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At least 1,387 records · Page 77

Badge Office Process Analysis

The purpose of this process analysis was to analyze the Badge Offices’ current processes from a systems perspective and consider ways of pursuing objectives set forth by SEC-PS, namely increased customer flow (throughput) and reduced customer wait times. Information for the analysis was gathered for the project primarily through Badge Office Subject Matter Experts (SMEs), and in-person observation of prevailing processes. Using the information gathered, a process simulation model was constructed to represent current operations and allow assessment of potential process changes relative to factors mentioned previously. The overall purpose of the analysis was to provide SEC-PS management with information and recommendations to serve as a basis for additional focused study and areas for potential process improvements in the future.

99 GENERAL AND MISCELLANEOUS↗

Fundamental Aspects of Selective Melting Additive Manufacturing Processes

Certain details of the additive manufacturing process known as selective laser melting (SLM) affect the performance of the final metal part. To unleash the full potential of SLM it is crucial that the process engineer in the field receives guidance about how to select values for a multitude of process variables employed in the building process. These include, for example, the type of powder (e.g., size distribution, shape, type of alloy), orientation of the build axis, the beam scan rate, the beam power density, the scan pattern and scan rate. The science-based selection of these settings con- stitutes an intrinsically challenging multi-physics problem involving heating and melting a metal alloy, reactive, dynamic wetting followed by re-solidification. In addition, inherent to the process is its considerable variability that stems from the powder packing. Each time a limited number of powder particles are placed, the stacking is intrinsically different from the previous, possessing a different geometry, and having a different set of contact areas with the surrounding particles. As a result, even if all other process parameters (scan rate, etc) are exactly the same, the shape and contact geometry and area of the final melt pool will be unique to that particular configuration. This report identifies the most important issues facing SLM, discusses the fundamental physics associated with it and points out how modeling can support the additive manufacturing efforts.

36 MATERIALS SCIENCE↗

Paired Straight Hearth Furnace - Transformational Ironmaking Process

The U. S. steel industry has reduced its energy intensity per ton of steel shipped by 33% since 1990. However, further significant gains in energy efficiency will require the development of new, transformational iron and steelmaking processes. The Paired Straight Hearth Furnace (PSH) process is an emerging alternative high productivity, direct reduced iron (DRI) technology that may achieve very low fuel rates and has the potential to replace blast furnace ironmaking. The PSH furnace can operate independently or may be coupled with other melting technologies to produce liquid hot metal that is both similar to blast furnace iron and suitable as a feedstock for basic oxygen steelmaking furnaces. The PSH process uses non-metallurgical coal as a reductant to convert iron oxides such as iron ore and steelmaking by-product oxides to DRI pellets. In this process, a multi-layer, nominally 120mm tall bed of composite “green balls” made from oxide, coal and binder is built up and contained within a moving refractory hearth. The pellet bed absorbs radiant heat energy during exposure to the high temperature interior refractory surfaces of the PSH while generating a strongly reducing gas atmosphere in the bed that yields a highly metalized DRI product. The PSH concept has been well tested in static hearth experiments. A moving bed design is being developed. The process developers believe that if successful, the PSH process has the potential to replace blast furnaces and coke ovens at a fraction of the operating and capital cost while using about 30% less energy relative to current blast furnace technology. DRI output could also feed electric arc furnaces (EAFs) by displacing a portion of the scrap charge.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Evaluating Acoustic Emission Signals as an in situ process monitoring technique for Selective Laser Melting (SLM)

In situ real-time monitoring of the Selective Laser Melting (SLM) process has significant implications for the AM community. The ability to adjust the SLM process parameters during a build (in real-time) can save time, money and eliminate expensive material waste. Having a feedback loop in the process would allow the system to potentially ‘fix’ problem regions before a next powder layer is added. In this study we have investigated acoustic emission (AE) phenomena generated during the SLM process, and evaluated the results in terms of a single process parameter, of an in situ process monitoring technique.

47 OTHER INSTRUMENTATION↗

Bench Scale Process for Low Cost CO 2 Capture Using a Phase-Changing Absorbent: Final Scientific/Technical Report

The objective of this project is to design and build a bench-scale process for a novel phase-changing aminosilicone-based CO 2 -capture solvent. The project will establish scalability and technical and economic feasibility of using a phase-changing CO 2 -capture absorbent for post-combustion capture of CO 2 from coal-fired power plants. The U.S. Department of Energy’s goal for Transformational Carbon Capture Technologies is the development of technologies available for demonstration by 2025 that can capture 90% of emitted CO 2 with at least 95% CO 2 purity for less than $40/tonne of CO 2 captured. In the first budget period of the project, the bench-scale phase-changing CO2 capture process was designed using data and operating experience generated under a previous project (ARPA-e project DE-AR0000084). Sizing and specification of all major unit operations was completed, including detailed process and instrumentation diagrams. The system was designed to operate over a wide range of operating conditions to allow for exploration of the effect of process variables on CO 2 capture performance. In the second budget period of the project, individual bench-scale unit operations were tested to determine the performance of each of each unit. Solids production was demonstrated in dry simulated flue gas across a wide range of absorber operating conditions, with single stage CO 2 conversion rates up to 75mol%. Desorber operation was demonstrated in batch mode, resulting in desorption performance consistent with the equilibrium isotherms for GAP-0/CO 2 reaction. Important risks associated with gas humidity impact on solids consistency and desorber temperature impact on thermal degradation were explored, and adjustments to the bench-scale process were made to address those effects. Corrosion experiments were conducted to support selection of suitable materials of construction for the major unit operations in the process. The bench scale unit operations were assembled into a continuous system to support steady state system testing. In the third budget period of the project, continuous system testing was conducted, including closed-loop operation of the absorber and desober systems. Slurries of GAP-0/GAP-0 carbamate/water mixtures produced in the absorber were pumped successfully to the desorber unit, and regenerated solvent was returned to the absorber. A techno-economic analysis, EH&S risk assessment, and solvent manufacturability study were completed.

20 FOSSIL-FUELED POWER PLANTS↗

SME Acceptability Determination For DWPF Process Control (U)

The statistical system described in this document is called the Product Composition Control System (PCCS). K. G. Brown and R. L. Postles were the originators and developers of this system as well as the authors of the first three versions of this technical basis document for PCCS. PCCS has guided acceptability decisions for the processing at the Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS) since the start of radioactive operations in 1996. The author of this revision to the document gratefully acknowledges the firm technical foundation that Brown and Postles established to support the ongoing successful operation at the DWPF. Their integration of the glass propertycomposition models, developed under the direction of C. M. Jantzen, into a coherent and robust control system, has served the DWPF well over the last 20+ years, even as new challenges, such as the introduction into the DWPF flowsheet of auxiliary streams from the Actinide Removal Process (ARP) and other processes, were met. The purpose of this revision is to provide a technical basis for modifications to PCCS required to support the introduction of waste streams from the Salt Waste Processing Facility (SWPF) into the DWPF flowsheet. An expanded glass composition region is anticipated by the introduction of waste streams from SWPF, and property-composition studies of that glass region have been conducted. Jantzen, once again, directed the development of glass property-composition models applicable for this expanded composition region. The author gratefully acknowledges the technical contributions of C.M. Jantzen leading to the development of these glass property-composition models. The integration of these models into the PCCS constraints necessary to administer future acceptability decisions for the processing at DWPF is provided by this sixth revision of this document.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Green-House-Gas-Reduced Coal-and-Biomass-to-Liquid-Based Jet Fuel (GHGR-CBTL) Process - Final Technical report

This Final Technical Report describes the work and accomplishments of the project entitled, “Green-House-Gas-Reduced Coal-and-Biomass-to-Liquid-Based Jet Fuel (GHGR-CBTL) Process”. The main objective of the project was to raise the Technology Readiness Level (TRL) of the GHGR-CBTL fuel-production technology from TRL 4 to TRL 5 by producing a drop-in synthetic Jet Propellant 8 (JP-8) with a greenhouse-gas footprint less than or equal to petroleum-based JP-8 by utilizing mixtures of coal and biomass as the feedstock. The system utilizes the patented Altex fuel-production technology, which incorporates advanced catalysts developed by Pennsylvania State University. While the system was not fabricated and tested, major efforts were expended to design the 1-TPD and a full-scale plant. The system was designed, a Block-Flow Diagram (BFD), a Process-Flow Diagram (PFD), and Piping-and-Instrumentation Diagrams (P&IDs) were produced, a Bill of Materials (BOM) and associated spec sheets were produced, commercially available components were selected and procured, custom components were designed and fabricated, catalysts were developed and screened for performance, and permitting activities were conducted. Optimization tests for JP-8 production using C2 olefin as the feed were performed over a range of temperatures, pressures and WHSVs. Liquid yields of between 63 to 65% with 65% JP-8 fraction (41-42% JP-8 yield) at 50 psig were achieved. Life-Cycle Analysis (LCA) was performed by Argonne National Laboratory (ANL), and a GHGR-CBTL module was added to the Greenhouse gases, Regulated Emissions, and Energy use in Transportation (GREET®) model. Based upon the experimental results, the plant design was reconfigured for zero natural-gas imports and minimal electricity imports. The LCA analysis of the reconfigured process utilizing the GREET model showed that if the char from the process was utilized to produce combined heat and power (CHP) then a feed containing 23 wt% biomass and 77 wt% lignite would be needed for parity with petroleum-based JP-8. If the char is not utilized for CHP, but sequestered in a land fill, 24 wt% biomass and 76 wt% lignite would be required. A TEA was performed on this configuration following DOE guidelines and using the ANL-developed GREET module that showed that the GHGR-CBTL TOC and ECO are 69% and 58% of those for the DOE FT-Liquids Baseline Case, respectively. This analysis shows that the economics of the GHGR-CBTL process are significantly better than a gasification/FT process. No technical barriers were identified. The lower costs and the detailed design that was performed under this project are being used by Altex to attract funding partners to move the GHGR-CBTL development forward.

01 COAL, LIGNITE, AND PEAT↗

Engineering Design of Advanced H 2 – CO 2 Pd and Pd/Alloy Composite Membrane Separations and Process Intensification

The integrated gasification combined cycle (IGCC) process is a way to co-produce synthesis gas, electricity, hydrogen, fuels and chemicals from coal and coal/biomass-mix in an environmentally responsible manner. The production of hydrogen via the water-gas shift (WGS) reaction is a key part of this process. Pd and Pd/Alloy-based catalytic membrane reactors used in the WGS process could significantly improve the efficiency of the IGCC process with a great potential for process intensification. Membrane reactors enable reaction, separation and product concentration to take place in a single unit operation, leading to conversion levels beyond thermodynamic equilibrium due to the continuous removal of H 2 . Worcester Polytechnic Institute (WPI) has developed composite Pd and Pd/alloy composite hydrogen separation membranes with high H 2 flux, excellent selectivity and long-term durability for this membrane reactor process. WPI membranes used in a natural gas reforming operation were stable for over 6,000 hours (>8 months) at 500°C and 40 bar. Under the DOE Hydrogen Pathway Program (DE-FC-26-07NT43058) Pd membranes prepared by WPI exceed the DOE 2015 targets for H 2 flux, selectivity and stability. Furthermore, the scalability of the WPI technology has been shown to be relatively easy, and composite Pd/Cu and Pd/Au alloy membranes have been shown to be sulfur resistant and permeance recoverable.

42 ENGINEERING↗

Development of Novel Foaming Solutions for High Level Waste (HLW) Processing

Foaming occurs during treatment of high level waste (HLW) at Savannah River Site’s Defense Waste Processing Facility (DWPF) in the Chemical Process Cell (CPC) due to high gas generation from process steam and chemical off gas products. The presence of amphiphilic particles in the waste slurry stabilizes the foam. Efficient processing of HLW requires foam control, as foamovers lead to lower productivity and potential radioactive contamination of condensate streams. DWPF currently employs Antifoam 747, a surfactant produced by Momentive Performance Materials, as an antifoaming agent during waste treatment. While it controls foam, processing issues have arisen from its use. During DWPF chemical processing, antifoam must be effective up to 103°C and between a pH range of 3-13. Antifoam 747 is efficient at pH 6-8 but degrades outside this optimal pH range. Savannah River National Laboratory (SRNL) has identified multiple flammable antifoam degradation products during laboratory scale experiments.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Automation Technologies Impact on the Work Process of Nuclear Power Plants

The current cost associated with the work process of nuclear power plants necessities modernizing the work process by augmenting it with automation technologies. This work was performed to assess various automation technologies and the means by which they assimilate into the work process in order to make gains in cost savings in modern nuclear power plants. The goal was to identify key informational items that would be useful to members of industry who are undertaking the large effort to reduce costs through automation by identifying technology maturity levels, recent research, and an analysis of cost impacts of the work process. The technologies cost saving was categorized into low, medium, and high cost savings. Through this effort, a substantive literature review and analysis of recent technological and market trends was performed. The key areas of cost impact were identified through communication with users in industry from operations and maintenance organizations. The results were assembled into a list of work process steps and technologies that are ready be implemented or researched for the automating aspects of that step. This effort aims to present to utilities opportunities of cost saving that are achievable in the short term, and gaps for research organizations and vendors to consider for further research and development. The results of this effort generated a list of technologies that fit each of the three cost saving categories. Electronic work packages remain a high cost saving technology, but data mining and integration, smart scheduling, and dynamic risk models are also indicated to yield a high cost savings. Video applications, spatial mapping, and image processing and identification technologies appear to provide solid cost savings in the medium category, and rounding out the low cost saving areas are deployable technologies such as bar codes, communication tools, and electronic tags.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Development of high-fidelity models for liquid fuel spray atomization and mixing processes in transportation and energy systems

Significant inadequacies of current models for multiphase flows present a major barrier to rapid development of advanced high-efficiency low-emissions combustion devices. Liquid spray atomization processes largely determine fuel-air mixture formation, which subsequently govern combustion and controls performance, emissions, and durability of a device. The current study presents a fundamentally-consistent framework to model the effects of breakup processes, liquid drop deformations, and internal flow dynamics on mass, momentum, and energy exchange functions. This framework builds on the Taylor Analogy Breakup (TAB) model which naturally quantifies local drop deformation dynamics. Real-fluid multicomponent thermodynamic property modeling and Gradient Theory simulations facilitate accurate calculations of molecular two-phase interface exchange functions, surface tensions forces, drop oscillations, and breakup processes. The analysis establishes that these drop dynamics, along with finite liquid viscosity effects, significantly alter gas-liquid exchange functions. The study quantifies these effects for the resulting drag coefficients of liquid drops and demonstrates significant deviations from the classic dynamic drag model, which is widely applied in modern simulations performed in academia and industry. This work also quantifies effects, which originate from gas-liquid coupling dynamics, on evaporation and heating rates. The analysis establishes that the consideration of these coupling dynamics modify mass and energy transfer rates even more significantly than the corresponding drag forces from momentum exchange. This physical complexity, however, is largely neglected in modern studies from academia and industry. A new set of equations is presented to improve the modeling of drop breakup processes to address the current shortcomings in the prediction of resulting drops proper- ties over the full range of relevant breakup conditions. The framework is based on a refined energy balance equation which explicitly enforces drop momentum conservation during the breakup process. The introduced modeling framework is entirely derived from conservation equations for mass, momentum, and energy and does not, as a consequence, introduce new modeling constants. The significance of the developed modeling advances to fuel injection processes is demonstrated using Large Eddy Simulation (LES) with a Lagrangian-Eulerian modeling approach.

42 ENGINEERING↗

DE-FE0026098 Final Report - Advanced Materials and Manufacturing Processes for SOFC Power Systems Revision 1

The aim of the project is to qualify an integrated material set and processing solution for selected metallic components of an advanced integrated stack block. As the integrated stack block is the “engine” of the solid oxide fuel cell power system, the project will also support significant cost reductions, increased reliability, and improved performance of the LG Fuel Cell Systems Inc. (“LGFCS”) cell and stack technology to be included in the initial commercial product offering. In the proposed work an integrated material set, and processing solution will be developed using powder metals processing which has been proven to be an enabling technology capable of delivering net or near net shape components, as well as for creating compositions, microstructures, and properties that are otherwise unattainable. Several advanced manufacturing processes will be screened to select one or more that are most advantageous for the selected metallic components when produced at commercial volumes. This work will be accomplished through the integration of metallurgists and processing engineers from Carpenter Technology, with the product design and cost engineers from LGFCS. The expected outcome of the proposed work is an optimized material set and processing solution that will reduce the current cost.

03 NATURAL GAS↗

Frit Recommendation For Sludge Batch 9 Coupled Operation With The Salt Waste Processing Facility

Prior to the processing of Sludge Batch 9 (SB9) with Frit 803 at the Defense Waste Processing Facility (DWPF), assessments and experimental glass work were completed to support SB9 coupled processing with streams from the Actinide Removal Process (ARP) and Modular Caustic Side Solvent Extraction Unit (MCU). This previous work did not address coupled processing with streams from the Salt Waste Processing Facility (SWPF) because the Product Composition Control System (PCCS) models limited the TiO2 concentration in glass to 2 weight percent (wt.%). These high activity streams from SWPF include monosodium titanate (MST) and sludge solids from the Sludge Solids Receipt Tank (SSRT) as well as Cscontaining strip effluent (SE). The SWPF streams are expected to reach TiO2 concentrations in glass greater than 2 wt.% based on an MST strike of 0.4 g MST/L of salt solution. Therefore, revisions to the models contained in PCCS were completed to allow the evaluation of glasses containing greater than 2 wt.% TiO2, but less than 6 wt.%. Since the initial SB9 qualification for ARP-MCU coupled operation, additional Tank 40 analyses have been completed, which served as the basis for an updated projection of the SB9 blend composition in Tank 40. This projection will be used to support SB9 coupled operation with SWPF in 2019. Savannah River Remediation (SRR) has requested that the Savannah River National Laboratory (SRNL) select a second frit to optimize SB9 coupled operation with SWPF. The selected frit would provide operational flexibility by allowing an acceptable waste loading (WL) to be targeted while maintaining an operating window of at least ± 4 percentage points around this target. The objective of this study was to select a second frit based on a paper-study utilizing Measurement Acceptance Region (MAR) assessments with DWPF PCCS. To support these assessments, SRNL developed a new method for rigorous and directed optimization of frit compositions, which allowed for rapid screening and an assessment of a large array of candidate frits, and the ability to simultaneously satisfy the following single and double MST strike operating scenarios.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Combined Sorbent/WGS-based CO 2 Capture Process with Integrated Heat Management for IGCC Systems

Southern Research has developed a combined CO 2 capture water-gas shift (WGS) process for integrated gasification combined cycle (IGCC) applications. A highly efficient regenerable magnesium based sorbent was prepared to remove CO 2 . It offers high and stable CO 2 capacity with minimum requirement for temperature and pressure swings. Under optimized conditions, the sorbents achieved up to 8 mmol/g of CO 2 working capacity and remained stable over 500 cycles of adsorption and regeneration. The selected WGS process achieved 96% CO per pass conversion and remained isothermal during the test duration that lasted over 500 cycles. The approach showed potential to reduce cost of electricity (COE) compared to the baseline carbon capture approaches. The process is for bench-scale and pilot development. In a commercial embodiment, syngas from the gasifier is cooled to warm gas conditions. It then enters the CO 2 sorbent-shift reactor that uses an efficient MgO-based CO 2 sorbent and a commercial catalyst to shift the CO to CO 2 and capture 90% + of the carbon. Using a dual-bed arrangement, the sorbent is regenerated periodically by a combination of pressure and temperature swing to maintain steady state conditions and produce a 95+ % CO 2 stream for sequestration. The hydrogen rich syngas is sent to the IGCC for power production. In addition to consolidating CO 2 capture with WGS, the proposed process reduces parasitic energy losses by operating at warm gas temperatures and reduces parasitic plant load (i.e., steam and auxiliary power) by reducing energy required for regeneration. The project consisted of 3 budget periods (BP) of laboratory-scale research and testing with go/no-go decisions after BP-1 and BP-2. In the 12 month BP-1, it was shown show that one promising sorbent maintained the required CO 2 capacity and durability of >1.5 mmol/g over 100 cycles. Also based on sorbent and WGS experiments in separate reactors and combined reactor modeling, it was shown that the process had the potential to capture 90% of the CO 2 at a lower than conventional amine-based approach. In the 18 month BP-2, a lab scale combined sorbent/WGS reactor system was built, commissioned, and tested with the promising sorbent from BP-1. 90% carbon capture was demonstrated over 100 cycles and it was shown that the process continued to have potential to capture 90% of the carbon at a cost that was less than the conventional amine-based approach. In the 6 month BP-3, a long term test was conducted using the best SR sorbent. The required durability of > 2 mmol/g was demonstrated after 500 cycles. Also, 90% carbon capture and 96% CO conversion was maintained over 1000 cycles. A technical and economic feasibility study was carried out to compare the proposed pre-combustion approach to a gasification plant employing a conventional pre-combustion approach and a conventional pulverized caol (PC) plant employing a conventional post combustion CO 2 capture approach.

01 COAL, LIGNITE, AND PEAT↗

Accounting for hydrological and microbial processes on greenhouse gas budgets from river systems (Final Report)

River systems have a disproportionately large impact on carbon and nitrogen cycling on this planet. For instance, despite their much smaller size in area, it is estimated that global carbon dioxide emission from river systems exceed the emission from lakes and reservoirs, and are on par with the estimated oceanic and land carbon sinks. Closing carbon and nitrogen budgets in river systems requires knowledge of end member greenhouse gas (GHG) products (e.g. carbon dioxide, nitrous oxide, methane), which typically have not been measured in river systems. Moreover, while the production of these gasses is thought to be microbially derived, little is known about microbial activities in sediments of large rivers, despite their potentially high influence on biogeochemical budgets. Typically, when we think of rivers we visualize the channels that carve through the earth, but this only represents a small part of the hydrologic exchange that a river participates in. Rivers are more than conduits; they are dynamically exchanging water and materials with surrounding terrestrial and subsurface environments. In fact, 96% of the carbon dioxide produced within river systems occurs in hyporheic zones, or sediment regions beneath and alongside a river where groundwater and river water mix. In fact, it is widely recognized that microbial processes in hyporheic zones, also known as the river’s liver, strongly influence the fate of carbon, nutrients, and contaminants transported through watersheds. Despite this general knowledge, observational studies linking nitrogen and carbon gas production to microbial activity, and studies of overall gas emissions, are limited across river systems, but especially absent from larger rivers. To identify microbial processes responsible for GHG emissions from large rivers, and to quantify their environmental drivers and dependencies, we selected the Columbia River as a representative field site. This is the largest river west of the North American Continental Divide, and produces a drainage and discharge roughly double of the Nile in Egypt. This river is also an important source for agricultural irrigation and generates more hydroelectric power than any other North American river. Dams manage the release of water in the river, with these changes in river discharge patterns strongly impacting microbial activities in hyporheic zones. Specifically, we target a region down-river from the Priest Rapids Dam (WA) associated with the PNNL SFA, where water discharge from the dam is highly controlled, resulting in 1.5 m fluctuations in river stage daily. This dynamic river stage creates an ideal research opportunity for investigating hydrological perturbations in GHG production, uptake, and emission from large river systems. In this exploratory 1-year project, we conducted data-driven field research to provide observations needed to support predictions about GHG flux from river ecosystems. Using porewater dialysis and surface flux measurements, we observed where and when GHGs were produced and is the emission impacted by river stage. Using meta-omics tools, we determined what microbial processes control production and consumption of GHG in these systems. Finally, we provided key observations to parameterize models that could predict the effect of environmental conditions on GHG emission in the Columbia River near shore environment, at the scale that the modeled processes operate. Closing knowledge gaps in the linkages between river stage, microbial processes, and GHG production and emission, as well as the spatial distribution and ecosystem dependencies of these processes, is necessary to better parameterize land surface models. We provide some of the first, detailed GHG measurements paired microbial activity from large river systems. Our findings have direct relevance to many other large rivers with flows altered by hydroelectric energy, reservoirs, snowmelt, tides, or agriculture.

54 ENVIRONMENTAL SCIENCES↗

Process Modeling of U-10wt% Mo Alloys Using Integrated Computational Materials Engineering

Low-enriched uranium alloyed with 10 wt% molybdenum (U-10Mo) has been identified as a promising alternative to highly enriched uranium as fuel for the nation’s high-performance research reactors. Manufacturing the U-10Mo alloy consists of multiple complex thermomechanical processes, which is highly challenging for computational modeling. The integrated computational materials engineering (ICME) concept supports building a microstructure-based framework to investigate the effect of manufacturing processes on the material microstructure. In this report, an ICME model that combines homogenization, hot rolling, annealing, and cold rolling is presented as an example of implementing the ICME concept for modeling the manufacturing processes of the U-10Mo alloy. The integrated model enables information to be passed between the different model components, leading to an improved prediction and a better understanding of microstructure across multiple processes. The integrated model was also implemented to investigate the variation of chemical composition, thickness of the zirconium interlayer, grain growth, and carbide redistribution and fracture of U-10Mo during the thermomechanical processes. With the homogenization model, a molybdenum concentration map can be reconstructed from any given microstructure, and the homogenization time needed to reach a desired homogenization level can also be approximated. The microstructure-based finite-element rolling model, shows that the homogenization process reduces the nonuniformity in the thickness of the zirconium interlayers on the U-10Mo. With the output from the rolling model, a statistical analysis of second-phase hard particles was conducted to quantify the particle redistribution and interparticle spacing between carbides during the deformation. Also, new stringer identification criteria were proposed to predict the correlation between stringer volume fractions and hot-rolling reduction. A macro-finite-element method hot-rolling model showed that higher reduction passes can be achieved within the mill separation force range, and a new “aggressive” rolling schedule was proposed. The model also showed the importance of can material on the quality of rolled foils, with stronger can materials resulting in hot-rolled U-10Mo free of defects (waviness, dog-boning). The deformation-induced recrystallization model demonstrated capability to use inputs from deformation simulations of strain accumulation in U-10Mo samples to predict grain growth behavior of the fuel during thermal treatment stages. Finally, a plane-strain compression mode simulated particle fracture and calculates the void volume fraction generated during cold rolling. The macro-finite-element method cold-rolling model showed that smaller diameter rolls are necessary to achieve the desired foil thickness.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Selection of Glasses in Support of the Sludge Batch 9 Sulfate Solubility Limit for Coupled Operation with the Salt Waste Processing Facility

For Sludge Batches 3 through 8, the sulfate (SO 4 2- )solubility limit for the Defense Waste Processing Facility (DWPF) has been determined by laboratory-scale crucible testing. In preparation for Sludge Batch 9 (SB9) processing, a comparison demonstrated that minor compositional differences existed between the Sludge Batch 8 (SB8)-Frit 803 and SB9-Frit 803 glass composition regions for sludge-only and coupled operations with the Actinide Removal Process (ARP) and Modular Caustic Side Solvent Extraction Unit (MCU). Thus, no experimental testing was necessary and the SB8 SO 4 2- limit of 0.65 wt.% was recommended for SB9 processing. This previous SB9 assessment did not address coupled processing with streams from the Salt Waste Processing Facility (SWPF), which is anticipated to start operations in November 2019. These high activity streams will include monosodium titanate (MST) and sludge solids from the Sludge Solids Receipt Tank (SSRT) as well as Cs-containing strip effluent (SE). The incorporation of these SWPF streams is expected to reach TiO 2 concentrations in glass greater than 2 wt.% based on single and double MST strike scenarios. In support of coupled operation with SWPF, the DWPF Product Composition Control System was revised and allows a TiO 2 concentration of up to 6 wt.% (minus measurement uncertainty) in glass. For the SB8-Frit 803 SO 4 2- solubility study, the maximum TiO 2 concentration evaluated was 0.94 wt.%. Since the influence of increased TiO 2 on the retention of SO 4 2- in the SB9 glass region is unknown, a test matrix of ten glass compositions has been proposed to determine whether the 0.65 wt.% SO 4 2- limit is still appropriate for SB9 coupled operation with SWPF. This report documents the development of a test matrix that will support this study.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Modeling of Pyroprocessing Hot Cell for Process Monitoring Evaluation

In this report, we examine studies undertaken to determine the applicability of applying measurements with a neutron counter within a pyroprocessing hot cell. The studies focus on the modeling of the hot cell and neutron counter in Monte Carlo N- Particle Code (MCNP) to determine expected radiation effects and applicability of neutron counters. The neutron counter of focus was the High Dose Neutron Detector (HDND) developed at Los Alamos National Laboratory (LANL). We studied the HDND to determine what would be the detector response under normal background conditions with operating process equipment as well as the background’s potential effect on counting applications involving a U/TRU ingot produced by the pyroprocessing electrorefiner. To perform this task, we were required to develop models of the pyroprocessing process cell and unit operations and generate source terms for various different times in the process. The data for the pyroprocessing materials came from SNL’s Safeguards and Security Process Model (SSPM) as part of MPACT’s advanced integration mission. This report will discuss the development of the pyroprocessing process cell and unit operations models in MCNP as well as various simulations to determine the applicability of the HDND for process monitoring efforts in the hot cell.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗