Aymeric Rousseau (ES) is one of the designers of Argonne's Powertain System Analysis Toolkit. Photo by George Joch.

Four Argonne technologies win R&D 100 awards

By Catherine Foster

Four technologies developed or co-developed at Argonne have been recognized with R&D 100 Awards, which highlight some of the best products and technologies newly available for commercial use from around the world. This is the 41st year the technology awards have been given by R&D Magazine to recognize the "100 most technologically significant new products" from the entries the magazine receives.

Argonne's award-winning technologies are:

• Hydrogen transport membrane for the separation of pure hydrogen at high temperatures;
• Grancrete bonded phosphate ceramic construction spray-on structural cement and rapid construction process for low-cost housing;
• Three-dimensional multiphase computer code to model glass furnace design and performance;
• Powertrain system analysis toolkit to aid in design of advanced hybrid vehicles.

"In every case these awards represent the outcome of Argonne scientists working closely with industry to apply basic science to meet real needs of the market for benefits to users," said Stephen D. Ban, director of Argonne's Office of Technology Transfer, which drives Argonne's efforts to link companies to appropriate Argonne-developed technologies.

"The spectrum of exciting emerging products represented -- from membranes for hydrogen production to low-cost housing in developing countries to advanced hybrid vehicle design -- is indicative of the contributions scientists at Argonne and other national laboratories are making to improve the quality of life across the planet," Ban said. "Support of basic and applied science by the Department of Energy makes this spectrum possible and will greatly enhance the economy when these applications enter the marketplace."

The hydrogen transport membrane for the separation of pure hydrogen at high temperatures was developed by Argonne scientist Balu Balachandran and colleagues Stephen Dorris and Tae Lee (all ET), in collaboration with Gary J. Steigel, Richard Dunst and John Winslow at the National Energy Technology Laboratory in Pittsburgh. This ceramic membrane provides pure hydrogen gas by selectively separating hydrogen from gas mixtures generated by fossil fuel-based processes. The membrane operates at the high temperatures and pressures required by such processes as coal gasification and methane reforming, without becoming embrittled by its interactions with hydrogen and sulfur.

The membrane was patented in 2003, and development of the technology is underway with industrial partners Eltron Research, Inc., and ITN Energy Systems, Inc. The technology is expected to advance the "hydrogen economy" by enabling the economical and environmentally friendly production of hydrogen from carbon-based feedstocks, permitting the highly efficient generation of electricity via fuel cells.

Grancrete spray-on structural phosphate ceramic cement was developed by Argonne scientist Arun Wagh (ET) in collaboration with Jim Paul of Casa Grande International of Mechanicsville, Va. The Grancrete magnesium-phosphate cement powder would be mixed at a construction site with water and sand into a slurry that would be sprayed onto polystyrene foam sheets in frames and set as structural cement.

Within two to four hours, Grancrete system forms a rigid, long-lasting structural wall or ceiling that is permanently bonded to the panels. The resulting structures make it possible to offer long-lasting, easily maintained housing to a large segment of the world's population that could not previously obtain adequate shelter. A Grancrete structure of approximately 800 square feet, for example, would cost $6,000 in labor and materials to construct.

The Glass Furnace Model was developed by Argonne scientist Brian Golchert and colleagues Steve Lottes, Michael Petrick, Chenn Qian Zhou and the late Shen Lin Chang (all ES) as a three-dimensional computer code, developed for the glass industry to evaluate furnace design, performance and operation.

The code is used to generate a computer simulation that allows engineers to visualize critical heat transfer, flow and reaction patterns within the interior of a glass furnace.

The simulation is used to conduct extensive experiments, inexpensively on the computer, by varying key operating and design parameters to determine their impact on overall furnace performance and lead to higher efficiency and increased productivity.

The Powertrain System Analysis Toolkit allows vehicle designers to develop realistic hybrid and powertrain control systems and assess performance of components. Developed by engineers Aymeric Rousseau, Phillip Sharer and Sylvain Pagerit (all ES), the computer simulation provides accurate performance, fuel economy and emissions simulations, allowing automotive and truck manufacturers and their suppliers to select appropriate advanced technologies, bringing them more quickly to the market in improved hybrid vehicle systems.

The Toolkit was released in 2003 and licensed not only to industry, including Ford Motor Co., DaimlerChrysler Corp., General Motors, Exxon/Mobil, and Lockheed Martin, but also to universities to develop designs for student competitions.

Idle reactor to be decontaminated, decommissioned

By Dinesh Ramde

After being used for neutron flux experiments in the 1960s, an on-site reactor that has been idle for 34 years is finally being decontaminated and decommissioned. The Juggernaut reactor will be dismantled and recycled or disposed of within the next year.

 The Juggernaut reactor, in the Building 335 high bay, is one of three decontamination and decommissioning (D&D) projects at Argonne-East expected to be funded by DOE's Office of Environmental Management over the next few years.

The other two are the hot cells in Building 301 and the Zero Power reactors in Building 315. 

Juggernaut was built in 1961 and went critical in 1962. Its objective, according to the plan for its disposal, was "to provide neutron flux levels of medium intensity for research and development experiments of the fast reactor program."

That research was completed in 1970, at which point the reactor was shut down and the fuel, primarily uranium-235, and neutron sources were removed. Since then, the facility has been used for storage and experimental work, said Chris Grandy, an NE Division department manager. Grandy manages the Argonne D&D programmatic work.

"Argonne is providing waste operations, coordination support and oversight for the DOE-D&D contractors, but it's the contractors who are doing the physical dismantlement," he said. 

The waste will be sent to different disposal sites depending on the degree of remaining radioactivity, but Grandy said Argonne will re-use as much of the material as possible. "For example, we're working with the pollution prevention group to see if Argonne or DOE can re-use the lead. We also have movable shield blocks which weren't contaminated at all, so we'll re-use them elsewhere."

"We try to recycle as much as we can," agreed Ed Collins (NE), a 14-year Argonne veteran who is the Argonne-East project manager for the Juggernaut D&D. Collins added that the reactor must be dismantled rather than re-used because it no longer has a programmatic mission and would not conform to current rules and regulations.

Grandy said the radioactivity is predominantly in activation products located inside the reactor. The radioactivity can become dispersible during the dismantlement, but DOE and the contractor will take the necessary precautions to prevent the spread of contamination.

"If the dismantlement is done correctly, the Juggernaut D&D presents no dangers to Argonne employees or the community," he said. "The contractor performed a safety analysis before the project was started which showed minimal risk from the decommissioning project."

Nextel tower gives better cell reception

By Dinesh Ramde

A new Nextel cell site installed at Argonne-East in June will improve phone reception on site as well as save the laboratory an expected $1.5 million next year.

The new system allows employees who relied on two-way radios to now use cheaper but equally reliable cell phones instead.

The cell site is dedicated for Argonne use and will enhance communication capabilities, ensuring that a minimum of 95 percent of calls inside buildings will connect. Mike Vonder Heide (CIS), section head of telecommunications, said reception quality is key.

"Our goal is to always have service of four bars out of four, which we never had before," he said, referring to the reception indicator on most cell phones.

One impetus for this move is a mandate that requires federal agencies to upgrade from wide-band radios to narrow-band digital by 2005, which would squeeze more communication into the same air waves.

To comply, Argonne would have had to purchase 600 new Motorola radios for as much as $2,500 each.

But with this Nextel agreement, Argonne can instead make do with 100 Motorola radios and replace the rest with Nextel phones for as little as 99 cents apiece, for substantial savings.

Nextel was not the only carrier Argonne considered.

"We negotiated with all the major cell phone companies," said Vic Omiecinski (CIS), a telecommunications engineer. "But Nextel was the only company to agree to install a dedicated cell tower."

Emergency Management Officer Gary Winner (EQO) said this technology will save money and improve safety for the people who work alone at night, on weekends, or in remote areas.

"Argonne policy requires personnel in remote areas or hazardous activities to have the capability to access help, which in the past meant providing them with a radio that costs several thousand dollars or assuring a land line telephone was available. Now there is an alternative: reliable cell phone capability for peanuts," Winner said.

That Argonne regular employees who are Nextel users will notice improved reception is an added bonus.

Omiecinski and Vonder Heide negotiated the agreement with Nextel, an agreement Vonder Heide calls a true win-win-win situation.

"We substantially cut our equipment costs, Nextel gets guaranteed business, and taxpayer dollars are being used wisely. Everyone wins," he said.

Pedal power brings employees to the lab during Bike to Work Week

By Elizabeth Quill

From Monday, June 14, to Friday, June 18, Anthony Levand Jr. (PHY) biked 40 miles to work and 40 miles home each day. He came from Elgin — it takes two and a half hours on his recumbent bike.

That's 400 total miles. He burned 17,060 calories and 4.87 lbs of fat and saved 6.4 pounds of toxic emissions. All because he rode his bike.

"I love riding my bike," Levand said. "It's good exercise."

More than 50 other Argonne employees joined Levand to log more than 4,000 miles in this year's Chicagoland Bicycle Federation's annual Bike to Work Week. The event gave them the chance to travel to work in a healthy, inexpensive and environmentally friendly way.

Larry Johnson, director of the Transportation Technology R&D Center, said he started participating in Bike to Work Week about 10 years ago when an avid cyclist from Lucent in Naperville told him about the event. When he first started, Johnson only kept track of bicyclists' hours when he ran into them. Since then, the number of participants has increased, and Argonne has developed a friendly competition with Lucent.

Last year 25 people from Argonne participated and logged just under 1,500 miles. Both figures more than doubled this year. There were 13 Lucent commuters.

Johnson said that Mike Dvorak (MCS), who helped organize the event and keep track of the results, was aggressive about getting information out.

"There were a lot of people doing their little part, which added up to a lot of miles commuted," Dvorak said.

Prizes were awarded to the employee with the longest commute, the employee who made the most trips, the employee who logged the most miles and the employee who prevented the most toxic waste. There were also two less formal awards for the oldest rider and the heaviest rider.

There was also good-natured, inter-divisional competition. The Chemical Engineering Division had the most participants, while the Mathematics and Computer Science Division logged the most miles.

As for the individuals, Levand had the longest commute, logged the most miles and burned the most calories and fat. But there were other standouts:

• Chris Fidkowski (MCS) had the most trips, the most toxic emissions saved and the most days commuting — eight.
• John Gasper (EAD) represented Argonne's Washington, D.C., Bureau.
• R. Dean Pierce (CMT) was the oldest biker at age 74. The youngest was 21 years old.
• And Tom Jaros (VEND) rode his bike during daily errands despite the fact that he is legally blind. He has 20/200 vision, which means he can see at 20 feet what a person with normal vision can see at 200 feet. He rode between the buildings during the week delivering some promotional prizes and collecting money.

"I've been biking for years," Jaros said. "I'm really, really cautious." Jaros used to belong to the Elmhurst Biking Club and used to bike 75- to 100-mile day trips.

Dvorak said the participation encouraged him.

"I thought I was the only one doing anything like this at Argonne," Dvorak said. "It gave me a lot of hope that there are a lot of people doing similar things."

The prizes are not large. Boulevard Bikes in Chicago provided a portable tire pump at cost and Bike Line in Naperville gave five $10 gift certificates. Dvorak said the prizes are not an incentive, just recognition.

He said most people who biked during Bike to Work Week regularly ride their bikes anyway, including Levand who said he is riding to work more often this year than in the past. On these days he leaves his house at 5 a.m. and returns around 6:20 p.m.

"Next year, I'll try to ride longer," Levand said.

Energy systems analyst spins into toy designing

By Elizabeth Quill

When he's not at work, energy systems analyst Jack VanKuiken (DIS) spends a lot of time with toys. But he's not just playing around: He's designing and making them.

His latest gadget by Yomega Corp. adds tops to his spinning toy repertoire, which already includes flying disks and yo-yos.

It is VanKuiken's design that makes the "Smart Top" smarter than the average top. Yomega wanted to make a top without a sharp pointed end. Not only did VanKuiken design this safer toy, but he also made it easy to use and durable.

"I wanted it to be made so that right out of the package almost any kid would get the hang of it," VanKuiken said. "So kids wouldn't get discouraged."

VanKuiken's toy-making did not begin with tops. In 1976, John Gasper (EAD) invited VanKuiken, along with others, to go camping in Door County, but charged everyone with finding Saturday night entertainment.

Electronics was VanKuiken's hobby and Frisbee his passion, so he put the two together and rigged a Frisbee with LED lights.

Next came yo-yos. After seeing a yo-yo act on the Smothers Brothers show about 15 years ago, VanKuiken made a light-up yo-yo. He mailed it to Tom Smothers, who put him in touch with the late Don Duncan Jr., former president of the famous yo-yo manufacturing company. Then VanKuiken met Alan Amaral, Yomega President and CEO, at the New York Toy Fair. VanKuiken has worked with Yomega for more than 10 years and released a yo-yo and a flying disk with strobe lights, the Strobe Yo and Photon Flyte Deck.

This time, instead of adding lights, VanKuiken challenged the traditional top shape and stringing system.

A normal top requires the child to wrap the string around a groove at the top and diagonally down to a groove at the bottom. Then the child must carefully layer it upward from the bottom groove. Once wrapped, the top has to be thrown upside down and the thrower has to snap the string at the right time so the top flips.

"That was the part that was so difficult to master without somebody there coaching to say `Throw it more at an angle, or pull it back harder, or don't pull it back at all,'" VanKuiken said.

He and his dad spent a rainy afternoon in Michigan trying to throw tops for hours. Though they had a lot of laughs, they only landed a few successfully.

With a Smart Top, the child simply wraps the string around a groove at the top's center, holds the string and throws the top like a flying disk.

VanKuiken spent six months perfecting the top. First he created an aluminum prototype and made a mold. He made prototypes out of rubber, plastic and elastomers until he got the material mixture and stout design right — until the top landed, bounced and spun correctly.

"It is neat to see something take shape out of a blank hunk of metal," he said.

And VanKuiken said he is doing it again. Another new yo-yo is already in the works. "I think everyone is an inventor and a toymaker," he said. "I am fortunate to have found companies open to my ideas."

Fitness action plan is the topic of July 15 talk

As part of the Medical Department's Wellness Series, Timothy L. Clark will give a talk about personal fitness Thursday, July 15, from noon to 1 p.m. at the Argonne-East Building 213 cafeteria.

Clark will talk about the type and frequency of exercise that leads to health benefits, discuss weight management techniques and healthy eating guidelines, and identify the main barriers to fitness and how to overcome them.

Those who attend will leave with a personal fitness action plan.

For more information, contact the Medical Department at ext. 2-2813.

Retirees

Mary Lou Gomora (OCF-ACT) retired June 15 with 20 years of service.

Beverly Malak (ET) retired June 1 with 32 years of service.

Benjamin T. Cope, Jr., a retired scientific associate with 25 years of service in the Chemistry Division, died May 14. His daughter, Susan, survives him.

James Lazar, a retired research program manager with 10 years of service in the Engineering Research Division, died June 10. His children, Theresa, James and Janine, survive him.

Myron Pugacz, a retired metallurgical engineer with 15 years of service in the Engineering Research Division, died June 11. His wife, Alice, survives him.

Kenneth E. Wilzbach, a retired senior chemist with 43 years of service in the Energy Systems Division, died April 4. His daughter, Margaret, survives him.

Margaret A. Zurek, a retired budget administrator with 21 years of service in the Environmental Assessment Division, died June 16. Her husband, Jack, survives her.