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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.

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At least 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Database development and exploration of process–microstructure relationships using variational autoencoders

The paper demonstrates graphical representation of a large database containing process–microstructure relationships using an unsupervised machine learning algorithm. Correlating microstructural features to processing is an essential first step to answer the difficult problem of process sequence design. Here, a large database of 346,200 orientation distribution functions resulting from a variety of process sequences is constructed, where each sequence comprises up to four stages of tension, compression and rolling along different directions in various permutations. This open-source database is constructed for collaborative development of process design algorithms. The paper demonstrates a novel application of the large database: graphical representation of texture–process relationships. A variational autoencoder is used to reduce the entire database to a two dimensional latent space where variations in processes and properties can be visualized. Using proximity analysis in this latent space, we can quickly unearth multiple process solutions to the problem of texture or property design.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Closed-loop pressure retarded osmosis draw solutions and their regeneration processes: A review

Pressure-Retarded Osmosis (PRO) is an osmotic process that has been used to harvest energy from salinity gradients using a semi permeable membrane. A comparison between open-loop PRO (OLPRO) and closed-loop PRO (CLPRO) was made regarding their performance and costs. In CLPRO, where the diluted draw solution is re-concentrated in the regeneration system to be reutilized in the process, has recently received an intensive focus as the most viable configuration for a standalone power plant. The choice of the PRO draw solution in CLPRO is crucial to garner a high osmotic pressure as the key for the feasibility of the process. Here, in this review, the draw solutions are critically evaluated in the literature in terms of energy output as well as the method of regeneration used to recirculate them. A set of practical criteria has been suggested to appraise the adequacy of the solution for CLPRO application. It was concluded that NH 3 – CO 2 theoretically can produce 170 W/m 2 of power density. Inorganic draw solutes such as NaCl can generate high power density up to 87 W/m 2 . Organic draw solutes with their remarkably low reverse salt flux (RSF) have promising potential for future application in PRO. Similarly, the regeneration systems of the diluted draw solutions have also been reviewed and discussed. How the energy consumption of the regeneration process affects the feasibility of CLPRO is explained. For the specific case of osmotic heat engines (OHEs), when the energy of the regeneration process is supplied by heat waste, the range of applicability of the heat waste in CLPRO in terms of efficiency is defined and compared to Organic Rankine Cycle (ORC). The results showed that CLPRO has better efficiency than ORC for temperatures T < 80 °C, which makes it a promising process or low-grade heat energy recovery. In addition, a PRO-RO hybrid system coupled with solar power can reduce the net specific energy consumption (SEC) to 0.39 kWh/m 3 . The conditions that regeneration processes should operate under to make PRO viable are discussed in the last section. Overall, the study indicates the key factors for optimizing the performance of CLPRO process.

42 ENGINEERING↗
DOE OSTI2018

Solution-Processed Layered Gallium Telluride Thin-Film Photodetectors

Using scalable solution processing, layered gallium telluride (GaTe) nanoflake dispersions are produced in surfactant-free, low-boiling-point, water–ethanol cosolvent mixtures. During exfoliation, chemical degradation of the ambient-reactive GaTe crystals is minimized by using deoxygenated solvents in a sealed tip ultrasonication system. The structural and chemical integrity of the solution-processed GaTe nanoflakes is subsequently confirmed with a comprehensive suite of microscopic and spectroscopic analyses. Furthermore, field-effect transistors and phototransistors based on individual solution-processed GaTe nanoflakes show electronic and optoelectronic properties, respectively, that are comparable to micromechanically exfoliated GaTe. Minimal solution-processing residues from the surfactant-free, low-boiling-point cosolvent dispersion medium coupled with the high intrinsic hole doping of GaTe produces the highest electrical conductivity among solution-processed layered nanoflake thin films without post-treatment. Large-area photodetectors based on these electrically percolating thin films of solution-processed GaTe nanoflakes show a positive correlation between responsivity and illumination intensity, with a high photoconversion gain that is explained by a combination of defect-mediated optical processes and photothermal effects. Finally, overall, this study establishes solution-processed layered GaTe nanoflakes as a leading candidate for high-performance, large-area, thin-film photodetectors.

47 OTHER INSTRUMENTATION↗
DOE OSTI2017

Frog: Asynchronous Graph Processing on GPU with Hybrid Coloring Model

GPUs have been increasingly used to accelerate graph processing for complicated computational problems regarding graph theory. Many parallel graph algorithms adopt the asynchronous computing model to accelerate the iterative convergence. Unfortunately, the consistent asynchronous computing requires locking or atomic operations, leading to significant penalties/overheads when implemented on GPUs. As such, coloring algorithm is adopted to separate the vertices with potential updating conflicts, guaranteeing the consistency/correctness of the parallel processing. Common coloring algorithms, however, may suffer from low parallelism because of a large number of colors generally required for processing a large-scale graph with billions of vertices. We propose a light-weight asynchronous processing framework called Frog with a preprocessing/hybrid coloring model. The fundamental idea is based on Pareto principle (or 80-20 rule) about coloring algorithms as we observed through masses of realworld graph coloring cases. We find that a majority of vertices (about 80%) are colored with only a few colors, such that they can be read and updated in a very high degree of parallelism without violating the sequential consistency. Accordingly, our solution separates the processing of the vertices based on the distribution of colors. In this work, we mainly answer three questions: (1) how to partition the vertices in a sparse graph with maximized parallelism, (2) how to process large-scale graphs that cannot fit into GPU memory, and (3) how to reduce the overhead of data transfers on PCIe while processing each partition. Here, we conduct experiments on real-world data (Amazon, DBLP, YouTube, RoadNet-CA, WikiTalk and Twitter) to evaluate our approach and make comparisons with well-known non-preprocessed (such as Totem, Medusa, MapGraph and Gunrock) and preprocessed (Cusha) approaches, by testing four classical algorithms (BFS, PageRank, SSSP and CC). On all the tested applications and datasets, Frog is able to significantly outperform existing GPU-based graph processing systems except Gunrock and MapGraph. MapGraph gets better performance than Frog when running BFS on RoadNet-CA. The comparison between Gunrock and Frog is inconclusive. Frog can outperform Gunrock more than 1.04X when running PageRank and SSSP, while the advantage of Frog is not obvious when running BFS and CC on some datasets especially for RoadNet-CA.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2019

Selection of glasses in support of the Sludge Batch 9 variability study for coupled operation with the Salt Waste Processing Facility

Prior to the processing of Sludge Batch 9 (SB9) with Frit 803 at the Defense Waste Processing Facility (DWPF), assessments and experimental glass work were completed to support the qualification of SB9 coupled processing with streams from the Actinide Removal Process (ARP) and Modular Caustic Side Solvent Extraction Unit (MCU). This previous work did not address coupled processing with streams from the Salt Waste Processing Facility (SWPF) because the Product Composition Control System (PCCS) models limited the TiO 2 concentration in glass to 2 weight percent (wt.%). These high activity streams from SWPF include monosodium titanate (MST) and sludge solids from the Sludge Solids Receipt Tank as well as Cs-containing strip effluent. The incorporation of these SWPF streams is expected to reach TiO2 concentrations in glass greater than 2 wt.% based on an MST addition of 0.4 g MST/L of salt solution. If double strike operation is required, then the MST addition is increased to 0.8 g MST/L of salt solution. Therefore, revisions to the models contained in PCCS were completed to allow the evaluation of glasses containing greater than 2 wt.% TiO 2 , but less than 6 wt.%. To support the implementation of the revised PCCS for SB9 – Frit 803 processing at DWPF prior to SWPF startup, the applicability of the new durability models for the SB9 variability study glasses was verified. Since the initial SB9 qualification for ARP-MCU coupled operation, additional Tank 40 analyses have been completed, which served as the basis for an updated projection of the SB9 blend composition in Tank 40. To identify a frit optimized for SB9 coupled operation with SWPF, the Savannah River National Laboratory (SRNL) performed a paper-study by utilizing Measurement Acceptance Region (MAR) assessments with DWPF PCCS. Based on these MAR assessment results, Frit 625 was recommended for processing both single and double MST strike scenarios. Savannah River Remediation (SRR) requested that SRNL perform a variability study with both Frit 803 and Frit 625 for SB9 coupled operation with SWPF. The objective of the variability study is to demonstrate that the Product Consistency Test (PCT) responses of the glasses are acceptable relative to the chemical durability of the Environmental Assessment (EA) reference glass and predictable by the current DWPF PCCS models for durability. This report documents the development of a test matrix that will support the variability study. To provide operational flexibility prior to SWPF startup, the predictability of glasses within the glass region for Frit 625-SB9 coupled operation with ARP-MCU was also confirmed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Transformational Sorbent-Based Process for a Substantial Reduction in the Cost of CO2 Capture

Adsorption processes have the potential to significantly reduce the CO2 capture cost from power plants and industrial flue gases. InnoSepra has developed several sorbent-based technologies to obtain very high CO2 recovery and high purity CO2 while meeting the EOR/sequestration product specifications. A first-generation process was shown to achieve CO2 recoveries greater than 94% at CO2 purities in the range of 98.5-99.5%. The absolute heat energy required for the process was not only 40% lower than MEA but also was needed at a much lower temperature. This work will present the performance of the second-generation InnoSepra process which is based on a breakthrough sorbent regeneration method. This process has a projected 45% lower capital cost compared to MEA, less than 16% loss in plant output for CO2 capture and compression, and a CO2 capture cost at least 55% lower than MEA. Lab scale testing and the process simulations indicate a CO2 capture performance similar to or better than the first-generation process. Pilot scale drying and breakthrough tests were carried out at the Technology Centre Mongstad (TCM), Norway, and lab-scale cyclic tests were carried out at InnoSepra to confirm the process improvement. During these tests, InnoSepra’s flue gas purification technology was also tested at TCM. It can provide a low-cost option for the removal of NO2 and SOX to sub-ppm levels as well as a significant reduction in aerosol emissions.

08 HYDROGEN↗
DOE OSTI2024

Materials Characterization, Prediction, and Control Project: Characterization of 316L Stainless Steel after Solid Phase Processing using Ultrasonic NDE Method

The Pacific Northwest National Laboratory undertook the Materials Characterization, Prediction, and Control Laboratory Directed Research and Development Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems produced via advanced manufacturing methods, such as solid phase processing, for use in national security and advanced energy applications (Smith 2021). A motivation of the Materials Characterization, Prediction, and Control Project was to demonstrate ultrasonic testing as a nondestructive evaluation method to complement traditional destructive methods for characterizing material microstructure with emphasis on grain size determination using a method that may have future applications for real-time inline process monitoring. The objective of the work described in this report is to establish the process and an analysis method for measuring grain sizes of polycrystalline metals with ultrafine grains using ultrasonic shear wave backscattering, building on prior studies on coarser-grained material. The work involves five tasks: Measured ultrasonic backscattering experimentally for a series of 316L stainless steel specimens with various grain sizes made by friction stir processing. Calculated ultrasonic backscattering coefficients from experimental data based on a physical measurement model. Measured ground truth grain sizes of the specimens from electron backscatter diffraction grain boundary images using a generalization of the ASTM E112 (ASTM 2021) intercept method. Built a curve of ultrasonic backscattering coefficients versus the ground truth intercept-based grain sizes to determine the correlation between mean grain sizes and ultrasonic measurements. Demonstrated the ability of using the correlation curve to deduce grain sizes with measured ultrasonic backscattering coefficients for a few 316L stainless steel specimens whose grain sizes were unknown beforehand but were targeted to be an extrapolation to larger grain sizes than used to formulate the correlation curves. Experimental procedures and computational algorithms are developed and validated for these tasks. This work establishes an ultrasonic technique for characterizing material microstructure with ultrafine grains that are often resulted by solid-phase processing. The technique is nondestructive, and it has the potential to be used for real time inline process monitoring. This work successfully demonstrates the viability of an ultrasonic nondestructive evaluation method for microstructural characterization of material having ultrafine grain structure (as small as 1?mm) and produced by an advanced manufacturing method. This includes a demonstration of the method to extrapolate to other conditions. While not demonstrated here, the method is expected to be viable for in-line, or near-inline, process monitoring in advanced manufacturing applications with suitable consideration for access of instrumentation to the material being manufactured.

316 L Stainless Steel↗
DOE OSTI2023

Coordination and divergence in community assembly processes across co-occurring microbial groups separated by cell size

Setting the pace of life and constraining the role of members in food webs, body size can affect the structure and dynamics of communities across multiple scales of biological organization (e.g., from the individual to the ecosystem). However, its effects on shaping microbial communities, as well as underlying assembly processes, remain poorly known. Here, we analyzed microbial diversity in the largest urban lake in China and disentangled the ecological processes governing microbial eukaryotes and prokaryotes using 16S and 18S amplicon sequencing. We found that pico/nano-eukaryotes (0.22–20 μm) and micro-eukaryotes (20–200 μm) showed significant differences in terms of both community composition and assembly processes even though they were characterized by similar phylotype diversity. We also found scale dependencies whereby micro-eukaryotes were strongly governed by environmental selection at the local scale and dispersal limitation at the regional scale. Interestingly, it was the micro-eukaryotes, rather than the pico/nano-eukaryotes, that shared similar distribution and community assembly patterns with the prokaryotes. This indicated that assembly processes of eukaryotes may be coupled or decoupled from prokaryotes’ assembly processes based on eukaryote cell size. While the results support the important influence of cell size, there may be other factors leading to different levels of assembly process coupling across size classes. Additional studies are needed to quantitatively parse the influence of cell size versus other factors as drivers of coordinated and divergent community assembly processes across microbial groups. Regardless of the governing mechanisms, our results show that there are clear patterns in how assembly processes are coupled across sub-communities defined by cell size. These size-structured patterns could be used to help predict shifts in microbial food webs in response to future disturbance.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Transient Microstructure Evolutions and Local Properties of Dual-Phase 980 MPa Grade Steel Via Friction Stir Spot Processing

Friction stir processing is a novel solid-state process to modify microstructures and their properties by intense, localized plastic deformation. However, little research has been reported for microstructure evolutions of advanced high-strength steels during the process. The present work focuses on the study of transient microstructure changes and local mechanical properties for friction stir spot processed dual-phase (DP) 980 MPa grade steel (DP980) under different peak temperatures. A pinless silicon nitride ceramic tool was used to produce relatively simple material deformation and flow near the tool. Friction stir spot processed steel samples were characterized by optical and electron microscopies. Furthermore, Vickers microhardness and nano-indentation measurements were used to study local mechanical properties for correlation with microstructures. A swallow layer of refined grains (<0.6 µm) was obtained with a low peak temperature (under 400 °C), whereas higher peak temperatures (>Ac 1 ) led to a change in grain size with different microstructures (fine-grained DP or martensite). Electron back-scattered diffraction characterizations revealed a large deformation in the as-received microstructures (mixture of ferrite and tempered martensite) induced by friction stir spot processing, leading to recrystallization and grain refinement around the stirred zone. Also, nano-indentation measurements showed a higher hardness than the hardness of the as-received DP980. Friction stir processing with different process conditions effectively changed microstructures and local mechanical properties.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

The Additive Manufacturing Moment Measure - A Parallel Computation Technique for Determining Build Variance in the Laser Powder Bed Fusion Process

Additive manufacturing (AM) has unique process attributes that facilitate the creation of optimized, complex, and unique parts for aerospace applications. However, the multi-scale and complicated building process for AM parts can cause unexpected build conditions that result in microstructural variability within the deposited material. The need for richer datasets and computational modeling capabilities to improve AM process reliability is a consequence of this microstructural variability. A computational approach, referred to as the Additive Manufacturing Moment Measure (AM3), addresses this need by leveraging the way AM processes fuse material in precise, incremental steps. During the layering sequence, each previous step contributes to the condition of the current step at the center of the heat source. The precise steps can be selected to systematically create a time-space point field with co-located machine input and in-situ sensor data. The sequential nature of the AM process, coupled with nearest neighbor calculations, allows for a fully parallel computation for part-scale build profile analysis. The AM3 concept introduced here enables part-scale assessment directly from build files and in-situ process monitoring sensors alike. The AM moment measures were calculated for build point fields and compared with co-located in-situ and ex-situ nondestructive evaluation and optical microscopy observations. These comparisons permit a better understanding of how the sequential process actions can affect the quality of a laser powder bed fusion (LPBF) build. Details of the AM3technique will be discussed and compared to measured LPBF part characteristics. The AM3 results indicate a strong potential to advance the qualification process for aerospace applications.

Additive Manufacturing↗
DOE OSTI2017

Modular Caustic-Side Solvent Extraction Unit (MCU) Improved Solvent Quality and Processing Results - 17496

The Modular Caustic-Side Solvent Extraction (CSSX) Unit (MCU) is a process for Cs-137 removal from legacy nuclear waste. MCU began hot operations in 2008 with an initial planned operating life of three years and a design life of five years. After eight years of operation, MCU has processed more than 23.8 million liters (6.3 million gallons) of waste. The MCU process uses a solvent developed by Oak Ridge National Laboratory (ORNL) to extract the fission product Cs-137 from liquid salt waste, or salt solution (SS), stored in the Tank Farms at Savannah River Site (SRS) after the material has been treated through the Actinide Removal Process (ARP). Batches of SS are prepared and first fed to the ARP, where it is treated to become clarified SS (CSS), then fed to MCU. Once the Cs-137 has been extracted by the solvent, the CSS becomes decontaminated SS (DSS), which is ultimately processed into a cementitious grout at the Saltstone Production Facility (SPF) and subsequently disposed of at the Saltstone Disposal Facility (SDF). The Cs-137 is then stripped from the solvent into an aqueous strip effluent (SE) stream for incorporation into borosilicate glass at the Defense Waste Processing Facility (DWPF). The solvent used in the MCU process is made of four components: the extractant (extracts Cs-137 from CSS), the modifier (increases solubility of extractant and suppressor in the diluent), the suppressor (suppresses the effects of anions and improves stripping), and the diluent (controls density and viscosity). There have been two solvents utilized during the lifetime of MCU. The first solvent was developed by ORNL and was used to design the plant based on its cesium removal capability. Due to the extended life of MCU, in order to continue to minimize the curies disposed at SDF, a new solvent capable of removing more cesium from the CSS was developed by ORNL and implemented at MCU. The second MCU solvent, Next-Generation Solvent (NGS), uses the same modifier and diluent as the original solvent, but a different extractant and suppressor. Subsequent changes to the overall MCU flowsheet were made for the use of NGS. The success of cesium removal from the CSS is often presented as the cesium decontamination factor (DF) achieved for each batch processed. The DF is the ratio of the concentration of cesium in the CSS to the cesium concentration in the DSS. The BOBCalixC6 based solvent was capable of achieving DFs between 100 and 400 for each DSS batch. The NGS solvent is capable of achieving DFs greater than 40,000 for each DSS batch. The NGS blend solvent is currently meeting the goals of the pure NGS solvent. (authors)

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

Alternative Treatment of Defense Waste Processing Facility Recycle via Reuse of Existing Liquid Waste Facilities - 20097

The Defense Waste Processing Facility (DWPF) at Savannah River Site (SRS) has been immobilizing high level waste since 1996. The chemical process within DWPF generates a large volume of condensate, which is recycled to the SRS H-Area Tank Farm. The recycle stream includes a small quantity of sludge solids, as well as soluble cesium that is volatilized during melter operation. The recycle waste is currently received into a large, underground waste tank that separates insoluble solids via decanting. The supernate is treated by an evaporator with a concentrate stream that is stored for future processing. The evaporator overheads are collected and sent to the Effluent Treatment Project (ETP) for final polishing and testing prior to discharge to local surface water. Recycle storage and treatment as described above complicates the overall mission within the tank farms, which are primarily engaged in waste retrieval and preparation activities that support sludge and salt disposition, as well as tank characterization and closure. The need to devote a portion of available storage space to recycle treatment limits operational flexibility, and ultimately the DWPF recycle stream must be diverted to fully close all the SRS waste tanks. An alternative treatment process is being explored to decouple the recycle stream from the tank farm. The proposed treatment process will accomplish solids separation via crossflow filtration and will utilize a wiped film evaporator to volume-reduce the filtrate stream. Evaporator overheads will continue to be further processed in ETP while the solids stream and evaporator concentrate stream will be returned for reprocessing with the DWPF and Salt Waste Processing Facility (SWPF). This process will utilize existing facilities within DWPF and the tank farm that were previously dedicated to Interim Salt Disposition (ISD), but no longer have an identified mission with the startup of SWPF. The reuse of these facilities will remove several constraints from the current Liquid Waste (LW) System Plan without expanding the current footprint of Department of Energy Environmental Management (EM) infrastructure within LW. (authors)

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

Analysis of Using a Hybrid ZIRCEX Process to Generate High-Assay Low-Enriched Uranium (HALEU) - 20158

Idaho National Lab (INL) is investigating the feasibility of providing High-Assay Low Enriched Uranium (HALEU) by recovering Highly Enriched Uranium (HEU) from spent nuclear fuel (SNF) and downblending the HEU with natural, low-enriched, or depleted uranium (NU, LEU, or DU). That investigation identified that significant quantities of HALEU could be produced with a Hybrid ZIRCEX process to further advanced reactor research while reducing INL's environmental liability. Many new advanced reactor designs are being developed with improved safety, efficiency, and economics. Most require nuclear fuel with U-235 enrichment between 5% and 20%, which is defined as HALEU. Although technically feasible, there is no current domestic capability to make HALEU in the US. While it is anticipated that industry will provide HALEU through commercial enrichment once advanced reactors mature, until a market is established, an interim source of HALEU is needed to enable research and demonstration. An interim source of HALEU could be provided by recovering the HEU in some DOE-managed SNF and downblending it to between 5% and 20% using the Hybrid ZIRCEX Process. ZIRCEX is a dry head-end process to remove cladding (zirconium or aluminum) from SNF. Drying of the SNF is needed prior to introduction to ZIRCEX. After cladding removal, uranium and fission products in the bed material are oxidized and elutriated. In a Hybrid ZIRCEX process, the HEU process stream is sent to a very compact, modular solvent extraction process for uranium purification. The uranyl nitrate from solvent extraction is denitrated and calcined to produce a HALEU product ready for fuel fabrication. The long-lived fission products from solvent extraction are immobilized in glass using a small in-can melt. By removing the cladding before dissolution, the volume of glass waste is reduced by a factor of up to 300 times (when compared to not removing the cladding from the fuel). Other radioactive wastes from the process could be disposed of as Class A or Class B low-level waste. In addition to producing HALEU for advanced reactors, consumption of SNF would reduce DoE's environmental liability. Incorporating low-enriched spent fuel (versus exclusive use of LEU, DU, or NU) into the downblending scheme could reduce the SNF inventory even further. Several downblending and enrichment scenarios using INL fuels were investigated in this study. The results of this analysis show that the Hybrid ZIRCEX process could make a significant contribution to needed HALEU feedstock and reduce the environmental liability of managing SNF at INL. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Oxidation of Glycolate in the Defense Waste Processing Facility (DWPF) Recycle Collection Tank - 20305

The Savannah River Site's Defense Waste Processing Facility (DWPF) operations are being upgraded with the introduction of the Nitric-Glycolic Flowsheet. Glycolic acid has been shown superior to formic acid as the reducing acid used during chemical processing. The new flowsheet improves or maintains necessary parameters such as 1) reduction of mercury, 2) adjustment of feed rheology and 3) adjustment of melter oxidation/reduction potential. Further, the potential for catalytic hydrogen generation in DWPF processing is virtually eliminated. DWPF process condensates are collected and returned to the SRS Concentration, Storage and Transfer Facilities (CSTF). The Recycle Collection Tank (RCT) collects off-gas condensate during chemical processing, vitrification, and other unit operations performed in DWPF and is the singular return vessel delivering recycle effluent back to CSTF. Each batch of recycle may contain a small amount of glycolate from chemical processing and melter off-gas condensates. To avoid potential flammability issues due to thermolysis of glycolate in the CSTF, chemical oxidation within the RCT has been investigated as an option for mitigating the transfer of glycolate. Sodium permanganate has been down-selected as the best option for oxidation of glycolate. Testing was performed using both 2-L and 22-L reactors (16,800:1 and 1,530:1 scale by volume) with non-radioactive waste simulants to approximate the expected RCT compositions. RCT simulants were evaluated at various process pH and temperature conditions. Also, RCT operations, namely the sequence of addition of corrosion inhibitors (NaOH and NaNO{sub 2}) versus a permanganate strike, were evaluated. Glycolate was introduced via a sludge simulant to mimic both expected entrainment and abnormal process foam-over conditions - the range being between 68 and 5100 mg/kg glycolate. Glycolate destruction was monitored by ion chromatography (IC). The corresponding manganese behavior was monitored in real-time using in situ ultraviolet-visible (UV-Vis) spectroscopy. RCT glycolate content can be reduced to below the IC detection limit within 90 minutes for all concentrations investigated. Ion Chromatography analysis revealed that under alkaline conditions, glycolate is primarily oxidized to oxalate with no significant formation of CO{sub 2} or carbonate, and nitrite is not oxidized to nitrate. Initially, complete oxidation of organics species and nitrite was assumed. Determination of the mechanistic chemical reaction has allowed the required amount of permanganate to be more accurately predicted and the total addition to be significantly reduced. UV-Vis measurements reveal that permanganate (Mn{sup 7+}) is reduced to manganate (Mn{sup 6+}) in the RCT. The oxidant stoichiometry is defined by using the initial permanganate to glycolate (P/G) molar ratio. At low initial glycolate concentration (68 and 140 mg/kg), the minimum required initial permanganate to glycolate (P/G) molar ratio was found to be 5-6. With high initial glycolate concentrations (5100 mg/kg) a lower (P/G) molar ratio of ∼2.5 was needed. The final portion of this effort supporting the nitric/glycolic flowsheet will be to test actual (fully radioactive) RCT samples as per the above simulant tests. (authors)

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

Enabling energy‐efficient manufacturing of pharmaceutical solid oral dosage forms via integrated techno‐economic analysis and advanced process modeling

Abstract The global pharmaceutical industry is a trillion‐dollar market. However, the pharmaceutical sector often lags in manufacturing innovation and automation which limits its potential to maximize energy efficiency. The integration of techno‐economic analysis (TEA) with advanced process models as part of an overarching smart manufacturing platform, can help industries create business models, which can be adapted for manufacturing to reduce energy consumption and operating costs while ensuring product quality which can further enable a more sustainable process operation. In this study, a rational design of experiment on three unit‐operations (wet granulation, drying, and milling) was performed on a batch (case 1) and continuous (case 2) pharmaceutical process to obtain experimental data. Process models for predicting product quality and energy efficiency of each of the three‐unit operations were developed. The experimental data were used to validate the models and good agreement was observed. The energy consumption of each unit operation was calculated using statistical models relating the power consumption and the process parameters. The developed process models and energy models were further integrated into a TEA framework, which quantified the energy and monetary cost of manufacturing for both batch and continuous manufacturing cases. With this integrated framework, energy costs savings of ~33% was obtained in the continuous manufacturing process (case 2) over the batch process (case 1).

Sampat, Chaitanya↗
DOE OSTI2024

Effects of process intensification on homogeneity of an IgG1:κ monoclonal antibody during perfusion culture

The pharmaceutical industry employs various strategies to improve cell productivity. These strategies include process intensification, culture media improvement, clonal selection, media supplementation and genetic engineering of cells. However, improved cell productivity has inherent risk of impacting product quality attributes (PQA). PQAs may affect the products’ efficacy via stability, bioavailability, or in vivo bioactivity. Variations in manufacturing process may introduce heterogeneity in the products by altering the type and extent of N-glycosylation, which is a PQA of therapeutic proteins. We investigated the effect of different cell densities representing increasing process intensification in a perfusion cell culture on the production of an IgG1-κ monoclonal antibody from a CHO-K1 cell line. This antibody is glycosylated both on light chain and heavy chain. Our results showed that the contents of glycosylation of IgG1-κ mAb increased in G0F and fucosylated type glycans as a group, whereas sialylated type glycans decreased, for the mAb whole protein. Overall, significant differences were observed in amounts of G0F, G1F, G0, G2FS1, and G2FS2 type glycans across all process intensification levels. G2FS2 and G2 type N-glycans were predominantly quantifiable from light chain rather than heavy chain. It may be concluded that there is a potential impact to product quality attributes of therapeutic proteins during process intensification via perfusion cell culture that needs to be assessed. Since during perfusion cell culture the product is collected throughout the duration of the process, lot allocation needs careful attention to process parameters, as PQAs are affected by the critical process parameters (CPPs).

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2019

Influence of Single-Point Incremental Force Process Parameters on Forming Characteristics and Microstructure Evolution of AA-6061 Alloy Sheet

Single-point incremental forming (SPIF) process comprises a set of process variables, such as forming tool diameter, vertical pitch, spindle rotation speed, and tool velocity, which may affect the forming behavior of the sheet to be deformed. The objective of this work is to study the effect of SPIF process parameters on forming characteristics and microstructure development for the AA-6061 (T6) aluminum alloy sheet. The SPIF experiments and finite element (FE) simulations were performed at different process parameters to achieve conical shapes from the AA-6061 blanks. The effect of process parameters on forming forces, thickness uniformity in wall region of the cone and surface roughness of the blank was analyzed. A detailed microstructure study was performed to analyze the effect of process variables on microstructure and texture evolution during the SPIF process. This study reveals that the process parameters are likely to influence the texture development especially at high tool diameter and vertical pitch values. Therefore, suitability and consequences of using different combinations of tool diameter and vertical pitch values are discussed for AA-6061 alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A novel chemical looping partial oxidation process for thermochemical conversion of biomass to syngas

The Biomass-to-Syngas (BTS) chemical looping process is an advanced thermochemical biomass conversion process for the production of sustainable fuels and chemicals. The BTS process is novel in that it converts biomass feedstock to high purity syngas with adjustable H 2 :CO molar ratio without needing an air separation unit (ASU), a tar reformer, a steam reformer, or a water-gas-shift (WGS) reactor. In the BTS process, biomass feedstock is partially oxidized to produce syngas by oxygen carriers in a reducer that is operated in a co-current gas-solid moving bed contact mode. The reduced oxygen carriers are regenerated in a fluidized bed combustor via the oxidation reaction with air. The BTS process uses the iron-titanium composite metal oxide (ITCMO) material as the oxygen carrier, which is capable of cracking the volatiles produced in biomass pyrolysis as well as regulating the syngas composition. The co-current moving bed reducer eliminates back-mixing, channeling, or bypassing of solid and gas reactants, resulting in a syngas composition that is close to the thermodynamic equilibrium. In this paper, the rationale of a successful BTS process is discussed along with the thermodynamic characteristics of the ITCMO oxygen carrier, that can effectively react with a woody biomass feedstock, analyzed based on an ASPEN Plus model. Bench scale moving bed reducer experiments are presented, indicating the conversion of wood pellets to syngas with a H 2 :CO ratio of 2, which is suitable for methanol or liquid fuel synthesis. The gas and solid composition produced in the bench scale reducer matches the prediction from the ASPEN Plus thermodynamic model. Furthermore, this model is further used to analyze the performance of the BTS process under autothermal conditions for methanol production, with a comparison with a baseline indirectly heated gasification process.

09 BIOMASS FUELS↗