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DOE OSTI2021

Vitrification of Hanford Tank Wastes for Condensate Recycle and Feed Composition Changeover Testing

During the vitrification of Hanford Site nuclear waste at the Waste Treatment and Immobilization Plant (WTP), which is a part of the safe and efficient retrieval, treatment, and disposal mission of the U.S. Department of Energy Office of River Protection, the offgas condensate generated from the waste-to-glass conversion is currently planned to be concentrated by evaporation in the Effluent Management Facility (EMF). This concentrated condensate can then be recycled back to the incoming waste and vitrified. To test the recycle process, an apparatus was designed and built to mimic the EMF evaporator and was then used to concentrate a volume of condensate produced during the vitrification of a sample of Hanford tank 241-AP-107 (referred to herein as AP-107) waste in a continuous laboratory-scale melter (CLSM). The concentrated condensate was added to an additional sample of AP-107 waste, to mimic one round of the recycle process, and the combined solution was vitrified, producing a second round of recycle condensate. In the current study, the EMF test apparatus was used to concentrate the second-round recycle condensate under evaporation conditions (at 45 °C and 1.4 psia) designed to emulate EMF operation. The condensate was successfully concentrated by a factor of ~10 while retaining over 95 % of the technetium-99 ( 99 Tc), Cs, and I inventories in the concentrate. Another portion of AP-107 waste was retrieved by Washington River Protection Solutions, LLC (WRPS) and transferred to Pacific Northwest National Laboratory (PNNL), where it was pretreated and then combined with the second-round recycle AP-107 condensate concentrate and glass-forming chemicals (GFCs) to form the two-time recycle AP-107 melter feed, approximating a second round to the recycling action to be performed at the WTP. A portion of AP-105 waste was also retrieved by WRPS and provided to PNNL for pretreatment and combining with GFCs to form AP-105 melter feed. The two-time recycle AP-107 and AP-105 melter feeds were processed consecutively in the CLSM. The CLSM run proceeded for 13.63 hours, producing 9.70 kg of glass for an average glass production rate of 1464 kg m 2 d -1 during the two-time recycle AP-107 feed charging and 1568 kg m 2 d -1 during the AP-105 feed charging. The rate during AP-107 charging was essentially equivalent to the rate when processing no-recycle AP-107 feed and lower than that achieved when processing one-time recycle AP-107 feed. However, all rates were within the potential range of variability when processing melter feeds with similar composition in the CLSM. Likewise, the rate during AP-105 charging was higher than the previous rate processing AP-105, but within the potential CLSM range. The cold-cap characteristics changed from the typically thin AP-107 cold cap to a foamy-edged cold cap as previously seen with AP-105 shortly after transitioning to the AP-105 melter feed. The glass produced during the CLSM run was within 10 % of its target composition for the primary glass components. The CaO and Li 2 O targets varied by more than 1 wt% between the two-time recycle AP-107 and AP-105 glass targets and it took about 2 turnovers of the CLSM glass inventory to reach a relative chemical steady state in the glass for CaO and Li 2 O after the melter feed inputs were switched. The 99 Tc and total cesium content in the melter feeds were maintained at concentrations expected to be experienced at the WTP. During the CLSM run, while processing the two-time recycle AP-107 melter feed at a relative chemical steady state, the 99 Tc/Cs ratio was 10, and 34% of 99 Tc and 74% of Cs were retained in the glass. These values were higher than those measured in the CLSM run with one-time recycle AP-107 melter feed. After the transition to processing the AP-105 melter feed, when the production reached a relative chemical steady state, the 99 Tc/Cs ratio was 77 while 44% of 99 Tc was retained in the glass. The C's retention during this time frame reached 200% due to the excess C's in the glass after the target content decreased to 15% of its initial level in the two-time recycle AP-107 melter feed to the lower target in the Ap-105 melter feed. While iodine was below inductively coupled plasma mass spectrometry analytical reporting limits in the melter feed and glass samples, it was detected in quantities above the analytical reporting limits in the liquid and filter samples collected from the CLSM offgas treatment system. The behavior of iodine in the CLSM offgas treatment system followed a similar pattern to those of 99 Tc and Cs.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Vitrification of Hanford Tank Wastes for Condensate Recycle and Feed Composition Changeover Testing (Rev. 1)

During the vitrification of Hanford Site nuclear waste at the Waste Treatment and Immobilization Plant (WTP), which is a part of the safe and efficient retrieval, treatment, and disposal mission of the U.S. Department of Energy Office of River Protection, the offgas condensate generated from the waste-to-glass conversion is currently planned to be concentrated by evaporation in the Effluent Management Facility (EMF). This concentrated condensate can then be recycled back to the incoming waste and vitrified. To test the recycle process, an apparatus was designed and built to mimic the EMF evaporator and was then used to concentrate a volume of condensate produced during the vitrification of a sample of Hanford tank 241-AP-107 (referred to herein as AP-107) waste in a continuous laboratory-scale melter (CLSM). The concentrated condensate was added to an additional sample of AP-107 waste, to mimic one round of the recycle process, and the combined solution was vitrified, producing a second round of recycle condensate. In the current study, the EMF test apparatus was used to concentrate the second-round recycle condensate under evaporation conditions (at 45 °C and 1.4 psia) designed to emulate EMF operation. The condensate was successfully concentrated by a factor of ~10 while retaining over 95 % of the technetium-99 (99Tc), Cs, and I inventories in the concentrate. Another portion of AP-107 waste was retrieved by Washington River Protection Solutions, LLC (WRPS) and transferred to Pacific Northwest National Laboratory (PNNL), where it was pretreated and then combined with the second-round recycle AP-107 condensate concentrate and glass-forming chemicals (GFCs) to form the two-time recycle AP-107 melter feed, approximating a second round to the recycling action to be performed at the WTP. A portion of AP-105 waste was also retrieved by WRPS and provided to PNNL for pretreatment and combining with GFCs to form AP-105 melter feed. The two-time recycle AP-107 and AP-105 melter feeds were processed consecutively in the CLSM. The CLSM run proceeded for 13.63 hours, producing 9.70 kg of glass for an average glass production rate of 1464 kg m 2 d -1 during the two-time recycle AP-107 feed charging and 1568 kg m 2 d -1 during the AP-105 feed charging. The rate during AP-107 charging was essentially equivalent to the rate when processing no-recycle AP-107 feed and lower than that achieved when processing one-time recycle AP-107 feed. However, all rates were within the potential range of variability when processing melter feeds with similar composition in the CLSM. Likewise, the rate during AP-105 charging was higher than the previous rate processing AP-105, but within the potential CLSM range. The cold-cap characteristics changed from the typically thin AP-107 cold cap to a foamy-edged cold cap as previously seen with AP-105 shortly after transitioning to the AP-105 melter feed. The glass produced during the CLSM run was within 10 % of its target composition for the primary glass components. The CaO and Li 2 O targets varied by more than 1 wt% between the two-time recycle AP-107 and AP-105 glass targets and it took about 2 turnovers of the CLSM glass inventory to reach a relative chemical steady state in the glass for CaO and Li 2 O after the melter feed inputs were switched.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1978

The production of ultrathin polyimide films for the solar sail program and Large Space Structures Technology (LSST): A feasibility study

Polyimide membranes of a thickness range from under 0.01 micron m to greater than 1 micron m can be produced at an estimated cost of 50 cents per sq m (plus the cost of the polymer). The polymer of interest is dissolved in a solvent which is solube in water. The polymer or casting solution is allowed to flow down an inclined ramp onto a water surface where a pool of floating polymer develops. The solvent dissolves into the water lowering the surface tension of the water on equently, the contact angle of the polymer pool is very low and the edge of the pool is very thin. The solvent dissolves from this thin region too rapidly to be replenished from the bulk of the pool and a solid polymer film forms. Firm formation is rapid and spontaneous and the film spreads out unaided, many feet from the leading edge of the pool. The driving force for this process is the exothermic solution of the organic solvent from the polymer solution into the water.

Forester, R. H.↗

NASA NTRS1987

Parallel processing architecture for computing inverse differential kinematic equations of the PUMA arm

In advanced robot control problems, on-line computation of inverse Jacobian solution is frequently required. Parallel processing architecture is an effective way to reduce computation time. A parallel processing architecture is developed for the inverse Jacobian (inverse differential kinematic equation) of the PUMA arm. The proposed pipeline/parallel algorithm can be inplemented on an IC chip using systolic linear arrays. This implementation requires 27 processing cells and 25 time units. Computation time is thus significantly reduced.

Hsia, T. C.↗

NASA NTRS1975

Segregation effects during solidification in weightless melts

Computer programs are developed and used in the study of the combined effects of evaporation and solidification in space processing. The temperature and solute concentration profiles during directional solidification of binary alloys with surface evaporation were mathematically formulated. Computer results are included along with an econotechnical model of crystal growth. This model allows: prediction of crystal size, quality, and cost; systematic selection of the best growth equipment or alloy system; optimization of growth or material parameters; and a maximization of zero-gravity effects. Segregation in GaAs crystals was examined along with vibration effects on GaAs crystal growth. It was found that a unique segregation pattern and strong convention currents exist in GaAs crystal growth. Some beneficial effects from vibration during GaAs growth were discovered. The implications of the results in space processing are indicated.

Li, C.↗

NASA NTRS1973

Numerical solution of equations governing longitudinal suspension line wave motion during the parachute unfurling process

Equations are presented which govern the dynamics of the lines-first parachute unfurling process, including wave motion in the parachute suspension lines. Techniques are developed for obtaining numerical solutions to the governing equations. Histories of tension at test data, and generally good agreement is observed. Errors in computed results are attributed to several areas of uncertainty, the most significant being a poorly defined boundary condition on the wave motion at the vehicle-suspension line boundary.

Poole, L. R.↗

NASA NTRS1983

Gravitational effects in dendritic growth

The theories of diffusion-controlled dendritic crystallization will be reviewed briefly, along with recently published critical experiments on the kinetics and morphology of dendritic growth in pure substances. The influence of the gravitational body force on dendrite growth kinetics will be shown to be highly dependent on the growth orientation with respect to the gravity vector and on the level of the thermal supercooling. In fact, an abrupt transition occurs at a critical supercooling, above which diffusional transport dominates the growth process and below which convective transport dominates. Our most recent work on binary mixtures shows that dilute solute additions influence the crystallization process indirectly, by altering the interfacial stability, rather than by directly affecting the transport mode. Directions for future studies in this field will also be discussed.

Glicksman, M. E.↗

NASA NTRS1990

A turbulent two-phase flow model for nebula flows

A new and very efficient turbulent two-phase flow numericaly model is described to analyze the environment of a protoplanetary nebula at a stage prior to the formation of planets. Focus is on settling processes of dust particles in flattened gaseous nebulae. The model employs a perturbation technique to improve the accuracy of the numerical simulations of such flows where small variations of physical quantities occur over large distance ranges. The particles are allowed to be diffused by gas turbulence in addition to settling under gravity. Their diffusion coefficients is related to the gas turbulent viscosity by the non-dimensional Schmidt number. The gas turbulent viscosity is determined by the means of the eddy viscosity hypothesis that assumes the Reynolds stress tensor proportional to the mean strain rate tensor. Zero- and two-equation turbulence models are employed. Modeling assumptions are detailed and discussed. The numerical model is shown to reproduce an existing analytical solution for the settling process of particles in an inviscid nebula. Results of nebula flows are presented taking into account turbulence effects of nebula flows. Diffusion processes are found to control the settling of particles.

Champney, Joelle M.↗

DOE OSTI2025

Zavitsas’ hydration model for electrolytes only stable in the presence of another: NaAl(OH) 4 in aqueous NaOH solution

Many aqueous electrolytes are only stable in the presence of another electrolyte, such as electrolytes that are only soluble in strong acid or base. An example is sodium aluminate [NaAl(OH) 4 ], which is only stable in aqueous NaOH. This complicates developing thermodynamic parameters because it is difficult to separate the contributions of individual electrolytes in multicomponent solutions to measured bulk thermodynamic properties. The present study develops a method to determine the liquid phase parameters from solubility data for Zavitsas’ Hydration model, a model that incorporates hydration parameters into the activities of dissolved species. Furthermore, this study uses gibbsite [Al(OH) 3 ] solubility data in aqueous NaOH solution to develop Zavitsas' model parameters for NaAl(OH) 4 simultaneously with the equilibrium constants. A good fit of the solubility data was found, showing that Zavitsas’ model is effective for this system.

Bayer process↗

DOE OSTI2025

Code associated with Publication “Analytic Solutions and Field-Scale Application for Verification of Coupled Thermo-Hydro-Mechanical Processes in Subsurface Fractured Media”

As part of a submitted paper, which is collection of previously published analytical solutions to coupled thermo-hydro-mechanical problems in subsurface flow and transport, we have prepared a collection of python scripts to compute and plot those analytic solutions. All code to be released implements existing methods; there are no novel algorithms nor any major innovations to existing software.

Hyman, Jeffrey↗

DOE OSTI2021

Hamiltonian systems, Toda lattices, solitons, Lax pairs on weighted Z -graded graphs

In this study, we consider discrete one-dimensional nonlinear equations and present the procedure of lifting them to Z -graded graphs. We identify conditions that allow one to lift one-dimensional solutions to solutions on graphs. In particular, we prove the existence of solitons for static potentials on graded fractal graphs. We also show that even for a simple example of a topologically interesting graph, the corresponding non-trivial Lax pairs and associated unitary transformations do not lift to a Lax pair on the Z -graded graph.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Winding Down: End of Service and Recycling for Wind Energy [Slides]

In this webinar hosted by the U.S. Department of Energy's WINDExchange initiative, experts from the National Renewable Energy Laboratory introduce attendees to key concepts in end-of-service processes for wind energy technologies and infrastructure, including decommissioning, repowering, and recycling. As wind energy projects across the United States become older, decisions about end-of-service options and component processing are of growing importance to project owners and operators, state and local decision-makers, and neighboring communities. There is also concern about the blade waste that must be processed, with a number of recycling solutions being developed to meet this need. This webinar introduces the processes and activities involved at the end of a wind energy project's lifespan; discusses the impacts these activities have on communities, landowners, the wind energy industry, and other stakeholders; explains different blade recycling methods; and discusses the future of recycling in the wind energy industry.

17 WIND ENERGY↗

NASA NTRS2018

Pretreatment Solution for Water Recovery Systems

Chemical pretreatments are used to produce usable water by treating a water source with a chemical pretreatment that contains a hexavalent chromium and an acid to generate a treated water source, wherein the concentration of sulfate compounds in the acid is negligible, and wherein the treated water source remains substantially free of precipitates after the addition of the chemical pretreatment. Other methods include reducing the pH in urine to be distilled for potable water extraction by pretreating the urine before distillation with a pretreatment solution comprising one or more acid sources selected from a group consisting of phosphoric acid, hydrochloric acid, and nitric acid, wherein the urine remains substantially precipitate free after the addition of the pretreatment solution. Another method described comprises a process for reducing precipitation in urine to be processed for water extraction by mixing the urine with a pretreatment solution comprising hexavalent chromium compound and phosphoric acid.

Muirhead, Dean↗

NASA NTRS2021

Generation-based Evolutionary Tool for the Optimization of Constellations (GenETOC)

With the rapid growth in the capabilities of smaller satellites, satellite architectures that replace a single, extremely capable spacecraft with multiple, cheaper ones are gaining in popularity. Unfortunately, the orbit design process for constellations can be significantly more involved, especiallywhen the relative placement of the individual spacecraft within the constellation is not constrained by mission and/or science objectives. Optimizing a satellite constellation in the presence of multiple, competing objectives is a highly complex problem to which many traditional mathematical optimization methods cannot be applied and few tools exist to help mission designers search for promising candidate mission designs. The Generation-based Evolutionary Tool for the Optimization of Constellations (GenETOC) has been created to search for near-optimal constellation design options. GenETOC combines a modified version of the Non-dominated Sorting Genetic Algorithm II (NSGA II) with STK Components libraries (a 3rdparty .NET package created by Analytical Graphics Inc.) to create a framework that enables a mission designer to generate a simulation that models the design problem and obtain a family of potential, near-optimal solutions that can be investigated more in detail. GenETOC was developed in C# using the .NET framework with Windows Presentation Foundation (WPF) serving as the framework from which to create the graphical user interface (GUI). GenETOC user inputs can be categorized into three major data components: definition of the problem (areas of interest, satellite decision parameters, and sensor configurations), definition of performance objectives, and specification of the genetic algorithm (GA) parameters. In the problem definition component, the user is prompted to define the areas of interest against which the performance metrics will be computed, define the sensor parameters and attach them to specific spacecraft, select which satellite orbital parameters will be added to the decision space of the GA, and specify the range of desired values for each optimization parameter. For performance objectives, the user is presented with a list of available coverage and revisit performance based calculation options from which two metrics are chosen to serve as the objective functions that the GA will use to evaluate solutions during the optimization process. Finally, the definition of the GA parameters provides user control over the number of generations (number of optimization iterations), the population size (number of candidate constellations created in each generation), and the adaptive mutation and crossover threshold values (control parameters for how frequently each process occurs during the optimization). GenETOC has been extensively tested to verify the individual components of the optimization process. The GA has been tested against a suite of GA test problems to confirm convergence to the known two and three-dimensional Pareto fronts. The coverage and revisit performance metrics obtained in GenETOC are compared with STK desktop scenarios, confirming the constellations are being appropriately modeled within GenETOC simulations. A walkthrough of a simple, example problem is provided to illustrate the workings of GenETOC and to demonstrate the output available to the mission designer.

mission design↗

DOE OSTI2023

A review on experimentally observed mechanical and microstructural characteristics of interfaces in multi-material laser powder bed fusion

Additive manufacturing (AM) is a revolutionary technology. One of the key AM categories, metal powder-based fusion processes, has many advantages compared to conventional methods for fabricating structural materials, such as permitting increased geometric complexity. While single material metal powder AM has advanced significantly in the past decade, multi-material AM is gradually attracting more attention owing to the recent breakthrough in multi-material feedstock delivery and the growing interest of fabricating functionally graded components. Multi-material AM offers an alternative route for applications that require location dependent material properties and high geometrical complexity. The AM community has invented several ways to achieve compositional gradients and discrete boundaries in two and three dimensions using mechanical spreading, nozzle-based, electrophotographic, and hybrid techniques. This article reviews the current state of laser powder bed fusion based multi-material AM of metals with focuses on the characteristics of the material interface as well as the properties and performance of the AM built functionally graded materials. We show the common challenges and issues related to material transitions, such as defects, segregation, phase separation, and the efficacy of some potential solutions including material and process optimizations. Additionally, this study evaluates the applicability and limitations of the existing testing standards and methods for measuring mechanical performance of functionally graded materials. Finally, we discuss mechanical testing development opportunities, which can help multi-material AM move towards higher technological maturity. In general, we find that the link between gradient microstructure and mechanical properties is not well understood or studied and suggest several mechanical tests that may better inform this knowledge gap.

42 ENGINEERING↗

DOE OSTI2023

Efficient Metal–Halide Perovskite Photovoltaic Cells Deposited via Vapor Transport Deposition

Photovoltaic cells based on metal-halide perovskites have exceeded the performance of other thin film technologies and rival the performance of devices based on archetypical silicon. Attractively, the perovskite active layer can be processed via a variety of solution- and vapor-based methods. Herein, emphasis is on the use of vapor transport codeposition (VTD) to process efficient n–i–p photovoltaic cells based on methylammonium lead iodide (MAPbI 3 ). VTD utilizes a hot-walled reactor operated under moderate vacuum in the range of 0.5–10 Torr. The organic and metal-halide precursors are heated with the resulting vapor transported by a N 2 carrier gas to a cooled substrate where they condense and react to form a perovskite film. The efficiency of photovoltaic devices based on VTD-processed MAPbI 3 is found to be highest in films with excess lead iodide content, with champion devices realizing exceeding 12%.

14 SOLAR ENERGY↗

DOE OSTI2024

Improving Additive Manufactured Component Performance through Multi-Scale Microstructure Simulation and Process Optimization

The purpose of this project was to utilize computational tools to understand the relationships between processing, microstructure, and properties for additively manufactured (AM) aluminum alloys for automotive applications, and to provide an engineering solution for helping to optimize process conditions. The project leverages ORNL developments in computational modeling, including AM process modeling, phase-field based microstructure evolution predictions, and data analytics techniques for mapping process conditions to material outcomes. The project utilized an Al-Cu-Mn-Zr alloy as a model material for studying formation of defects and microstructural features in response to variations in process conditions. Based on both pre-existing experimental data and simulation results, statistical process maps were constructed to identify regions of process space with minimal defect formation and advantageous microstructures and properties. The software tools used for this purpose were successful disseminated to GM, who were able to successful compile the relevant HPC codes within their own computing ecosystem and perform initial calculations to reproduce ORNL results.

36 MATERIALS SCIENCE↗

NASA NTRS2006

An improved method for precise automatic co-registration of moderate and high-resolution spacecraft imagery

Improvements to the automated co-registration and change detection software package, AFIDS (Automatic Fusion of Image Data System) has recently completed development for and validation by NGA/GIAT. The improvements involve the integration of the AFIDS ultra-fine gridding technique for horizontal displacement compensation with the recently evolved use of Rational Polynomial Functions/ Coefficients (RPFs/RPCs) for image raster pixel position to Latitude/Longitude indexing. Mapping and orthorectification (correction for elevation effects) of satellite imagery defies exact projective solutions because the data are not obtained from a single point (like a camera), but as a continuous process from the orbital path. Standard image processing techniques can apply approximate solutions, but advances in the state-of-the-art had to be made for precision change-detection and time-series applications where relief offsets become a controlling factor. The earlier AFIDS procedure required the availability of a camera model and knowledge of the satellite platform ephemeredes. The recent design advances connect the spacecraft sensor Rational Polynomial Function, a deductively developed model, with the AFIDS ultrafine grid, an inductively developed representation of the relationship raster pixel position to latitude /longitude. As a result, RPCs can be updated by AFIDS, a situation often necessary due to the accuracy limits of spacecraft navigation systems. An example of precision change detection will be presented from Quickbird.

co-registration↗