SEARCH · Engineering Papers

Results for “ENCAPSULATION”

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.

SourceResearch connectionFrom yearThrough year

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

At least 937 records · Page 52

All sources NASA NTRS DOE OSTI

NASA NTRS2005

An Improved Thermal Conductivity Polyurethane Composite for a Space Borne 20KV Power Supply

This effort was designed to find a way to reduce the temperature rise of critical components of a 20KV High Voltage Power Supply (HVPS) by improving the overall thermal conductivity of the encapsulated modules. Three strategies were evaluated by developing complete procedures, preparing samples, and performing tests. The three strategies were: 1. Improve the thermal conductivity of the polyurethane encapsulant through the addition of thermally conductive powder while minimizing impact on other characteristics of the encapsulant. 2. Improve the thermal conductivity of the polyurethane encapsulated assembly by the addition of a slab of thermally conductive, electrically insulating material, which is to act as a heat spreader. 3. Employ a more thermally conductive substrate (Al203) with the existing encapsulation scheme. The materials were chosen based on the following criteria: high dielectric breakdown strength; high thermal conductivity, ease of manufacturing, high compliance, and other standard space qualified materials properties (low out-gassing, etc.). An optimized cure was determined by a statistical design of experiments for both filled and unfilled materials. The materials were characterized for the desired properties and a complete process was developed and tested. The thermal performance was substantially improved and the strategies may be used for space flight.

Pb free↗

NASA NTRS2011

Zero-Copy Objects System

Zero-Copy Objects System software enables application data to be encapsulated in layers of communication protocol without being copied. Indirect referencing enables application source data, either in memory or in a file, to be encapsulated in place within an unlimited number of protocol headers and/or trailers. Zero-copy objects (ZCOs) are abstract data access representations designed to minimize I/O (input/output) in the encapsulation of application source data within one or more layers of communication protocol structure. They are constructed within the heap space of a Simple Data Recorder (SDR) data store to which all participating layers of the stack must have access. Each ZCO contains general information enabling access to the core source data object (an item of application data), together with (a) a linked list of zero or more specific extents that reference portions of this source data object, and (b) linked lists of protocol header and trailer capsules. The concatenation of the headers (in ascending stack sequence), the source data object extents, and the trailers (in descending stack sequence) constitute the transmitted data object constructed from the ZCO. This scheme enables a source data object to be encapsulated in a succession of protocol layers without ever having to be copied from a buffer at one layer of the protocol stack to an encapsulating buffer at a lower layer of the stack. For large source data objects, the savings in copy time and reduction in memory consumption may be considerable.

Burleigh, Scott C.↗

NASA NTRS2016

Corrosion-Activated Micro-Containers for Environmentally Friendly Corrosion Protective Coatings

This work concerns the development of environmentally friendly encapsulation technology, specifically designed to incorporate corrosion indicators, inhibitors, and self-healing agents into a coating, in such a way that the delivery of the indicators and inhibitors is triggered by the corrosion process, and the delivery of self-healing agents is triggered by mechanical damage to the coating. Encapsulation of the active corrosion control ingredients allows the incorporation of desired autonomous corrosion control functions such as: early corrosion detection, hidden corrosion detection, corrosion inhibition, and self-healing of mechanical damage into a coating. The technology offers the versatility needed to include one or several corrosion control functions into the same coating.The development of the encapsulation technology has progressed from the initial proof-of-concept work, in which a corrosion indicator was encapsulated into an oil-core (hydrophobic) microcapsule and shown to be delivered autonomously, under simulated corrosion conditions, to a sophisticated portfolio of micro carriers (organic, inorganic, and hybrid) that can be used to deliver a wide range of active corrosion ingredients at a rate that can be adjusted to offer immediate as well as long-term corrosion control. The micro carriers have been incorporated into different coating formulas to test and optimize the autonomous corrosion detection, inhibition, and self-healing functions of the coatings. This paper provides an overview of progress made to date and highlights recent technical developments, such as improved corrosion detection sensitivity, inhibitor test results in various types of coatings, and highly effective self-healing coatings based on green chemistry. The NASA Kennedy Space Centers Corrosion Technology Lab at the Kennedy Space Center in Florida, U.S.A. has been developing multifunctional smart coatings based on the microencapsulation of environmentally friendly corrosion indicators, inhibitors and self-healing agents. This allows the incorporation of autonomous corrosion control functionalities, such as corrosion detection and inhibition as well as the self-healing of mechanical damage, into coatings. This paper presents technical details on the characterization of inhibitor-containing particles and their corrosion inhibitive effects using electrochemical and mass loss methods.Three organic environmentally friendly corrosion inhibitors were encapsulated in organic microparticles that are compatible with desired coatings. The release of the inhibitors from the microparticles in basic solution was studied. Fast release, for immediate corrosion protection, as well as long-term release for continued protection, was observed.The inhibition efficacy of the inhibitors, incorporated directly and in microparticles, on carbon steel was evaluated. Polarization curves and mass loss measurements showed that, in the case of 2MBT, its corrosion inhibition effectiveness was greater when it was delivered from microparticles.

Corrosion Control↗

NASA NTRS2021

Modular Composite Damage Detection System (MCDDS)

The 2020 CIF funded Modular Composite Damage Detection System (MCDDS) aims to advance the technology of damage detection in composites in the areas of thin, flexible damage detection panel construction, encapsulation techniques in composite matrixes, innovative integration and interfacing techniques with flexible embedded sensory panels, repair methods of composite materials, and improved packaging of the MCDDS. Custom thin, flexible polyimide printed circuit boards (PCBs) were designed and procured for fabrication of test specimens. A custom interface PCB was designed and fabricated to monitor the newly developed damage detection test specimens. Test specimens were fabricated using the novel flexible circuitry that were either fully or partially encapsulated. The fully encapsulated specimens were used to demonstrate embedded damage detection concepts and the partially encapsulated specimens were used to demonstrate surface-mounted (laminate) damage detection concepts. The new composite damage detection test specimens were tested and evaluated to determine if the novel damage detection sensory panels could withstand low-cycle threshold fatigue loading per a modified version of American Society for Testing and Materials (ASTM) D 7264 for up to 50 cycles without void formation. The data for multiple sensory panels indicates that the newly fabricated sensory panels are robust and do indeed withstand three-point bend flexural loading for more than 50 cycles. Additionally, testing was performed to determine if damage could be detected in damage detection test specimens subjected to failure using a 3-point bend test per a modified version of ASTM D 7264. Again, multiple sensory panels (both fully and partially encapsulated) showed the ability to detect damage to specimens subjected to failure per a modified version of ASTM D 7264. Additionally, a novel concept for tracking and monitoring of cracking (and potentially delamination) in composites was designed and developed that utilizes painted-on conductors.

Christopher Forney↗

DOE OSTI2018

Photovoltaic module and laminate

A photovoltaic module is disclosed. The photovoltaic module has a first side directed toward the sun during normal operation and a second, lower side. The photovoltaic module comprises a perimeter frame and a photovoltaic laminate at least partially enclosed by and supported by the perimeter frame. The photovoltaic laminate comprises a transparent cover layer positioned toward the first side of the photovoltaic module, an upper encapsulant layer beneath and adhering to the cover layer, a plurality of photovoltaic solar cells beneath the upper encapsulant layer, the photovoltaic solar cells electrically interconnected, a lower encapsulant layer beneath the plurality of photovoltaic solar cells, the upper and lower encapsulant layers enclosing the plurality of photovoltaic solar cells, and a homogenous rear environmental protection layer, the rear environmental protection layer adhering to the lower encapsulant layer, the rear environmental protection layer exposed to the ambient environment on the second side of the photovoltaic module.

14 SOLAR ENERGY↗

DOE OSTI2021

Solar mirrors and methods of making solar mirrors having improved properties

A solar reflective mirror includes a parting film between solar reflecting sublayers to improve optics and stability of the solar mirror. The coating stack of the solar reflector mirror is encapsulated to increase the useable life of the solar mirror, and to eliminate the need for a permanent protection overcoat. Omission of the PPO film which is electrically non-conductive makes the coating stack electrically conductive eliminating the need for a two layer encapsulant when the encapsulant is e-coated.Another feature of the invention is applying the base coat of the encapsulant over the marginal edges of the PPO film leaving a center section without coverage and adding the top coating of the encapsulant over the base coat and the uncoated area.

Medwick, Paul A.↗

DOE OSTI2013

Evaluation of moisture ingress from the perimeter of photovoltaic modules: Evaluation of moisture ingress

Many thin film photovoltaic (PV) technologies can be sensitive to corrosion induced by the presence of water vapor in the packaging materials. Typically impermeable front and backsheets are used in conjunction with an edge-seal around the perimeter to prevent water vapor ingress. These edge-seal materials are often made of a polyisobutylene resin filled with desiccant, which dramatically increases the time for moisture to reach sensitive module components. While edge-seals can prevent moisture ingress, even the lowest diffusivity transparent encapsulant materials are insufficient for the lifetime of a module. To evaluate the performance of edge-seal and encapsulant materials in a manner that simulates their function in a PV module, an optical method was devised where ingress is detected by reaction of a Ca film with water. Using this method, we have exposed test samples to heat and humidity allowing quantitative comparison of different edge-seal and encapsulant materials. Next, we use measurements of polymer diffusivity and solubility to evaluate the ability to model this moisture ingress. Here, we find good agreement between these two methods highlighting the much greater ability of polyisobutylene materials to keep moisture out as compared with typical encapsulant materials used in the PV industry.

14 SOLAR ENERGY↗

DOE OSTI2017

From cells to laminate: probing and modeling residual stress evolution in thin silicon photovoltaic modules using synchrotron X-ray micro-diffraction experiments and finite element simulations

Fracture of silicon crystalline solar cells has recently been observed in increasing percentages especially in solar photovoltaic (PV) modules involving thinner silicon solar cells (<200 μm). Many failures due to fracture have been reported from the field because of environmental loading (snow, wind, etc.) as well as mishandling of the solar PV modules (during installation, maintenance, etc.). However, a significantly higher number of failures have also been reported during module encapsulation (lamination) indicating high residual stress in the modules and thus more prone to cell cracking. Here in this paper we report through the use of synchrotron X-ray submicron diffraction coupled with physics-based finite element modeling, the complete residual stress evolution in mono-crystalline silicon solar cells during PV module integration process. For the first time, we unravel the reason for the high stress and cracking of silicon cells near soldered inter-connects. Our experiments revealed a significant increase of residual stress in the silicon cell near the solder joint after lamination. Moreover, our finite element simulations show that this increase of stress during lamination is a result of highly localized bending of the cell near the soldered inter-connects. Further, the synchrotron X-ray submicron diffraction has proven to be a very effective way to quantitatively probe mechanical stress in encapsulated silicon solar cells. Thus, this technique has ultimately enabled these findings leading to the enlightening of the role of soldering and encapsulation processes on the cell residual stress. This model can be further used to suggest methodologies that could lead to lower stress in encapsulated silicon solar cells, which are the subjects of our continued investigations.

14 SOLAR ENERGY↗

DOE OSTI2018

Biodegradable Polymer Composites as Coating Materials for Granular Fertilizers

The composites consisting of poly(vinyl alcohol), horn meal, rapeseed cake, glycerol and phosphogypsum were proposed for the encapsulation of mineral fertilizers. Poly(vinyl alcohol) was used as a binder. The other components making ca. 70% of the mass of the composites were waste materials or by-products. They contain phosphorus, nitrogen, calcium, potassium and sulphur, which are useful nutrients for plants. The effect of the amount of glycerol and of the composition of the mixture of the fillers on the mechanical, sorption properties, water vapour permeability, solubility in water, dimensional stability of the composite films was studied. The addition of phosphogypsum and increase of the concentration of glycerol in the composites lead to the decrease of the tensile strength, water vapour permeability and to the increase of elongation at break and of the solubility of the composite films in water. The composites prepared were used for encapsulation of fertilizers. It was established that encapsulation resulted in the increase of the time of release of the fertilizers. In addition, encapsulation improved mechanical properties of the fertilizers. The fertilizer granules were coated with composite films and tested in the cultivation of tomato sprouts. They showed considerable positive effect on the development of the roots of the plants.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

CO 2 Capture with Capsules of Ionic Liquid/Amines

Carbon capture remains an urgent issue that has gained a great deal of attention over the past few decades. Aqueous amines have excellent selectivity, but present corrosion and volatility issues, whereas ionic liquids (ILs) have negligible volatility and tunable physical properties, but high viscosities. One approach to improve the practical performance of these liquids is encapsulating them in a CO 2 permeable polymer shell to enhance the accessibility of the liquid and the CO 2 absorption rate. In this work, we report the encapsulation of a mixture of amine and IL (i.e., monoethanolamine (MEA) and 1-butyl-3-methylimidazolium tetrafluoroborate ([BMIM][BF 4 ])) and demonstrate enhanced carbon capture performance. A soft-template approach and interfacial polymerization are used to give capsules with liquid core (64 wt %) and polyurea shell. Compared to the bulk liquid, the encapsulated liquid shows improved thermal stability over cycles of absorption at 25 °C, and desorption at 75 °C. The capsules with core of [BMIM][BF 4 ]-MEA show 0.2 mol CO 2 /kg of capsules at 1 bar CO 2 , compared to the bulk liquid, which has 0.05 mol CO 2 /kg of sorbent. This is attributed to the limited evaporation of the amines. Alternatively, the same capsules but with 5 wt % of piperazine (Pz) in the core have doubled gravimetric CO 2 capacity of the capsules (0.4 mol CO 2 /kg of capsules); performance is evaluated over 10 capture–release cycles showing minimal mass loss. Characterization of the CO 2 uptake of the polymer shell itself reveals that the shell contributes only ~10% of the observed capacity, likely attributed to amine functionalities of the polymer. Here, this facile approach to encapsulating such “active” liquids can be applied to other CO 2 selective solvents that are volatile, viscous, and corrosive.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Nanoscopic Titanium Dioxide Overlayers Improve the Durability of Porphyrin Molecular Electrocatalysts while Maintaining Molecular Structure and Redox Activity

Molecular catalysts, such as metalated porphyrins, are attractive cocatalysts for photocatalytic water splitting owing to their potential to simultaneously catalyze target reactions at their metal center, extend charge-separated-state lifetimes, and accumulate the requisite charge for product formation. However, porphyrin catalysts, like most molecular catalysts, are often limited by poor stability associated with demetalation, inactivation by undesired bonding (e.g., O2 coordination/redox/dimerization), and detachment from electrode supports or semiconducting photoabsorbers. In this study, nanoscopic titanium dioxide (TiO2) overlayers, deposited by atomic layer deposition (ALD), are demonstrated to encapsulate cobalt(III) meso-tetra(4-carboxyphenyl) porphyrin chloride (CoTCPP) molecular catalysts and thereby improve their adhesion to electrode surfaces over a wide range of electrode potentials spanning from -1.0 V vs RHE to +1.8 V vs RHE. Through analysis of Raman and ultraviolet-visible spectroscopy, it was confirmed that the metalloporphyrin structure was maintained when the surface-bound CoTCPP was encapsulated by 10 - 250 ALD cycles (~2 - 18 nm thick) of TiO2. Additional characterization of CoTCPP catalysts before and after electrochemical measurements reveals that up to 97% of the encapsulated CoTCPP remains tethered to the electrode surface after chronoamperometry tests under hydrogen evolution reaction (HER) conditions, compared to <36% for unencapsulated CoTCPP. This study also shows that encapsulated CoTCPP molecules remain partially redox active for overlayers up to 8 nm, which can also attenuate undesired redox mediator back reactions like ferricyanide reduction.

08 HYDROGEN↗

DOE OSTI2019

Nondestructive Characterization and Accelerated UV Testing of Browned Field-Aged PV Modules

Encapsulant browning is one of the most common degradation modes found in crystalline silicon field-aged photovoltaic modules. Browning, usually undetected unless severe, reduces the short-circuit current (Isc) produced by a module. Therefore, field-aged browned modules have been subjected to accelerated UV testing to obtain true end-of-life activation energy for the encapsulant browning mechanism. A novel time- and resource-saving accelerated UV exposure testing method simultaneously allowing multiple module temperatures to be maintained in a single chamber run is presented. Six field-aged crystalline silicon modules of glass/backsheet construction (three each from BP Solar/Solarex MSX 60 and Siemens M55) with similar glass and encapsulant formulation were exposed to a UV dosage of 450 kWh/m2 . Through passive heating, the average module temperatures for the BP Solar/Solarex modules were 60 degrees C, 77 degrees C, and 85 degrees C and those of Siemens M55 were 75 degrees C, 80 degrees C, and 837 degrees C. To study UV browning, the modules were intermittently characterized through visual imaging, UV fluorescence imaging, electroluminescence imaging, quantum efficiency measurements, module, and cell-level light I-V measurements. An Isc decrease corroborated the increased extent of browning with increased module temperature. For the BP Solar/Solarex modules, the Low T, Mid T, and the High T modules showed a 1.37%, 2.48%, and 3.26% Isc drop, respectively. The Siemens modules showed a 4.11%, 5.65%, and 6.95% Isc drop. The multiple cell-level Isc data points obtained for each module temperature increased provided statistical significance. Activation energy for encapsulant browning was calculated as 0.44 and 0.72 eV for MSX 60 and M55 modules, respectively.

14 SOLAR ENERGY↗

DOE OSTI2015

Influence of PEDOT:PSS on the effectiveness of barrier layers prepared by atomic layer deposition in organic light emitting diodes

Organic light emitting diodes (OLEDs) are well suited for energy saving lighting applications, especially when thinking about highly flexible and large area devices. In order to avoid the degradation of the organic components by water and oxygen, OLEDs need to be encapsulated, e.g., by a thin sheet of glass. As the device is then no longer flexible, alternative coatings are required. Atomic layer deposition (ALD) is a very promising approach in this respect. The authors studied OLEDs that were encapsulated by 100 nm Al{sub 2}O{sub 3} deposited by ALD. The authors show that this coating effectively protects the active surface area of the OLEDs from humidity. However, secondary degradation processes still occur at sharp edges of the OLED stack where the extremely thin encapsulation layer does not provide perfect coverage. Particularly, the swelling of poly(3,4-ethylenedioxythiophene) mixed with poly(styrenesulfonate), which is a popular choice for the planarization of the bottom electrode and at the same time acts as a hole injection layer, affects the effectiveness of the encapsulation layer.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Novel Transparent Phosphor Conversion Matrix with High Thermal Conductivity for Next Generation Phosphor-Converted LED-based Solid State Lighting

The low thermal conductivity of state-of-the-art polymer encapsulants (k ~ 0.15 Wm-1K-1) limits the efficiency and power density of current phosphor conversion light emitting diodes (pc-LEDs). The technical objective of this project was to demonstrate synthesis and processing schemes for the fabrication of polymer hybrid encapsulants with a thermal conductivity exceeding k = 0.4 Wm-1K-1 for LED applications. The ‘hybrid polymer’ approach encompasses the dispersion of high thermal conductivity particle fillers (zinc oxide, ZnO as well as the alpha-polymorph of alumina, Al2O3) within a polysiloxane matrix (poly(dimethylsiloxane), PDMS as well as poly(phenyl methyl siloxane), PPMS) to increase the thermal conductivity while maintaining optical transparency and photothermal stability at levels consistent with LED applications. To accomplish this goal, a novel synthesis method for the fabrication of nanosized ZnO particles was developed and a novel surface chemistry was established to modify the surface of zinc oxide particle fillers and thus to enable their dispersion in poly(dimethyl siloxane) (PDMS) matrix polymers. Molecular dynamics and Mie simulations were used to optimize ligand structure and to enable the concurrent mixing of particles in PDMS/PPMS embedding media while also minimizing the thermal boundary resistance as well as optical scattering of particle fillers. Using this approach the synthesis of PDMS/ZnO hybrid encapsulants exhibiting a thermal conductivity of 0.64 Wm-1K-1 and optical transparency > 0.7 mm-1 was demonstrated. A forming process based on micromolding was developed to demonstrate the forming of particle filled PDMS into film and lens shapes. Photothermal stability testing revealed stability of the materials for approximately 4000 min when exposed to blue light LED (450 nm, 30 W/cm2). One postgraduate and seven graduate students were supported by the project. The research performed within this project led to fifteen publications in peer-reviewed journals and one patent application. The grant stimulated a multi-investigator research collaborations among seven investigators at Carnegie Mellon University to address the challenge of encapsulants in pc-LED applications. The grant also catalyzed the future collaboration between researchers at Carnegie Mellon University and OSRAM Sylvania to address challenges associated with the use if polymers in LED applications.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Managing Low-Level Waste at Dounreay - 16269

Dounreay Site Restoration Limited (DSRL) is the site licence company responsible for the clean-up and demolition of Britain's former centre of fast reactor research and development. The Dounreay site requires facilities to dispose of up to 175,000 cubic metres of low level waste (LLW) that has been and will continue to be generated during the decommissioning and restoration of the site. In May 2014, construction of two new vaults for the disposal of LLW at Dounreay was completed, including the necessary roads, infrastructures and services, followed by an encapsulation plant in September 2014. The vaults are located immediately to the northeast of the Dounreay licensed site, on NDA-owned land. The facilities are for disposal of the solid LLW generated at Dounreay and the adjacent Vulcan site only. In 2004, following consultation with stakeholders and members of the public, Dounreay issued the 'Best Practicable Environmental Option (BPEO) Report' on the management of Dounreay LLW. This report assessed potential management options for LLW against a range of criteria, including technical, environmental, cost, health and safety issues. The study was conducted in line with best practice and involved consultation with a range of people, including the local community and organisations with an interest in radioactive waste management. The recommendations and conclusions from the study provided the basis for the 'Dounreay Solid LLW Overall Strategy', which was published in March 2005. A fundamental component of this strategy was the development of new below-ground disposal vaults for LLW at Dounreay. Siting the vaults on land at Dounreay avoids any need to transport the LLW away from Dounreay on public roads. Disposal at Dounreay therefore satisfies the proximity principle of managing the waste at source. Disposal at Dounreay is also consistent with UK Government Policy on LLW management, the Scottish Government's Radioactive Waste Management Policy and the Nuclear Decommissioning Authority's (NDA's) strategy on management of LLW from the UK nuclear industry. A planning application was initially lodged with the Highland Council in June 2006. The period for the determination of this application was extended to allow the Scottish Environment Protection Agency (SEPA) sufficient time to assess fully the supporting Environmental Safety Case (ESC). The planning application was re-activated in May 2008, and planning permission was granted by Highland Council in April 2009. The planning permission included 26 conditions on DSRL, covering a wide range of environmental issues such as construction noise/dust, traffic, visual impact and also a condition to develop a community fund aimed at socio-economic development of the area around the Dounreay site. After undertaking the necessary detailed design work, construction of the phase one vaults commenced in November 2011 by principal contractor, Graham Construction. Work was undertaken on both vaults simultaneously, excavating around 243,000 m{sup 3} of rock. When excavation was complete, steel reinforcement was placed and concrete poured to construct the floor slabs. This was followed by the construction of the reinforced walls and then the installation of the steel support structure and materials that form the roof. Mechanical and electrical installation then followed, in parallel with the construction of the vault apron, ramps and access roads. A pumping system and control building was also constructed to remove groundwater from around the vaults to allow the vaults to be kept dry while they are being filled with waste. A layer of excavated material, approximately 3 m thick, was placed across the existing ground surface between the vaults and the coast, to ensure the water table lies well below the new ground surface after closure of the vaults, and that any future trace contaminated groundwater flows out to the sea rather than to the soil zone. This layer is referred to in project documents as the 'enhanced geosphere'. After disposals are completed and the vaults are closed, this layer will be joined to the capping over the vaults so that the ensemble merges visually with the surrounding landscape. The original vegetation and soil mix will be returned as far as is practicable. An encapsulation plant has been constructed to fill the LLW containers with grout prior to disposal in the vault, similar to the process used at the national Low-Level Waste Repository facility (LLWR), near Drigg in Cumbria. The plant has the capacity to grout up to four containers per day. The grout fills voids in the container and helps provide chemical conditions in the vault that limit the release of radionuclides in the far future, after the vault has been penetrated by groundwater. On April 24 2015, active commissioning began at the Encapsulation Plant and LLW Vaults. Half-height ISO containers packed with low level waste are currently being filled with grout and disposed of in the LLW Vault. Also packaged Demolition Low Level Waste (DLLW) is being processed and disposed of in the Demolition Low Level Waste Vault. To date over 2500 packages of DLLW and 70 containers LLW have been disposed of. Completion of construction and the start of operating the Phase One vaults and encapsulation plant are fundamental to the successful and efficient decommissioning of the Dounreay site, upon which many millions of pounds of investment and hundreds of jobs rely.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Immobilization of Organic Liquid Radioactive Waste (LWR) in a Sulfur Composite Matrix at the BN-350 Fast Neutron Reactor Site, Kazakhstan - 18031

The immobilization treatment and final disposition of all forms of organic radioactive liquids, such as pump oil, spent solvent, tri-butyl-phosphate (TBP) and scintillation fluids, remain a significant challenge for nuclear waste generators and national regulators. The majority of nuclear nations have instituted regulations that require some form of encapsulation of treated organic liquid, notwithstanding LLW organic liquids that can be safely incinerated. In most cases cement is the designated material for encapsulation; however, cement can pose certain problems with the containment of treated organic liquids. In 2013, with funding from the U.S. Department of Energy - National Nuclear Security Administration through its Global Initiative for Proliferation Prevention Program (GIPP), a proven U.S. technology for the treatment of radioactive organic liquids was introduced at the BN-350 fast neutron reactor facility in Aktau, Kazakhstan. As the facility was undergoing full decommissioning, one hundred and sixty cubic meters of contaminated pump oil (including Cs-137, Sr-90 and U-235/238) contained in large above ground tanks had to be treated for final disposal. As a result of the research conducted over a two-year period, a new 2-step treatment process was invented by combining the U.S. solidification technology with a newly developed inorganic filler and molecular sulfur, referred to as radiation-resistant composite (RRC) to fully encapsulate the waste oil. The outcome of extensive test program indicates that the final form can reach up to 60 wt.% with a compressive strength of about 100 kg/cm{sup 2}. Preliminary conclusions indicate that RRC outperforms cement as an encapsulation form for final waste treatment which meets U.S. Nuclear Regulatory requirements for final disposal. This paper examines the preliminary experimental work that was conducted in Kazakhstan with the U.S. polymer technology and radioactive pump oil, and the subsequent secondary process of combining the solidified material into a homogeneous final form utilizing RRC. Topics covered in the paper include: - Kazakhstan's regulatory requirements for attaining an achievable waste form for acceptance, which led to the RRC invention; - Technical objectives for the application of polymer technology and RRC materials to radioactive liquid waste; - Polymer solidification with radioactive oil and the result; step one of the RRC process; - Description of RRC materials, their origin and chemical characteristics; - Process of combining the solidified polymer mass with RRC materials into a solid, homogeneous matrix; step two of the RRC process; - Experimental results including leaching data, waste loading estimates and heat process calculations to create the matrix; - Cost advantages of the RRC process over cementation; - Limitations of the RRC process; - Next steps to verify conformance of the RRC technology to the U.S. requirements. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Damaged Fuel Rod Service with German Turnkey Technology NCS 45 Transport Casks and Under-Water-Brazing Technology - 18182

Transportation of damaged irradiated fuel rods with the package NCS 45 developed and operated by DAHER Nuclear Technologies GmbH (DNT) saves considerable technical and financial resources in the German phase-out scenario. The technology can be used world-wide to speed up decommissioning of NPPs. In each German reactor (and most likely in all reactors in the world) a small number of damaged fuel rods have accumulated over the operation phase. In general, transport and storage solutions for fuel are concentrated on the bulk of material, i. e. complete fuel assemblies containing undamaged fuel rods. It is hence a rather straightforward process to remove almost all the fuel from the reactor pools. However, damaged fuel rods - which have to be removed from the pool prior to dismantling - can cause considerable delay in dismantling and high costs for safe-guarding and specialized solutions, even though they only contain a comparatively very tiny amount of fuel. DNT has all required tools, equipment and experience to mitigate the described problem: - The package NCS 45 licensed for the transport of damaged Uranium Oxide (UOX) and Mixed Oxide (MOX) fuel rods with a burn-up of up to 120 GWd/MgHM; - A patented underwater brazing (encapsulation) technology to render very high burn-up damaged fuel rods fit for transport; - Qualified personnel to plan, license and operate such encapsulation process and the NCS 45 in a NPP and to carry out the transports; - Proven record of successful removal of damaged fuel rods from several shut-down reactors in Germany. The package NCS 45 is currently licensed in several European countries. Due to its state-of-technique design - type B(U)F-96 approval - it could be licensed and used for world-wide applications. The underwater brazing technology was developed and patented by DNT to address the challenge of transporting high burn-up and/or damaged UOX and MOX fuel rods. Above a burn-up of 55 GWd/MgHM there are neither enough data to assess the behavior of the cladding under stress nor sufficient benchmarks available to validate the source terms of the fuel. Hence, high burn-up fuel rods are encapsulated in the fuel pool by using the underwater-brazing-technology before they are loaded into the package NCS 45. Furthermore, the capacity of the NCS 45 to transport damaged fuel rods can be considerably enhanced by encapsulating these rods. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Immobilization of Radioactive Wastes Using Geopolymers - 19483

This work explores an encapsulation and immobilization technology for spent radioactive ion exchange (IX) resins using geopolymer materials as a matrix. Geopolymer-IX resin composites with different IX resin loadings were prepared by mixing an aluminosilicate material (metakaolin), sodium hydroxide and inactive IX resin (Amberlite IRN 150) and curing the mixture at room temperature with or without γradiation applied using an external radiation source. The metakaolin and sodium hydroxide reacted to form a geopolymer framework encapsulating the IX resin beads. The IX resin loading capacity and the encapsulation efficiency of the geopolymer material were investigated by examining the morphology and distribution of resins within the geopolymer framework using optical microscopy, and by measuring the compressive strengths of the geopolymer-IX resin composites. These properties of the geopolymer-IX resin composites were compared with those of ordinary Portland cement (OPC)-IX resin composites. The geopolymer matrix allowed for a higher IX resin loading capacity than OPC. The geopolymer-IX resin composite was stable under γ-radiation for 28 d. In leaching tests performed with encapsulated Sr-loaded IX resins, the ability of the geopolymer to prevent leaching of Sr{sup 2+} into solution was greatly superior to that of OPC. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗