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DOE OSTI2015

In-situ Condition Monitoring of Components in Small Modular Reactors Using Process and Electrical Signature Analysis. Final report, volume 1. Development of experimental flow control loop, data analysis and plant monitoring

The research and development under this project was focused on the following three major objectives: Objective 1: Identification of critical in-vessel SMR components for remote monitoring and development of their low-order dynamic models, along with a simulation model of an integral pressurized water reactor (iPWR). Objective 2: Development of an experimental flow control loop with motor-driven valves and pumps, incorporating data acquisition and on-line monitoring interface. Objective 3: Development of stationary and transient signal processing methods for electrical signatures, machinery vibration, and for characterizing process variables for equipment monitoring. This objective includes the development of a data analysis toolbox. The following is a summary of the technical accomplishments under this project: - A detailed literature review of various SMR types and electrical signature analysis of motor-driven systems was completed. A bibliography of literature is provided at the end of this report. Assistance was provided by ORNL in identifying some key references. - A review of literature on pump-motor modeling and digital signal processing methods was performed. - An existing flow control loop was upgraded with new instrumentation, data acquisition hardware and software. The upgrading of the experimental loop included the installation of a new submersible pump driven by a three-phase induction motor. All the sensors were calibrated before full-scale experimental runs were performed. - MATLAB-Simulink model of a three-phase induction motor and pump system was completed. The model was used to simulate normal operation and fault conditions in the motor-pump system, and to identify changes in the electrical signatures. - A simulation model of an integral PWR (iPWR) was updated and the MATLAB-Simulink model was validated for known transients. The pump-motor model was interfaced with the iPWR model for testing the impact of primary flow perturbations (upsets) on plant parameters and the pump electrical signatures. Additionally, the reactor simulation is being used to generate normal operation data and data with instrumentation faults and process anomalies. A frequency controller was interfaced with the motor power supply in order to vary the electrical supply frequency. The experimental flow control loop was used to generate operational data under varying motor performance characteristics. Coolant leakage events were simulated by varying the bypass loop flow rate. The accuracy of motor power calculation was improved by incorporating the power factor, computed from motor current and voltage in each phase of the induction motor.- A variety of experimental runs were made for steady-state and transient pump operating conditions. Process, vibration, and electrical signatures were measured using a submersible pump with variable supply frequency. High correlation was seen between motor current and pump discharge pressure signal; similar high correlation was exhibited between pump motor power and flow rate. Wide-band analysis indicated high coherence (in the frequency domain) between motor current and vibration signals. - Wide-band operational data from a PWR were acquired from AMS Corporation and used to develop time-series models, and to estimate signal spectrum and sensor time constant. All the data were from different pressure transmitters in the system, including primary and secondary loops. These signals were pre-processed using the wavelet transform for filtering both low-frequency and high-frequency bands. This technique of signal pre-processing provides minimum distortion of the data, and results in a more optimal estimation of time constants of plant sensors using time-series modeling techniques.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

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↗

DOE OSTI2016

Natal kicks and time delays in merging neutron star binaries: implications for r-process nucleosynthesis in ultra-faint dwarfs and in the Milky Way

Merging neutron star binaries are prime candidate sources for heavy r-process nucleosynthesis. The amount of heavy r-process material is consistent with the mass ejection and rates of mergers, and abundances of relic radioactive materials suggest that heavy r-process material is produced in rare events. Observations of possible macronovae provide further support for this model. Still, some concerns remain. One is the observation of heavy r-process elements in ultra-faint dwarf (UFD) galaxies. The escape velocities from UFDs are so small that the natal kicks, taking place at neutron stars’ birth, might eject such binaries from UFDs. Furthermore, the old stellar populations of UFDs require that r-process nucleosynthesis must have taken place very early on, while it may take several Gyr for compact binaries to merge. This last problem arises also within the Milky Way where heavy r-process materials have been observed in some low-metallicity stars. We show here that ≳0.5 of neutron star binaries form with a sufficiently small proper motion to remain bound even in a UFD. Furthermore, approximately 90% of double neutron stars with an initial separation of 10{sup 11} cm merge within 300 Myr and ≈15% merge in less than 100 Myr. This population of “rapid mergers” explains the appearance of heavy r-process material in both UFDs and in the early Milky Way.

79 ASTRONOMY AND ASTROPHYSICS↗

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 OSTI2013

Chemical System Decontamination at PWR Power Stations Biblis A and B by Advanced System Decontamination by Oxidizing Chemistry (ASDOC-D) Process Technology - 13081

For chemical decontamination of PWR primary systems the so called ASDOC-D process has been developed and qualified at the German PWR power station Biblis. In comparison to other chemical decontamination processes ASDOC-D offers a number of advantages: - ASDOC-D does not require separate process equipment but is completely operated and controlled by the nuclear site installations. Feeding of chemical concentrates into the primary system is done by means of the site's dosing systems. Process control is performed by standard site instrumentation and analytics. - ASDOC-D safely prevents any formation and precipitation of insoluble constituents - Since ASDOC-D is operated without external equipment there is no need for installation of such equipment in high radioactive radiation surrounding. The radioactive exposure rate during process implementation and process performance may therefore be neglected in comparison to other chemical decontamination processes. - ASDOC-D does not require auxiliary hose connections which usually bear high leakage risk. The above mentioned technical advantages of ASDOC-D together with its cost-effectiveness gave rise to Biblis Power station to agree on testing ASDOC-D at the volume control system of PWR Biblis unit A. By involving the licensing authorities as well as expert examiners into this test ASDOC-D received the official qualification for primary system decontamination in German PWR. As a main outcome of the achieved results NIS received contracts for full primary system decontamination of both units Biblis A and B (each 1.200 MW) by end of 2012. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Using GIS for Processing, Analysis and Visualization of Hydrological Model Data - 16202

The Applied Research Center at Florida International University (ARC-FIU) is supporting the soil and groundwater remediation efforts of the U.S. Department of Energy's (DOE's) Savannah River Site (SRS) by developing a surface water model to simulate the hydrology and the fate and transport of contaminants and sediment in the Tims Branch watershed. Advances in ArcGIS software through the development of spatial GIS database (geo-database) technology, coupled with the development of data models such as ArcHydro which possesses a spatial relational database management system (RDMS) schema and relationship structure specific to hydrologic systems, provides modelers with tools and applications to assist in the processing, analysis and visualization of flow and contaminant transport data. In addition, the coupling of this type of geo-database structure with a numerical modeling package such as MIKE SHE/MIKE 11 can serve as an efficient tool that significantly reduces the time needed for data preparation. The MIKE modeling system has a geographic information systems (GIS) user interface built into its system that can directly use GIS data for model inputs. GIS-based hydrologic models can provide a spatial element that other hydrologic models lack. GIS is important for processing and analysis of large spatio-temporal datasets derived from multiple sources that are being used for setting up of models, model calibration and simulation of flow and contaminant fate and transport. GIS-based approaches in hydrological modeling can also provide the benefit of combining different layers of geographic data to create new integrated information which can be quite useful for creating dependent or independent hydrological variables. ARC-FIU has developed an ArcGIS geo-database to support the hydrological modeling work being conducted at SRS. The SRS geo-database was developed based on the ArcHydro and ArcGIS Base Map data models with modifications made for project specific input parameters. The significance of this approach was to ensure its replicability for potential application at other DOE sites. The SRS geo-database assists in the storage and management of GIS and time series data being used for hydrological model development at Savannah River Site. Other GIS tools such as ArcGIS Model Builder coupled with Python scripting have enabled the automation of many of the repetitive geo-processing tasks required for pre- and post-processing of the hydrological modeling data. Automation of many of the data processing tasks has facilitated faster and hence more complex analyses of field test data. The toolbox created is also a scalable and reusable application that can be implemented in other watersheds. This paper describes the use of ArcGIS tools for the pre-processing, spatial delineation and analysis of hydrological model data; for automation of repetitive geo-processing tasks; and for visualization of different hydrological components of the Tims Branch watershed. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

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 OSTI2014

Assessment of Controlling Processes for Field-Scale Uranium Reactive Transport under Highly Transient Flow Conditions

This paper presents the results of a comprehensive model-based analysis of a uranium tracer test conducted at the U.S Department of Energy Hanford 300 Area (300A) IFRC site. A three-dimensional multi-component reactive transport model was employed to assess the key factors and processes that control the field-scale uranium reactive transport. Taking into consideration of relevant physical and chemical processes, the selected conceptual/numerical model replicates the spatial and temporal variations of the observed U(VI) concentrations reasonably well in spite of the highly complex field conditions. A sensitivity analysis was performed to interrogate the relative importance of various processes and factors for reactive transport of U(VI) at the field-scale. The results indicate that multi-rate U(VI) sorption/desorption, U(VI) surface complexation reactions, and initial U(VI) concentrations were the most important processes and factors controlling U(VI) migration. On the other hand, cation exchange reactions, the choice of the surface complexation model, and dual-domain mass transfer processes, which were previously identified to be important in laboratory experiments, played less important roles under the field-scale experimental condition at the 300A site. However, the model simulations also revealed that the groundwater chemistry was relatively stable during the uranium tracer experiment and therefore presumably not dynamic enough to appropriately assess the effects of ion exchange reaction and the choice of surface complexation models on U(VI) sorption and desorption. Furthermore, it also showed that the field experimental duration (16 days) was not sufficiently long to precisely assess the role of a majority of the sorption sites that were accessed by slow kinetic processes within the dual domain model. The sensitivity analysis revealed the crucial role of the intraborehole flow that occurred within the long-screened monitoring wells and thus significantly affected both field-scale measurements and simulated U(VI) concentrations as a combined effect of aquifer heterogeneity and highly dynamic flow conditions. Overall, this study, which provides one of the few detailed and highly data-constrained uranium transport simulations, highlights the difference in controlling processes between laboratory and field scale that prevent a simple direct upscaling of laboratory-scale models.

07 ISOTOPE AND RADIATION SOURCES↗