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Nuclear Liquid Wastes Calcination: The High-Level French Experience - 17184
Calcination is an efficient process for volume reduction and stabilization of nuclear liquid wastes. It is often the first step of waste containment processes such as vitrification or grouting. The CEA (French Alternative Energies and Atomic Energy Commission) and AREVA have acquired a high-level experience in the field of calcination through more than forty years of R and D and industrial operation. During this period, a broad range of liquid wastes have been studied and treated. R and D work and associated engineering studies allowed defining the design and sizing of the equipment and the process control parameters to be applied for the calcination of all kinds of solutions. The calcination process has been qualified for the following effluents amongst others: - Liquid waste from UOx fuel reprocessing; - Liquid waste from UMo fuel reprocessing (high molybdenum and phosphorus contents); - Hanford HLW; - Liquid waste from D and D operation (sodium bearing waste). This paper presents several studies led by the Joint Vitrification Laboratory (L.C.V), a common research laboratory between CEA and AREVA in charge of qualifying new processes and matrices for waste containment. These studies allowed defining the calcination rules, in particular for very hard to process solutions such as effluents with high boron, molybdenum and sodium contents. The feedback from industrial operation of the calcination process with fission products and effluents from D and D operations, highly loaded with sodium, is also presented. (authors)
Modeling transport kinetics in clinoptilolite-phosphate rock systems
Nutrient release in clinoptilolite-phosphate rock (Cp-PR) systems occurs through dissolution and cation-exchange reactions. Investigating the kinetics of these reactions expands our understanding of nutrient release processes. Research was conducted to model transport kinetics of nutrient release in Cp-PR systems. The objectives were to identify empirical models that best describe NH4, K, and P release and define diffusion-controlling processes. Materials included a Texas clinoptilolite (Cp) and North Carolina phosphate rock (PR). A continuous-flow thin-disk technique was used. Models evaluated included zero order, first order, second order, parabolic diffusion, simplified Elovich, Elovich, and power function. The power-function, Elovich, and parabolic-diffusion models adequately described NH4, K, and P release. The power-function model was preferred because of its simplicity. Models indicated nutrient release was diffusion controlled. Primary transport processes controlling nutrient release for the time span observed were probably the result of a combination of several interacting transport mechanisms.
Properties of coated and modified surfaces
The ability to create surface and near-surface properties distinct from the bulk properties of a material by means of coating or surface modification techniques is an important new field of development for engineering materials, encompassing ion implantation, plasma processing, reactive deposition methods, ion beam deposition and modification, molecular beam epitaxy, and fast quench thermal processing. Attention is given to specific areas of process control which illustrate (1) the use of process development to control material properties, (2) the importance of surface modification and coating to the tribology and ion-surface interactions of semiconductor film growth, and (3) recent findings in surface science which exemplify potential applications of ion-surface interactions that generate novel material qualities.
Program control in NASA: Needs and opportunities
NASA has successfully managed some of this country's most complex technology and development programs. These successes have included the application of sound program control processes. The impetus for this study arose from the NASA Management Study Group findings that over time, some program control tools and disciplined procedures and processes had weakened. The Study Group recommended that steps be taken to establish a comprehensive training approach in program management, and specifically, in program control functions. This study looks at program control processes within NASA currently in use, defines a 'model' of program control functions, and provides recommendations on program control training needs and opportunities.
Understanding and Controlling Cesium Loading on Crystalline Silicotitanate - 19601
Savannah River Remediation (SRR) contracted with Westinghouse Electric Corporation (WEC), Columbia Energy and Environmental Services (CEES), to build and deliver a modular ion exchange process that will be used to remove radioactive cesium from dissolved salt solution contained in Tank 10 at the Savannah River Site (SRS). The resulting decontaminated salt solution will be sent to Tank 11 and then to Tank 50 for final disposition in grout at the Saltstone facility. At the end of processing, the loaded ion exchange (IX) columns are drained, rinsed, and dried. The IX columns are removed from the modular unit and stored at Interim Safe Storage (ISS). This ion exchange process is called the Tank Closure Cesium Removal (TCCR) system. The TCCR system consists of several unit operations and process monitoring capability housed within three modular units. The first modular unit contains the process control computer, the second modular unit contains the main process equipment (two prefilters, four IX columns, and resin trap (post filtration)), and the third modular unit is the ventilation system. The main unit operations of the TCCR system are filtration, ion exchange, and ventilation. The ion exchange media utilized is a form of inorganic Crystalline Silicotitanate (CST), IONSIV{sup TM} R9120-B supplied by UOP Honeywell. CST has a high selectivity for cesium (Cs) and has some affinity for other Group IA alkali metals on the periodic chart (hydrogen, lithium, sodium, potassium, rubidium, and francium). CST has also been shown to have affinity for strontium and actinides. Cesium loading on the CST is dependent on many factors including chemical composition (cations and anions), temperature, and pH of the salt solution. The actual amount of Cs loaded onto an IX column is dependent on the factors above along with the salt solution volume fed to the IX column. Because of CST's high selectivity for Cs, the Cs-137 equilibrium loading can contribute enough decay heat to result in an ion exchange column boiling event under no flow conditions in the IX column. The boiling event under no flow is a safety concern that must be prevented from occurring. To prevent boiling of the column under no flow conditions, the Cs-137 equilibrium loading must be determined and understood. Several methodologies were evaluated for performing the Cs-137 equilibrium loading determination for CST. After review of available research and development (R and D), batch equilibrium contact test data, and Zheng Anthony Miller (ZAM) model predictions for the salt solution chemistry in Tank 10, a methodology for determining the Cs-137 equilibrium loading on CST was selected. The methodology selected involves an in-tank batch equilibrium contact test performed in duplicate that considers additional corrections to account for anticipated operational evolutions. The in-tank batch equilibrium contact test utilizes ∼0.1 grams of CST secured in a slotted sample vial. The slotted sample vial design allows for salt solution to be in contact with the CST. The slotted sample vials containing the CST are submerged in Tank 10 and exposed to the salt solution for ten days. After ten days, the samples are retrieved and sent to the Savannah River National Laboratory (SRNL) for analysis of the Cs-137 equilibrium loading. Additional corrections are then made to the Cs-137 results to account for anticipated operational evolutions. Anticipated operational evolutions include external additions (water/caustic) to Tank 10 that result in a change to its chemical composition, tank temperature effects, departures from the laboratory testing (mixed vs. stagnant tank conditions), and IX column flushes. A description of the methodologies considered, feasibility of methodology deployment, and the down select process (benefits vs. risks) is discussed in this paper. (authors)
IMPACTS OF SMALL COLUMN ION EXCHANGE STREAMS ON DWPF GLASS FORMULATION: KT08, KT09, AND KT10-SERIES GLASS COMPOSITIONS
This report is the fourth in a series of studies of the impacts of the addition of Crystalline Silicotitanate (CST) and Monosodium Titanate (MST) from the Small Column Ion Exchange (SCIX) process on the Defense Waste Processing Facility (DWPF) glass waste form and the applicability of the DWPF process control models. MST from the Salt Waste Processing Facility (SWPF) is also considered in the study. The KT08-series of glasses was designed to evaluate any impacts of the inclusion of uranium and thorium in glasses containing the SCIX components. The KT09-series of glasses was designed to study the effect of increasing Al{sub 2}O{sub 3} and K{sub 2}O concentrations on the propensity for crystallization of titanium containing phases in high TiO{sub 2} concentration glasses. Earlier work on the KT05-series glasses recommended that the impact of these two components be studied further. Increased Al{sub 2}O{sub 3} concentrations have been shown to improve the properties and performance of high waste loading glasses, and K{sub 2}O has been reported to improve the retention of TiO{sub 2} in silicate glasses. The KT10-series of compositions was designed to evaluate any impacts of the SCIX components at concentrations 50% higher than currently projected.a The glasses were fabricated in the laboratory and characterized to identify crystallization, to verify chemical compositions, to measure viscosity, and to measure durability. Liquidus temperature measurements for the KT10-series glasses are underway and will be reported separately. All but one of the KT08-series glasses were found to be amorphous by X-ray diffraction (XRD). One of the slowly cooled glasses contained a small amount of trevorite, which had no practical impact on the durability of the glass and is typically found in DWPF-type glasses. The measured Product Consistency Test (PCT) responses for the KT08-series glasses are well predicted by the DWPF models. The viscosities of the KT08-series glasses were generally well predicted by the DWPF model. No unexpected issues were encountered when uranium and thorium were added to the glasses with SCIX components. Increased Al{sub 2}O{sub 3} concentrations were not successful in preventing the formation of iron titanate crystals in the KT09-series glasses. Increased K{sub 2}O concentrations were successful in hindering the formation of iron titanates in some of the glasses after the canister centerline cooled (CCC) heat treatment. However, this result did not apply to all of the CCC versions of the glasses, indicating a compositional dependence of this effect. In addition, high concentrations of K{sub 2}O have been shown to hinder the ability of the DWPF durability and viscosity models to predict the performance of these glasses. The usefulness of increased K{sub 2}O concentrations in preventing the formation of iron titanates may therefore be limited. Further characterization was not performed for the KT09-series glasses since the type of crystallization formed was the characteristic of interest for these compositions. All of the KT10-series glasses were XRD amorphous, regardless of heat treatment. Chemical composition measurements showed that the glasses met the targeted concentrations for each oxide. In general, the measured PCT responses of the KT10-series glasses were well predicted by the DWPF models. The measured, normalized release values for silicon for some of the glasses fell above the 95% confidence interval for the predicted values; however, the PCT responses for these glasses remain considerably lower than that of the benchmark Environmental Assessment (EA) glass. The viscosities of the KT10-series glasses were generally well predicted by the DWPF model. The next step in this study will be to compile all of the data developed and further compare the measured properties and performance with those predicted by the current DWPF Product Composition Control System (PCCS) models. Recommendations will then be made as to which models, if any, may need to be modified in order to accommodate the material from SCIX into DWPF glass production.
Virtual Control Systems Environment (VCSE)
Will Atkins, a Sandia National Laboratories computer engineer discusses cybersecurity research work for process control systems. Will explains his work on the Virtual Control Systems Environment project to develop a modeling and simulation framework of the U.S. electric grid in order to study and mitigate possible cyberattacks on infrastructure.
TESTING OF THE DUAL ROTARY FILTER SYSTEM
The Savannah River National Laboratory (SRNL) installed and tested two hydraulically connected SpinTek rotary microfilter (RMF) units to determine the behavior of a multiple filter system. Both units were successfully controlled by a control scheme written in DELTA-V architecture by Savannah River Remediation (SRR) Process Control Engineering personnel. The control system was tuned to provide satisfactory response to changing conditions during the operation of the multi-filter system. Stability was maintained through the startup and shutdown of one of the filter units while the second was still in operation. The installation configuration originally proposed by the Small Colum Ion Exchange (SCIX) project of independent filter and motor mountings may be susceptible to vibration. Significant stiffening of the filter and motor mounts was required to minimize the vibration. Alignment of the motor to the filter was a challenge in this test configuration. The deployment configuration must be easy to manipulate and allow for fine adjustment. An analysis of the vibration signature of the test system identified critical speeds. Whether it corresponds to the resonance frequency of a rotor radial vibration mode that was excited by rotor unbalance is uncertain based upon the measurements. A relative motion series should be completed on the filter with the final shaft configuration to determine if the resonances exist in the final filter design. The instrumentation selected for deployment, including the concentrate discharge control valve and flow meters, performed well. Automation of the valve control integrated well with the control scheme and when used in concert with the other control variables, allowed automated control of the dual RMF system. The one area of concern with the instrumentation was the condition resulting when the filtrate flow meter operated with less than three gpm. This low flow was at the lower range of performance for the flow meter. This should not be an issue in deployment where the desired flow rate will be within the normal operating range of the meter. Testing demonstrated that the use of a flexible line for the filtrate discharge is highly desired at the outlet of the rotary union to transition to the system piping. Isolating the vibration from the rotary union will significantly improve the lifetime of the seals. Methods to monitor and isolate individual filters should be considered during deployment. The ability to diagnose issues and isolate individual filters would allow isolation prior to failure. Thus, filters may be cleaned or repaired instead of requiring complete replacement if the condition were to continue unnoticed. Isolating the filtrate line of each filter during startup will minimize the premature buildup of solids on the filter disks. Several tests have shown that the method of filter startup can improve performance lifetime of the filters. The installation must factor in an air inlet for the draining of a filter that does not involve a reverse flow through the filter disks. The reverse flow may cause deformation of the disks or may damage other components of the filters themselves.
Thermal Catalytic Oxidation of Airborne Contaminants by a Reactor Using Ultra-Short Channel Length, Monolithic Catalyst Substrates
Contaminated air, whether in a crewed spacecraft cabin or terrestrial work and living spaces, is a pervasive problem affecting human health, performance, and well being. The need for highly effective, economical air quality processes spans a wide range of terrestrial and space flight applications. Typically, air quality control processes rely on absorption-based processes. Most industrial packed-bed adsorption processes use activated carbon. Once saturated, the carbon is either dumped or regenerated. In either case, the dumped carbon and concentrated waste streams constitute a hazardous waste that must be handled safely while minimizing environmental impact. Thermal catalytic oxidation processes designed to address waste handling issues are moving to the forefront of cleaner air quality control and process gas decontamination processes. Careful consideration in designing the catalyst substrate and reactor can lead to more complete contaminant destruction and poisoning resistance. Maintenance improvements leading to reduced waste handling and process downtime can also be realized. Performance of a prototype thermal catalytic reaction based on ultra-short waste channel, monolith catalyst substrate design, under a variety of process flow and contaminant loading conditions, is discussed.
Application of Koopman operator for model-based control of fracture propagation and proppant transport in hydraulic fracturing operation
This work explores the application of the recently developed Koopman operator approach for model identification and feedback control of a hydraulic fracturing process. Controlling fracture propagation and proppant transport with precision is a challenge due in large part to the difficulty of constructing approximate models that accurately capture the characteristic moving boundary and highly-coupled dynamics exhibited by the process. Koopman operator theory is particularly attractive here as it offers a way to explicitly construct linear representations for even highly nonlinear dynamics. The method is data-driven and relies on lifting the states to an infinite-dimensional space of functions called observables where the dynamics are governed by a linear Koopman operator. Here this work considers two problems: (a) fracture geometry control, and (b) proppant concentration control. In both cases, an approximate linear model of the corresponding dynamics is constructed and used to design a model predictive controller (MPC). The manuscript shows that in the case of highly nonlinear dynamics, as observed in the proppant concentration, use of canonical functions in the observable basis fails. In such cases, a priori system knowledge can be leveraged to choose the required basis. The numerical experiments demonstrate that the Koopman linear model shows excellent agreement with the real system and successfully achieves the desired target values maximizing the oil and gas productivity. Additionally, due to its linear structure, the Koopman models allow convex MPC formulations that avoid any issues associated with nonlinear optimization.
Shift changes, updates, and the on-call architecture in space shuttle mission control
In domains such as nuclear power, industrial process control, and space shuttle mission control, there is increased interest in reducing personnel during nominal operations. An essential element in maintaining safe operations in high risk environments with this 'on-call' organizational architecture is to understand how to bring called-in practitioners up to speed quickly during escalating situations. Targeted field observations were conducted to investigate what it means to update a supervisory controller on the status of a continuous, anomaly-driven process in a complex, distributed environment. Sixteen shift changes, or handovers, at the NASA Johnson Space Center were observed during the STS-76 Space Shuttle mission. The findings from this observational study highlight the importance of prior knowledge in the updates and demonstrate how missing updates can leave flight controllers vulnerable to being unprepared. Implications for mitigating risk in the transition to 'on-call' architectures are discussed.
OPSAID improvements and capabilities report.
Process Control System (PCS) and Industrial Control System (ICS) security is critical to our national security. But there are a number of technological, economic, and educational impediments to PCS owners implementing effective security on their systems. Sandia National Laboratories has performed the research and development of the OPSAID (Open PCS Security Architecture for Interoperable Design), a project sponsored by the US Department of Energy Office of Electricity Delivery and Energy Reliability (DOE/OE), to address this issue. OPSAID is an open-source architecture for PCS/ICS security that provides a design basis for vendors to build add-on security devices for legacy systems, while providing a path forward for the development of inherently-secure PCS elements in the future. Using standardized hardware, a proof-of-concept prototype system was also developed. This report describes the improvements and capabilities that have been added to OPSAID since an initial report was released. Testing and validation of this architecture has been conducted in another project, Lemnos Interoperable Security Project, sponsored by DOE/OE and managed by the National Energy Technology Laboratory (NETL).
Taguchi Method Applied in Optimization of Shipley SJR 5740 Positive Resist Deposition
Taguchi Methods of Robust Design presents a way to optimize output process performance through an organized set of experiments by using orthogonal arrays. Analysis of variance and signal-to-noise ratio is used to evaluate the contribution of each of the process controllable parameters in the realization of the process optimization. In the photoresist deposition process, there are numerous controllable parameters that can affect the surface quality and thickness of the final photoresist layer.
A technique for optimizing the selection of quantized coefficients in digital controllers.
Coefficient quantization in digital continuous time process controllers, applying results to nominal transfer function approximation
Control technology applied to production problems
Computer process control applications with emphasis on oil and chemical industries
Optimal Discounted Stochastic Control for Diffusion Processes
Optimal cost discounted stochastic control for diffusion processes
SU-E-T-136: Assessment of Seasonal Linear Accelerator Output Variations and Associated Impacts
Purpose: Application of process control theory in quality assurance programs promises to allow earlier identification of problems and potentially better quality in delivery than traditional paradigms based primarily on tolerances and action levels. The purpose of this project was to characterize underlying seasonal variations in linear accelerator output that can be used to improve performance or trigger preemptive maintenance. Methods: Review of runtime plots of daily (6 MV) output data acquired using in house ion chamber based devices over three years and for fifteen linear accelerators of varying make and model were evaluated. Shifts in output due to known interventions with the machines were subtracted from the data to model an uncorrected scenario for each linear accelerator. Observable linear trends were also removed from the data prior to evaluation of periodic variations. Results: Runtime plots of output revealed sinusoidal, seasonal variations that were consistent across all units, irrespective of manufacturer, model or age of machine. The average amplitude of the variation was on the order of 1%. Peak and minimum variations were found to correspond to early April and September, respectively. Approximately 48% of output adjustments made over the period examined were potentially avoidable if baseline levels had corresponded to the mean output, rather than to points near a peak or valley. Linear trends were observed for three of the fifteen units, with annual increases in output ranging from 2–3%. Conclusion: Characterization of cyclical seasonal trends allows for better separation of potentially innate accelerator behaviour from other behaviours (e.g. linear trends) that may be better described as true out of control states (i.e. non-stochastic deviations from otherwise expected behavior) and could indicate service requirements. Results also pointed to an optimal setpoint for accelerators such that output of machines is maintained within set tolerances and interventions are required less frequently.