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DOE OSTI2019

Size effects on thermo-mechanical performance of U-10Mo monolithic fuel plates

Monolithic fuel is a fuel form that is considered for the conversion of high performance research reactors. This plate-type fuel consists of a high density U-Mo fuel in monolithic form that is sandwiched between zirconium diffusion barriers, and encapsulated in an aluminum cladding. To date, large number of plates have been irradiated with satisfactory perforamce. The program is now moving into the qualification phase, a predecessor to the timely conversion of the target reactors. It must be shown that the fuel system meets the safety standards and performs well in reactor. The requirement to satisfactory irradiation performance under normal operating conditions is primarily demonstrated by a successful testing. Since each reactor employs distinct fuel plate geometries for various consideration with unique plate design features and attributes, a single “generic” plate geometry capturing all of the extremities is not achievable. Furthermore, testing all these geometric and irradiation parameters on a large size plate is not practical. Therefore, a smaller, “down-scaled” versions of fuel plates, are often employed for experimental purposes. This limitation consequently requires much more cautious performance evaluations, as thermal and mechanical response of a plate with certain geometry may not be representative for a plate with a different geometry. To investigate if plate size has any effects on irradiation performance, the plates with various geometric dimensions were parametrically evaluated. In particular, length and width of the plates were varied between the bounding values. Temperature, deformation, stress values were comparatively evaluated. The results have indicated that effects of geometric ratios and plate size variations in length and width directions are insignificant. However, wider plates could become more prone to a warping-type deformation, if there are nonlinearities.

42 ENGINEERING↗

DOE OSTI2019

Size effects on thermo-mechanical performance of U-10Mo monolithic fuel plates

42 ENGINEERING↗

DOE OSTI2016

Comparison of Laboratory Analytical Methods for Uranium Analysis Superior Steel FUSRAP Site - 16606

The Superior Steel Site processed uranium metal in support of the Atomic Energy Commission's fuel-element development program in the 1950's, and was subsequently classified as a Formerly Utilized Sites Remedial Action Program (FUSRAP) Site. Previous investigations at the site identified uranium contamination both inside and outside the buildings associated with historic uranium metalworking activities. The U.S. Army Corps of Engineers (USACE) is currently engaged in the Remedial Investigation (RI) phase in accordance with the Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) of 1980, as amended. As part of the RI, gamma spectroscopy analysis of environmental samples was performed on-site using a laboratory-grade, high-purity germanium (HPGe) spectrometer. The gamma spectroscopy analysis included isotopes of uranium and their progeny. As a quality assurance measure, a subset of samples already analyzed on-site were sent to a certified, commercial, off-site laboratory for analysis using a suite of analytical methods including gamma spectroscopy, alpha spectroscopy, and mass spectroscopy. As an element of the quality assurance program implemented for the RI, an assessment of the correlations between the various analytical methods employed by both the on-site and off-site laboratory was performed. This assessment revealed inconsistencies between on-site and off-site gamma spectroscopy analytical results, which raised concerns about the appropriateness and suitability of the analytical data. To resolve the data quality concerns and better understand the source(s) of analytical results variability, the Superior Steel RI team (USACE together with its contractor, Amec Foster Wheeler) developed a quality control test whose design objective was to control or practically eliminate sampling and sample preparation variability in order to focus more clearly on analytical variability. This paper discusses the results of this supplemental quality control test, showing the differences in the various analytical methods (both on-site and off-site). It demonstrates in a practical and real world setting how sample preparation and analytical variability, if not controlled and understood can impact data quality and data defensibility. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

A Sequential Quadratic Programming Algorithm for Nonsmooth Problems with Upper- ${\boldsymbol{\mathcal{C}^2}}$ Objective

An optimization algorithm for nonsmooth nonconvex constrained optimization problems with upper- ${\boldsymbol{\mathcal{C}^2}}$ objective functions is proposed and analyzed. Upper- ${\boldsymbol{\mathcal{C}^2}}$ is a weakly concave property that exists in difference of convex (DC) functions and arises naturally in many applications, particularly certain classes of solutions to parametric optimization problems e.g., recourse of stochastic programming and projection onto closed sets. The algorithm can be viewed as an extension of sequential quadratic programming (SQP) to nonsmooth problems with upper- ${\boldsymbol{\mathcal{C}^2}}$ objectives or a simplified bundle method. It is globally convergent with bounded algorithm parameters that are updated with a trust-region criterion. The algorithm handles general smooth constraints through linearization and uses a line search to ensure progress. The potential inconsistencies from the linearization of the constraints are addressed through a penalty method. In conclusion, the capabilities of the algorithm are demonstrated by solving both simple upper- ${\boldsymbol{\mathcal{C}^2}}$ problems and a real-world optimal power flow problem used in current power grid industry practices.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Embedded Sensors and Controls to Improve Component Performance and Reliability - Final Report

Oak Ridge National Laboratory has researched embedded instrumentation and controls (I&C) for extreme environments under the Department of Energy, Office of Nuclear Energy's Nuclear Energy Enabling Technology program. Advanced sensors and controls have the potential to dramatically increase the performance and efficiency of nuclear reactor components, however, the extreme environments of exiting and advanced reactor designs limit the options for sensors, actuators, and control designs. To address two of the extreme environment challenges to embedded I&C, the focus of this research is to fill technology gaps needed for electromagnetic systems that can operate at temperatures greater than 700 C in corrosive environments. A magnetically suspended, canned-rotor pump was chosen for the embedded I&C development platform because it is a system with a practical need in industry and because the sensors, actuators, and embedded I&C technologies needed to successfully build this platform will be widely applicable to any high-temperature components that utilize electromagnetic interactions. This design also eliminates the need for pump seals and mechanical bearings which are the main sources of pump failures and maintenance costs. During the project a conceptual design for the high-temperature magnetically suspended pump was developed and analyzed for manufacturability and reliability. Specifications for the materials, control system, sensors, mechanical performance, high-temperature wiring, and electromagnetic properties were developed for the conceptual design. The canned rotor design of the high-temperature pump presents unique fluid force characteristics arising from the thin fluid channel between the rotor and stator. A model of the fluid forces was developed and the impact of these forces on the stability and performance of magnetic bearing controllers was studied. Then a room temperature bench-scale magnetic testbed was designed and fabricated for testing the performance of sensors and electromagnetic actuators, modern control design techniques, closed-loop system identification, state estimation, and model uncertainty. Finally, a loop-scale testbed with submerged magnetic bearings was designed and fabricated. This testbed will be used to analyze the stability and performance of control system designs in response to the nonlinear and cross-coupling fluid effects between the shaft axes of motion, rotordynamics, gyroscopic effects, and impeller disturbances.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

National Hurricane Program Metrics Framework

The need for metrics for planning and response measures was identified as key gap to be addressed in the National Hurricane Program's (NHP) Technology Modernization effort. This document proposes a framework for defining a set of metrics for planning and response that will be implemented in the NHP products of hurricane evacuation studies (HES) and post-storm assessments (PSA). To determine the feasibility of this framework, a survey of current HES and PSAs was carried out followed by and then used to determine if the proposed metrics are currently captured. While there is a wide variety in data availability and detail, the implementation of these metrics is not only feasible but presents an opportunity to improve on current practices. The final implementation of this framework shall require the ongoing feedback from local, state, tribal, and federal stakeholders.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

On the Convergence of Inexact Predictor-Corrector Methods for Linear Programming

Interior point methods (IPMs) are a common approach for solving linear programs (LPs) with strong theoretical guarantees and solid empirical performance. The time complexity of these methods is dominated by the cost of solving a linear system of equations at each iteration. In common applications of linear programming, particularly in machine learning and scientific computing, the size of this linear system can become prohibitively large, requiring the use of iterative solvers, which provide an approximate solution to the linear system. However, approximately solving the linear system at each iteration of an IPM invalidates the theoretical guarantees of common IPM analyses. To remedy this, we theoretically and empirically analyze (slightly modified) predictor-corrector IPMs when using approximate linear solvers: our approach guarantees that, when certain conditions are satisfied, the number of IPM iterations does not increase and that the final solution remains feasible. We also provide practical instantiations of approximate linear solvers that satisfy these conditions for special classes of constraint matrices using randomized linear algebra.

Dexter, Gregory↗

DOE OSTI2019

Panel Session 51: Idaho Transuranic Waste Challenges, Solutions and Implications for the Future (3/5)

This panel focused on the retrieval, characterization, treatment, certification, and shipping of transuranic (TRU) waste at the Idaho National Laboratory (INL) Site, Idaho, USA. The INL began receiving TRU waste from offsite generators (primarily the Rocky Flats Plant in Colorado, USA) beginning in 1954. Until 1970, the INL Site disposed of barrels, boxes, and other debris in a shallow, unlined landfill. Beginning in 1970, the INL Site began storing TRU waste on an asphalt pad, which was then covered with several feet of soil. This practice continued until the late 1980's at which time a large air support building was erected over the waste. In the mid-to-late 1990's, the air support building was removed and a massive building was constructed over the entire dirt mound. Contractors retrieved the waste from the early 2000's through February 2017 to support an Idaho Settlement Agreement milestone that required the retrieval of 65,000 cubic meters of TRU waste and removal from Idaho. This panel focused on the Idaho Transuranic Waste Challenges, Solutions and Implications for the Future. The Idaho Transuranic Waste Program includes buried and stored waste retrieval and processing of contact- and remote-handled transuranic waste. Over the duration of the program, the Idaho site has conducted targeted retrieval of buried waste from the 1950's and 1960's; designed, permitted, built, operated, and completed the mission of a facility to process 65,000 cubic meters of waste; and shipped more than 57,000 cubic meters of waste to WIPP. Presentation proposed: Transuranic Waste Challenges and Solutions (Hoss Brown, Fluor Idaho, LLC (USA), John McCoy, Fluor Idaho, LLC (USA), James Malmo, US DOE (USA), Doug Pruitt, Department of Energy Idaho Field Office (USA), Kenneth Princen, US DOE (USA))

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Digitizing Today’s Buildings in the Real World: Lessons from Field Demonstrations

Digital twins, created by generating a virtual replica of a building, enable safe evaluation of operational scenarios and applications like fault detection and diagnosis and advanced controls. However, a prerequisite is the creation of a machine-readable digital representation of a building, currently hindered by fragmented information scattered across mechanical drawings, point lists, and natural language sequences. As a result, digital twin development remains labor-intensive, error-prone, and difficult to validate. To address these challenges, two efforts from ASHRAE aim to support the digitalization of buildings. ASHRAE s223 establishes a semantic model of buildings, representing system components, configuration, and data sources. ASHRAE s231 defines a vendor-neutral programming language for expressing their control logic. As the industry evaluates implementing them in their products, understanding the challenges that vendors and implementers may face is crucial. In this paper, we present findings and lessons learned from field demonstrations in five buildings that implemented control applications using ASHRAE s223 and s231. The demonstrations highlight how semantic modeling and formalized control descriptions can significantly reduce software development time, manual point mapping, and hard-coding. Beyond time efficiency, they enable reliable automation by minimizing human interpretation and providing a means for consistency across projects. We describe the processes and best practices for model creation and model usage, from translating heterogeneous building documentation into semantic representations to implementing control logic in real-world systems. Finally, we discuss the challenges that persist, including integration with legacy software environments, gaps in interoperability, and the level of expertise still required to effectively leverage semantic models.

Prakash, Anand Krishnan↗

DOE OSTI2025

Optimization of an aerostructural machining process using physics-guided Bayesian stability modelling

Existing algorithms for predicting milling chatter have not been widely adopted in industry since they require specialized instruments to measure the stability inputs. This study describes how the machining process for a meter-scale aluminum aerostructure was optimized using a physics-guided Bayesian stability model. The study was performed in collaboration with an industrial partner on production machines to evaluate the practicality of the proposed method under real-world conditions. For each cutting tool, the Bayesian approach automatically selected a small number of cutting tests, which were monitored using a microphone to observe the chatter frequency. The algorithm learned the system dynamics, cutting forces, and stability map from these test results. A novel algorithm for predicting tool bending stress was incorporated into the test selection algorithm to avoid tool breakage. On average, each set of optimized cutting parameters required less than six tests to identify and were 97% more productive than baseline parameters from the cutting tool manufacturer. The machining program was then further optimized using commercial feedrate scheduling software to remove cutting force spikes and reduce air cutting time. Five components were machined using the optimized process. These results demonstrate the potential for physics-guided Bayesian models to improve productivity in industrial settings.

Cornelius, Aaron [UT Knoxville]↗

DOE OSTI2022

Deadlock prediction via generalized dependency

Deadlocks are notorious bugs in multithreaded programs, causing serious reliability issues. However, they are difficult to be fully expunged before deployment, as their appearances typically depend on specific inputs and thread schedules, which require the assistance of dynamic tools. However, existing deadlock detection tools mainly focus on locks, but cannot detect deadlocks related to condition variables. This paper presents a novel approach to fill this gap. It extends the classic lock dependency to generalized dependency by abstracting the signal for the condition variable as a special resource so that communication deadlocks can be modeled as hold-and-wait cycles as well. It further designs multiple practical mechanisms to record and analyze generalized dependencies. In the end, this paper presents the implementation of the tool, called UnHang. Experimental results on real applications show that UnHang is able to find all known deadlocks and uncover two new deadlocks. Overall, UnHang only imposes around 3% performance overhead and 8% memory overhead, making it a practical tool for the deployment environment.

Zhou, Jinpeng↗

DOE OSTI2015

Hoosier Magnetics

Hoosier Magnetics proposes to replace the indirect clinker water cooling system with a cooling system that recycles heat from the hot ferrite to preheat the combustion air. This innovative process would significantly reduce the amount of natural gas required to heat the combustion air while eliminating Hoosier’s largest source of downtime. According to the Department of Energy’s Industrial Technologies Program for Energy Efficiency and Renewable Energy, process temperature is customarily used as a rough indication of where preheating air will be cost effective. Previous studies have concluded that processes operating above 1,600° F are ideal candidates for the utilization of pre-heated combustion air. Hoosier Magnetics’ operating temperatures run between 1800-2200° F making Hoosier the perfect candidate. Using preheated air at 1200° F will result in 35% fuel savings, or $298,935 annually. Additionally, the new system would have improved process reliability and result in both production efficiency increases and cost savings. This technology is NOT practiced or utilized on a wide-spread basis but could have a significant energy reduction impact in many different high heat utilizing industries in the country. While the energy savings is apparent with this theory the application and design of such a process has not been studied.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

FEMP Facility Evaluation (Audit) Decision Tree

This document is a resource to be used in concert with FEMP Audit Definitions, FEMP Consolidated Facility Management Guidance, and agency best practices and expert judgment—for agencies to use to determine the best approaches to evaluate their facilities. It features a decision tree that provides a framework for agencies to interpret gathered facility data to understand the existing conditions; benchmark the facility against others in the portfolio to determine whether an on-site or remote audit is appropriate for a facility; determine the best remote or on-site audit level of detail to meet agency facility auditing goals, such as meeting Energy Independence and Security Act of 2007 requirements and developing projects; and improve their energy and water management programs.

auditing↗

DOE OSTI2017

URS/WTP's Future Leader Program and AECOM's Early Career Professional Technology Exchange - 17239

URS Energy and Construction, Inc. (URS), a subsidiary of AECOM, is the Bechtel National, Inc. (BNI) teaming subcontractor on the Hanford Tank Waste Treatment and Immobilization Plant (WTP) Project. Recently, the WTP Project has begun a transition toward facility turnover and commissioning. With that transition came the hiring of staff for the startup and commissioning workforce. With many of these individuals being Early Career Professionals (ECPs), URS recognized a need to create and implement a workforce development program to give these professionals the skills to thrive in a professional environment and provide a sense of community to improve talent retention. The result of this recognition of need was the creation of URS/WTP Future Leaders. This paper will share the successes and lessons learned related to founding the URS/WTP Future Leaders. This includes establishing programs such as the Continuous Learning Workshops, Rotational Program, and implementing a mentor program. In addition, establishing a budget and obtaining support from Human Resources will be discussed. By March 2017, the ECP program will have been in effect for approximately two years. As a separate effort, many of AECOM's major waste remediation contractors have started having Early Career Professional Technology Exchanges (ECP TE) in an effort to create collaboration between sites and to establish industry contacts that will continue to be a resource for years to come. Washington River Protection Solutions, LLC; URS/WTP; Savannah River Remediation, LLC; and Nuclear Waste Partnership, LLC have conducted ECP TE, with each site hosting an event. For these events, each participant prepares a presentation and answers questions on the presentation topic. This allows ECPs to practice presentation skills, develop skills in answering questions from their peers and management, and be the expert in the room on a particular topic. Tours of the onsite facilities also are given as a way for ECPs to gain a broader understanding of the waste remediation industry and the challenges that other sites are facing. Accomplishments, lessons learned, and future plans for ECP TE will be discussed. The ECP TE events allow AECOM, as the parent company, to provide a unique learning opportunity to the next generation of engineers within the DOE nuclear field and to ensure the safe operations of these nuclear sites for years to come. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Land-Use Change Impact on Soil Sustainability in a Climate and Vegetation Transition Zone

A growing world population and climate change are expected to influence future agricultural productivity and land use. This study determined the impact of land-use change on soil sustainability and discussed the factors contributing to these changes. South Dakota was selected as a model system because corn ( Zea mays L.) grain prices tripled between 2006 and 2012 and it is located in a climate and grassland/cropland transition zone. High resolution imagery was used to visually determine land uses (cropland, grassland, nonagricultural, habitat, and water) at 14,400 points in 2006 and 2012. At each point, land-use change and the USDA land capability class (LCC) were determined. Over the 6-yr study period, 6.87% of the grasslands (730,000 ha) were converted to cropland, with 93% occurring on lands generally considered suitable for crop production (LCC ≤ IV) if appropriate practices are followed. Converted grasslands, however, had higher LCC values than existing croplands and lower LCC values than remaining grasslands. In addition, 4.2% of the croplands (250,000 ha) were converted to grasslands, and statewide, 20,000 ha of croplands were converted to grasslands in areas limited by excess water (LCC V). The conversion of grasslands could not be linked to one specific factor and may be related to: (i) a desire to increase financial returns, (ii) changes in the land ownership structure, (iii) technology improvements, (iv) governmental policies, (v) climate change, and (vi) an aging workforce. Here, research and outreach programs that balance the goods and services of different land uses are needed to maintain sustainable agroecosystems.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Resilience Lessons From the Southeast United States Woody Pellet Supply Chain Response to the COVID-19 Pandemic†

The Coronavirus Disease 2019 (COVID-19) instigated a pandemic that impacted economies, employment, and shipping worldwide. This paper reviews how one international supply chain performed and identifies lessons that may be helpful to improve future resilience. Economic and employment data through November 2020 are used to review the effects of COVID-19 on operations of the bioenergy supply chain in the southeastern United States (SE United States) that utilizes wood fiber to fabricate pellets. Conditions associated with the production of pellets in the SE United States changed with the outbreak of COVID-19. Federal and state government programs and classification of workers in this sector as “essential” during the pandemic helped maintain the woody pellet supply chain and other industries during a period of general shut down in 2020. The availability of personal protective equipment, long-term supply contracts, and established safety cultures are among the factors that enhance supply chain resilience while limited availability of skilled workers, inadequate stakeholder engagement, and dependence on external policies are among factors that reduce resilience. The analysis concludes with recommendations for the SE pellet supply chain, and other biomass supply chains, to improve their resilience to future disturbances. When best practices are implemented, SE United States biomass offers opportunities to contribute to post-pandemic economic recovery while incentivizing better forest resource management.

09 BIOMASS FUELS↗

DOE OSTI2024

Preparation and Characterization of Materials for Low- to Intermediate-Temperature CO2 Adsorption

Global carbon dioxide emissions are rising and the use of fossil fuels in several sectors are the leading causes. As global population and economies continue to grow significantly, the most practical method of lowering such emissions is to capture CO2. Although other technologies are more developed, adsorption is very promising and has attracted much attention. To ensure this technology’s success, it is essential to have suitable CO2 adsorbent materials. In this work, several new hydrotalcites (HTs) with different initial concentrations of ion precursors were prepared for the first time by the co-precipitation method—it was possible to verify that the ion concentrations influence the characteristics of the materials. The prepared HTs were characterized by thermogravimetric analysis (TG), X-Ray diffraction (XRD), surface area measurements and temperature-programmed desorption of CO2 (TPD-CO2) to relate their CO2 capture capacity to their physicochemical properties; the CO2 adsorption equilibrium isotherms were determined at 35 and 300 °C for the prepared samples, as well as for some commercial materials: magnesium oxide, calcium oxide, aluminium oxide and Zeolite 13X. After determining which materials present the best CO2 adsorption capacity, these were submitted to adsorption-desorption cycles to study their stability. The main objective of the work was to prepare and study different CO2 adsorbents for processes that are carried out at low and intermediate temperatures. From the experimental results, it was possible to conclude that the Zeolite 13X showed the best capacity at 35 °C, 3.38 mmol·g−1 (@ pCO2 = 1 bar), and a prepared calcined HT (c-HT2) was the best at 300 °C, 0.97 mmol·g−1 (@ pCO2 = 1 bar). Moreover, it seems there is an optimum initial concentration of the ions’ solutions for the tested HTs, which depends on the final application—c-HT1 showed a better capacity at 35 °C and c-HT2 at 300 °C. From the adsorption-desorption cycles—performed at 35 and 300 °C with the best materials using a magnetic suspension microbalance at 1 bar of CO2 partial pressure —, a working cyclic capacity of 2.69 mmol∙g−1 was achieved by the Zeolite at 35 °C; in turn, c-HT2 showed a working cyclic capacity of 0.79 mmol∙g−1 at 300 °C.

Figueiredo, Anabela↗

DOE OSTI2020

Carbon Cycling, Environmental & Rural Economic Impacts of Collecting & Processing Specific Woody Feedstocks in Biofuels

Woody biomass will be an essential feedstock for a large-scale cellulosic biofuel industry. The life cycle carbon accounting for the production of biofuels from woody feedstocks is complex and has engendered significant controversy. Issues such as below ground carbon, carbon debt, varied regional forest practices, multiple parallel forest product lines, and development of realistic counterfactual scenarios all contribute to the complexity. DOE funded CORRIM to develop comprehensive and definitive lifecycle inventories and assessments on the production of fuels from woody feedstocks. CORRIM brought together expertise in forest practices, short rotation woody crops, bioconversion of woody biomass, process modeling, and life cycle assessment to successfully accomplish this goal. The CORRIM team has developed data on forest productivity, fuel usage, and fuel production for six regionally specific forest systems. These six forest systems include three current commercial systems; southern pine plantations, Douglas-fir plantations, naturally regenerated Northeastern (NE) spruce/fir, and three ‘short rotation woody crops’, poplar, eucalyptus and willow, which are at different stages of demonstration in the US. The fuel production systems include cellulosic ethanol and bio-oil based hydrocarbons. The project was successfully reviewed at the BETO Program review in March 2015, 2017, and 2019 and has resulted currently in 19 publications and reports and 35 presentations at both national and international conferences, with more in the pipeline. See publications and presentations for links to each document. Finally, and most importantly, CORRIM has gone beyond the scope of the original DOE proposal to work closely with GREET at Argonne National Laboratory (ANL) to incorporate all the life cycle data and scenario models into their modeling system. GREET is the most widely used and definitive information source for evaluating lifecycle carbon emissions for fuels. The incorporation of CORRIM data from this project guarantees the results of the research will be extensively used and widely disseminated. Technical process improvements and policy relevant accomplishments are detailed in the relevant programmatic sections in the full report including citations therein. Highlights are summarized here for easy reference.

09 BIOMASS FUELS↗