Search NASA⌕ Search

SEARCH · Search NASA

Results for “PROCESSING”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Data from Technical and Economic Feasibility of an Integrated Ethanol and Anthocyanin Coproduction Process Using Purple Corn Stover

The coproduction of high-value anthocyanin extract in the cellulosic ethanol process would diversify the co-product market, increase revenue, and potentially improve the economics of the process. The high anthocyanin concentration in the cob and structural carbohydrates in residual stover make purple corn stover an attractive source for anthocyanin and ethanol coproduction. This study aimed to develop simulation models for processes integrating ethanol production and anthocyanin extraction using purple corn stover, to evaluate their techno-economic feasibility, and to compare their performance with the conventional ethanol production process using corn stover. The annual ethanol production for plants processing 2000 MT dry feedstock / day was 148.6 million L/year for the integrated processes compared with 222.6 million L/year for the conventional process. Anthocyanin production in the modified processes using dilute acid-based and water-based anthocyanin extraction processes was 1779 and 1099 MT/year, respectively. Capital investments for the integrated processes ($448.1 to $443.8 million) were higher than the conventional process ($371.9 million). Due to high revenue from anthocyanin extract, the ethanol production cost for the integrated process using acid-based anthocyanin extraction ($0.36/L) was 34.5% lower than conventional ethanol production ($0.55/L). The ethanol production cost for the integrated process using water-based anthocyanin extraction ($0.68/L) was higher than conventional ethanol production due to low ethanol and anthocyanin yields. The minimum ethanol selling price for the integrated process using acid-based anthocyanin extraction ($0.65/L) was also lower than the conventional process ($0.72/L), indicating an improvement in economic performance.

Conversion↗
DOE OSTI2025

Advanced Brine Processing to Enable U.S. Lithium Independence (CRADA Report)

Current production of LiOH, which is needed to make Li-ion battery cathode active materials, utilizes a multistep process including solar evaporation, precipitation with Na 2 CO 3 and then conversion to LiOH using Ca(OH) 2 . This process requires a large amount of land area for solar evaporation, the right weather conditions, and chemicals for the conversion process that result in NaCl and CaCO 3 waste products. The production of Ca(OH) 2 is very energy intensive and evolves significant quantities of CO 2 . An alternative process flow utilizing direct lithium extraction techniques, followed by a chemical free conversion process can have benefits in reducing the needed land requirements and chemicals for traditional brine processing. There are many potential direct lithium extraction technologies that are currently being developed. The direct lithium extraction process from typical brine sources will produce a LiCl solution with some impurities including typically high concentrations of Na. This brine then needs to be converted to LiOH for use in battery cathode production. Ideally this conversion could occur without the use of additional chemicals. Electrochemistry can do this conversion either via electrolysis or bipolar membrane electrodialysis (BPED) to produce LiOH and HCl in solution. BPED utilized bipolar membranes to split water, which has a reduced potential as compared to splitting water at electrodes into hydrogen and oxygen gas. This reduced potential required results in a significant energy savings for BPED over electrolysis methods. This CRADA project aimed to develop such an integrated process using direct lithium extraction followed by BPED to produce a LiOH solution. That solution can then be crystallized into battery grade LiOH. In particular, Albemarle utilized a direct lithium extraction process to produce a concentrated LiCl solution that could be used for the BPED process. The BPED process was first tested using various LiCl solutions with impurity ions added at bench scale to understand the effects of impurities and determine processing parameters. Then testing was performed using the direct lithium extracted brine at the bench scale before scaling the process up. After the process was scaled up a long duration test was carried out to estimate the lifetime of the membranes, which is key to the economics of the BPED process.

25 ENERGY STORAGE↗
DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1999

Launch Vehicle Design Process Description and Training Formulation

A primary NASA priority is to reduce the cost and improve the effectiveness of launching payloads into space. As a consequence, significant improvements are being sought in the effectiveness, cost, and schedule of the launch vehicle design process. In order to provide a basis for understanding and improving the current design process, a model has been developed for this complex, interactive process, as reported in the references. This model requires further expansion in some specific design functions. Also, a training course for less-experienced engineers is needed to provide understanding of the process, to provide guidance for its effective implementation, and to provide a basis for major improvements in launch vehicle design process technology. The objective of this activity is to expand the description of the design process to include all pertinent design functions, and to develop a detailed outline of a training course on the design process for launch vehicles for use in educating engineers whose experience with the process has been minimal. Building on a previously-developed partial design process description, parallel sections have been written for the Avionics Design Function, the Materials Design Function, and the Manufacturing Design Function. Upon inclusion of these results, the total process description will be released as a NASA TP. The design function sections herein include descriptions of the design function responsibilities, interfaces, interactive processes, decisions (gates), and tasks. Associated figures include design function planes, gates, and tasks, along with other pertinent graphics. Also included is an expanded discussion of how the design process is divided, or compartmentalized, into manageable parts to achieve efficient and effective design. A detailed outline for an intensive two-day course on the launch vehicle design process has been developed herein, and is available for further expansion. The course is in an interactive lecture/workshop format to engage the participants in active learning. The course addresses the breadth and depth of the process, requirements, phases, participants, multidisciplinary aspects, tasks, critical elements,as well as providing guidance from previous lessons learned. The participants are led to develop their own understanding of the current process and how it can be improved. Included are course objectives and a session-by-session outline of course content. Also included is an initial identification of visual aid requirements.

Atherton, James↗
DOE OSTI2021

Multi-Process Tooling

Decisions made early in the automotive design process influence material selection, which in turn dictates process selection and tool design. Because of tool build time and cost of tooling, the original path is not easily altered, even if there is compelling evidence that another material or process would be beneficial. This project focused on tool design that is agile enough to allow its use in multiple processes—injection, injection compression, and extrusion-compression. This tool design allows for the manufacture of components with the most efficient process or materials, without building multiple, single-process tools. The primary purpose of the Multi-Process Tool project was to physically demonstrate that a single, well-designed tool could be used to manufacture parts with a variety of materials that require different processes. A multi-process tool would be beneficial to providing data for any changes to the process since materials and processes can be interchanged without incurring additional tool cost(s). Battery tray parts, (representative of a multi-process tool, were successfully manufactured using various types of materials, such as fiber reinforced (carbon fiber and/or glass fibers, recycled carbon fibers), amorphous (PP, TPU), semi-crystalline (PA6, PA66), and crystalline (thermoset epoxy resin) polymers. Processing of the parts was achieved by injection molding, compression molding, compression overmolding, and injection overmolding. Specimens extracted from various locations on the battery tray parts were evaluated for mechanical properties (flexure and interlaminar shear strength properties). The results show that the tool can be used to produce parts from a wide range of materials and processes with no degradation of the physical or cosmetic properties.

42 ENGINEERING↗
DOE OSTI2025

Chemical Process Safety at TRISO-Based, Metal-Based, and Salt-Based Fuel Fabrication Facilities: Technical Assessment and Guidance Assessment

As part of efforts to prepare for potential and ongoing safety reviews for licensing of advanced non-light-water reactor fuel cycles, the U.S. Nuclear Regulatory Commission (NRC) tasked Pacific Northwest National Laboratory to prepare an assessment on the state of knowledge of potential chemical processes at fuel cycle facilities supporting the front end of these fuel cycles, and to assess the associated regulatory guidance. This report provides a technical assessment of chemical process safety considerations to support NRC licensing reviews of fabrication processes for tri-structural isotropic (TRISO) based, metallic-based, and salt-based fuels. The assessments involved collecting publicly available information on the fuel fabrication processes to (i) identify the operational process steps, characteristics and chemicals involved, (ii) identify the physical safety considerations and health safety considerations during licensing reviews of the various process steps, and (iii) collect information to support assessments of severity of accidents and potential mitigative measures to be implemented. The assessment provides a foundational basis on chemical process safety considerations for advanced fuel fabrication activities, although it is recognized that licensing reviews may necessitate design-specific considerations. The specific conditions under which chemical hazards emerge will require process-specific considerations, highlighting the importance of process-informed interpretation. The assessment also determined that exposure guidelines and limits to assess the consequences of acute exposures are limited for some chemicals, although alternative limits and supplementary information from databases or safety data sheets provide sufficient information to evaluate consequences of acute exposures. In addition, it was identified that metallic and salt fuel fabrication processes may involve beryllium, which is an exposure hazard. The regulatory framework for the licensing of advanced fuel cycle facilities, per 10 CFR Part 70 Domestic Licensing of Special Nuclear Material, is deemed robust and flexible to address the chemical safety considerations in this report. A review was conducted on various regulatory guidance and technical basis documents. This included reviewing NUREG-1520, Revision 2, Standard Review Plan for Fuel Cycle Facilities License Applications – Final Report and the process descriptions in Appendix A of NUREG/CR-6410, Nuclear Fuel Cycle Facility Accident Analysis Handbook, to address advanced fuel types. As new fuels will involve process-specific chemical uses, process-specific considerations are provided in this report. Additionally, it is noted that the U.S. Department of Energy protective action criteria database includes Temporary Emergency Exposure Limits (TEELs) for process-specific chemicals. This report provides technical information to support chemical safety assessments of new advanced fuel cycle facilities and identifies technical and safety information to support licensing reviews. No regulatory barriers were identified for the licensing of advanced fuel cycle facilities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1971

A model for process representation and synthesis

The problem of representing groups of loosely connected processes is investigated, and a model for process representation useful for synthesizing complex patterns of process behavior is developed. There are three parts, the first part isolates the concepts which form the basis for the process representation model by focusing on questions such as: What is a process; What is an event; Should one process be able to restrict the capabilities of another? The second part develops a model for process representation which captures the concepts and intuitions developed in the first part. The model presented is able to describe both the internal structure of individual processes and the interface structure between interacting processes. Much of the model's descriptive power derives from its use of the notion of process state as a vehicle for relating the internal and external aspects of process behavior. The third part demonstrates by example that the model for process representation is a useful one for synthesizing process behavior patterns. In it the model is used to define a variety of interesting process behavior patterns. The dissertation closes by suggesting how the model could be used as a semantic base for a very potent language extension facility.

Thomas, R. H.↗
NASA NTRS2008

Standardizing Interfaces for External Access to Data and Processing for the NASA Ozone Product Evaluation and Test Element (PEATE)

NASA's traditional science data processing systems have focused on specific missions, and providing data access, processing and services to the funded science teams of those specific missions. Recently NASA has been modifying this stance, changing the focus from Missions to Measurements. Where a specific Mission has a discrete beginning and end, the Measurement considers long term data continuity across multiple missions. Total Column Ozone, a critical measurement of atmospheric composition, has been monitored for'decades on a series of Total Ozone Mapping Spectrometer (TOMS) instruments. Some important European missions also monitor ozone, including the Global Ozone Monitoring Experiment (GOME) and SCIAMACHY. With the U.S.IEuropean cooperative launch of the Dutch Ozone Monitoring Instrument (OMI) on NASA Aura satellite, and the GOME-2 instrumental on MetOp, the ozone monitoring record has been further extended. In conjunction with the U.S. Department of Defense (DoD) and the National Oceanic and Atmospheric Administration (NOAA), NASA is now preparing to evaluate data and algorithms for the next generation Ozone Mapping and Profiler Suite (OMPS) which will launch on the National Polar-orbiting Operational Environmental Satellite System (NPOESS) Preparatory Project (NPP) in 2010. NASA is constructing the Science Data Segment (SDS) which is comprised of several elements to evaluate the various NPP data products and algorithms. The NPP SDS Ozone Product Evaluation and Test Element (PEATE) will build on the heritage of the TOMS and OM1 mission based processing systems. The overall measurement based system that will encompass these efforts is the Atmospheric Composition Processing System (ACPS). We have extended the system to include access to publically available data sets from other instruments where feasible, including non-NASA missions as appropriate. The heritage system was largely monolithic providing a very controlled processing flow from data.ingest of satellite data to the ultimate archive of specific operational data products. The ACPS allows more open access with standard protocols including HTTP, SOAPIXML, RSS and various REST incarnations. External entities can be granted access to various modules within the system, including an extended data archive, metadata searching, production planning and processing. Data access is provided with very fine grained access control. It is possible to easily designate certain datasets as being available to the public, or restricted to groups of researchers, or limited strictly to the originator. This can be used, for example, to release one's best validated data to the public, but restrict the "new version" of data processed with a new, unproven algorithm until it is ready. Similarly, the system can provide access to algorithms, both as modifiable source code (where possible) and fully integrated executable Algorithm Plugin Packages (APPs). This enables researchers to download publically released versions of the processing algorithms and easily reproduce the processing remotely, while interacting with the ACPS. The algorithms can be modified allowing better experimentation and rapid improvement. The modified algorithms can be easily integrated back into the production system for large scale bulk processing to evaluate improvements. The system includes complete provenance tracking of algorithms, data and the entire processing environment. The origin of any data or algorithms is recorded and the entire history of the processing chains are stored such that a researcher can understand the entire data flow. Provenance is captured in a form suitable for the system to guarantee scientific reproducability of any data product it distributes even in cases where the physical data products themselves have been deleted due to space constraints. We are currently working on Semantic Web ontologies for representing the various provenance information. A new web site focusing on consolidating informaon about the measurement, processing system, and data access has been established to encourage interaction with the overall scientific community. We will describe the system, its data processing capabilities, and the methods the community can use to interact with the standard interfaces of the system.

Tilmes, Curt A.↗
NASA NTRS2015

Integration of Product, Package, Process, and Environment: A Food System Optimization

The food systems slated for future NASA missions must meet crew nutritional needs, be acceptable for consumption, and use resources efficiently. Although the current food system of prepackaged, moderately stabilized food items works well for International Space Station (ISS) missions, many of the current space menu items do not maintain acceptability and/or nutritive value beyond 2 years. Longer space missions require that the food system can sustain the crew for 3 to 5 years without replenishment. The task "Integration of Product, Package, Process, and Environment: A Food System Optimization" has the objective of optimizing food-product shelf life for the space-food system through product recipe adjustments, new packaging and processing technologies, and modified storage conditions. Two emergent food processing technologies were examined to identify a pathway to stable, wet-pack foods without the detrimental color and texture effects. Both microwave-assisted thermal sterilization (MATS) and pressure-assisted thermal stabilization (PATS) were evaluated against traditional retort processing to determine if lower heat inputs during processing would produce a product with higher micronutrient quality and longer shelf life. While MATS products did have brighter color and better texture initially, the advantages were not sustained. The non-metallized packaging film used in the process likely provided inadequate oxygen barrier. No difference in vitamin stability was evident between MATS and retort processed foods. Similarly, fruit products produced using PATS showed improved color and texture through 3 years of storage compared to retort fruit, but the vitamin stability was not improved. The final processing study involved freeze drying. Five processing factors were tested in factorial design to assess potential impact of each to the quality of freeze-dried food, including the integrity of the microstructure. The initial freezing rate and primary freeze drying temperature and pressure were linked to final product quality in freeze-dried corn, indicating processing modifications that could lead to improved product shelf life. Storage temperatures and packaging systems were also assessed for the impact to food quality. Reduced temperature storage had inconclusive impact to the progression of rancidity in butter cookies. Frozen storage was detrimental to fruit and vegetable textural attributes but refrigerated storage helped to sustain color and organoleptic ratings for plant-based foods. With regard to packaging systems, the metallized film overwrap significantly decreased the progression of the rancidity of butter cookies as compared to the highest barrier non-metallized film. The inclusion of oxygen scavengers resulted in noticeable moisture gains in butter cookies over time, independent of packaging film systems. Neither emergent processing technology nor the freeze dry optimization resulted in compelling quality differences from current space food provisions such that a five-year shelf life is likely with these processing changes alone. Using a combination of refrigeration and PATS processing is expected to result in organoleptically-acceptable fruit quality for most fruits through five years. The vitamin degradation will be aided somewhat by the cold temperatures but, given the labile nature of vitamin C, a more stable fortification method, such as encapsulation, should also be investigated to ensure vitamin delivery throughout the product life. Similarly, significant improvement to the packaging film used in the MATS processing, optimization of formulation for dielectric properties, vitamin fortification, and reduced temperature storage should be investigated as a hurdle approach to reach a five year shelf life in wet-pack entrees and soups. Baked goods and other environmentally-sensitive spaceflight foods will require an almost impenetrable barrier to protect the foods from oxygen and moisture ingress but scavengers and reduced storage temperature did not improve baked good shelf life and are not recommended at this time for these foods.

Cooper, Maya R.↗
DOE OSTI2017

Savannah River Site HB-Line Plutonium Oxide Production Process Simulation Model - 17458

The AFS II/Plutonium Oxide Production process is in its initial operational phase at the Savannah River Site's (SRS) HB-Line. The process is new for the facility where it is being performed, but the facility itself has been in use on and off for over 50 years. Beginning this process inside the facility has resulted in multiple process delays, due to both equipment issues and process restrictions. In order to better understand the process and to identify ways to improve facility performance, Savannah River Nuclear Solutions (SRNS), in conjuncture with Newport News Shipbuilding (NNS), developed the HB-Line Process Simulation Model. This tool completely replicates the operations that comprise the HB-Line process and simulates all of the constraints associated with the process. The model realistically accounts for the number of personnel required for a process step, the time required for a process step to occur, rules related to the parallel operation of process steps, and realistic equipment and operational delay data. The result is a tool that allows SRNS to test different scenarios for improving the process throughput, while realistically accounting for potential process delays and restrictions. The tool is currently in use and has allowed SRNS to present to their customer, the National Nuclear Security Administration (NNSA), estimated production capabilities over wide-ranging timetables and assumptions. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Instrumentation for Hanford Direct-Feed Low-Activity Waste Real-Time, In-Line Process Monitoring - 18339

The direct-feed low-activity waste (DFLAW) process will utilize facilities in the Hanford tank farms to stage tank waste feed, a new facility to pretreat the tank waste feed, and facilities in the Hanford Waste Treatment and Immobilization Plant (WTP) to immobilize the low-activity waste (LAW) and disposition effluents from the vitrification process. Process sampling is used extensively throughout the DFLAW process to qualify waste feeds, control the process, and demonstrate compliance with regulatory and contractual commitments. The U.S. Department of Energy's Office of River Protection (ORP) has started a program to evaluate the potential benefits of replacing some sample collection requirements with realtime, in-line monitoring (RTIM). The program will identify, develop, and evaluate technologies that can reduce the number of samples required for WTP operation. Potential benefits of RTIM include elimination of process holds for sample analysis, a reduction in worker exposure to radiation and chemical hazards, decreased secondary waste volume, reducing the cost for sample collection and analysis, an improvement in product quality, and timely indication of process anomalies. In order to incorporate RTIM, the process control strategy for the overall process, as well as each unit operation, was reviewed and revisions to the strategies proposed. The following items were identified for incorporation of RTIM: - Real-time material balance calculations linked to the process control system; - Use of RTIM instruments to validate the material balance for selected analytes; - Anion analysis for determination of selected semi-volatile species (e.g., chlorine, sulfur, and fluorine) in the recycle stream. Based on the proposed process control strategy, a preliminary list of potential analytical equipment was developed. This was followed by a preliminary survey of instrument technologies currently on the market building on surveys performed for ORP, literature reviews, vendor web sites, and subject matter experts from the Savannah River National Laboratory and other U.S. Department of Energy national laboratories. Each technology was evaluated for measurement capability, operations and maintenance requirements, space requirements, and potential for application as process control instrumentation. The instrument technologies were chosen based on the following criteria: - Ability to perform analyses needed; - Potential to be used or adapted for use as process control instruments; - Potential to be adapted to size and operational constraints of standard WTP sample cabinets; - Operational and maintenance requirements. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Plant-wide modeling and techno-economic analysis of a direct non-oxidative methane dehydroaromatization process via conventional and microwave-assisted catalysis

Direct non-oxidative methane dehydroaromatization (DHA) process via conventional and microwave (MW)-assisted thermo-catalytic catalysis is studied. Rate models for methane DHA reactions, including the effect of catalyst deactivation, are developed by using the in-house experimental data. Model results for gas concentration profile and catalyst deactivation are in good agreement with the experimental data. This rate model is then used for the development of dynamic multi-scale, multi-physics commercial-scale reactor models. Total number of fixed bed reactors desired for a cyclic steady state process is estimated. Plant-wide models are then developed for conventional and MW-assisted processes for producing products of desired specifications. Techno-economic analysis of the methane DHA process is undertaken. Economics of these methane DHA processes are compared with the typical multi-step natural gas to aromatics production process via methanol synthesis. Sensitivity of internal rate of return (IRR) and net present value (NPV) to various economic and process parameters such as plant scale, desired rate of return, reactor cost, feedstock and utility cost, catalyst variable cost, and MW reactor cost is studied. Here, electric equivalent efficiency of the conventional methane DHA process is found to be 69.2 % and 67.3 % at 750 °C and 800 °C, respectively, while the MW-assisted methane DHA process has the electric equivalent efficiency of 48.9 % at 800 °C. IRRs of the conventional methane DHA process at 750 °C and 800 °C, and MW-assisted process are 15.2 %, 17.5 %, and 18.8 %, respectively for a methane feed flowrate of 19,782 kg/h, while the IRR of the multi-step natural gas to aromatics production process is estimated to be 0 % for the same plant scale. Impact of change in the methane price, electricity price, and catalyst cost is found to be considerable on the process economics, while the cost of the MW reactor is found to have negligible impact.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

The Innovative Universal Separation Process (USEP) for Disposal of Mixed Liquid Waste Via Unconditional Clearance Approach - 17570

Historically, Mixed Liquid Waste (MLW) drums from Canadian nuclear facilities containing Tritium (H-3) and other radionuclides (alpha as well as beta/gamma emitting) were shipped to a licensed US facility for destruction via incineration. This option is relatively complex considering the logistics associated with cross-border shipments and the destruction costs (e.g. H-3 surcharge). Because of this, Kinectrics has developed a novel and flexible process for disposal of oily as well as other (solvents, aqueous etc.) MLW within Canada. This process avoids the need for cross-border shipments and significantly reduces the complexity as well as cost for waste disposal. An overview of the various approaches and activities undertaken by Kinectrics during the period 2009-2013 for successfully processing and disposing of several MLW drums (oils, solvents, aqueous and solids) was reported at the WM-2013 conference. One of the key approaches for management of both oily Polychlorinated Biphenyls (PCB) as well as non-PCB MLW involves treatment of the mixed waste using various well-known unit operations such as filtration, treatment with commercial sorbents, and various proprietary treatment methods developed at Kinectrics. These approaches result in reduction of radionuclide activity levels to below the unconditional clearance criteria and allows disposal of the waste via incineration at a conventional chemical waste facility. A small amount of radioactive secondary waste (the captured radionuclides) is returned to the customer. This approach was successfully employed for processing several drums of PCB and non-PCB MLW. Kinectrics recently completed two projects involving processing for disposal of legacy oily and solvent MLW inventory for a Canadian nuclear customer. Waste treatment processes used previously for unconditional clearance of oily/solvent MLW were ineffective for treatment of these legacy waste drums. Some drums were particularly challenging to process since H-3 was chemically associated with the oil backbone. To address these challenges, Kinectrics developed the innovative Universal Separation (USEP) process for disposal of problematic MLW. This paper presents an overview of the USEP process, the latest results of drum scale (205 L) process demonstration work, and the design concept of a Mobile Processing Unit (MPU) for large scale batch (1500 L) processing of MLW employing the USEP process. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

TCCR Operational Summary and Optimization for Tank 9 Processing - 20314

Savannah River Remediation (SRR) manages and operates the liquid waste facilities at Savannah River Site (SRS) for the Department of Energy (DOE). Stored liquid waste is a complex mixture of insoluble solids (sludge) and soluble salts in an alkaline solution. SRR has deployed the Tank Closure Cesium Removal (TCCR) system, a tank-side ion exchange process, to remove radioactive cesium from salt waste and enable onsite disposal of the resulting decontaminated salt solution as low-level waste at the Saltstone facilities. The TCCR system consists of two prefilters, four ion exchange (IX) columns, one resin trap, and a ventilation system. The IX process uses a form of inorganic crystalline silicotitanate (CST), which has a high affinity for cesium and other alkali metals, strontium, and actinides. This process is currently deployed utilizing salt feed from Tank 10, with future plans to dissolve solid salt in Tank 9 and transfer the salt solution to Tank 10 for processing through TCCR. The feed for TCCR must be created from salt-cake in Tank 10 through a dissolution process. Once enough salt has been dissolved, a qualification process is entered. This process characterizes the feed and ensures the cesium loading on the columns will not cause boiling of waste within the columns during or after processing. Once the batch has been qualified, salt waste is fed to the TCCR system through a transfer pump in the center of the tank. The waste is filtered through a set of two shielded, dead-end prefilters that prevent solids buildup in the columns. The filtered salt solution then travels to the shielded IX columns, which can be operated individually or in series, where the cesium is sorbed on the CST media. The decontaminated salt solution (DSS) then travels through a resin trap and out of the module to Tank 11. TCCR has successfully processed approximately 795,000 L of Tank 10H radioactive salt waste over two batches to date. There has not yet been a system induced shutdown. The prefilters performed as expected with only minor degradation in recovery of differential pressure after a backflush sequence. The time between backflushes decreased as each batch reached the end of processing. The hydraulics in the IXCs mostly performed as expected at all flow rates, except for one IXC that will be further investigated during Batch 3 processing. The TCCR system has shown some opportunities for more efficient processing during the length of the demonstration so far. For future processing of material from Tank 9H through Tank 10H and the TCCR unit, TCCR 1A will implement changes to the prefilters and the IXCs. The prefilters will have an increased surface area and a new filter media in an effort to increase time between filter swaps and improve backwashing cleaning capability. The IXCs will have a reduced diameter to allow for increased heat transfer out of the column and increased loading of Cs-137. Additionally, a new form of CST with an increased kinetic performance is being investigated for use during TCCR 1A operation. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

A Novel Process for Converting Coal to High-Value Polyurethane Products

Battelle has demonstrated a patented process for making high-value, polyurethane (PU) foam from coal, based on preparing liquefied coal via direct liquefaction, converting it to polyols as an intermediate via ozonation, and then making PU foams from these polyols. This process represents a breakthrough in innovative utilization of U.S. coals, and is applicable to bituminous as well as sub-bituminous coals. The resulting PU foam products are projected to have an extremely high value (i.e., over $\$5,000$ /ton), with nearly 100% of carbon utilization from coalderived liquid feedstock, and 31.5% to 43.5% of the carbon in the PU foam polyol product being bio-based. The targeted products represent an extremely large (i.e., over $80 billion/year), existing PU foam market, which could expand into making coatings and adhesives. The process can further help reduce petroleum imports, while improving the economics of PU foam production. This work was completed with funding from the National Energy Technology Laboratory (NETL), with cost share from the State of Ohio’s Ohio Development Services Agency (ODSA) and others, and has advanced the process to 10 kg/day continuous scale and thus to Technology Readiness Level (TRL) 5. A total of 48 coal-based polyols were prepared and evaluated. The initial 28 polyols focused on range finding for ideal conditions. The later 20 polyols were produced as part of process optimizations. These optimizations were targeted around a continuous ozonolysis process to evaluate extended time reactions and to create the necessary intermediate for production of 1-gallon samples of polyol. The most unique attribute of Battelle’s polyol is in the utilization of coal’s aromaticity to gain final foam rigidity. Typically, polyols depend on the isocyanate fraction and cross-linking to gain rigidity. By utilizing coal, we were able to maintain rigidity while reducing the overall hydroxyl value of the polyol. This is important as lower hydroxyl value leads to greater percent weight of the coal-based polyol because less isocyanate is required for foaming. This leads to greater foam cost savings. This report provides the details, process, and process cost models of the conversion of coal to polyols and further to PU foams. Battelle’s process begins with coal liquids. These liquids can be obtained by two processes: coal coking or pyrolysis to produce coal tar, and Battelle’s biobased coal-to-liquids (CTL) process to produce heavy syncrude after liquifying >85% coal. After liquification, Battelle utilizes ozonolysis to create functionalization on the polyaromatic coal structure. The functionalization is then converted to the final polyester polyol through transesterification, or to hydroxyamide polyol through amidification. Equivalent or better standard properties have been obtained for 2 lb/ft 3 density rigid, water and freon-alternative blown foams, including compressive strength, density, R-value, and dimensional stability. Target applications for these foams are insulation, packaging, and energy-absorbing foams. Some exploratory testing also showed promise for adhesives applications. A detailed economic analysis showed that Battelle’s polyol process is economical, at a 140 metric tons per day (MTD) polyol production scale. An attractive return on investment (ROI) at competitive pricing validates the process is ready for a pilot-plant demonstration. A scale-up plan is provided.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Mirostructure Characterization of Friction Consolidated Copper-Nickel using a Machine Learning Approach: Developing Process to Microstructure Associations

Friction consolidation (FC) is a solid phase processing approach where discrete material forms such as powders, chips, nuggets, etc. are densified via shear deformation. The precursors are placed in a billet container and brought in contact with a rotating tool that applying the desirable amount of normal force. Under the combined action of the rotation and normal pressure, the discrete precursor is consolidated through porosity reduction and shear deformation. FC is increasingly being studied as an attractive approach to manufacturing fully dense parts from powder forms owing to its ability to mix, alloy and consolidate difficult-to-process precursors in minimal number of process steps. Material consolidation and deformation in shear consolidation processes have been studied extensively previously for different material combinations previously. However, despite the extensive research in this area, understanding of the mechanistic processes in pore consolidation, deformation-induced mixing and material solubility during FC is still evolving. Material development using solid phase processing approaches such as FC is often performed based on research experience/education, which can be biased. Conventional analysis and simulation tools in this area tend to be successful only when material thermodynamic pathways and microstructural evolution sequences resulting from processing are clearly defined or known. They are not as effective for emerging advanced manufacturing technologies where material evolution pathways are not well established. The ability to predict optimal process parameters based on material chemistry and bulk properties is essential to accelerate materials design and processing, as are an understanding of the relevant structure-processing-property relationships. These structure-processing-property-performance relationships are at the core of materials science research. Microstructure characterization provides the link to these four core areas, often through visualizing material microstructure using imaging techniques. However, linking microstructure image data (i.e., micrographs) to variables of interest (e.g., processing parameters, material chemistry) in a reproducible, generalizable, and quantitative manner is a significant challenge. Typically, quantitatively linking image data to processing history relies on significant domain knowledge and manual or subject matter expert (SME)-heuristic based image analysis. Such an approach to image analysis has the potential to be biased, inefficient, and difficult to replicate.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The Novel Charfuel® Coal Refining Process 18 TPD Pilot Plant Project for Co- Producing an Upgraded Coal Product, and Commercially Valuable Co- Products: Area of Interest #3 – Coal Beneficiation Pilot Plant Testing (Final Report)

Operation of Carbon Fuels, LLC’s (“CF”) existing, permitted 18 TPD pilot plant located in Golden, Colorado using two individually ranked (ASTM D 388) coal types (two campaigns), employing the novel Charfuel® coal refining process to produce an upgraded coal product and a number of high-valued organic and inorganic coproducts (for which there presently exists large commercial markets) in order to produce engineering and product data which will then be utilized toward the design of a commercial scale integrated facility (pre-feed document). Carbon Fuels, LLC has developed the Charfuel® Coal Refining Process which refines domestically abundant, raw coal (in the same manner as crude oil is refined) to produce the identical, high value co-products that are refined from crude oil. Thus, gasoline, jet fuel, “green diesel”, fuel oil, and marine fuels, as well as petrochemicals such as benzene, toluene, xylene, and methanol are refined from raw coal using this process. The Charfuel® Coal Refining Process is not a coal conversion process, like pyrolysis, or indirect liquefaction. Nor is it an alternative energy system. Rather it is a coal refining process that has the ability to economically produce products traditionally associated with the refining of crude oil but using only abundant, raw coal as the refinery feed stock. The Charfuel® Coal Refining Process is more economical than crude oil refining and is environmentally benign. Therefore, this value added process yields a return on investment well above 50% for a commercial facility. Furthermore, the Charfuel® process, unlike alternatives such as ethanol and hydrogen, can utilize the existing transportation, delivery, and other petroleum based systems. Hence, there is no need for new engines, pipelines, tankers, or product acceptance. As a result, the profitability of the process is increased. Objectives: (1) Operation of the integrated 18 tpd pilot plant, using two coal types (ranks); (2) Demonstration of process flexibility in being able to produce different products (gas, liquid, and char), as well as determination of operating parameters for identifying scale up criteria for two coal types (ranks); (3) Generation of engineering and design information (process specifications) for use in designing a commercial scale plant (scale-up); (4) Determination of important environmental issues surrounding the process and the products such as fate of trace elements (mercury and other heavy metals) and distributions of SO2, NOx, and CO 2 by analysis of effluent streams; (5) Production of sufficient product to allow reliable commercial economic evaluation of both the refined coal product and the coproducts; and, (6) Assessment of longer-term reliability of unit operations. Period 1: reconfiguration of the 18 TPD plant to meet specific FOA requirements and to qualify the facility for operation; and, Period 2: operation of the 18 TPD plant for two campaigns using two coals types (ranks) which are widely commercially used and abundant - the first being a subbituminous (Powder River Basin (“PRB”)) coal, and the second a bituminous (Illinois #6) coal.

01 COAL, LIGNITE, AND PEAT↗