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An aerosol jet printhead comprising an in-line static mixer can mix multiple aerosol streams for co-deposition from a single nozzle. A printhead was designed, fabricated, and tested, demonstrating in-plane functionally graded films. The inline mixing printhead can be used with a compact aerosol jet deposition system.
Creation of a novel extractant that can improve rare earth separations both economically and environmentally will be pivotal for industry progression. Diglycolamide (DGA) extractants provide chemistries that support this goal by serving as an extractant with high affinity for lanthanides and improved separation factors for light rare earths as compared to current extractants like PC88A. Initial organic phase loading capacity and phase dispersion tests performed with various modified DGAs generated results that were unfavorable for industrial processing, but further modification of the DGA alkyl chain substituents have resulted in new structures with promising results. Dispersion time measurements taken in small scale batch contacts of the extractant with a simulated leach liquor containing La, Ce, Nd, and Pr support implementation in both mixer-settlers and centrifugal contactors for larger scale separations. Furthermore, this confirmation allowed for preliminary flowsheet design using extraction equilibria at various organic to aqueous flow ratios (O/A) for extraction, scrubbing, and stripping stages. These values along with expected product/effluent compositions for each section aid in the testing for specific distribution ratios and final flowsheet design. Implementation of the DGA extractant into solvent extraction equipment will provide essential information for the next steps of this project and how this extractant may be optimized for future applications.
Hydrogen/ Hydrogen-rich flame is a potential strategy to reduce carbon emissions for the development of next-generation lean premixed combustors. However, the higher flashback propensity with hydrogen-enrichment owing to faster chemical kinetics is one of the key challenges in existing natural gas turbine combustors. In this study, the fundamentals of stabilized flame dynamics and flashback events in a premixed low swirl burner (LSB) configuration are visualized experimentally using nanosecond (ns)-based high-speed hydroxyl radical planar laser-induced fluorescence (OH-PLIF). The LSB has an optically accessible pre-mixing tube allowing laser diagnostic investigation of flashback events. The inlet conditions are varied systematically with respect to pre-mixer velocities, flame equivalence ratio (ϕ), and hydrogen content and OH-PLIF characterization is performed in stable flame at 20 kHz repetition rate. An increase in flashback propensity is observed with increasing ϕ, hydrogen content, and decreasing V via detailed investigation of flame lift-off length (L) above the burner rim. Flashback ϕ investigations show an expected linearly increasing trend with decreasing hydrogen content and increasing V for each swirler studied and the results agree well with detailed L investigations in stable flame configuration. The propagating flame anchored likely on the back side of the perforated plate within 30-40 ms of the entrance forming the distorted conical flame front.
This study reports flashback mechanism observed in hydrogen-enriched flames stabilized in a low swirl burner (LSB) at atmospheric pressure and temperature conditions. The fundamentals of hydrogen-rich stable flames and spatiotemporal investigation of flashback phenomena were observed experimentally using a high-repetition-rate nanosecond (ns)-duration hydroxyl radical planar laser-induced fluorescence (OH-PLIF) diagnostic. Testing was conducted in an optically accessible pre-mixing section of LSB with inlet pre-mixing velocities from 5 to 10 m/s for methane and hydrogen (50 – 90% by mole) blends. Swirlers with two different turning angles, 26 and 33 degrees and three different perforated plate hole diameters, 1.08, 1.12 and 1.16 mm with measured swirl numbers varying from 0.43 to 0.49 were used. The flashback propensity showed dependence on the proximity of the lifted flame to the burner exit which was dependent on pre-mixer velocity, hydrogen content and equivalence ratio (ER). High-speed OH-PLIF images revealed lifted flames were first observed at low ER condition which is changed to M-shaped flame attached to burner rim with the increase in ER. Then, further increase in ER triggers flame flashback into the nozzle. Flashback occurred when burning occurs in the outer shear layer and the leading flame brush ingresses into the nozzle.
Hydrogen-enrichment is a potential strategy to reduce carbon emissions for the development of next-generation lean premixed combustors. However, the higher flashback propensity with hydrogen enrichment owing to the faster chemical kinetics is one of the key challenges in existing natural gas turbine combustors. The fundamentals of stabilized flame dynamics and flashback events in a premixed low swirl burner (LSB) configuration are visualized experimentally using nanosecond (ns)-based high-speed hydroxyl radical planar laser-induced fluorescence (OH-PLIF). Swirlers with two different turning angles, 26 and 33 and three different center-body hole diameters, 1.08, 1.12 and 1.16 mm with measured swirl numbers varying from 0.43 to 0.49 are tested in this study at atmospheric temperature and pressure inlet conditions. The inlet conditions are varied systematically with respect to pre-mixer velocities (V), flame equivalence ratio (ϕ) and hydrogen content (X_(H_2 )) for 50%-90% (H2, by mole) H2/ CH4 reactant mixtures and OH-PLIF characterization is performed in a stable flame at 20 kHz repetition rate. An increase in flashback propensity is observed with increasing ϕ, X_(H_2 ) and decreasing V via detailed investigation of flame lift-off length (L) above the burner rim.
This paper reports flashback events observed in hydrogen-enriched flames stabilized in a low swirl burner (LSB) at atmospheric pressure and temperature conditions. The fundamentals of hydrogen-rich stable flames and spatiotemporal investigation of flashback phenomena were observed experimentally using a high-repetition-rate nanosecond (ns)-duration hydroxyl radical planar laser-induced fluorescence (OH-PLIF) diagnostic. Testing was conducted in an optically accessible pre-mixing section of a LSB with inlet pre-mixing velocities ranging from 5 to 10 m/s for methane and hydrogen (50 – 90% by mole) blends. Swirlers with two different turning angles, 26o and 33o, and three different perforated plate hole diameters, 1.08, 1.12 and 1.16 mm, with measured swirl numbers varying from 0.43 to 0.49 were used in this study at atmospheric temperature and pressure inlet conditions. The flashback propensity showed a dependence on the proximity of the lifted flame to the burner exit (termed as lift-off length, L) which was dependent on the pre-mixer velocity (V), hydrogen content (XH2) and equivalence ratio (ϕ) at constant temperature and pressure conditions. High-speed OH-PLIF images revealed lifted flames were first observed at low ϕ/ XH2 condition which then changed to a M-shaped flame attached to burner rim with the increase in ϕ/ XH2. Further increases in ϕ/XH2, depending upon other inlet parameters, triggered flame flashback into the pre-mixing section. Flashback occurred when burning began in the outer shear layer and the leading flame brush propagated into the nozzle. Such spatiotemporally resolved high-speed OH-PLIF imaging provides insights on different stages of flashback in a LSB – flashback initiation, transition of flame propagation from burner exit to the swirler and flashback to flame holding transition. Flame ϕ at flashback showed an expected linearly increasing trend with increasing V and decreasing XH2 and the conclusions drawn aligned well with detailed investigations. For identical inlet conditions, flashback propensity decreased with increasing perforated-plate hole diameter and increasing swirler vane angle.
An approach that combines experimental and numerical analyses has been implemented to characterize the fundamentals of flashback events and flame-holding phenomena during high-hydrogen combustion in a jet-in-crossflow (JICF) configuration. Such flame dynamics are visualized experimentally using nanosecond (ns)-based hydroxyl planar laser-induced fluorescence (OH-PLIF) and chemiluminescence diagnostics techniques. The JICF burner has an optically accessible pre-mixing tube allowing the optical diagnostics. The testing was conducted for varied pre-mixer velocities (V) and equivalence ratio (ϕ) for 90%-100% (H2, by mole) H2/CH4 reactant mixtures at atmospheric temperature and pressure conditions. Two distinct flashback events were identified – conventional rich flashback and lean flashback, recorded while increasing ϕ and decreasing ϕ, respectively. The cause of lean flashback was attributed to the lower momentum flux ratio which bends the jet sharply, closer toward the injection plane. The mean OH-PLIF images characterized the flame-holding behavior where the flame was found to be stabilized on the leeward side only or on both windward and leeward sides as a lifted flame near the fuel port. A Large Eddy Simulation (LES) with detailed chemistry combustion modeling approach was implemented along an OH* sub-mechanism, and it showed qualitative agreement with the integrated line-of-sight chemiluminescence results as well as the planar OH-PLIF measurements.
The Proton Improvement Project-2 centers on building a new superconducting linear particle accelerator (Linac) at Fermilab. At the heart of the accelerator is the reference line, a critical system that defines the ideal path for the particle beam as it passes through magnets, RF cavities, and other beamline elements. Temperature stability is crucial for the reliable operation of RF components, such as mixers and filters. Fluctuations affect key performance parameters like conversion loss, isolation, and linearity. To mitigate any drift caused by ambient temperature changes, a heating plate assembly is utilized to maintain key components at a controlled temperature of 40°C. The system utilizes an aluminum 36”x36”x0.5” heat plate powered by a MOSFET-based control circuit, delivering approximately 460 W of thermal energy through a resistor array. Real-time temperature feedback is provided by a PT100 Resistance Temperature Detector (RTD), which interfaces with a Proportional–Integral–Derivative (PID) control algorithm to maintain closed-loop temperature regulation. The control signal actively modulates the gate voltage of an N channel MOSFET, dynamically adjusting power delivery in response to deviations from the temperature setpoint. Simulations and LTspice models validate the functionality and responsiveness of the circuit under varying conditions. The prototype has successfully demonstrated stable thermal control, paving the way for integration into the PIP-II infrastructure. The final design will feature an expanded resistor array, as well as communication with a PLC for continuous data acquisition and diagnostics. This work directly supports Fermilab’s broader mission by contributing to the stability and reliability of core accelerator systems, enhancing the precision of particle beam delivery for future physics experiments.
As part of the homogeneous actinides recycling strategy, the EURO-GANEX process is one of the most promising options to achieve the goal of minor actinides recovery. Improvements made to EURO-GANEX system have resulted in the emergence of the so-called New EURO-GANEX process, where the composition of the solvent has been modified by replacing TODGA and DMDOHEMA with cis-mTDDGA in the organic phase and SO3-Ph-BTP with PyTri-Diol in the aqueous phase in order to resolve important issues. The objective of this work is twofold: evaluate the gamma radiolytic resistance of the new EURO-GANEX process by dynamic irradiation conditions simulating the three main steps of the process, and validate the design of CIEMAT Náyade, CEA Marcel and INL irradiation loop devices since each of them mimics different aspects of the real process. Náyade and the INL loops could irradiate the organic and aqueous phases together, whereas in the CEA loop, the irradiated solvent is recycled continuously inside a platform with several stages of mixer-settlers containing aqueous flows simulating the three main steps of the process. The extraction performances and changes in the composition of the solvent have been analyzed during the irradiation experiment by different techniques: gamma spectrometry and ICP-MS/OES for cations or radioactive tracer extraction, and HPLC-MS to identify and quantify the degradation compounds. Despite some differences between the three-irradiation facilities, this inter-institutional study shows that these three comparative tools provide similar trends in the radiolytic stability of a liquid-liquid extraction system. Favourable extraction results for the different steps are obtained according to the static irradiation studies found in literature. However, the degradation of cis-mTDDGA is appreciable leading to degradation compounds, some of which form precipitates and produce important changes in viscosity, important aspects that must be addressed prior to the successful industrial application of the new EURO-GANEX process.
Micromix combustion presents a promising solution for integrating hydrogen into gas turbine combustors, offering rapid and compact air-fuel mixing that effectively shortens the combustion zone and significantly reduces nitrogen oxides (NOX) emissions. A major challenge in hydrogen combustion systems is flashback, which is mitigated through short mixing lengths and high flow velocities. This study investigates three fuel injector designs – zero swirl, low swirl, and high swirl – for a 6-mm inner diameter nozzle, where hydrogen is injected through six 0.3 mm diameter holes in a jet-in-crossflow configuration relative to the airstream. Numerical simulations indicate stable flame formation, moderate peak flame temperatures, and subsequent low NOx potential for all designs. These injectors have been fabricated using additive manufacturing, and upcoming experiments will explore flame structure and NOx behavior across varying fuel injection angles, equivalence ratios and pre-mixer velocities. These efforts aim to advance the development of low-emission hydrogen micromix combustion.
Radiolysis of water in nuclear waste storage generates hydrogen gas that can accumulate within sludge style waste and be rapidly released during agitation events, creating a significant flammability hazard. Engineering controls are therefore required to limit hydrogen concentrations during both quiescent storage and transient disturbances. Catalytic recombination of hydrogen in waste storage offgas is a proven mitigation strategy, maintaining hydrogen levels below flammability limits and managing sudden concentration spikes. Conventional recombiners rely on platinum and/or palladium catalysts, with development efforts focused on extending service life, increasing active surface area, and ensuring safe deployment in radioactive environments. Savannah River National Laboratory (SRNL) is evaluating a newly developed hydrogen recombiner catalyst from Canadian Nuclear Laboratories as a cost-effective and durable alternative for nuclear waste applications. Testing was conducted in SRNL’s Shielded Cells facility, which enables reduced-scale experimental modeling under radiation fields and near-use-case conditions relevant to radioactive waste storage. Catalyst performance was evaluated using a custom offgas characterization system designed for near-zero flow conditions. The experimental apparatus consisted of a gas-tight 2.7 L PTFE vessel equipped with temperature monitoring, gas flow controls, and a variable-speed mixer to simulate sludge agitation. Offgas composition was monitored using a dedicated gas chromatograph with argon carrier gas and a krypton internal standard. Measurements were obtained for an empty vessel, the vessel containing a well characterized radioactive tank waste sample, and the same configuration with the candidate catalyst installed. Results demonstrate that the new catalyst effectively reduced hydrogen concentrations in the offgas within the constraints of the experimental design. In addition to confirming catalytic activity, the testing provided valuable insights into experimental optimization and considerations for future performance evaluations. These findings support the potential scalability of the technology and highlight its applicability to broader nuclear waste management operations, offering improved safety and reduced operational costs through enhanced catalyst durability and lower replacement frequency.
For future waste disposal operations, Savannah River Mission Completion (SRMC) plans to operate Tank 27 as a blend tank. It is desirable to avoid additional worker exposure by using the planned commercial submersible mixing pump (CSMP) installations in Risers B2 and B4 to function as the blend pumps for prolonged blend tank operations. The purpose of this task is to evaluate the impacts to mixing across a range of pump installation heights from 1 to 201 inches. Specifications include: A maximum pump diameter of 22.5 inches, dual nozzles placed tangentially opposed with nominal inside diameter of 2 inches, a total flow range (both nozzles combined) of 500 to 1950 gallons per minute (gpm) and a maximum revolutions per minute (RPM) of 1800. Tank 27 is expected to have maximum fill height of 360 inches.
Modified diglycolamide (DGA) extractants show high affinity for light lanthanides and improved separation factors compared to phosphonic acids used commercially. Previous studies with DGAs included flowsheet design and implementation into solvent extraction equipment but with low extractant concentration. Modifications on the alkyl chains of previous DGA extractants led to a competitive product for light rare earth separation with a higher extractant concentration. The scope of this project is to test a recently developed DGA extractant for application in pilot scale solvent extraction equipment with single stage testing, by narrowing down scrubbing conditions, and collecting distribution values for flowsheet planning.