A one-piece, composite open-bottom casting mold with integral withdrawal section is fabricated by thermal spraying of materials compatible with and used for the continuous casting of shaped products of reactive metals and alloys such as, for example, titanium and its alloys or for the gas atomization thereof.

This report discusses Test Campaign TC08 of the Kellogg Brown & Root, Inc. (KBR) Transport Gasifier train with a Siemens Westinghouse Power Corporation (Siemens Westinghouse) particle filter system at the Power Systems Development Facility (PSDF) located in Wilsonville, Alabama. The Transport Gasifier is an advanced circulating fluidized-bed gasifier designed to operate as either a combustor or a gasifier in air- or oxygen-blown mode using a particulate control device (PCD). The Transport Gasifier was operated as a pressurized gasifier in air- and oxygen-blown modes during TC08. Test Run TC08 was started on June 9, 2002 and completed on June 29. Both gasifier and PCD operations were stable during the test run with a stable baseline pressure drop. The oxygen feed supply system worked well and the transition from air to oxygen blown was smooth. The gasifier temperature was varied between 1,710 and 1,770 F at pressures from 125 to 240 psig. The gasifier operates at lower pressure during oxygen-blown mode due to the supply pressure of the oxygen system. In TC08, 476 hours of solid circulation and 364 hours of coal feed were attained with 153 hours of pure oxygen feed. The gasifier and PCD operations were stable in both enriched …

This report discusses Test Campaign TC09 of the Kellogg Brown & Root, Inc. (KBR) Transport Gasifier train with a Siemens Westinghouse Power Corporation (Siemens Westinghouse) particle filter system at the Power Systems Development Facility (PSDF) located in Wilsonville, Alabama. The Transport Gasifier is an advanced circulating fluidized-bed gasifier designed to operate as either a combustor or a gasifier in air- or oxygen-blown mode of operation using a particulate control device (PCD). The Transport Gasifier was operated as a pressurized gasifier during TC09 in air- and oxygen-blown modes. Test Run TC09 was started on September 3, 2002, and completed on September 26, 2002. Both gasifier and PCD operations were stable during the test run, with a stable baseline pressure drop. The oxygen feed supply system worked well and the transition from air to oxygen was smooth. The gasifier temperature varied between 1,725 and 1,825 F at pressures from 125 to 270 psig. The gasifier operates at lower pressure during oxygen-blown mode due to the supply pressure of the oxygen system. In TC09, 414 hours of solid circulation and over 300 hours of coal feed were attained with almost 80 hours of pure oxygen feed.

This report discusses Test Campaign TC10 of the Kellogg Brown & Root, Inc. (KBR) Transport Gasifier train with a Siemens Westinghouse Power Corporation (Siemens Westinghouse) particle filter system at the Power Systems Development Facility (PSDF) located in Wilsonville, Alabama. The Transport Gasifier is an advanced circulating fluidized-bed gasifier designed to operate as either a combustor or a gasifier in air- or oxygen-blown mode of operation using a particulate control device (PCD). The Transport Gasifier was operated as a pressurized gasifier during TC10 in air- (mainly for transitions and problematic operations) and oxygen-blown mode. Test Run TC10 was started on November 16, 2002, and completed on December 18, 2002. During oxygen-blown operations, gasifier temperatures varied between 1,675 and 1,825 F at pressures from 150 to 180 psig. After initial adjustments were made to reduce the feed rate, operations with the new fluidized coal feeder were stable with about half of the total coalfeed rate through the new feeder. However, the new fluidized-bed coal feeder proved to be difficult to control at low feed rates. Later the coal mills and original coal feeder experienced difficulties due to a high moisture content in the coal from heavy rains. Additional operational difficulties were experienced …

This document presents the findings of a technology demonstration for magnetically-coupled adjustable speed drives. Although many devices can provide speed control in motor systems, the two devices evaluated were chosen for their unique packaging for specific applications. The U.S. Department of Energy and Pacific Northwest National Laboratory do not specifically endorse or sponsor the devices or manufacturers described in this study, other than to present the specific data collected during this study. The goal of this document is to report the test results of two devices that are unique packaging to evaluate whether these devices could cost effectively produce energy savings in Federal facilities.

A typical communications channel is subjected to a variety of signal distortions, including multipath, that corrupt the information being transmitted and reduce the effective channel capacity. The mitigation of the multipath interference component is an ongoing concern for communication systems operating in complex environments such as might be experienced inside buildings, urban environments, and hilly or heavily wooded areas. Communications between mobile units and distributed sensors, so important to national security, are dependent upon flawless conveyance of information in complex environments. The reduction of this multipath corruption necessitates better channel equalization, i.e., the removal of channel distortion to extract the transmitted information. But, the current state of the art in channel equalization either requires a priori knowledge of the channel or the use of a known training sequence and adaptive filtering. If the ''assumed'' model within the equalization processor does not at least capture the dominant characteristics of the channel, then the received information may still be highly distorted and possibly useless. Also, the processing required for classical equalization is demanding in computational resources. To remedy this situation, many techniques have been investigated to replace classical equalization. Such a technique, the subject of this feasibility study, is Time Reversal Signal …

This report presents the findings of a U.S. DOE Environmental Management technology transfer initiative of waste-reducing ground water sampling systems between Savannah River Site (SRS) and Lawrence Livermore National Laboratory (LLNL) which occurred during fiscal years 2001 and 2002. The report describes the collaboration between the two sites, the deployment of the Savannah River Site Purge Water Management System at LLNL, the changes made to that system for use at LLNL, and documents the return-on-investment derived from the system's use at LLNL as well as other benefits generated through this inter-laboratory collaboration. An evaluation of the deployment of the LLNL EasyPump sampling technology at SRS will be covered in a separate report from SRS.

The A2 LITE is a 2 liter, 2000 MPa, 750 K ultra-high pressure (UHP) vessel used to demonstrate UHP technology and to provide an air flow for wind tunnel nozzle development. It is the largest volume UHP vessel in the world. The design is based on a 100:1 pressure intensification using a hydraulic ram as a low pressure driver and a three-layer compound cylinder UHP section. Active control of the 900 mm piston stroke in the 63.5 mm bore permits pressure-time profiles ranging from static to constant pressure during flow through a 1 mm throat diameter nozzle for 1 second.

The corrosion resistance of Alloy 22 (UNS No.: N06022) was studied in 5 M CaCl{sub 2} electrolyte at various temperatures. Potentiodynamic polarization was used to examine the electrochemical behavior and measure the key potentials. Alloy 22 was found to be susceptible to localized corrosion in this high chloride [10M Cl{sup -}] environment at temperatures as low as 6O C.

To predict contaminant release to the groundwater, it is necessary to understand the hydraulic properties of the material between the release point and the water table. Measurements of the hydraulic properties of the Hanford unsaturated sediments that buffer the water table are available from many areas of the site; however, the documentation is not well cataloged nor is it easily accessible. The purpose of this report is to identify what data is available for characterization of the unsaturated hydraulic properties at Hanford and Where these data can be found.

Our proposal focused on the following research areas: (1) Development of intermolecular potentials for water and aqueous solutions; (2) Molecular-based study of polymorphic phase transitions and growth of nanocrystalline aggregates in hydrothermal solutions; (3) Molecular simulation of ion-pairing in high-temperature high-pressure electrolyte solutions; and (4) SAFT equation of state modeling of supercritical aqueous solutions - (a) Solubility of alkanes in supercritical water, and (b) Ion speciation in ambient and supercritical aqueous solutions We have made progress in all four areas, details of which are described in the paper. Before doing so, however, we reflect on some of the significant changes impacting the research program during the past year.

This report summarizes the development of automobile emissions sensors at Argonne National Laboratory. Three types of sensor technologies, i.e., ultrasound, microwave, and ion-mobility spectrometry (IMS), were evaluated for engine-out emissions monitoring. Two acoustic sensor technologies, i.e., surface acoustic wave and flexural plate wave, were evaluated for detection of hydrocarbons. The microwave technique involves a cavity design and measures the shifts in resonance frequency that are a result of the presence of trace organic compounds. The IMS technique was chosen for further development into a practical emissions sensor. An IMS sensor with a radioactive {sup 63}Ni ion source was initially developed and applied to measurement of hydrocarbons and NO{sub x} emissions. For practical applications, corona and spark discharge ion sources were later developed and applied to NO{sub x} emission measurement. The concentrations of NO{sub 2} in dry nitrogen and in a typical exhaust gas mixture are presented. The sensor response to moisture was evaluated, and a cooling method to control the moisture content in the gas stream was examined. Results show that the moisture effect can be reduced by using a thermoelectric cold plate. The design and performance of a laboratory prototype sensor are described.

The OXY-operated Class 2 Project at West Welch is designed to demonstrate how the use of advanced technology can improve the economics of miscible CO{sub 2} injection projects in lower quality Shallow Shelf Carbonate reservoirs. The research and design phase (Budget Period 1) primarily involved advanced reservoir characterization. The current demonstration phase (Budget Period 2) is the implementation of the reservoir management plan for an optimum miscible CO{sub 2} flood design based on the reservoir characterization. Although Budget Period 1 for the Project officially ended 12/31/96, reservoir characterization and simulation work continued during the Budget Period 2. During the fifth and sixth annual reporting periods (8/3/98-8/2/00) covered by this report, work continued on interpretation of the cross well seismic data to create porosity and permeability profiles which were distributed into the reservoir geostatistically. The initial interwell seismic CO{sub 2} monitor survey was conducted, the acquired data processed and interpretation started. Only limited well work and facility construction was conducted in the project area. The CO{sub 2} injection initiated in October 1997 was continued, although the operator had to modify the operating plan in response to low injection rates, well performance and changes in CO{sub 2} supply. CO{sub 2} injection was …

The objective of this activity is to show that the use of the traditional strength of materials approach to the drip shield and the waste package (WP) designs is bounding and appropriate when compared to the fracture mechanics approach. The scope of this activity is limited to determining the failure assessment diagrams for the two materials at issue: Ti-7 and Alloy 22. This calculation is intended for use in support of the license application design of the drip shield and the WP. This activity is associated with the drip shield and the WP designs. The activity evaluation for work package number P32 12234F2, included in ''Technical Work Plan for: Waste Package Design Description for LA'' (Ref. 1, p. A-6), has determined that the development of this document is subject to ''Quality Assurance Requirements and Description'' requirements. The control of the electronic management of data is accomplished in accordance with the methods specified in Reference 1, Section 10. AP-3.124, ''Design Calculations and Analysis'' (Ref. 2), is used to develop and document the calculation.

Boiler combustion dynamics change continuously due to several factors including coal quality, boiler loading, ambient conditions, changes in slag/soot deposits and the condition of plant equipment. NO{sub x} formation, Particulate Matter (PM) emissions, and boiler thermal performance are directly affected by the sootblowing practices on a unit. As part of its Power Plant Improvement Initiative program, the US DOE is providing cofunding (DE-FC26-02NT41425) and NETL is the managing agency for this project at Tampa Electric's Big Bend Station. This program serves to co-fund projects that have the potential to increase thermal efficiency and reduce emissions from coal-fired utility boilers. A review of the Big Bend units helped identify intelligent sootblowing as a suitable application to achieve the desired objectives. The existing sootblower control philosophy uses sequential schemes, whose frequency is either dictated by the control room operator or is timed based. The intent of this project is to implement a neural network based intelligent soot-blowing system, in conjunction with state-of-the-art controls and instrumentation, to optimize the operation of a utility boiler and systematically control boiler fouling. Utilizing unique, online, adaptive technology, operation of the sootblowers can be dynamically controlled based on real-time events and conditions within the boiler. This could …

Gas reservoirs developed within the Colorado Plateau and Southern Rocky Mountains region are natural laboratories for studying the factors that promote long-term storage of CO{sub 2}. They also provide sites for storing additional CO{sub 2} if it can be separated from the flue gases of coal-fired power plants in this part of the U.S.A. These natural reservoirs are developed primarily in sandstones and dolomites; shales, mudstones and anhydrite form seals. In many fields, stacked reservoirs are present, indicating that the gas has migrated up through the section. There are also geologically young travertine deposits at the surface, and CO{sub 2}-charged groundwater and springs in the vicinity of known CO{sub 2} occurrences. These near-surface geological and hydrological features also provide examples of the environmental effects of leakage of CO{sub 2} from reservoirs, and justify further study. During reporting period covered here (the second quarter of Year 2 of the project, i.e. January 1-March 31, 2002), the main achievements were: (1) Field trips to the central Utah and eastern Arizona travertine areas to collect data and water samples to support study of surface CO{sub 2}-rich fluid leakage in these two areas. (2) Partial completion of a manuscript on natural analogues CO{sub 2} …

To advance the state of the art in science and technology communication to the public a conference was held March 6-8, 2002 at the National Institute of Standards and Technology in Gaithersburg, MD. This report of the conference proceedings includes a summary statement by the conference steering committee, transcripts or other text summarizing the remarks of conference speakers, and abstracts for 48 "best practice" communications programs selected by the steering committee through an open competition and a formal peer review process. Additional information about the 48 best practice programs is available on the archival conference Web site at www.nist.gov/bestpractices.

Foster Wheeler Power Group, Inc. is working under US Department of Energy contract No. DE-FC26-00NT40972 to develop a partial gasification module (PGM) that represents a critical element of several potential coal-fired Vision 21 plants. When utilized for electrical power generation, these plants will operate with efficiencies greater than 60% and produce near zero emissions of traditional stack gas pollutants. The new process partially gasifies coal at elevated pressure producing a coal-derived syngas and a char residue. The syngas can be used to fuel the most advanced power producing equipment such as solid oxide fuel cells or gas turbines, or processed to produce clean liquid fuels or chemicals for industrial users. The char residue is not wasted; it can also be used to generate electricity by fueling boilers that drive the most advanced ultra-supercritical pressure steam turbines. The amount of syngas and char produced by the PGM can be tailored to fit the production objectives of the overall plant, i.e., power generation, clean liquid fuel production, chemicals production, etc. Hence, PGM is a robust building bock that offers all the advantages of coal gasification but in a more user-friendly form; it is also fuel flexible in that it can use alternative …

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The substantial efficiency improvements which have been realized in residential refrigerators over the last twenty years due to implementation of the National Appliance Energy Conservation Act and changing consumer reactions to energy savings give an indication of the potential for improvement in the commercial sector, where few such efficiency improvements have been made to date. The purchase decision for commercial refrigerators is still focused primarily on first cost and product performance issues such as maximizing storage capacity, quick pulldown, durability, and reliability. The project applied techniques used extensively to reduce energy use in residential refrigeration to a commercial reach-in refrigerator. The results will also be applicable to other commercial refrigeration equipment, such as refrigerated vending machines, reach-in freezers, beverage merchandisers, etc. The project described in this paper was a collaboration involving the Appliance and Building Technology Sector of TIAX, the Delfield Company, and the U. S. Department of Energy's Office of Building Technologies. Funding was provided by DOE through Cooperative Agreement No. DE-FC26-00NT41000. The program plan and schedule were structured to assure successful integration of the TIAX work on development of efficient design concepts into Delfield's simultaneous development of the Vantage product line. The energy-saving design options evaluated as part …

Recently, a method for evaluating the fracture toughness of ceramics has been proposed based on the computed crack-opening displacements of cracks emanating from Vickers hardness indentations. In order to verify this method, experiments were carried out to determine the toughness of a commercial silicon carbide ceramic, Hexaloy SA, by measuring the crack-opening profiles of such Vickers indentation cracks. While the obtained toughness value of Ko = 2.3 MPavm was within 10% of that measured using conventional fracture toughness testing, the computed crack-opening profiles corresponding to this toughness displayed poor agreement with those measured experimentally, raising concerns about the suitability of this method for determining the toughness of ceramics. The effects of subsurface cracking and cracking during loading are considered as possible causes of such discrepancies, with the former based on evidence observed for secondary radial cracking which affected the crack opening profile and deduced toughness values.

The quantitative estimation of changes in water saturation (S{sub W}) and effective pressure (P), in terms of changes in compressional and shear impedance, is becoming routine in the interpretations of time-lapse surface seismic data. However, when the number of reservoir constituents increases to include in situ gas and injected CO{sub 2}, there are too many parameters to be determined from seismic velocities or impedances alone. In such situations, the incorporation of electromagnetic (EM) images showing the change in electrical conductivity ({sigma}) provides essential independent information. The purpose of this study was to demonstrate a methodology for jointly interpreting crosswell seismic and EM data, in conjunction with detailed constitutive relations between geophysical and reservoir parameters, to quantitatively predict changes in P, S{sub W}, CO{sub 2} gas saturation (S{sub CO2}), CO{sub 2} gas/oil ratio (R{sub CO{sub 2}}), hydrocarbon gas saturation (S{sub g}), and hydrocarbon gas/oil ration (R{sub g}) in a reservoir undergoing CO{sub 2} flood.

This Technical Quarterly Report is for the reporting period March 31, 2002 to June 30, 2002. The report provides details of the work done on the project entitled ''Enhanced Oil Recovery with Downhole Vibration Stimulation in Osage County Oklahoma''. The project is divided into nine separate tasks. Several of the tasks are being worked on simultaneously, while other tasks are dependent on earlier tasks being completed. The vibration stimulation Well 111-W-27 is located in section 8 T26N R6E of the North Burbank Unit (NBU), Osage County Oklahoma. It was drilled to 3090-feet cored, logged, cased and cemented. The rig moved off August 6, 2001. Phillips Petroleum Co. has performed several core studies on the cores recovered from the test well. Standard porosity, permeability and saturation measurements have been conducted. In addition Phillips has prepared a Core Petrology Report, detailing the lithology, stratigraphy and sedimentology for Well 111-W27, NBU. Phillips has also conducted the sonic stimulation core tests, the final sonic stimulation report has not yet been released. Calumet Oil Company, the operator of the NBU, began collecting both production and injection wells information to establish a baseline for the project in the pilot field test area since May 2001. The …

Under contract DE-AC26-98FT-40370, SRI International has completed the third phase of a planned three-phase effort to develop a laboratory prototype continuous emission monitor (CEM) for dioxins and furans generated during the incineration of waste materials at DOE remediation sites. The project was initiated on July 29, 1998 with the technical effort completed in October 2001. During this research effort, SRI has made numerous improvements in our jet-REMPI instrument. These improvements have involved characterization and optimization of the molecular cooling in the gas jet, implementation of a custom-fabricated, four pulsed valve assembly, new data acquisition and display software, and preliminary development of a wavelength and mass calibration approach. We have also measured the REMPI excitation spectra of numerous organic compounds that are likely to be present in the exhaust stream of a waste incinerator. These spectra must be well characterized in the laboratory to understand any potential interferences that might arise when monitoring for dioxin and furan congeners. Our results to date continue to validate the original concept of using jet-REMPI as the detection method in a dioxin CEM. Using only commercial components with minor modifications, we have already demonstrated a detection sensitivity in the low ppt range with sufficient chemical …