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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Non-biodegradable landfill leachate treatment by combined process of agitation, coagulation, SBR and filtration

Highlights: • A novel method of stripping (agitation) was investigated for NH{sub 3}-N removal. • PFS coagulation followed agitation process enhanced the leachate biodegradation. • Nitrification–denitrification achieved by changing operation process in SBR treatment. • A dual filter of carbon-sand is suitable as a polishing treatment of leachate. • Combined treatment success for the complete treatment of non-biodegradable leachate. - Abstract: This study describes the complete treatment of non-biodegradable landfill leachate by combined treatment processes. The processes consist of agitation as a novel stripping method used to overcome the ammonia toxicity regarding aerobic microorganisms. The NH{sub 3}-N removal ratio was 93.9% obtained at pH 11.5 and a gradient velocity (G) 150 s{sup −1} within a five-hour agitation time. By poly ferric sulphate (PFS) coagulation followed the agitation process; chemical oxygen demand (COD) and biological oxygen demand (BOD{sub 5}) were removed at 70.6% and 49.4%, respectively at an optimum dose of 1200 mg L{sup −1} at pH 5.0. The biodegradable ratio BOD{sub 5}/COD was improved from 0.18 to 0.31 during pretreatment step by agitation and PFS coagulation. Thereafter, the effluent was diluted with sewage at a different ratio before it was subjected to sequencing batch reactor (SBR) treatment. Up to 93.3% BOD{sub 5}, 95.5% COD and 98.1% NH{sub 3}-N removal were achieved by SBR operated under anoxic–aerobic–anoxic conditions. The filtration process was carried out using sand and carbon as a dual filter media as polishing process. The final effluent concentration of COD, BOD{sub 5}, suspended solid (SS), NH{sub 3}-N and total organic carbon (TOC) were 72.4 mg L{sup −1}, 22.8 mg L{sup −1}, 24.2 mg L{sup −1}, 18.4 mg L{sup −1} and 50.8 mg L{sup −1} respectively, which met the discharge standard. The results indicated that a combined process of agitation-coagulation-SBR and filtration effectively eliminated pollutant loading from landfill leachate.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Modeling Analysis of Ball-Milling Process for Battery-Electrode Synthesis

The mechanical alloying process is a promising method for synthesizing electrode materials for batteries owing to its benefits such as the ability to produce nanostructured, high-performing electrode alloys, no adverse effects on the solid electrolyte for solid-state batteries, stable production of thick electrodes, simple processing steps, and low processing costs. It is gaining intensive attention in the battery industry as one of the best methods to replace the conventional wet-slurry-solvent method, and its application is rapidly increasing these days. However, the operation is currently conducted purely based on trial-and-error methods without fully utilizing the features of its functions. Here, this may be attributed to a lack of understanding of the effect of operating parameters on the alloying process and final products. Surprisingly, there is a scarcity of the literature conducting fundamental research to comprehend the underlying physics of the entire mechanical alloying process, resulting in a significant knowledge gap. To address this knowledge gap, extensive research was conducted. The existing literature on mechanical alloying was reviewed to comprehend the current state of understanding and to discuss the direction for future research. Mathematical expressions were developed to create physics-based models capable of capturing the entire mechanical alloying process, including milling kinetics and defect-enhanced phase evolution. These methods were then applied to investigate the impact of operating parameters such as milling frequency, initial mole ratio of the alloyed materials, density of grinding balls, and energy required for the powders to become amorphous (i.e., the amorphization energy threshold). This research aimed not only to comprehend the direct effects of these operating parameters but also to unveil the physics underlying the ball-milling process. The results of our study can serve as crucial information for the battery industry in designing or operating the ball-milling process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

A General Framework for Process Synthesis, Integration, and Intensification

Process synthesis, integration, and intensification are the three pillars of process design. Current synthesis and integration methods are able to find optimal design targets and process configurations when all the alternatives are known beforehand. Process intensification, on the other hand, combines multiple physicochemical phenomena and exploits their interactions to create innovative designs. Often times, these designs are not known beforehand, and a phenomena-level representation of chemical processes are required to identify them. This disconnection between the three paradigms limits the ability to systematically discover optimal design pathways. We demonstrate that the building block representation, originally proposed in our earlier work on process intensification, has the potential to bridge this gap. Depending on the attributes assigned to the interior and the boundaries of these two-dimensional abstract building blocks, they can represent various intensified or isolated phenomena at the lowest level, various tasks at the equipment level, and various unit operations at the flowsheet level. Here, this common multiscale representation enables an mixed-integer nonlinear optimization-based single framework for the sequential or simultaneous synthesis, integration, and intensification of chemical processes. Such a general framework is critical to reduce the risk of eliminating potential intensification pathways and candidate flowsheets at the conceptual design stage. The framework is demonstrated using a case study on an ethylene glycol process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Non‐Linear Dimensionality Reduction With a Variational Encoder Decoder to Understand Convective Processes in Climate Models

Abstract Deep learning can accurately represent sub‐grid‐scale convective processes in climate models, learning from high resolution simulations. However, deep learning methods usually lack interpretability due to large internal dimensionality, resulting in reduced trustworthiness in these methods. Here, we use Variational Encoder Decoder structures (VED), a non‐linear dimensionality reduction technique, to learn and understand convective processes in an aquaplanet superparameterized climate model simulation, where deep convective processes are simulated explicitly. We show that similar to previous deep learning studies based on feed‐forward neural nets, the VED is capable of learning and accurately reproducing convective processes. In contrast to past work, we show this can be achieved by compressing the original information into only five latent nodes. As a result, the VED can be used to understand convective processes and delineate modes of convection through the exploration of its latent dimensions. A close investigation of the latent space enables the identification of different convective regimes: (a) stable conditions are clearly distinguished from deep convection with low outgoing longwave radiation and strong precipitation; (b) high optically thin cirrus‐like clouds are separated from low optically thick cumulus clouds; and (c) shallow convective processes are associated with large‐scale moisture content and surface diabatic heating. Our results demonstrate that VEDs can accurately represent convective processes in climate models, while enabling interpretability and better understanding of sub‐grid‐scale physical processes, paving the way to increasingly interpretable machine learning parameterizations with promising generative properties.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Improved thermonuclear rate of 42 Ti( p , γ ) 43 V and its astrophysical implication in the rp process

Context. Accurate 42 Ti(p,γ) 43 V reaction rates are crucial for understanding the nucleosynthesis path of the rapid capture process (rp process) that occurs in X-ray bursts. Aims. We aim to improve the thermonuclear rates of 42 Ti(p,γ) 43 V based on more complete resonance information and a more accurate direct component, together with the recently released nuclear masses data. We also explore the impact of the newly obtained rates on the rp process. Methods. We reevaluated the reaction rate of 42 Ti(p,γ) 43 V by the sum of the isolated resonance contribution instead of the Hauser-Feshbach statistical model. We used a Monte Carlo method to derive the associated uncertainties of new rates. The nucleosynthesis simulations were performed via the NuGrid post-processing code ppn. Results. The new rates differ from previous estimations due to the use of a series of updated resonance parameters and a direct S factor. Compared with the previous results from the Hauser-Feshbach statistical model, which assumes compound nucleus 43 V with a sufficiently high-level density in the energy region of astrophysical interest, large differences exist over the entire temperature region of rp-process interest, up to two orders of magnitude. We consistently calculated the photodisintegration rate using our new nuclear masses via the detailed balance principle, and found the discrepancies among the different reverse rates are much larger than those for the forward rate, up to ten orders of magnitude at the temperature of 10 8 K. Using a trajectory with a peak temperature of 1.95×10 9 K, we performed the rp-process nucleosynthesis simulations to investigate the impact of the new rates. Our calculations show that the adoption of the new forward and reverse rates result in abundance variations for Sc and Ca of 128% and 49%, respectively, compared to the variations for the statistical model rates. On the other hand, the overall abundance pattern is not significantly affected. The results of using new rates also confirm that the rp-process path does not bypass the isotope 43 V. Conclusions. Our study found that the Hauser-Feshbach statistical model is inappropriate to the reaction rate evaluation for 42 Ti(p,γ) 43 V. The adoption of the new rates confirms that the reaction path of 42 Ti(p,γ) 43 V(p,γ) 44 Cr(β + ) 44 V is a key branch of the rp process in X-ray bursts.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2018

The impact of (n, γ ) reaction rate uncertainties of unstable isotopes near N = 50 on the i-process nucleosynthesis in He-shell flash white dwarfs

The first-peak s-process elements Rb, Sr, Y and Zr in the post-AGB star Sakurai's object (V4334 Sagittarii) have been proposed to be the result of i-process nucleosynthesis in a post-AGB very-late thermal pulse event. We estimate the nuclear physics uncertainties in the i-process model predictions to determine whether the remaining discrepancies with observations are significant and point to potential issues with the underlying astrophysical model. We find that the dominant source in the nuclear physics uncertainties are predictions of neutron capture rates on unstable neutron rich nuclei, which can have uncertainties of more than a factor 20 in the band of the i-process. We use a Monte Carlo variation of 52 neutron capture rates and a 1D multi-zone post-processing model for the i-process in Sakurai's object to determine the cumulative effect of these uncertainties on the final elemental abundance predictions. We find that the nuclear physics uncertainties are large and comparable to observational errors. Within these uncertainties the model predictions are consistent with observations. A correlation analysis of the results of our MC simulations reveals that the strongest impact on the predicted abundances of Rb, Sr, Y and Zr is made by the uncertainties in the (n, γ) reaction rates of 85 Br, 86 Br, 87 Kr, 88 Kr, 89 Kr, 89 Rb, 89 Sr, and 92 Sr. This conclusion is supported by a series of multi-zone simulations in which we increased and decreased to their maximum and minimum limits one or two reaction rates per run. We also show that simple and fast one-zone simulations should not be used instead of more realistic multi-zone stellar simulations for nuclear sensitivity and uncertainty studies of convective–reactive processes. Lastly, our findings apply more generally to any i-process site with similar neutron exposure, such as rapidly accreting white dwarfs with near-solar metallicities.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2012

Multi-core processing and scheduling performance in CMS

Commodity hardware is going many-core. We might soon not be able to satisfy the job memory needs per core in the current single-core processing model in High Energy Physics. In addition, an ever increasing number of independent and incoherent jobs running on the same physical hardware not sharing resources might significantly affect processing performance. It will be essential to effectively utilize the multi-core architecture. CMS has incorporated support for multi-core processing in the event processing framework and the workload management system. Multi-core processing jobs share common data in memory, such us the code libraries, detector geometry and conditions data, resulting in a much lower memory usage than standard single-core independent jobs. Exploiting this new processing model requires a new model in computing resource allocation, departing from the standard single-core allocation for a job. The experiment job management system needs to have control over a larger quantum of resource since multi-core aware jobs require the scheduling of multiples cores simultaneously. CMS is exploring the approach of using whole nodes as unit in the workload management system where all cores of a node are allocated to a multi-core job. Whole-node scheduling allows for optimization of the data/workflow management (e.g. I/O caching, local merging) but efficient utilization of all scheduled cores is challenging. Dedicated whole-node queues have been setup at all Tier-1 centers for exploring multi-core processing workflows in CMS. We present the evaluation of the performance scheduling and executing multi-core workflows in whole-node queues compared to the standard single-core processing workflows.

Hernandez, J. M.↗
DOE OSTI2013

Influence of inert gases on the reactive high power pulsed magnetron sputtering process of carbon-nitride thin films

The influence of inert gases (Ne, Ar, Kr) on the sputter process of carbon and carbon-nitride (CN{sub x}) thin films was studied using reactive high power pulsed magnetron sputtering (HiPIMS). Thin solid films were synthesized in an industrial deposition chamber from a graphite target. The peak target current during HiPIMS processing was found to decrease with increasing inert gas mass. Time averaged and time resolved ion mass spectroscopy showed that the addition of nitrogen, as reactive gas, resulted in less energetic ion species for processes employing Ne, whereas the opposite was noticed when Ar or Kr were employed as inert gas. Processes in nonreactive ambient showed generally lower total ion fluxes for the three different inert gases. As soon as N{sub 2} was introduced into the process, the deposition rates for Ne and Ar-containing processes increased significantly. The reactive Kr-process, in contrast, showed slightly lower deposition rates than the nonreactive. The resulting thin films were characterized regarding their bonding and microstructure by x-ray photoelectron spectroscopy and transmission electron microscopy. Reactively deposited CN{sub x} thin films in Ar and Kr ambient exhibited an ordering toward a fullerene-like structure, whereas carbon and CN{sub x} films deposited in Ne atmosphere were found to be amorphous. This is attributed to an elevated amount of highly energetic particles observed during ion mass spectrometry and indicated by high peak target currents in Ne-containing processes. These results are discussed with respect to the current understanding of the structural evolution of a-C and CN{sub x} thin films.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Modular Chemical Process Intensification: A Review

Modular chemical process intensification can dramatically improve energy and process efficiencies of chemical processes through enhanced mass and heat transfer, application of external force fields, enhanced driving forces, and combinations of different unit operations, such as reaction and separation, in single-process equipment. Dramatic improvements such as these lead to several benefits such as compactness or small footprint, energy and cost savings, enhanced safety, less waste production, and higher product quality. Because of these benefits, process intensification can play a major role in industrial and manufacturing sectors, including chemical, pulp and paper, energy, critical materials, and water treatment, among others. This article provides an overview of process intensification, including definitions, principles, tools, and possible applications, with the objective to contribute to the future development and potential applications of modular chemical process intensification in industrial and manufacturing sectors. Drivers and barriers contributing to the advancement of process intensification technologies are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Multi-process tooling for discontinuous carbon and hybrid glass fiber thermoplastics

Expensive tooling often constraints the use of composites in the design and development of automotive parts. While there is significant confidence and knowledge in sheet and bulk metals, composite processes are less understood in mass production environment. The processes used to produce composites and resulting properties are influenced by fiber length attrition, resin to fiber ratio, process waste etc. Tool designs are determined very early in the engineering process. It is cost prohibitive to build additional tools, in the event it becomes obvious a better processing method and material would be beneficial, the original decision is not easily changed. In the present work we recognize the bottleneck of tooling costs and provide an approach of multi-process tooling. The innovation of this work is the design and demonstration of a single tool for different processes namely injection, injection-compression and extrusion-compression. The materials used in this study were long and short fiber thermoplastics (LFTs and SFTs). The resulting structure-property relationships have been reported for the materials and processing methods with a battery tray (BT) tool.

Vaidya, Uday↗
DOE OSTI2023

IN SITU PLASMA PROCESSING OF SUPERCONDUCTING CAVITIES AT JLAB, 2023 UPDATE

Jefferson Lab has an ongoing R&D program in plasma processing which just completed a round of production processing in the CEBAF accelerator. Plasma processing is a common technique for removing hydrocarbons from surfaces, which increases the work function and reduces the secondary emission coefficient. The initial focus of the effort was processing C100 cavities by injecting RF power into the higher order mode (HOM) coupler ports. Results from processing cryomodules in the CEBAF accelerator as well as vertical test results will be present-ed. The goal of in-situ processing is to improve the operational gradients and the energy margin of the linacs. This work will describe the systems and methods used at JLAB for processing cavities using an argon-oxygen gas mixture as well as a helium-oxygen gas mixture. Before and after plasma processing results will also be presented.

Powers, Thomas↗
DOE OSTI2012

Literature Review for Oxalate Oxidation Processes and Plutonium Oxalate Solubility

A literature review of oxalate oxidation processes finds that manganese(II)-catalyzed nitric acid oxidation of oxalate in precipitate filtrate is a viable and well-documented process. The process has been operated on the large scale at Savannah River in the past, including oxidation of 20 tons of oxalic acid in F-Canyon. Research data under a variety of conditions show the process to be robust. This process is recommended for oxalate destruction in H-Canyon in the upcoming program to produce feed for the MOX facility. Prevention of plutonium oxalate precipitation in filtrate can be achieved by concentrated nitric acid/ferric nitrate sequestration of oxalate. Organic complexants do not appear practical to sequester plutonium. Testing is proposed to confirm the literature and calculation findings of this review at projected operating conditions for the upcoming campaign. H Canyon plans to commence conversion of plutonium metal to low-fired plutonium oxide in 2012 for eventual use in the Mixed Oxide Fuel (MOX) Facility. The flowsheet includes sequential operations of metal dissolution, ion exchange, elution, oxalate precipitation, filtration, and calcination. All processes beyond dissolution will occur in HB-Line. The filtration step produces an aqueous filtrate that may have as much as 4 M nitric acid and 0.15 M oxalate. The oxalate needs to be removed from the stream to prevent possible downstream precipitation of residual plutonium when the solution is processed in H Canyon. In addition, sending the oxalate to the waste tank farm is undesirable. This report addresses the processing options for destroying the oxalate in existing H Canyon equipment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Real-Time Detection Methods to Monitor TRU Compositions in UREX+Process Streams

The U.S. Department of Energy has developed advanced methods for reprocessing spent nuclear fuel. The majority of this development was accomplished under the Advanced Fuel Cycle Initiative (AFCI), building on the strong legacy of process development R&D over the past 50 years. The most prominent processing method under development is named UREX+. The name refers to a family of processing methods that begin with the Uranium Extraction (UREX) process and incorporate a variety of other methods to separate uranium, selected fission products, and the transuranic (TRU) isotopes from dissolved spent nuclear fuel. It is important to consider issues such as safeguards strategies and materials control and accountability methods. Monitoring of higher actinides during aqueous separations is a critical research area. By providing on-line materials accountability for the processes, covert diversion of the materials streams becomes much more difficult. The importance of the nuclear fuel cycle continues to rise on national and international agendas. The U.S. Department of Energy is evaluating and developing advanced methods for safeguarding nuclear materials along with instrumentation in various stages of the fuel cycle, especially in material balance areas (MBAs) and during reprocessing of used nuclear fuel. One of the challenges related to the implementation of any type of MBA and/or reprocessing technology (e.g., PUREX or UREX) is the real-time quantification and control of the transuranic (TRU) isotopes as they move through the process. Monitoring of higher actinides from their neutron emission (including multiplicity) and alpha signatures during transit in MBAs and in aqueous separations is a critical research area. By providing on-line real-time materials accountability, diversion of the materials becomes much more difficult. The objective of this consortium was to develop real time detection methods to monitor the efficacy of the UREX+ process and to safeguard the separated TRUs against unlawful diversion from within a processing facility. To achieve this, a comprehensive strategy was implemented to incorporate traditional detectors and advanced Tensioned Metastable Fluid (TMFD) metastable fluid detectors (developed, in part, under this project) into a novel detector assembly coupled to the UREX+ centrifugal contactor array. The sections below provide a brief summary of the technical achievements completed during this project. The principal outcomes are documented in more complete details contained the doctoral dissertations and masters theses, journal papers, conference proceedings and additional items for more than the 35 publications that are listed in the program bibliography in Section 3.

McDeavitt, Sean M.↗
DOE OSTI2013

Evaluation of a Combined Cyclone and Gas Filtration System for Particulate Removal in the Gasification Process

The Wabash gasification facility, owned and operated by sgSolutions LLC, is one of the largest single train solid fuel gasification facilities in the world capable of transforming 2,000 tons per day of petroleum coke or 2,600 tons per day of bituminous coal into synthetic gas for electrical power generation. The Wabash plant utilizes Phillips66 proprietary E-Gas™ Gasification Process to convert solid fuels such as petroleum coke or coal into synthetic gas that is fed to a combined cycle combustion turbine power generation facility. During plant startup in 1995, reliability issues were realized in the gas filtration portion of the gasification process. To address these issues, a slipstream test unit was constructed at the Wabash facility to test various filter designs, materials and process conditions for potential reliability improvement. The char filtration slipstream unit provided a way of testing new materials, maintenance procedures, and process changes without the risk of stopping commercial production in the facility. It also greatly reduced maintenance expenditures associated with full scale testing in the commercial plant. This char filtration slipstream unit was installed with assistance from the United States Department of Energy (built under DOE Contract No. DE-FC26-97FT34158) and began initial testing in November of 1997. It has proven to be extremely beneficial in the advancement of the E-Gas™ char removal technology by accurately predicting filter behavior and potential failure mechanisms that would occur in the commercial process. After completing four (4) years of testing various filter types and configurations on numerous gasification feed stocks, a decision was made to investigate the economic and reliability effects of using a particulate removal gas cyclone upstream of the current gas filtration unit. A paper study had indicated that there was a real potential to lower both installed capital and operating costs by implementing a char cyclone-filtration hybrid unit in the E-Gas™ gasification process. These reductions would help to keep the E-Gas™ technology competitive among other coal-fired power generation technologies. The Wabash combined cyclone and gas filtration slipstream test program was developed to provide design information, equipment specification and process control parameters of a hybrid cyclone and candle filter particulate removal system in the E-Gas™ gasification process that would provide the optimum performance and reliability for future commercial use. The test program objectives were as follows: 1. Evaluate the use of various cyclone materials of construction; 2. Establish the optimal cyclone efficiency that provides stable long term gas filter operation; 3. Determine the particle size distribution of the char separated by both the cyclone and candle filters. This will provide insight into cyclone efficiency and potential future plant design; 4. Determine the optimum filter media size requirements for the cyclone-filtration hybrid unit; 5. Determine the appropriate char transfer rates for both the cyclone and filtration portions of the hybrid unit; 6. Develop operating procedures for the cyclone-filtration hybrid unit; and, 7. Compare the installed capital cost of a scaled-up commercial cyclone-filtration hybrid unit to the current gas filtration design without a cyclone unit, such as currently exists at the Wabash facility.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2013

Crystalline Ceramic Waste Forms: Comparison Of Reference Process For Ceramic Waste Form Fabrication

The research conducted in this work package is aimed at taking advantage of the long term thermodynamic stability of crystalline ceramics to create more durable waste forms (as compared to high level waste glass) in order to reduce the reliance on engineered and natural barrier systems. Durable ceramic waste forms that incorporate a wide range of radionuclides have the potential to broaden the available disposal options and to lower the storage and disposal costs associated with advanced fuel cycles. Assemblages of several titanate phases have been successfully demonstrated to incorporate radioactive waste elements, and the multiphase nature of these materials allows them to accommodate variation in the waste composition. Recent work has shown that they can be produced from a melting and crystallization process. The objective of this report is to explore the phase formation and microstructural differences between lab scale melt processing in varying gas environments with alternative densification processes such as Hot Pressing (HP) and Spark Plasma Sintering (SPS). The waste stream used as the basis for the development and testing is a simulant derived from a combination of the projected Cs/Sr separated stream, the Trivalent Actinide - Lanthanide Separation by Phosphorous reagent Extraction from Aqueous Komplexes (TALSPEAK) waste stream consisting of lanthanide fission products, the transition metal fission product waste stream resulting from the transuranic extraction (TRUEX) process, and a high molybdenum concentration with relatively low noble metal concentrations. Melt processing as well as solid state sintering routes SPS and HP demonstrated the formation of the targeted phases; however differences in microstructure and elemental partitioning were observed. In SPS and HP samples, hollandite, pervoskite/pyrochlore, zirconolite, metallic alloy and TiO 2 and Al 2 O 3 were observed distributed in a network of fine grains with small residual pores. The titanate phases that incorporate M +3 rare earth elements were observed to be distinct phases (ex. Nd 2 Ti 2 O 7 with less degree of substitution as compared to the more homogeneous melt processed samples where a high degree of substitution and variation of composition within grains was observed. Liquid phase sintering was enhanced in reducing gas environments and resulted in large (10-200 microns) irregular shaped grains along with large voids associated with the melt process; SPS and HP samples exhibited finer grain size with smaller voids. Metallic alloys were observed in the bulk of the sample for SPS and HP samples, but were found at the bottom of the crucible in melt processed trials. These results indicate that for a first melter trial, the targeted phases can be formed in air by utilizing Ti/TiO 2 additives which aid phase formation and improve the electrical conductivity. Ultimately, a melter run in reducing gas environments would be beneficial to study differences in phase formation and elemental partitioning.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Development and Testing of the Advanced CHP System Utilizing the Off-Gas from the Innovative Green Coke Calcining Process in Fluidized Bed

Green petroleum coke (GPC) is an oil refining byproduct that can be used directly as a solid fuel or as a feedstock for the production of calcined petroleum coke. GPC contains a high amount of volatiles and sulfur. During the calcination process, the GPC is heated to remove the volatiles and sulfur to produce purified calcined coke, which is used in the production of graphite, electrodes, metal carburizers, and other carbon products. Currently, more than 80% of calcined coke is produced in rotary kilns or rotary hearth furnaces. These technologies provide partial heat utilization of the calcined coke to increase efficiency of the calcination process, but they also share some operating disadvantages. However, coke calcination in an electrothermal fluidized bed (EFB) opens up a number of potential benefits for the production enhancement, while reducing the capital and operating costs. The increased usage of heavy crude oil in recent years has resulted in higher sulfur content in green coke produced by oil refinery process, which requires a significant increase in the calcinations temperature and in residence time. The calorific value of the process off-gas is quite substantial and can be effectively utilized as an “opportunity fuel” for combined heat and power (CHP) production to complement the energy demand. Heat recovered from the product cooling can also contribute to the overall economics of the calcination process. Preliminary estimates indicated the decrease in energy consumption by 35-50% as well as a proportional decrease in greenhouse gas emissions. As such, the efficiency improvement of the coke calcinations systems is attracting close attention of the researchers and engineers throughout the world. The developed technology is intended to accomplish the following objectives: - Reduce the energy and carbon intensity of the calcined coke production process. - Increase utilization of opportunity fuels such as industrial waste off-gas from the novel petroleum coke calcination process. - Increase the opportunity of heat (chemical and physical) utilization from process off-gases and solid product. - Develop a design of advanced CHP system utilizing off-gases as an “opportunity fuel” for petroleum coke calcinations and sensible heat of calcined coke. A successful accomplishment of the aforementioned objectives will contribute toward the following U.S. DOE programmatic goals: - Drive a 25% reduction in U. S. industrial energy intensity by 2017 in support of EPAct 2005; - Contribute to an 18% reduction in U.S. carbon intensity by 2012 as established by the Administration’s “National Goal to Reduce Emissions Intensity.” 8

02 PETROLEUM↗
DOE OSTI2014

ACTINIDE REMOVAL PROCESS SAMPLE ANALYSIS, CHEMICAL MODELING, AND FILTRATION EVALUATION

Filtration within the Actinide Removal Process (ARP) currently limits the throughput in interim salt processing at the Savannah River Site. In this process, batches of salt solution with Monosodium Titanate (MST) sorbent are concentrated by crossflow filtration. The filtrate is subsequently processed to remove cesium in the Modular Caustic Side Solvent Extraction Unit (MCU) followed by disposal in saltstone grout. The concentrated MST slurry is washed and sent to the Defense Waste Processing Facility (DWPF) for vitrification. During recent ARP processing, there has been a degradation of filter performance manifested as the inability to maintain high filtrate flux throughout a multi-batch cycle. The objectives of this effort were to characterize the feed streams, to determine if solids (in addition to MST) are precipitating and causing the degraded performance of the filters, and to assess the particle size and rheological data to address potential filtration impacts. Equilibrium modelling with OLI Analyzer{sup TM} and OLI ESP{sup TM} was performed to determine chemical components at risk of precipitation and to simulate the ARP process. The performance of ARP filtration was evaluated to review potential causes of the observed filter behavior. Task activities for this study included extensive physical and chemical analysis of samples from the Late Wash Pump Tank (LWPT) and the Late Wash Hold Tank (LWHT) within ARP as well as samples of the tank farm feed from Tank 49H. The samples from the LWPT and LWHT were obtained from several stages of processing of Salt Batch 6D, Cycle 6, Batch 16.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Development and Validation of an Acid Mine Drainage Treatment Process for Source Water

Throughout Northern Appalachia and surrounding regions, hundreds of abandoned mine sites exist which frequently are the source of Acid Mine Drainage (AMD). AMD typically contains metal ions in solution with sulfate ions which have been leached from the mine. These large volumes of water, if treated to a minimum standard, may be of use in Hydraulic Fracturing (HF) or other industrial processes. This project’s focus is to evaluate an AMD water treatment technology for the purpose of providing treated AMD as an alternative source of water for HF operations. The HydroFlex™ technology allows the conversion of a previous environmental liability into an asset while reducing stress on potable water sources. The technology achieves greater than 95% water recovery, while removing sulfate to concentrations below 100 mg/L and common metals (e.g., iron and aluminum) below 1 mg/L. The project is intended to demonstrate the capability of the process to provide AMD as alternative source water for HF operations. The second budget period of the project has been completed during which Battelle conducted two individual test campaigns in the field. The first test campaign demonstrated the ability of the HydroFlex system to remove sulfate to levels below 100 mg/L, meeting the requirements indicated by industry stakeholders for use of the treated AMD as source water. The second test campaign consisted of a series of focused confirmatory tests aimed at gathering additional data to refine the economic projections for the process. Throughout the project, regular communications were held with a group of project stakeholders to ensure alignment of the project objectives with industry requirements. Finally, the process byproduct generated by the HydroFlex process was evaluated for the treatment of produced water against commercial treatment chemicals. It was found that the process byproduct achieved similar results for produced water treatment as the chemicals currently in use. Further, the process byproduct demonstrated better settling characteristics in bench scale testing. The field testing conducted in the second project budget period demonstrated the ability of the HydroFlex technology to meet industry requirements for AMD water chemical composition so that it can be used as source water in HF activities. System and operational improvements were identified in an additional series of confirmatory tests to achieve competitive cost targets. Finally, the application of the HydroFlex process byproduct in produced water treatment was demonstrated, further supporting the commercial implementation of the technology. Overall, the project results demonstrate a path to the economic treatment of AMD to support its increased use as source water in HF, particularly in regions with limited local freshwater availability.

54 ENVIRONMENTAL SCIENCES↗