential and lowest risk. The key results from TERA included a digitalization opportunity score for each activity, and a calculation of potential cost savings. These two outputs formed the bases for calculating a priority index and rank for the activities/processes assessed. From the prioritization calculations, TERA can then help the utility 1) decide what digitalization priorities to invest money in implementing and then 2) calculates how much should be invested in the digitalization initiatives selected to achieve cost savings and/or an acceptable return on investment. Last, onsite interviews revealed several inefficiencies in the standard work processes that occur cross-departmentally that are due to the absence of digitized and digitalized processes. Examples of these include time spent scanning paper documents and then uploading the documents electronically, obtaining signatures, and searching for desired information. This represents a digital but not digitalized process. Over 15 opportunities to improve work processes were identified through this multi-method digitalization assessment. The various analytical assessments used (e.g., TERA, digitalization health indicator scores), as well as discussions with the utility partner, corroborated that all the opportunities identified had a strong potential to make work processes more efficient and to improve overall performance of the NPP.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Temperature‐Dependent Aggregation Donor Polymers Enable Highly Efficient Sequentially Processed Organic Photovoltaics Without the Need of Orthogonal Solvents

Abstract The conventional method to prepare bulk‐heterojunction organic photovoltaics (OPVs) is a one‐step method from the blend solution of donor and acceptor materials, known as blend‐casting (BC). Recently, an alternative method was demonstrated to achieve high efficiencies (13%) comparable to state‐of‐the‐art BC devices. This two‐step‐coating method, known as “sequential processing,” (SqP) involves sequential deposition of the donor and then the acceptor from two orthogonal solvents. However, the requirement of orthogonal solvents to process the donor and acceptor constrains the choice of materials and processing solvents. In this paper, an improved version of SqP method without the need for using orthogonal solvents is reported. The success is based on donor polymers with strong temperature‐dependent aggregation properties whose solution can be processed at a high temperature, but the resulting film becomes completely insoluble at room temperature, which allows for the processing of overlying acceptors from a wide range of nonorthogonal solvents. With this approach, efficient SqP OPVs is demonstrated based on a range of donor/acceptor materials and processing solvents, and, in every single case, SqP OPVs can outperform their BC counterparts. The results broaden the solvent choices and open a much larger window to optimize the processing parameters of SqP method.

Arunagiri, Lingeswaran↗

DOE OSTI2023

Introducing a Phenyl End Group in the Inner Side Chains of A‐DA'D‐A Acceptors Enables High‐Efficiency Organic Solar Cells Processed with Nonhalogenated Solvent

Abstract Power conversion efficiency (PCE) of organic solar cells (OSCs) processed by nonhalogenated solvents is unsatisfactory due to the unfavorable morphology. Herein, two new small molecule acceptors (SMAs) Y6‐Ph and L8‐Ph are synthesized by introducing a phenyl end group in the inner side chains of the SMAs of Y6 and L8‐BO, respectively, for overcoming the excessive aggregation of SMAs in the long‐time film forming processed by nonhalogenated solvents. First, the effect of the film forming time on the aggregation property and photovoltaic performance of Y6, L8‐BO, Y6‐Ph, and L8‐Ph is studied by using the commonly used solvents: chloroform (CF) (rapid film forming process) and chlorobenzene (CB) (slow film forming process). It is found that Y6‐ and L8‐BO‐based OSCs exhibit a dramatic drop in PCE from CF‐ to CB‐processed devices owing to the large phase separation, while the Y6‐Ph and L8‐Ph based OSCs show obviously increased PCEs Furthermore, L8‐Ph‐based OSCs processed by nonhalogenated solvento‐xylene (o‐XY) achieved a high PCE of 18.40% with an FF of 80.11%. The results indicate that introducing a phenyl end group in the inner side chains is an effective strategy to modulate the morphology and improve the photovoltaic performance of the OSCs processed by nonhalogenated solvents.

Chemistry↗