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DOE OSTI2016

SU-F-T-294: The Analysis of Gamma Criteria for Delta4 Dosimetry Using Statistical Process Control

Purpose: To evaluate the sensitivity of gamma criteria for patient-specific volumetric modulated arc therapy(VMAT) quality assurance of the Delta{sup 4} dosimetry program using the statistical process control(SPC) methodology. Methods: The authors selected 20 patient-specific VMAT QA cases which were undertaken MapCHECK and ArcCHECK with gamma pass rate better than 97%. The QAs data were collected Delta4 Phantom+ and Elekta Agility six megavolts without using an angle incrementer. The gamma index(GI) were calculated in 2D planes with normalizing deviation to local dose(local gamma). The sensitivity of the GI methodology using criterion of 3%/3mm, 3%/2mm and 2%/3mm was analyzed with using process acceptability indices. We used local confidence(LC) level, the upper control limit(UCL) and lower control limit(LCL) of I-MR chart for process capability index(Cp) and a process acceptability index (Cpk). Results: The lower local confidence levels of 3%/3mm, 3%/2mm and 2%/3mm were 92.0%, 83.6% and 78.8% respectively. All of the calculated Cp and Cpk values that used LC level were under 1.0 in this study. The calculated LCLs of I-MR charts were 89.5%, 79.0% and 70.5% respectively. These values were higher than 1.0 which means good quality of QA. For the generally used lower limit of 90%, we acquired over 1.3 of Cp value for the gamma index of 3%/3mm and lower than 1.0 in the rest of GI. Conclusion: We applied SPC methodology to evaluate the sensitivity of gamma criteria and could see the lower control limits of VMAT QA for the Delta 4 dosimetry and could see that Delta 4 phantom+ dosimetry more affected by the position error and the I-MR chart derived values are more suitable for establishing lower limits. Acknowledgement: This research was supported by Basic Science Research Program through the National Research Foundation of Korea(NRF) funded by the Ministry of Education (No. 2015R1D1A1A01060463)

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

TRA Warm Waste Treatment Facility Process Controller Replacement

This poster details the work I did to replace the TRA Warm Waste Treatment System Process Controller. Additionally, my poster explains what Warm waste is, how the warm waste treatment system functions, and the next steps moving forward in the engineering process.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Existence of a robust optimal control process for efficient measurements in a two-qubit system

The verification of quantum entanglement is essential for quality control in quantum communication. In this work we propose an efficient protocol to directly verify the two-qubit entanglement of a known target state through a single-expectation-value measurement. Our method provides exact entanglement quantification using the concurrence measure without performing quantum state tomography. We prove the existence of a unitary transformation that drives a known initial state of a two-qubit system to a designated final state, where the trace over a chosen observable directly yields the concurrence of the initial state. Furthermore, we implement an optimal control process of that transformation and demonstrate its effectiveness through numerical simulations. We also show that this process is robust to environmental noise. Our approach offers advantages in directly verifying entanglement with low circuit depth, making it suitable for industrial-scale quality control of entanglement generation. Our results presented here provide mathematical justification for our earlier computational experiments.

Rodriguez, Ricardo [McPherson Coll.] (ORCID:000000↗

DOE OSTI2019

Operation and Process Control Development for a Pilot-Scale Leaching and Solvent Extraction Circuit Recovering Rare Earth Elements from Coal-Based Sources

The US Department of Energy in 2010 has identified several rare earth elements as critical materials to clean technologies. As part of ongoing research in REEs recovery from coal sources, the University of Kentucky has designed, developed and is demonstrating a ¼ ton/hour pilot-scale processing plant to produce high grade REEs from coal sources. To accomplish process control, PLC systems design/deployment, overall operational design and the utilization of Six Sigma design methodology by the team will be presented. Furthermore, application of the controls design, both procedural and electronic, team’s utilization of data analysis and integration for database decision-making will be discussed.

Leaching↗

DOE OSTI2019

Accurately estimating and minimizing costs for the cellulosic biomass supply chain with statistical process control and the Taguchi Loss Function

This research focuses on the statistical evaluation of the feedstock attributes of the biomass supply chain and the estimation of attribute costs as a function of the feedstock variability. Challenges of using cellulosic feedstocks include the variability of feedstock quality (e.g., ash content and moisture content), which impacts the final cost of the manufactured product. Statistical Process Control (SPC), Taguchi Loss Function, and components of variance techniques were illustrated for quantifying cumulative variance in the biomass supply chain. Costs in the presence of cumulative variance were estimated for switchgrass (Panicum virgatum L.) and loblolly pine residues (Pinus taeda L.). Findings of the study indicated that additional costs from ash content variability in switchgrass increased the net cost by $\$19.15$ per dry tonne. Additional costs from densification due to particle size variation increased net cost by $\$11.59$ per dry tonne. Moisture content variation increased costs by $\$14.86$ per dry tonne. This would represent a 50 to 100% increase in costs due to variation based on a $\$60$ to $\$70$ per dry tonne manufactured product cost. This study illustrates that total costs may be considerably underestimated if the influence of variance for key factors in the supply chain and associated costs are not estimated.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2018

Influence of Thermomechanically Controlled Processing on Microstructure and Hydrogen Induced Cracking Susceptibility of API 5L X70 Pipeline Steel

The effect of different thermomechanical controlled processing routes on susceptibility of X70 pipeline steel to hydrogen induced cracking (HIC) have been studied. Two X70 pipeline steel specimens labelled WE and WD were investigated. These specimens have the same chemical composition, but they were processed with seperate thermomechanical treatments parameters. Microstructural examinations showed that WE consists of mainly acicular ferrite and polygonal ferrite, while WD consists of acicular ferrite and bainitic ferrite. After subjecting both specimens to hydrogen charging for 12 and 16 h in 0.2 M sulfuric acid and 3 g/L ammonium thiocyanate, early onset of HIC was observed in specimen WD. Post-hydrogen charging microstructural evaluation showed the nucleation of discontinuous cracks in WD after 12 h of charging. However, extended charging for up to 16 h resulted in HIC along the mid-thickness region of both specimens. Hydrogen diffusion across specimen WE was better than that of specimen WD. Therefore, hydrogen trapping at grain boundaries, banded deformed grains, inclusions and secondary phases such as martensite and cementite aided initiation and propagation of HIC in specimens. Nevertheless, the adverse effect of these features on HIC risks was more prominent in specimen WD compared to specimen WE. The Vickers microhardness values measured in WD (349.6 HV) and WE (307.4 HV) suggest that WD is harder than WE; and higher kernel average misorientation of 0.66° in WD than in WE (0.58°) shows higher dislocation density in WD. The results from slow strain rate tensile test confirmed that specimen WD was stronger and more susceptible to HIC than specimen WE. It was concluded that microstructural phases developed during thermomechanical processing improved strength in WD at the expense of its crack resistance, while WE with lower strength showed more ductility and higher resistance to HIC.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Operation and Process Control Development for a Pilot-Scale Leaching and Solvent Extraction Circuit Recovering Rare Earth Elements From Coal-Based Sources

The US Department of Energy in 2010 has identified several rare earth elements as critical materials to enable clean technologies. As part of ongoing research in REEs (rare earth elements) recovery from coal sources, the University of Kentucky has designed, developed and is demonstrating a ¼ ton/hour pilot-scale processing plant to produce high-grade REEs from coal sources. Due to the need to control critical variables (e.g. pH, tank level, etc.), process control is required. To ensure adequate process control, a study was conducted on leaching and solvent extraction control to evaluate the potential of achieving low-cost REE recovery in addition to developing a process control PLC system. The overall operational design and utilization of Six Sigma methodologies is discussed. Further, the application of the controls design, both procedural and electronic for the control of process variables such as pH is discussed. Variations in output parameters were quantified as a function of time. Data trends show that the mean process variable was maintained within prescribed limits. Future work for the utilization of data analysis and integration for data-based decision-making will be discussed.

coal, rare earth elements, pilot plant, automation↗

DOE OSTI2023

Optimization of nutrient utilization efficiency and productivity for algal cultures under light and dark cycles using genome-scale model process control

Abstract Algal cultivations are strongly influenced by light and dark cycles. In this study, genome-scale metabolic models were applied to optimize nutrient supply during alternating light and dark cycles of Chlorella vulgaris . This approach lowered the glucose requirement by 75% and nitrate requirement by 23%, respectively, while maintaining high final biomass densities that were more than 80% of glucose-fed heterotrophic culture. Furthermore, by strictly controlling glucose feeding during the alternating cycles based on model-input, yields of biomass, lutein, and fatty acids per gram of glucose were more than threefold higher with cycling compared to heterotrophic cultivation. Next, the model was incorporated into open-loop and closed-loop control systems and compared with traditional fed-batch systems. Closed-loop systems which incorporated a feed-optimizing algorithm increased biomass yield on glucose more than twofold compared to standard fed-batch cultures for cycling cultures. Finally, the performance was compared to conventional proportional-integral-derivative (PID) controllers. Both simulation and experimental results exhibited superior performance for genome-scale model process control (GMPC) compared to traditional PID systems, reducing the overall measured value and setpoint error by 80% over 8 h. Overall, this approach provides researchers with the capability to enhance nutrient utilization and productivity of cell factories systematically by combining genome-scale models and controllers into an integrated platform with superior performance to conventional fed-batch and PID methodologies.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Integrated RMP-based ELM-crash-control process for plasma performance enhancement during ELM crash suppression in KSTAR

The integrated Resonant Magnetic Perturbation (RMP)-based Edge-Localized Mode (ELM)-crash-control process aims to enhance the plasma performance during the RMP-driven ELM crash suppression, where the RMP induces an unwanted confinement degradation. In this study, the normalized beta ($\beta_\textrm{N}$) is introduced as a metric for plasma performance. The integrated process incorporates the latest achievements in the RMP technique to enhance $\beta_\textrm{N}$ efficiently. The integrated process triggers the n = 1 Edge-localized RMP (ERMP) at the L–H transition timing using the real-time Machine Learning (ML) classifier. The pre-emptive RMP onset can reduce the required external heating power for achieving the same $\beta_\textrm{N}$ by over 10% compared to the conventional onset. During the RMP phase, the adaptive feedback RMP ELM controller, demonstrating its performance in previous experiments, plays a crucial role in maximizing $\beta_\textrm{N}$ during the suppression phase and sustaining the $\beta_\textrm{N}$-enhanced suppression state by optimizing the RMP strength. The integrated process achieves $\beta_\textrm{N}$ up to ~2.65 during the suppression phase, which is ~10% higher than the previous KSTAR record but ~6% lower than the target of the K-DEMO first phase ($\beta_\textrm{N}$ = 2.8), and maintains the suppression phase above the lower limit of target $\beta_\textrm{N}$ (= 2.4) for ~4 s (~60$\tau_\textrm{E}$). In addition to $\beta_\textrm{N}$ enhancement, the integrated process demonstrates quicker restoration of the suppression phase and recovery of $\beta_\textrm{N}$ compared to the adaptive control with the n = 1 Conventional RMP (CRMP). The post-analysis of the experiment shows the localized effect of the ERMP spectrum in radial and the close relationship between the evolution of $\beta_\textrm{N}$ and the electron temperature.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Process Control Plan to Monitor Acceptable Levels of Flux and other residues

IPC J-STD –001G, Amendment 1 requires that the assembler have a sampling plan to assure that the process remains in control once qualified and validated. It is well documented that electrochemical failures occur at component sites where flux residues are not fully activated. It is also well known that specific components have a higher risk of electrochemical failure. Selecting a control plan that monitors the process and its performance on challenging components provides assurance that the process maintains control once established during process qualification. The test board used to qualify the process establishes an upper and lower spec limit for each of the component types on the test board. Surface Insulation Resistance upper and lower control limits, using challenging components that are representative of production hardware, represent a golden process condition. The golden image is a measure of process deviations that represents the performance of a resistance curve within a specific period. The objective is to judge whether the process in or out of control.

42 ENGINEERING↗

DOE OSTI2013

Spectroscopic Online Monitoring for Process Control and Safeguarding of Radiochemical Fuel Reprocessing Streams

spectroscopic process monitoring, Pu, U, Np↗

DOE OSTI2013

SPECTROSCOPIC ONLINE MONITORING FOR PROCESS CONTROL AND SAFEGUARDING OF RADIOCHEMICAL STREAMS

There is a renewed interest worldwide to promote the use of nuclear power and close the nuclear fuel cycle. The long term successful use of nuclear power is critically dependent upon adequate and safe processing and disposition of the used nuclear fuel. Liquid-liquid extraction is a separation technique commonly employed for the processing of the dissolved used nuclear fuel. The instrumentation used to monitor these processes must be robust, require little or no maintenance, and be able to withstand harsh environments such as high radiation fields and aggressive chemical matrices. This paper summarizes application of the absorption and vibrational spectroscopic techniques supplemented by physicochemical measurements for radiochemical process monitoring. In this context, our team experimentally assessed the potential of Raman and spectrophotometric techniques for online real-time monitoring of the U(VI)/nitrate ion/nitric acid and Pu(IV)/Np(V)/Nd(III), respectively, in solutions relevant to spent fuel reprocessing. These techniques demonstrate robust performance in the repetitive batch measurements of each analyte in a wide concentration range using simulant and commercial dissolved spent fuel solutions. Spectroscopic measurements served as training sets for the multivariate data analysis to obtain partial least squares predictive models, which were validated using on-line centrifugal contactor extraction tests. Satisfactory prediction of the analytes concentrations in these preliminary experiments warrants further development of the spectroscopy-based methods for radiochemical process control and safeguarding. Additionally, the ability to identify material intentionally diverted from a liquid-liquid extraction contactor system was successfully tested using on-line process monitoring as a means to detect the amount of material diverted. A chemical diversion and detection from a liquid-liquid extraction scheme was demonstrated using a centrifugal contactor system operating with the simulant PUREX extraction system of Nd(NO3)3/nitric acid aqueous phase and TBP/n-dodecane organic phase. During a continuous extraction experiment, a portion of the feed from a counter-current extraction system was diverted while the spectroscopic on-line process monitoring system was simultaneously measuring the feed, raffinate and organic products streams. The amount observed to be diverted by on-line spectroscopic process monitoring was in excellent agreement with values based from the known mass of sample directly taken (diverted) from system feed solution.

fuel reprocessing↗

DOE OSTI2020

Process Control and Energy Efficiency

We review the impact of control systems and strategies on the energy efficiency of chemical processes. We show that, in many ways, good control performance is a necessary but not sufficient condition for energy efficiency. The direct effect of process control on energy efficiency is manyfold: Reducing output variability allows for operating chemical plants closer to their limits, where the energy/economic optima typically lie. Further, good control enables novel, transient operating strategies, such as conversion smoothing and demand response. Indirectly, control systems are key to the implementation and operation of more energy-efficient plant designs, as dictated by the process integration and intensification paradigms. Our conclusions are supported with references to numerous examples from the literature.

42 ENGINEERING↗

DOE OSTI2014

US NDC Modernization Iteration E1 Prototyping Report: Processing Control Framework

During the first iteration of the US NDC Modernization Elaboration phase (E1), the SNL US NDC modernization project team developed an initial survey of applicable COTS solutions, and established exploratory prototyping related to the processing control framework in support of system architecture definition. This report summarizes these activities and discusses planned follow-on work.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

Perspective on identifying and characterizing the processes controlling iron speciation and residence time at the atmosphere-ocean interface

It is well recognized that the atmospheric deposition of iron (Fe) affects ocean productivity, atmospheric CO 2 uptake, ecosystem diversity, and overall climate. Despite significant advances in measurement techniques and modeling efforts, discrepancies persist between observations and models that hinder accurate predictions of processes and their global effects. Here, we provide an assessment report on where the current state of knowledge is and where future research emphasis would have the highest impact in furthering the field of Fe atmosphere-ocean biogeochemical cycle. These results were determined through consensus reached by diverse researchers from the oceanographic and atmospheric science communities with backgrounds in laboratory and in situ measurements, modeling, and remote sensing. We discuss i) novel measurement methodologies and instrumentation that allow detection and speciation of different forms and oxidation states of Fe in deliquesced mineral aerosol, cloud/rainwater, and seawater; ii) oceanic models that treat Fe cycling with several external sources and sinks, dissolved, colloidal, particulate, inorganic, and organic ligand-complexed forms of Fe, as well as Fe in detritus and phytoplankton; and iii) atmospheric models that consider natural and anthropogenic sources of Fe, mobilization of Fe in mineral aerosols due to the dissolution of Fe-oxides and Fe-substituted aluminosilicates through proton-promoted, organic ligand-promoted, and photo-reductive mechanisms. In addition, the study identifies existing challenges and disconnects (both fundamental and methodological) such as i) inconsistencies in Fe nomenclature and the definition of bioavailable Fe between oceanic and atmospheric disciplines, and ii) the lack of characterization of the processes controlling Fe speciation and residence time at the atmosphere-ocean interface. Such challenges are undoubtedly caused by extremely low concentrations, short lifetime, and the myriad of physical, (photo)chemical, and biological processes affecting global biogeochemical cycling of Fe. However, we also argue that the historical division (separate treatment of Fe biogeochemistry in oceanic and atmospheric disciplines) and the classical funding structures (that often create obstacles for transdisciplinary collaboration) are also hampering the advancement of knowledge in the field. Finally, the study provides some specific ideas and guidelines for laboratory studies, field measurements, and modeling research required for improved characterization of global biogeochemical cycling of Fe in relationship with other trace elements and essential nutrients. In conclusion, the report is intended to aid scientists in their work related to Fe biogeochemistry as well as program managers at the relevant funding agencies

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Understanding Processes Controlling the Temporal and Spatial Variations of PBL Structures Over the ARM SGP Site

The surface heat, moisture, and momentum fluxes are transferred to the atmosphere above through the planetary boundary layer (PBL), where vertical mixing due to turbulent eddies of different sizes plays critical roles. Therefore, reliably representing PBL processes in numerical models is critical for weather, climate, and air quality prediction. Currently, there are over ten PBL schemes that are selectable within the advanced research version of the Weather Research and Forecasting (WRF) model, indicative of the challenges in capturing the impacts of turbulence within the PBL in models. Further improvements in PBL parameterizations are needed for both weather and climate models, as emphasized in many recent national reports, but require an advanced understanding of the underlying boundary layer processes from observations. This project takes advantage of Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) investments in the atmospheric boundary layer observations and Large-Eddy Simulation (LES) ARM Symbiotic Simulation and Observation (LASSO) simulations to characterize PBL structures, understand key physical processes controlling the mixed layer development, and to evaluate PBL parameterization.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Out-of-Distribution Detection and Radiological Data Monitoring Using Statistical Process Control

Abstract Machine learning (ML) models often fail with data that deviates from their training distribution. This is a significant concern for ML-enabled devices as data drift may lead to unexpected performance. This work introduces a new framework for out of distribution (OOD) detection and data drift monitoring that combines ML and geometric methods with statistical process control (SPC). We investigated different design choices, including methods for extracting feature representations and drift quantification for OOD detection in individual images and as an approach for input data monitoring. We evaluated the framework for both identifying OOD images and demonstrating the ability to detect shifts in data streams over time. We demonstrated a proof-of-concept via the following tasks: 1) differentiating axial vs. non-axial CT images, 2) differentiating CXR vs. other radiographic imaging modalities, and 3) differentiating adult CXR vs. pediatric CXR. For the identification of individual OOD images, our framework achieved high sensitivity in detecting OOD inputs: 0.980 in CT, 0.984 in CXR, and 0.854 in pediatric CXR. Our framework is also adept at monitoring data streams and identifying the time a drift occurred. In our simulations tracking drift over time, it effectively detected a shift from CXR to non-CXR instantly, a transition from axial to non-axial CT within few days, and a drift from adult to pediatric CXRs within a day—all while maintaining a low false positive rate. Through additional experiments, we demonstrate the framework is modality-agnostic and independent from the underlying model structure, making it highly customizable for specific applications and broadly applicable across different imaging modalities and deployed ML models.

Zamzmi, Ghada↗

DOE OSTI2014

TU-F-18A-01: Preliminary Results of a Prototype Quality Control Process for Spectral CT

Purpose: A prototype quality control (QC) phantom and analysis process has been designed specifically to monitor dual-energy CT and address the current lack of quantitative oversight of the spectral capabilities of these scanners. Methods: A prototype solid water phantom was designed with multiple material inserts, and to support both head and body protocols. Inserts included tissue equivalent and material rods (iodine, iron, calcium) at various concentrations. The oval body phantom, measuring 30cm×40cm×15cm, was scanned using four dual-energy protocols with CTDIvol ranges of 19.6–62mGy (0.516 pitch) and 10.3–32.5mGy (0.984 pitch), and rotation times ranging from 0.5-1sec. The circular head phantom, measuring 22cm in diameter by 15cm, was scanned using three dual-energy protocols with CTDIvol ranges of 67–132.6mGy (0.531 pitch) and 36.7–72.7mGy (0.969 pitch), and rotation times ranging from 0.5–0.9sec. All images were reconstructed at 50, 70, 110 and 140 keV, and using a water-iodine material basis pair. The images were evaluated for iodine quantification accuracy and stability of monoenergetic reconstructions. The phantom was scanned twice on ten GE 750HD CT scanners to evaluate inter-scanner agreement, as well as ten times on a single scanner over a oneweek period to evaluate intra-scanner repeatability. Results: Preliminary analysis revealed consistent (inter- and intra-scanner) iodine quantification accuracy within 10% was only achieved for protocols in the upper half of dose levels assessed when grouped by pitch. Although all scanners undergo rigorous daily single-energy QC, iodine quantification accuracy from one scanner unexpectedly deviated from the other nine substantially. In general, inter-scanner agreement and intra-scanner repeatability varied with dose, rotation time and reconstructed keV. Conclusion: Preliminary results indicate the need for a dual-energy QC process to ensure inter-scanner agreement and intra-scanner repeatability. In particular, iodine quantification accuracy within 10% may not be achievable using lower dose techniques. Future plans include longer term dual-energy CT QC data collection. In-kind financial support was provided by GE Healthcare.

60 APPLIED LIFE SCIENCES↗