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In the context of lab modernization, careful consideration must be given to existing technologies, processes, and knowledge to support the ongoing production, maintenance, and improvement of products for the nuclear enterprise. This consideration often involves analyzing manufacturing processes both to pursue modernization or automation and to ensure the ability to maintain manufacturing capability.
Essential trace minerals play vital roles in maintaining human and animal health. However, an overdose of the existing inorganic trace minerals is prone to induce detrimental effects that outweigh positive benefits. In this study, an extracellular polymeric substances (EPS)-producing bacterium, identified as Bacillus licheniformis CCTCC M2020298, was isolated from marine using glutinous rice processing wastewater as enrichment medium. The EPS yield of Bacillus licheniformis CCTCC M2020298 could reach 8.62 g/L by using glutinous rice-processing wastewater containing medium. Furthermore, the potential of the EPS as a carrier for synthesizing EPS-iron (Fe) and EPS-copper (Cu) complex was explored. The results showed that the optimum condition for the synthesis EPS-Fe were the reaction temperature 70°C, pH 8.5–9.0 and mass ratio of EPS to trisodium citrate 2:1. The iron content of EPS-Fe reached 77.4 mg/g. Under the same condition, the copper content of EPS-Cu reached 90.7 mg/g. The elemental composition, functional groups and valence state of the mineral elements of EPS-Fe and EPS-Cu were well characterized. The EPS-Fe and EPS-Cu exhibited antioxidant activity in scavenging ·OH, DPPH and ·O 2− free radicals, thereby leading to reduced oxidative stress and apoptosis levels in human colonic epithelial cells in vitro . They also inhibited the proliferation of mouse hepatocellular carcinoma H22 and the growth of intestinal pathogens in vitro . This study provided an effective avenue for EPS production from glutinous rice processing wastewater and proved the potential of EPS-Fe and EPS-Cu complexes as a new-type comprehensive essential trace mineral supplement.
Current production of LiOH, which is needed to make Li-ion battery cathode active materials, utilizes a multistep process including solar evaporation, precipitation with Na 2 CO 3 and then conversion to LiOH using Ca(OH) 2 . This process requires a large amount of land area for solar evaporation, the right weather conditions, and chemicals for the conversion process that result in NaCl and CaCO 3 waste products. The production of Ca(OH) 2 is very energy intensive and evolves significant quantities of CO 2 . An alternative process flow utilizing direct lithium extraction techniques, followed by a chemical free conversion process can have benefits in reducing the needed land requirements and chemicals for traditional brine processing. There are many potential direct lithium extraction technologies that are currently being developed. The direct lithium extraction process from typical brine sources will produce a LiCl solution with some impurities including typically high concentrations of Na. This brine then needs to be converted to LiOH for use in battery cathode production. Ideally this conversion could occur without the use of additional chemicals. Electrochemistry can do this conversion either via electrolysis or bipolar membrane electrodialysis (BPED) to produce LiOH and HCl in solution. BPED utilized bipolar membranes to split water, which has a reduced potential as compared to splitting water at electrodes into hydrogen and oxygen gas. This reduced potential required results in a significant energy savings for BPED over electrolysis methods. This CRADA project aimed to develop such an integrated process using direct lithium extraction followed by BPED to produce a LiOH solution. That solution can then be crystallized into battery grade LiOH. In particular, Albemarle utilized a direct lithium extraction process to produce a concentrated LiCl solution that could be used for the BPED process. The BPED process was first tested using various LiCl solutions with impurity ions added at bench scale to understand the effects of impurities and determine processing parameters. Then testing was performed using the direct lithium extracted brine at the bench scale before scaling the process up. After the process was scaled up a long duration test was carried out to estimate the lifetime of the membranes, which is key to the economics of the BPED process.
Pyrolysis is a promising technology for converting plastic waste into valuable raw materials while offering a potential solution to the global plastic pollution crisis. In this study, the thermal pyrolysis of high-density polyethylene (HDPE) is investigated in a drop tube reactor under nearly isothermal conditions. The impact of reaction temperature and gas/volatile residence time on carbon conversion and product distribution is examined across a range of 500–900°C and 3.6–32.2s, respectively. Non-condensable gas products detected by online mass spectrometry are H 2 , CH 4 , C 2 H 4 , C 2 H 6 , C 3 H 6 , and C 3 H 8 . At elevated temperatures and prolonged residence time, H 2 yield reaches as high as 8.6 wt% of the initial HDPE mass due to intensified cracking reactions of C 2 –C 3 hydrocarbons and long-chain aliphatic compounds. Consequently, pyrolysis tars consist mainly of polycyclic aromatic hydrocarbons (PAHs) with 5–7 rings, accompanied by visible coke deposition within the reactor. HDPE decomposition to volatiles is an endothermic process and it is complete at a temperature between 492°C and 525°C, depending on the heating rate employed, from non-isothermal thermogravimetric analysis and differential scanning calorimetry (TGA-DSC) measurements. The thermal degradation of HDPE pellets follows the two-dimensional nucleation growth model for conversion levels up to 0.8 with an apparent activation energy of 259–270 kJ/mol and a pre-exponential factor of 4.83 × 10 17 –1.37 × 10 19 min -1 , determined from various isoconversional methods such as Flynn-Wall-Ozawa (FWO), Kissinger-Akahira-Sunose (KAS), and Starink, along with Criado's master plots. Further, these findings provide valuable insights into optimizing process parameters and refining reactor design for pyrolysis, which can be integrated with gasification and reforming processes to enhance hydrogen production on a larger scale.
As wind turbine blades continue to scale in length and total mass, the acceptability of traditional approaches for the engineering of processes to build these products has reached a limit. The continued need to reduce the levelized cost of energy (LCOE) drives manufacturing cycle times lower and the net mass of critical components challenges even the most experienced fabricators to meet the quality requirements for safe operating performance over the 25-year design life of the blade. In trying to reduce cycle time for key components of wind turbines, manufacturers discovered occasional buckling of fibers in wind turbine blade spar caps. The cause of the buckling was unknown. The goal of this project was to show that a comprehensive simulation, which considered all of the physics of the VARTM process, could identify the cause of the fiber buckling in spar caps that has been observed during the manufacturing process. Ultimately, the simulation determined the manufacturing process and parameters could lead to significant compressive stresses in the fibers eventually causing buckling. Simulation results suggest that the stress introduced from friction is the largest source of compressive stress in the fibers, the stress from the weight of gravity is significant but secondary, and the compressive stress from cure shrinkage does not play a significant role in the buckling of fibers. This report provides details of the testing and simulation methodology used to identify the cause of the fiber buckling.
Accurate and realistic geological modeling is the core of oil and gas development and production. In recent years, process-based methods are developed to produce highly realistic geological models by simulating the physical processes that reproduce the sedimentary events and develop the geometry. However, the complex dynamic processes are extremely expensive to simulate, making process-based models difficult to be conditioned to field data. In this work, we propose a comprehensive generative adversarial network framework as a machine-learning-assisted approach for mimicking the outputs of process-based geological models with fast generation. The main objective of our work is to obtain a continuous parametrization of the highly realistic process-based geological models which enables us to calibrate the models and condition the models to data. Numerical results are presented to illustrate the capability of our proposed methodology.
The U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) User Facility maintains a suite of advanced atmospheric radar systems that serve as critical tools in ARM’s mission to provide continuous, high-quality observations for advancing the understanding and modeling of atmospheric processes. These radar systems enable detailed characterization of clouds, precipitation, and dynamic structures in the atmosphere, supporting a broad range of scientific applications. The number of deployed systems exceeds what current staffing levels can fully support for continuous 24/7/365 operation. As such, it is essential to have a clearly defined and community-informed plan that prioritizes radar operations and communicates ARM’s strategy for sustaining and evolving these observational assets. This FY2026 Radar Plan outlines ARM’s approach to managing its radar portfolio—balancing scientific impact, operational feasibility, and long-term sustainability. It reflects ARM’s continued commitment to delivering calibrated, well-documented radar data products that enable process-level studies and support the development and evaluation of weather and climate models. Through this plan, ARM aims to ensure transparency in decision-making, alignment with user needs, and support for innovative science across the facility’s fixed and mobile observatories. Given uncertainties around the Fiscal Year (FY) 2026 budget, this plan was developed to assume business as usual and will be updated as budgets and plans may change. It should be noted that, given the limited timeframe involved, this plan will be more succinct than previous plans.
Chemical-free hydrothermal pretreatment of Miscanthus x giganteus (Mxg) at the lab scale using high liquid-to-solid ratios resulted in the recovery of anthocyanins and enhanced enzymatic digestibility of residual biomass. In this study, the process is scaled up by using a continuous hydrothermal pretreatment reactor operated at a low liquid-to-solid ratio (50 % w/w solids) as an important step towards commercialization. Anthocyanin yield was 70 % w/w at the pilot scale (50 kg of Mxg), compared to the 94 % w/w yield achieved at the lab scale (0.5 g of Mxg). The pretreated biomass was subsequently refined mechanically using a disc mill to increase the accessibility of cellulose by cellulases. Enzymatic saccharification of the pretreated and disc-milled residue yielded 238 g/L sugar concentration by operating in fed-batch mode at 50 % w/v solids content. Two strains of Rhodosporidium toruloides were evaluated for converting the hydrolysate sugars into microbial lipids, and strain Y-6987 had the highest lipid titer (11.0 g/L). Further, the residue left after enzymatic saccharification was determined to be enriched 1.7-fold in the lignin content. This lignin-rich residue has value as a feedstock for the production of sustainable aviation fuel precursors and other high-value lignin-based chemicals. Hence the proposed biorefinery based on Mxg creates an opportunity for generating revenue from multiple high-value products. As the demand for biofuels and biobased products is rising, the biorefinery products from Mxg would create a niche in the industrial sector.
The 21 st Century Power Plant Gasification Based Polygeneration power plant layout is a relatively straightforward retrofit of well-established ammonia synthesis technology to the baseline IGCC process and envisions co-production of power and chemicals from coal in the context of carbon capture. A Dual Stage Membrane Process (DSMP) for pre-combustion CO 2 capture in a coal fired IGCC power plant has been demonstrated by Media and Process Technology Inc (MPT) (DE-FE0013064) in bench-scale live gas testing at the NCCC. This work, however, highlighted the importance of permeate purge capability to deliver deep H 2 recovery at moderate pressures and high carbon capture performance. Further, in the area of warm gas processing, a permeate purgeable membrane support for a wide range of inorganic high-performance membrane materials (CMS, Pd-alloy, zeolite, ZIF, graphene, etc.) was not available and hence had been a common and significant barrier to their commercialization. Hence, the Critical Technology Gap to implementing the DSMP in the Polygeneration power plant and more broadly in advanced warm gas separation applications was the inability to permeate purge the membranes coupled with the lack of the availability of a high packing density scalable package design. To overcome this Critical Technology Gap, in this project, the primary objective was the development of a permeate purgeable full ceramic support for these high-performance inorganic membranes and the complementary high packing density housing. Our goal and approach were to extend our “candle filter” design to a “dual end open” package to enable permeate purge and scalability. Microporous ceramic membranes have been proven to be a low cost, stable material for high temperature applications under harsh environment. They are the leading support choice of researchers in advanced inorganic membrane development in applications such as pre-combustion CO 2 capture. The new 2nd Generation “dual end open” bundle developed in this project is a universal support for these existing and emerging inorganic membrane technologies that up to now have lacked a pathway out of the laboratory. The full ceramic permeate purgeable support represents a transformational technology and opens the door to commercialization of these advanced membrane materials in a wide array of mega scale commercial applications in gas (and liquid) processing under aggressive conditions not suited to conventional polymeric membranes.
The widespread adoption of networked devices, sophisticated automation, and data-driven processes in the industry - also known as Industry 4.0 - has boosted the quantity and quality of manufacturing products. With these benefits, however, comes a substantial increase in the attack surface of these systems. In addition to affecting the readiness and the quality of critical products, the attacks against manufacturing processes and systems carry the potential to have severe physical consequences, including human injury and death. In this paper we present the results of a remote network-based control injection attack on a CNC mill. Specifically, we focus on the impact of this type of the attack on the movement of CNC mill during operation. Evaluating the physical effect of these attacks on a workpiece, we provide machine agnostic, affordable, and scalable solution for their monitoring. We then demonstrate a simple threshold-based method for the detection of these attacks and evaluate the effectiveness of detection.
Document Configuration Management (DCM) is the ongoing process of identifying and managing changes to deliverables and other work products. ALDW’s Document Configuration Plan provides a systematic, standardized process for the configuration management of documents to ensure that the most current and/or appropriate documents are being used, that any canceled or superseded document is properly processed, and that both a clear history and traceability of previous revisions are available.
Marine and lacustrine carbonate minerals preserve carbon cycle information, and their stable carbon isotope values (δ 13 C) are frequently used to infer and reconstruct paleoenvironmental changes. However, multiple processes can influence the δ 13 C values of bulk carbonates, confounding the interpretation of these values in terms of conditions at the time of mineral precipitation. Co-existing carbonate forms may represent different environmental conditions, yet few studies have analyzed δ 13 C values of syndepositional carbonate grains of varying morphologies to investigate their origins. Here, we combine stable isotope analyses, metagenomics, and geochemical modeling to interpret δ 13 C values of syndepositional carbonate spherules (>500 μm) and fine-grained micrite (<63 μm) from a ~1600-year-long sediment record of a hypersaline lake located on the coral atoll of Kiritimati, Republic of Kiribati (1.9°N, 157.4°W). Petrographic, mineralogic, and stable isotope results suggest that both carbonate fractions precipitate in situ with minor diagenetic alterations. The δ 13 C values of spherules are high compared to the syndepositional micrite and cannot be explained by mineral differences or external perturbations, suggesting a role for local biological processes. We use geochemical modeling to test the hypothesis that the spherules form in the surface microbial mat during peak diurnal photosynthesis when the δ 13 C value of dissolved inorganic carbon is elevated. In contrast, we hypothesize that the micrite may precipitate more continuously in the water as well as in sub-surface, heterotrophic layers of the microbial mat. Both metagenome and geochemical model results support a critical role for photosynthesis in influencing carbonate δ 13 C values. The down-core spherule–micrite offset in δ 13 C values also aligns with total organic carbon values, suggesting that the difference in the δ13C values of spherules and micrite may be a more robust, inorganic indicator of variability in productivity and local biological processes through time than the δ 13 C values of individual carbonate forms.
Industrial separations require enormous amounts of energy, accounting for approximately half the industrial energy use and 10–15% of the total energy consumption. Distillation alone accounts for about half the energy demand for industrial separations. If these processes could be replaced by an energy-efficient membrane separation process, this energy demand could be reduced by 90%. However, although some membrane processes have made inroads into thermal distillation, for membrane-based separations to replace the distillation process to a far more significant and practical level, new membranes with higher robustness, selectivity, and flux still need be developed. In this membrane development program, we leveraged Temple University’s prior work in spiroligomers to develop robust membrane structures. These structures can be formed into atomically precise pores by controlling the chemical synthesis and the oligomer building blocks to first build precisely controlled macrocycles and then subsequently crosslinking these macrocycles to produce a membrane. Furthermore, through the highly controllable chemistry of our molecular building blocks, not only can we integrate pores with highly controllable and reproducible size and morphology, but we can also target internal functionalization. By using a range of scalable membrane synthesis approaches, combined with control of each and every pores internal chemistry and molecular conformation we can achieve membrane structures that can display the ultimate in high selectivity and permeance. The Mainstream-Temple University membranes can be designed to achieve ultra-selective separations based on the key factors of molecular size, shape, and functionality. In our approach to fabricate scalable atomically precise membranes, we used our molecular Lego nanostructures. We demonstrated an approach to create atomically precise pores within the membrane with pores that are the dimensions of the molecule we are trying to separate. Moreover, in addition to controlling the morphology of the membrane structure by controlling the size of every pore, we can also decorate every pore with precisely targeted and placed functional groups. These accurately placed functional groups can provide selective binding to molecules and provide enhanced selectivity via a facilitated transport mechanism. In Phase II, the Mainstream-Temple University team demonstrated the scalable synthesis of oligomers and the ability to control the pore internal and external functionality, or chemistry, to allow the fabrication of a thin-film membrane. The initial steps of the spiroligomer synthesis to produce the two key bis-amino enantiomer building blocks were scaled from the gram scale to the kilogram scale, obtaining 25 kg of the materials by transferring the procedure to a toll manufacturer. Finally, we successfully optimized the fabrication of these macrocycles into robust membranes. We successfully transitioned from a laboratory based, hard-to-scale Langmuir trough synthesis to a highly scalable, roll-to-roll applicable, interfacial polymerization process. During this Phase II program, we established a platform of atomically precise membranes where our highly controllable, atomically precise macrocycles served as a scaffold with precisely and uniformly controlled pores. Furthermore, this layer can be tailored to accommodate a diverse range of functional groups, which both further controlled the pore size to enhance the sieving effect as well as imparting precisely controlled targeted selectivity through biomimetic molecular interactions. In this Phase II, we established and scaled up a platform approach to both tune the pore size and chemistry as well as scale it to produce membranes that can be applied to a wide range of industries. In future development, the project team expects to scale up both the macrocycle building block production and interfacial polymerization process to produce the atomically precise membrane with targeted pore sizes and pore chemistries.
Advanced oxidation processes (AOPs) have recently gained increasing attention as promising alternatives to conventional water and wastewater treatment technologies. As an AOP, there has been a growing interest in UV/chlorine due to its multiple disinfection modes and ability to maintain chlorine residuals in drinking water distribution systems. Compared to the popular UV/H 2 O 2 AOP treatment process, UV/chlorine AOP possesses several advantages including a higher radical production efficiency and a lower power demand. The process has recently been applied for the degradation of a wide range of natural and synthetic organic as well as inorganic compounds including pharmaceutical and personal care products, natural organic matter, herbicides and insecticides, taste and odor, and different types of water and wastewaters. The focus of the present work is to review and evaluate the efficiency of the UV/chlorine process on the oxidation of these pollutants. Here a critical overview is provided of the fundamentals of UV/chlorine, controlling factors of the process performance, and a comparison with other UV-based AOPs. The formation of disinfection by-products (DBPs), one of the concerns associated with UV/chlorine treatment, is discussed and strategies to tackle this obstacle are provided for future studies and applications.
Hydrothermal liquefaction (HTL) presents a promising pathway for converting wet biomass resources into biofuels, offering significant advantages over conventional methods. However, numerous challenges must be addressed for HTL scale-up, including energy provision for the endothermic process, heat and mass transfer limitations, slurry concentration and pumpability challenges, char and coke formation, and continuous phase separation. This review explores key strategies such as autothermal HTL, which improves process efficiency and reduces external energy requirements by coupling exothermic and endothermic reactions within the same reactor, thereby simplifying reactor design and reducing operational costs. Additionally, multistage HTL processes are highlighted for their ability to optimize biocrude quality and yield by fractionating biomass conversion stages, resulting in higher energy returns on investment and better-quality biocrude. Solvothermal HTL and integration techniques for aqueous phase are also discussed. Furthermore, the HTL patent landscape is discussed to provide insights into current technological advancements. This review aims to offer a comprehensive understanding of process intensification in HTL, highlighting innovative solutions to enhance the efficiency and scalability of the process for sustainable biofuel production.
3-Hydroxypropionic acid (3-HP) and 1,3-propanediol (1,3-PDO) are value-added chemicals with versatile applications in the chemical, pharmaceutical, and food industries. Nevertheless, sustainable production of 3-HP and 1,3-PDO is often limited by the lack of efficient strains and suitable fermentation configurations. We report attempts have been made to improve the co-production of both metabolites through metabolic engineering of Escherichia coli and process optimization. First, the 3-HP and 1,3-PDO co-biosynthetic pathways were recruited and optimized in E. coli, followed by coupling the pathways to the transhydrogenase-mediated cofactor regeneration systems that increased cofactor availability and product synthesis. Next, pathway rebalancing and block of by-product formation significantly improved 3-HP and 1,3-PDO net titer. Subsequently, glycerol flux toward 3-HP and 1,3-PDO synthesis was maximized by removing metabolic repression and fine-tuning the glycerol oxidation pathway. Lastly, the combined fermentation process optimization and two-stage pH-controlled fed-batch fermentation co-produced 140.50 g/L 3-HP and 1,3-PDO, with 0.85 mol/mol net yield.
Recent studies suggest that the most energetic cosmic rays, exceeding 100 EeV, may primarily consist of 𝑟-process nuclei. This highlights binary neutron star mergers and collapsars as promising sources of ultrahigh-energy cosmic rays (UHECRs). Building on these insights, we examine the conditions that facilitate the efficient production of UHE 𝑟-process nuclei during the prompt radiation (PR), extended emission (EE), and plateau emission phases of short gamma-ray bursts (sGRBs) following neutron star mergers. Our study reveals that jets associated with the PR phase, characterized by typical bulk Lorentz factors (≳ 400–500), dissipation radii, and magnetic field strengths, can accelerate 𝑟-process nuclei to energies ≳ 100 EeV, while preserving them during propagation within the source. Additionally, we investigate the production of HE neutrinos from photomeson and hadronic interactions, as well as from the 𝛽 decay of accelerated 𝑟-process nuclei. We find that the HE neutrino fluxes from sGRBs, mainly produced via photomeson interactions, are significantly limited to preserve the accelerated heavy nuclei, leading to lower fluxes than the predictions without allowing for contributions to UHECRs. Our results suggest that sGRBs may potentially contribute to UHECRs during the PR phase and to HE neutrinos during the EE phase—a scenario that can be tested by future neutrino observatories.
The research goal of this EPSCoR-DOE partnership is to mitigate defects in parts made using a new type of additive manufacturing (AM) process called metal Big Area Additive Manufacturing (m-BAAM). To realize this goal, the PIs will detect and correct defects in the part as it is being printed by combining fundamental knowledge of the thermal physics and metallurgy of m-BAAM with in-process sensor data. Developed at the DOE-funded Manufacturing Demonstration Facility at Oak Ridge National Laboratory, the m-BAAM process involves one or more robots working together to produce a part by fusing metal wire layer-by-layer using arc welding. The process can print large metal parts such as turbine blades, which is not possible using other AM processes. In addition, m-BAAM production rates are more than ten times faster than other AM processes while requiring one-tenth of the material cost. Despite their potential to become a critical force multiplier in the energy generation industry, m-BAAM parts may fail to print accurately due to retention of heat and uneven cooling. Overheating and anomalous cooling rates in turn can cause inconsistencies in the microstructure, leading to sudden failure when used in safety-critical applications. In other words, flaw formation in m-BAAM parts is governed by the thermal history – intensity and spatial distribution of heat inside the part during printing. The thermal history is a complex function of the part shape and process settings such as welding energy, path taken by the welding torch for deposition (tool path), wire feed rate, among others.