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Advanced Process Monitoring Techniques for Safeguarding Reprocessing Facilities

The International Atomic Energy Agency (IAEA) has established international safeguards standards for fissionable material at spent fuel reprocessing plants to ensure that significant quantities of weapons-grade nuclear material are not diverted from these facilities. For large throughput nuclear facilities, it is difficult to satisfy the IAEA safeguards accountancy goal for detection of abrupt diversion. Currently, methods to verify material control and accountancy (MC&A) at these facilities require time-consuming and resource-intensive destructive assay (DA). Leveraging new on-line non destructive assay (NDA) process monitoring techniques in conjunction with the traditional and highly precise DA methods may provide an additional measure to nuclear material accountancy which would potentially result in a more timely, cost-effective and resource efficient means for safeguards verification at such facilities. By monitoring process control measurements (e.g. flowrates, temperatures, or concentrations of reagents, products or wastes), abnormal plant operations can be detected. Pacific Northwest National Laboratory (PNNL) is developing on-line NDA process monitoring technologies, including both the Multi-Isotope Process (MIP) Monitor and a spectroscopy-based monitoring system, to potentially reduce the time and resource burden associated with current techniques. The MIP Monitor uses gamma spectroscopy and multivariate analysis to identify off-normal conditions in process streams. The spectroscopic monitor continuously measures chemical compositions of the process streams including actinide metal ions (U, Pu, Np), selected fission products, and major cold flowsheet chemicals using UV-Vis, Near IR and Raman spectroscopy. This paper will provide an overview of our methods and report our on-going efforts to develop and demonstrate the technologies.

process monitoring↗

Development of advanced Czochralski growth process to produce low cost 150 kg silicon ingots from a single crucible for technology readiness

The process development continued, with a total of nine crystal growth runs. One of these was a 150 kg run of 5 crystals of approximately 30 kg each. Several machine and process problems were corrected and the 150 kg run was as successful as previous long runs on CG2000 RC's. The accelerated recharge and growth will be attempted when the development program resumes at full capacity in FY '82. The automation controls (Automatic Grower Light Computer System) were integrated to the seed dip temperature, shoulder, and diameter sensors on the CG2000 RC development grower. Test growths included four crystals, which were grown by the computer/sensor system from seed dip through tail off. This system will be integrated on the Mod CG2000 grower during the next quarter. The analytical task included the completion and preliminary testing of the gas chromatograph portion of the Furnace Atmosphere Analysis System. The system can detect CO concentrations and will be expanded to oxygen and water analysis in FY '82.

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Seven Processes that Enable NASA Software Engineering Technologies

This slide presentation reviews seven processes that NASA uses to ensure that software is developed, acquired and maintained as specified in the NPR 7150.2A requirement. The requirement is to ensure that all software be appraised for the Capability Maturity Model Integration (CMMI). The enumerated processes are: (7) Product Integration, (6) Configuration Management, (5) Verification, (4) Software Assurance, (3) Measurement and Analysis, (2) Requirements Management and (1) Planning & Monitoring. Each of these is described and the group(s) that are responsible is described.

Housch, Helen↗

Decision Gate Process for Assessment of a Technology Development Portfolio

The NASA Dust Management Project (DMP) was established to provide technologies (to TRL 6 development level) required to address adverse effects of lunar dust to humans and to exploration systems and equipment, which will reduce life cycle cost and risk, and will increase the probability of sustainable and successful lunar missions. The technology portfolio of DMP consisted of different categories of technologies whose final product is either a technology solution in itself, or one that contributes toward a dust mitigation strategy for a particular application. A Decision Gate Process (DGP) was developed to assess and validate the achievement and priority of the dust mitigation technologies as the technologies progress through the development cycle. The DGP was part of continuous technology assessment and was a critical element of DMP risk management. At the core of the process were technology-specific criteria developed to measure the success of each DMP technology in attaining the technology readiness levels assigned to each decision gate. The DGP accounts for both categories of technologies and qualifies the technology progression from technology development tasks to application areas. The process provided opportunities to validate performance, as well as to identify non-performance in time to adjust resources and direction. This paper describes the overall philosophy of the DGP and the methodology for implementation for DMP, and describes the method for defining the technology evaluation criteria. The process is illustrated by example of an application to a specific DMP technology.

Kohli, Rajiv↗

An overview of process systems engineering approaches for process intensification: State of the art

Process intensification offers the potential to drastically reduce the energy consumption and cost of producing chemicals from both bulk and distributed feedstocks. This review article aims to offer an extensive survey on state-of-the-art process systems engineering (PSE) approaches for process intensification. From both academic and industrial perspectives, this paper provides an overview of the development of various process intensification technologies, specifically those under the categories of separation, reaction, hybrid reaction/separation, and alternative energy sources. A current status analysis in the areas of modeling and simulation is then provided. An indicative list of PSE publications specialized on process intensification is presented to illustrate the progresses made so far towards the deployment of novel process intensification technologies. We also highlight some recent advances for the modeling, design, and synthesis of intensified systems, as well as for the assessment of their controllability/operability/safety performance. As a result, key open questions in these areas include: (i) how to systematically derive intensified designs, and (ii) how to ensure the operability and optimality of the derived intensified structures while delivering their expected functionality.

42 ENGINEERING↗

Alstom's Chemical Looping Combustion Prototype for CO 2 Capture from Existing Pulverized Coal-Fired Power Plants

Alstom’s Limestone Chemical Looping (LCL™) process has the potential to capture CO 2 from new and existing coal-fired power plants while maintaining high plant power generation efficiency. This new power plant concept is based on a hybrid combustion- gasification process utilizing high temperature chemical and thermal looping technology. This process could also be potentially configured as a hybrid combustion-gasification process producing a syngas or hydrogen for various applications while also producing a separate stream of CO 2 for use or sequestration. The targets set for this technology is to capture over 90% of the total carbon in the coal at cost of electricity which is less than 20% greater than Conventional PC or CFB units. Previous work with bench scale test and a 65 kWt Process Development Unit Development (PDU) has validated the chemistry required for the chemical looping process and provided for the investigation of the solids transport mechanisms and design requirements. The objective of this project is to continue development of the combustion option of chemical looping (LCL-C™) by designing, building and testing a 3 MWt prototype facility. The prototype includes all of the equipment that is required to operate the chemical looping plant in a fully integrated manner with all major systems in service. Data from the design, construction, and testing will be used to characterize environmental performance, identify and address technical risks, reassess commercial plant economics, and develop design information for a demonstration plant planned to follow the proposed Prototype. A cold flow model of the prototype will be used to predict operating conditions for the prototype and help in operator training. Operation of the prototype will provide operator experience with this new technology and performance data of the LCL-C™ process, which will be applied to the commercial design and economics and plan for a future demonstration plant.

20 FOSSIL-FUELED POWER PLANTS↗

Exploration Medical Capability - Technology Watch

The objectives of the Technology Watch process are to identify emerging, high-impact technologies that augment current ExMC development efforts, and to work with academia, industry, and other government agencies to accelerate the development of medical care and research capabilities for the mitigation of potential health issues that could occur during space exploration missions. The establishment of collaborations with these entities is beneficial to technology development, assessment and/or insertion. Such collaborations also further NASA s goal to provide a safe and healthy environment for human exploration. The Tech Watch project addresses requirements and capabilities identified by knowledge and technology gaps that are derived from a discrete set of medical conditions that are most likely to occur on exploration missions. These gaps are addressed through technology readiness level assessments, market surveys, collaborations and distributed innovation opportunities. Ultimately, these gaps need to be closed with respect to exploration missions, and may be achieved through technology development projects. Information management is a key aspect to this process where Tech Watch related meetings, research articles, collaborations and partnerships are tracked by the HRP s Exploration Medical Capabilities (ExMC) Element. In 2011, ExMC will be introducing the Tech Watch external website and evidence wiki that will provide access to ExMC technology and knowledge gaps, technology needs and requirements documents.

Krihak, Michael↗

Some inadequacies of the current human factors certification process of advanced aircraft technologies

Automation related accidents or serious incidents are not limited to advanced technology aircraft. There is a full history of such accidents with conventional technology aircraft. However, this type of occurrence is far from sparing the newest 'glass cockpit' generation, and it even seems to be a growing contributor to its accident rate. Nevertheless, all these aircraft have been properly certificated according to the relevant airworthiness regulations. Therefore, there is a growing concern that with the technological advancement of air transport aircraft cockpits, the current airworthiness regulations addressing cockpit design and human factors may have reached some level of inadequacy. This paper reviews some aspects of the current airworthiness regulations and certification process related to human factors of cockpit design and focuses on questioning their ability to guarantee the intended safety objectives.

Paries, Jean↗

Technology for Treatment of Liquid Radioactive Waste Generated during Uranium and Plutonium Chemical and Metallurgical Manufacturing in FSUE PO Mayak - 13616

Created technological scheme for treatment of liquid radioactive waste generated while uranium and plutonium chemical and metallurgical manufacturing consists of: - Liquid radioactive waste (LRW) purification from radionuclides and its transfer into category of manufacturing waste; - Concentration of suspensions containing alpha-nuclides and their further conversion to safe dry state (calcinate) and moving to long controlled storage. The following technologies are implemented in LRW treatment complex: - Settling and filtering technology for treatment of liquid intermediate-level waste (ILW) with volume about 1500m{sup 3}/year and alpha-activity from 10{sup 6} to 10{sup 8} Bq/dm{sup 3} - Membrane and sorption technology for processing of low-level waste (LLW) of radioactive drain waters with volume about 150 000 m{sup 3}/year and alpha-activity from 10{sup 3} to 10{sup 4} Bq/dm{sup 3}. Settling and filtering technology includes two stages of ILW immobilization accompanied with primary settling of radionuclides on transition metal hydroxides with the following flushing and drying of the pulp generated; secondary deep after settling of radionuclides on transition metal hydroxides with the following solid phase concentration by the method of tangential flow ultrafiltration. Besides, the installation capacity on permeate is not less than 3 m{sup 3}/h. Concentrates generated are sent to calcination on microwave drying (MW drying) unit. Membrane and sorption technology includes processing of averaged sewage flux by the method of tangential flow ultrafiltration with total capacity of installations on permeate not less than 18 m{sup 3}/h and sorption extraction of uranium from permeate on anionite. According to radionuclide contamination level purified solution refers to general industrial waste. Concentrates generated during suspension filtering are evaporated in rotary film evaporator (RFE) in order to remove excess water, thereafter they are dried on infrared heating facility. Solid concentrate produced is sent for long controlled storage. Complex of the procedures carried out makes it possible to solve problems on treatment of LRW generated while uranium and plutonium chemical and metallurgical manufacturing in Federal State Unitary Enterprise (FSUE) Mayak and cease its discharge into open water reservoirs. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Technology Assessment of Laser-Assisted Materials Processing in Space

Lasers are useful for performing operations such as joining, machining, built-up freeform fabrication, shock processing, and surface treatments. These attributes are attractive for the supportability of longer-term missions in space due to the multi-functionality of a single tool and the variety of materials that can be processed. However, current laser technology also has drawbacks for space-based applications, specifically size, power efficiency, lack of robustness, and problems processing highly reflective materials. A review of recent laser developments will be used to show how these issues may be reduced and indicate where further improvement is necessary to realize a laser-based materials processing capability in space. The broad utility of laser beams in synthesizing various classes of engineering materials will be illustrated using state-of-the art processing maps for select lightweight alloys typically found on spacecraft. With the advent of recent breakthroughs in diode-pumped solid-state lasers and fiber optic technologies, the potential to perform multiple processing techniques is increasing significantly. Lasers with suitable wavelengths and beam properties have tremendous potential for supporting future space missions to the moon, Mars and beyond.

Nagarathnam, Karthik↗

Technology Assessment of Laser-Assisted Materials Processing in Space

Lasers are useful for performing operations such as joining, machining, built-up freeform fabrication, shock processing, and surface treatments. These attributes are attractive for the supportability of longer-term missions in space due to the multi-functionality of a single tool and the variety of materials that can be processed. However, current laser technology also has drawbacks for space-based applications, specifically size, power efficiency, lack of robustness, and problems processing highly reflective materials. A review of recent laser developments will be used to show how these issues may be reduced and indicate where further improvement is necessary to realize a laser-based materials processing capability in space. The broad utility of laser beams in synthesizing various classes of engineering materials will be illustrated using state-of-the art processing maps for select lightweight alloys typically found on spacecraft. With the advent of recent breakthroughs in diode-pumped solid-state lasers and fiber optic technologies, the potential to perform multiple processing techniques is increasing significantly. Lasers with suitable wavelengths and beam properties have tremendous potential for supporting future space missions to the moon, Mars and beyond.

Nagarathnam, Karthik↗

Flexible control techniques for a lunar base

The fundamental elements found in every terrestrial control system can be employed in all lunar applications. These elements include sensors which measure physical properties, controllers which acquire sensor data and calculate a control response, and actuators which apply the control output to the process. The unique characteristics of the lunar environment will certainly require the development of new control system technology. However, weightlessness, harsh atmospheric conditions, temperature extremes, and radiation hazards will most significantly impact the design of sensors and actuators. The controller and associated control algorithms, which are the most complex element of any control system, can be derived in their entirety from existing technology. Lunar process control applications -- ranging from small-scale research projects to full-scale processing plants -- will benefit greatly from the controller advances being developed today. In particular, new software technology aimed at commercial process monitoring and control applications will almost completely eliminate the need for custom programs and the lengthy development and testing cycle they require. The applicability of existing industrial software to lunar applications has other significant advantages in addition to cost and quality. This software is designed to run on standard hardware platforms and takes advantage of existing LAN and telecommunications technology. Further, in order to exploit the existing commercial market, the software is being designed to be implemented by users of all skill levels -- typically users who are familiar with their process, but not necessarily with software or control theory. This means that specialized technical support personnel will not need to be on-hand, and the associated costs are eliminated. Finally, the latest industrial software designed for the commercial market is extremely flexible, in order to fit the requirements of many types of processing applications with little or no customization. This means that lunar process control projects will not be delayed by unforeseen problems or last minute process modifications. The software will include all of the tools needed to adapt to virtually any changes. In contrast to other space programs which required the development of tremendous amounts of custom software, lunar-based processing facilities will benefit from the use of existing software technology which is being proven in commercial applications on Earth.

Kraus, Thomas W.↗

The Application of Current Mineral Processing and Extractive Metallurgy Technologies to Potential Rare Earth Ores in the U.S. Coal Measures: Near-Term Opportunities to Fill Out the U.S. Value Chain

This report is intended to provide the background on domestic rare earth production and provide potential opportunities for the near-term restoration of the rare earth value chain in the U.S. Background and contextual material is provided on the domestic rare earth industry, as is an overview of the economics of processing rare earth ores through the value chain, including a deeper assessment of different mineral processing pathways and opportunities. This is followed by a discussion on knowledge gaps and key research areas that can address them in developing rare earth production in the near term.

58 GEOSCIENCES↗

Decision Insight into Stakeholder Conflict for ERN

Participatory modeling has become an important tool in facilitating resource decision making and dispute resolution. Approaches to modeling that are commonly used in this context often do not adequately account for important human factors. Current techniques provide insights into how certain human activities and variables affect resource outcomes; however, they do not directly simulate the complex variables that shape how, why, and under what conditions different human agents behave in ways that affect resources and human interactions related to them. Current approaches also do not adequately reveal how the effects of individual decisions scale up to have systemic level effects in complex resource systems. This lack of integration prevents the development of more robust models to support decision making and dispute resolution processes. Development of integrated tools is further hampered by the fact that collection of primary data for decision-making modeling is costly and time consuming. This project seeks to develop a new approach to resource modeling that incorporates both technical and behavioral modeling techniques into a single decision-making architecture. The modeling platform is enhanced by use of traditional and advanced processes and tools for expedited data capture. Specific objectives of the project are: (1) Develop a proof of concept for a new technical approach to resource modeling that combines the computational techniques of system dynamics and agent based modeling, (2) Develop an iterative, participatory modeling process supported with traditional and advance data capture techniques that may be utilized to facilitate decision making, dispute resolution, and collaborative learning processes, and (3) Examine potential applications of this technology and process. The development of this decision support architecture included both the engineering of the technology and the development of a participatory method to build and apply the technology. Stakeholder interaction with the model and associated data capture was facilitated through two very different modes of engagement, one a standard interface involving radio buttons, slider bars, graphs and plots, while the other utilized an immersive serious gaming interface. The decision support architecture developed through this project was piloted in the Middle Rio Grande Basin to examine how these tools might be utilized to promote enhanced understanding and decision-making in the context of complex water resource management issues. Potential applications of this architecture and its capacity to lead to enhanced understanding and decision-making was assessed through qualitative interviews with study participants who represented key stakeholders in the basin.

97 MATHEMATICS AND COMPUTING↗

Digital image processing for the earth resources technology satellite data.

This paper discusses the problems of digital processing of the large volumes of multispectral image data that are expected to be received from the ERTS program. Correction of geometric and radiometric distortions are discussed and a byte oriented implementation is proposed. CPU timing estimates are given for a System/360 Model 67, and show that a processing throughput of 1000 image sets per week is feasible.

Will, P. M.↗

Materials science and engineering in space

The influences of gravitational forces on processes used in the preparation of materials employed in earth-based applications are addressed and the benefits which may be derived from the microgravity environment of space in improving on such constraints are considered. Attention is given to the fact that Materials Processing in Space is directed toward the utilization of the unique space environment as a tool to establish a scientific characterization of materials processes for technological exploitation in the public benefit. In the context of enhancement to earth-based technology or implementation of space-based processes for specialized, low volume, high value materials, the thrust of the Materials Processing in Space program is surveyed.

Zoller, L. K.↗

The future of crystalline silicon technology in the US Department of Energy program

Two basic findings were presented in the outlined report. The first is that silicon has a very high potential efficiency, demonstrated improvement in reliability and a significant potential for cost reductions. The second is that the photovoltaic technology development process is highly uncertain, but crystalline silicon technology has a substantial knowledge base to draw from, improving its chances of success. Several issues to be addressed are outlined.

Scolaro, A. F.↗

Mirror Technology

Under a NASA contract, MI-CVD developed a process for producing bulk silicon carbide by means of a chemical vapor deposition process. The technology allows growth of a high purity material with superior mechanical/thermal properties and high polishability - ideal for mirror applications. The company employed the technology to develop three research mirrors for NASA Langley and is now marketing it as CVD SILICON CARBIDE. Its advantages include light weight, thermal stability and high reflectivity. The material has nuclear research facility applications and is of interest to industrial users of high power lasers.

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