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DOE OSTI2020

Computationally Aided Design of a Small-Scale Waste-Glass Melter - 20452

To provide mission support to the WTP for the vitrification of legacy nuclear tank waste at the Hanford site, a reduced-scale vitrification pilot system is being designed to process simulated and actual radioactive tank wastes. The waste stored in underground tanks will be separated into HLW and LAW fractions, where the majority is LAW by mass (approximately 90%) and HLW by activity (greater than 95%). The first tank waste to be processed at the WTP will be LAW. Because Hanford tank waste and the resultant melter feed compositions are known to vary widely, pilot-scale operations are essential to identify potential problems, provide needed data, confirm assumptions, and determine impacts to full-scale melters and off-gas systems from these different feeds. In addition, the reduced-scale melter system must be capable of quickly providing results to operations without the typically high cost of full-scale radioactive operations and to provide an engineering platform in close proximity to local operations staff. The objectives of this computational modeling effort are to produce process conditions like those encountered in the WTP LAW melters and to minimize the volume of radioactive waste necessary for the evaluations. To this end, melter design features are being explored to increase production without significantly increasing surface area or melter-glass volumes or compromising data quality. In support of these objectives, a set of computational fluid dynamic models was developed to provide insight into the flow patterns within these small melters and evaluate design features to increase production without significantly increasing glass inventory. Computed velocities were evaluated at the interface between the cold cap and the molten-glass pool and within the bulk-glass pool. Since melt rate correlates with the velocity underneath the cold cap, this information can be used to select design features that produce the highest gains. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Computer Based Procedures for Field Workers - FY16 Research Activities

The Computer-Based Procedure (CBP) research effort is a part of the Light-Water Reactor Sustainability (LWRS) Program, which provides the technical foundations for licensing and managing the long-term, safe, and economical operation of current nuclear power plants. One of the primary missions of the LWRS program is to help the U.S. nuclear industry adopt new technologies and engineering solutions that facilitate the continued safe operation of the plants and extension of the current operating licenses. One area that could yield tremendous savings in increased efficiency and safety is in improving procedure use. A CBP provides the opportunity to incorporate context-driven job aids, such as drawings, photos, and just-in-time training. The presentation of information in CBPs can be much more flexible and tailored to the task, actual plant condition, and operation mode. The dynamic presentation of the procedure will guide the user down the path of relevant steps, thus minimizing time spent by the field worker to evaluate plant conditions and decisions related to the applicability of each step. This dynamic presentation of the procedure also minimizes the risk of conducting steps out of order and/or incorrectly assessed applicability of steps. This report provides a summary of the main research activities conducted in the Computer-Based Procedures for Field Workers effort since 2012. The main focus of the report is on the research activities conducted in fiscal year 2016. The activities discussed are the Nuclear Electronic Work Packages – Enterprise Requirements initiative, the development of a design guidance for CBPs (which compiles all insights gained through the years of CBP research), the facilitation of vendor studies at the Idaho National Laboratory (INL) Advanced Test Reactor (ATR), a pilot study for how to enhance the plant design modification work process, the collection of feedback from a field evaluation study at Plant Vogtle, and path forward to commercialize INL’s CBP system.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

System, method, and computer program for creating an internal conforming structure

A system for creating an internal formation of a tubular structure having an inner surface via additive manufacturing. The system broadly includes a computer modeling system and an additive manufacturing system. The computer modeling system may include a processor for generating a lattice cellular component via computer-aided design software according to inputs received from a user. The processor may also generate an internal formation lattice structure based on the lattice cellular component and modify the lattice structure to follow and/or conform to the curvature of the inner surface of the outer wall of the tubular structure. The additive manufacturing system may be configured to produce the lattice structure and the tubular structure via additive manufacturing material deposited layer by layer according to the lattice structure.

42 ENGINEERING↗

DOE OSTI2016

Lightweight Mechanical Metamaterials with Tunable Negative Thermal Expansion

Ice floating on water is a great manifestation of negative thermal expansion (NTE) in nature. The limited examples of natural materials possessing NTE have stimulated research on engineered structures. Previous studies on NTE structures were mostly focused on theoretical design with limited experimental demonstration in two-dimensional planar geometries. Here, in this work, aided with multimaterial projection microstereolithography, we experimentally fabricate lightweight multimaterial lattices that exhibit significant negative thermal expansion in three directions and over a temperature range of 170 degrees. Such NTE is induced by the structural interaction of material components with distinct thermal expansion coefficients. The NTE can be tuned over a large range by varying the thermal expansion coefficient difference between constituent beams and geometrical arrangements. Our experimental results match qualitatively with a simple scaling law and quantitatively with computational models.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Research Software Engineering Efforts for DataFed: FY2021 Developments

DataFed is a scientific data management system for big data providing simple and uniform data access, organization, discovery, and sharing within and across scientific facilities - with the goals of enhancing productivity and scientific reproducibility. We hope to aid in communicating development contributions to DataFed over the last year and any planning we can provide for the future developments in the next year

42 ENGINEERING↗

DOE OSTI2017

Techbelt Energy Innovation Center

This project consisted of three main components 1) The primary goal of the project was to renovate and upgrade an existing commercial building to the highest possible environmentally sustainable level for the purpose of creating an energy incubator. This initiative was part of the Infrastructure Technologies Program, through which a sustainable energy demonstration facility was to be created and used as a research and community outreach base for sustainable energy product and process incubation; 2) In addition, fundamental energy related research on wind energy was performed; a shrouded wind turbine on the Youngstown State University campus was commissioned; and educational initiatives were implemented; and 3) The project also included an education and outreach component to inform and educate the public in sustainable energy production and career opportunities. Youngstown State University and the Tech Belt Energy Innovation Center (TBEIC) renovated a 37,000 square foot urban building which is now being used as a research and development hub for the region’s energy technology innovation industry. The building houses basic research facilities and business development in an incubator format. In addition, the TBEIC performs community outreach and education initiatives in advanced and sustainable energy. The building is linked to a back warehouse which will eventually be used as a build-out for energy laboratory facilities. The projects research component investigated shrouded wind turbines, and specifically the “Windcube” which was renamed the “Wind Sphere” during the course of the project. There was a specific focus on the development in the theory of shrouded wind turbines. The goal of this work was to increase the potential efficiency of wind turbines by improving the lift and drag characteristics. The work included computational modeling, scale models and full-sized design and construction of a test turbine. The full-sized turbine was built on the YSU campus as a grid-tie system that supplies the YSU research facility. Electrical power meters and weather monitors were installed to record the power generated and aid in continued study. In addition, an education/outreach component to help elicit creative engineering and design from amongst area students, faculty, entrepreneurs, and small business in the energy related fields was performed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Science &Technology Review (September 2022)

Computer modeling is essential to scientific research. Models simulate natural phenomena to aid scientists in understanding their underlying principles. While the most complex models running on supercomputers may contain millions of lines of code and generate billions of data points, models never simulate reality perfectly. Experiments—in contrast—have been fundamental to the study of natural phenomena from science’s earliest days. However, some of today’s complex experiments generate too much data for the human mind to interpret.

42 ENGINEERING↗

DOE OSTI2016

Computational homogenization at extreme scales

Multi-scale simulations at extreme scales in terms of both physical length scales and computational resources are presented. In this letter, we introduce a hierarchically parallel computational homogenization solver that employs hundreds of thousands of computing cores and resolves in material length scales (from to ). Simulations of this kind are important in understanding the multi-scale essence of many natural and synthetically made materials. Thus, we present a simulation consisting of 53.8 Billion finite elements with 28.1 Billion nonlinear equations that is solved on 393,216 computing cores (786,432 threads). The excellent parallel performance of the computational homogenization solver is demonstrated by a strong scaling test from 4,096 to 262,144 cores. A fully coupled multi-scale damage simulation shows a complex crack profile at the micro-scale and the macroscopic crack tunneling phenomenon. Such large and predictive simulations are an important step towards Virtual Materials Testing and can aid in development of new material formulations with extreme properties. Furthermore, the high computational efficiency of our computational homogenization solver holds great promise for utilizing the next generation of exascale parallel computing platforms that are expected to accelerate computations through orders of magnitude increase in parallelism rather than speed of each processor.

Engineering↗

DOE OSTI2021

Low voltage drop tunnel junctions grown monolithically by MOCVD

Tunnel junction devices grown monolithically by metal organic chemical vapor deposition were optimized for minimization of the tunnel junction voltage drop. Here, two device structures were studied: an all-GaN homojunction tunnel junction and a graded InGaN heterojunction-based tunnel junction. This work reports a record-low voltage drop in the graded-InGaN heterojunction based tunnel junction device structure achieving a de-embedded tunnel junction voltage drop of 0.17 V at 100 A/cm 2 . The experimental data were compared with a theoretical model developed through technology computer-aided design (TCAD) simulations that offer a physics-based approach to understanding the key components of the design space, which lead to a more efficient tunnel junction.

42 ENGINEERING↗

DOE OSTI2020

Computationally-Aided Design of a Small-Scale Radioactive Waste Glass Melter

To provide mission support to the Hanford Waste Immobilization and Treatment Plant for the vitrification of legacy nuclear tank waste, a reduced-scale vitrification pilot system is being designed to process simulated and actual radioactive tank wastes. The tank waste will be separated into high-level waste (HLW) and low-activity waste (LAW) fractions, where the majority by mass (~90%) is LAW and by activity (>95%) is HLW. The first tank waste to be processed at the WTP will be LAW. Since Hanford tank waste and the resultant melter feed compositions are known to vary widely, pilot-scale operations are essential to identify potential problems, provide needed data, confirm assumptions, and determine impacts to full-scale melters and off-gas systems from these different feeds. In addition, the reduced-scale melter system must be capable of quickly providing results to operations without the typically high costs of radioactive operations and provide an engineering platform in close proximity to local operations staff. The objective is to produce similar process conditions to those encountered in the full-scale LAW melters and minimize the volume of radioactive waste necessary for the evaluations. To this end, melter design features are being explored to increase production without significantly increasing surface area, melter glass volumes or compromising data quality. In support of these objectives, a set of computational fluid dynamic models have been developed to provide insight into the flow patterns within these small melters and evaluate design features to increase production without significantly increasing glass inventory. Computed velocities were evaluated at the interface between the cold cap and the molten glass pool and within the bulk glass pool. A method was developed to correlate results to an estimated melt rate and down-select design features that produce the highest gains.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Computationally-Aided Design of a Small-Scale Radioactive Waste Glass Melter

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Interpreting and designing microbial communities for bioprocess applications, from components to interactions to emergent properties

Interest in microbial communities for bioprocessing has surged in recent years based on the potential to optimize multiple tasks simultaneously and to enhance process productivity and stability. The presence and magnitude of these desirable system properties often result from interactions between functionally distinct community members. The importance of interactions, while appreciated by some disciplines for decades, has gained interest recently due to the development of ‘omics techniques, polymicrobial culturing approaches, and computational methods which has made the systems-level analysis of interacting components more tractable. This review defines and categorizes natural and engineered system components, interactions, and emergent properties, as well as presents three ecological theories relevant to microbial communities. Case studies are interpreted to illustrate components, interactions, emergent properties and agreement with theoretical concepts. A general foundation is laid to facilitate interpretation of current systems and to aid in future design of microbial systems for the next generation of bioprocesses.

community↗

DOE OSTI2015

Surface Triangulation for CSG in Mercury

Visualization routines for rendering complicated geometries are very useful for engineers and scientists who are trying to build 3D prototypes of their designs. A common way to rapidly add interesting features to a 3D model is through the use of a concept called Constructive Solid Geometry. CSG uses compositions of the boolean set operations to manipulate basic geometric primitives to form more complicated objects. The most common boolean operations employed are union, intersection, and subtraction. Most computer-aided design software packages contain some sort of ability visualize CSG. The typical workflow for the user is as follows: The user specifies the individual primitive components, the user arbitrarily combines each of these primitives with boolean operations, the software generates a CSG tree structure which normally stores these solids implicitly with their defining equation, the tree is traversed and a general algorithm is applied to render the appropriate geometry onto the screen. Algorithms for visualizing CSG have been extensively developed for over a decade. Points sampled from the implicit solids are typically used as input by variations of algorithms like marching cubes and point-cloud surface reconstruction. Here, we explain a surface triangulation method from the graphics community that is being used for surface visualization in the framework of a Monte-Carlo neutron transport code called Mercury.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Leveraging 3D CAD and Virtual Reality in Design of the Calcine Disposition Project - 20512

Fluor Idaho's Calcine Disposition Project (CDP) is leveraging the power of three-dimensional (3D) visualization, light detection and ranging (Lidar), and virtual reality to improve designs and worker safety. With the use of computer-aided design (CAD) modeling software, the CDP has created 3D models of the facility and systems to aid in the design, development, and operation of its retrieval and transfer system. This by itself is nothing new and has been done in industry for years. The CDP project however is taking this a few steps farther with the use of Lidar and virtual reality software. The CRP is tasked with removing a radioactive granular material from stainless steel bins located in concrete vaults that were constructed in the late 1950's and early 1960's. While construction drawings are available, it is not certain that the drawings are as-built or how accurate they truly are. Part of the project requires precise placement of equipment on to bins around multiple pipe, electrical lines, and bin stiffeners. Relying solely on the existing drawings and models created from these drawings is highly risky and prone to failure. The first step to determine the precise location and orientation of all obstructions in the vault the project will use a Lidar system to scan the vault structure and precisely locate all vault and bin components. Once this information is obtained, the data will be integrated into the CAD model. The model will then be verified, and a true as-built model developed. Precise component location, size, and orientation will be used for final design and placement of retrieval components. The second step will be to take the verified 3D model and scan data and import it into virtual reality software creating a virtual world. While some work on the project requires all work to be completed remotely due to high radiation fields, some areas have low enough radiation levels that personnel can enter and perform work. With the use of a virtual reality headset, operators and technicians will be able to enter our virtual world and become familiar with the surroundings and perform work prior to ever entering the radiation environment. This training is expected to pay dividends by improving worker efficiency, reducing errors, and improving confidence that the work can be performed as expected. It will play a key aspect in as low as reasonably achievable (ALARA) principles. An additional aspect in using the Lidar scans and virtual environment, is that it will give engineers and managers an opportunity to revisit the facility, especially radiation areas, at any time to obtain design information and measurements that may be costly or impossible to obtain once the facility transitions into radiation operations. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2013

Hierarchical Krylov and nested Krylov methods for extreme-scale computing

The solution of large, sparse linear systems is typically a dominant phase of computation for simulations based on partial differential equations, which are ubiquitous in scientific and engineering applications. While preconditioned Krylov methods are widely used and provide many advantages for solving sparse linear systems that do not have highly convergent, geometric multigrid solvers or specialized fast solvers, Krylov methods encounter well-known scaling difficulties for over 10,000 processor cores because each iteration requires at least one vector inner product, which in turn requires a global synchronization that scales poorly because of internode latency. To aid in overcoming these difficulties, we have developed hierarchical Krylov methods and nested Krylov methods in the PETSc library that reduce the number of global inner products required across the entire system (where they are expensive), though freely allow vector inner products across smaller subsets of the entire system (where they are inexpensive) or use inner iterations that do not invoke vector inner products at all. Nested Krylov methods are a generalization of inner-outer iterative methods with two or more layers. Hierarchical Krylov methods are a generalization of block Jacobi and overlapping additive Schwarz methods, where each block itself is solved by Krylov methods on smaller blocks. Conceptually, the hierarchy can continue recursively to an arbitrary number of levels of smaller and smaller blocks. As a specific case, we introduce the hierarchical FGMRES method, or h-FGMRES, and we demonstrate the impact of two-level h-FGMRES with a variable preconditioner on the PFLOTRAN subsurface flow application. We also demonstrate the impact of nested FGMRES, BiCGStab and Chebyshev methods. These hierarchical Krylov methods and nested Krylov methods significantly reduced overall PFLOTRAN simulation time on the Cray XK6 when using 10,000 through 224,000 cores through the combined effects of reduced global synchronization due to fewer global inner products and stronger inner hierarchical or nested preconditioners.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2016

TH-EF-BRB-03: Significant Cord and Esophagus Dose Reduction by 4π Non-Coplanar Spine Stereotactic Body Radiation Therapy and Stereotactic Radiosurgery

Purpose: To demonstrate significant organ-at-risk (OAR) sparing achievable with 4π non-coplanar radiotherapy on spine SBRT and SRS patients. Methods: Twenty-five stereotactic spine cases previously treated with VMAT (n = 23) or IMRT (n = 2) were included in this study. A computer-aided-design model of a Linac with a 3D-scanned human surface was utilized to determine the feasible beam space throughout the 4π steradian and beam specific source-to-target-distances (STD) required for collision avoidance. 4π radiotherapy plans integrating beam orientation and fluence map optimization were then created using a column-generation algorithm. Twenty optimal beams were selected for each case. To evaluate the tradeoff between dosimetric benefit and treatment complexity, 4π plans including only isocentrically deliverable beams were also created. Beam angles of all standard and isocentric 4π plans were imported into Eclipse to recalculate the dose using the same calculation engine as the clinical plans for unbiased comparison. OAR and PTV dose statistics for the clinical, standard-4π, and isocentric-4π plans were compared. Results: Comparing standard-4π to clinical plans, particularly significant average percent reduction in the [mean, maximum] dose of the cord and esophagus of [41%, 21.7%], and [38.7%, 36.4%] was observed, along with global decrease in all other OAR dose statistics. The average cord volume receiving more than 50% prescription dose was substantially decreased by 76%. In addition, improved PTV coverage was demonstrated with a maximum dose reduction of 0.93% and 1.66% increase in homogeneity index (D95/D5). All isocentric-4π plans achieved dosimetric performance equivalent to that of the standard-4π plans with higher delivery complexity. Conclusion: 4π radiotherapy significantly improves stereotactic spine treatment dosimetry. With the substantial OAR dose sparing, PTV dose escalation is considerably safer. Isocentric-4π is sufficient to achieve the dosimetric gain. The successful implementation of 4π using an FDA approved planning system paves the way for a prospective clinical trial. Varian Medical Systems, NIH R43CA183390 and R01CA188300, NSF graduate research fellowship DGE-1144087.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

The Concept of a Quantum Edge Simulator: Edge Computing and Sensing in the Quantum Era

Sensors, enabling observations across vast spatial, spectral, and temporal scales, are major data generators for information technology (IT). Processing, storing, and communicating this ever-growing amount of data pose challenges for the current IT infrastructure. Edge computing—an emerging paradigm to overcome the shortcomings of cloud-based computing—could address these challenges. Furthermore, emerging technologies such as quantum computing, quantum sensing, and quantum communications have the potential to fill the performance gaps left by their classical counterparts. Here, we present the concept of an edge quantum computing (EQC) simulator—a platform for designing the next generation of edge computing applications. An EQC simulator is envisioned to integrate elements from both quantum technologies and edge computing to allow studies of quantum edge applications. The presented concept is motivated by the increasing demand for more sensitive and precise sensors that can operate faster at lower power consumption, generating both larger and denser datasets. These demands may be fulfilled with edge quantum sensor networks. Envisioning the EQC era, we present our view on how such a scenario may be amenable to quantification and design. Given the cost and complexity of quantum systems, constructing physical prototypes to explore design and optimization spaces is not sustainable, necessitating EQC infrastructure and component simulators to aid in co-design. We discuss what such a simulator may entail and possible use cases that invoke quantum computing at the edge integrated with new sensor infrastructures.

47 OTHER INSTRUMENTATION↗

DOE OSTI2014

Light Water Reactor Sustainability Program: Computer-Based Procedures for Field Activities: Results from Three Evaluations at Nuclear Power Plants

The Computer-Based Procedure (CBP) research effort is a part of the Light-Water Reactor Sustainability (LWRS) Program, which is a research and development (R&D) program sponsored by Department of Energy (DOE) and performed in close collaboration with industry R&D programs that provides the technical foundations for licensing and managing the long-term, safe, and economical operation of current nuclear power plants. One of the primary missions of the LWRS program is to help the U.S. nuclear industry adopt new technologies and engineering solutions that facilitate the continued safe operation of the plants and extension of the current operating licenses. One area that could yield tremendous savings in increased efficiency and safety is in improving procedure use. Nearly all activities in the nuclear power industry are guided by procedures, which today are printed and executed on paper. This paper-based procedure process has proven to ensure safety; however, there are improvements to be gained. Due to its inherent dynamic nature, a CBP provides the opportunity to incorporate context driven job aids, such as drawings, photos, and just-in-time training. Compared to the static state of paper-based procedures (PBPs), the presentation of information in CBPs can be much more flexible and tailored to the task, actual plant condition, and operation mode. The dynamic presentation of the procedure will guide the user down the path of relevant steps, thus minimizing time spent by the field worker to evaluate plant conditions and decisions related to the applicability of each step. This dynamic presentation of the procedure also minimizes the risk of conducting steps out of order and/or incorrectly assessed applicability of steps.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗