This research focuses on the engineering and design of a flow loop at Pacific Northwest National Laboratory (PNNL) to enable the testing of different online sensors in a skid configuration. The goal is to integrate high technology readiness level (TRL) sensors into a single platform, providing real-time data for improved mass accountancy and process monitoring in waste processing applications. The flow loop is designed to facilitate the integration of various sensing technologies implemented as removable spool pieces. These sensing technologies include Raman spectroscopy, laser induced breakdown spectroscopy (LIBS), ultrasonic sensors, and flow meters, but could include other sensors based on project need. The flow loop is being designed to enable testing of slurries with similar hydrodynamic properties to wastes found at the Hanford Site with respect to flow rates, chemical compositions, and physical properties. This flow loop enables the use of data fusion techniques to combine outputs from different sensors, enhancing the accuracy and robustness of real-time monitoring. A first generation flow loop in a 1.5 inch line was designed and tested with turbid slurries focusing on a Raman sensor spool piece. A second generation flow loop will size up to enable testing on 2” and 3” lines, enabling testing of slurries at flow velocities up to 18 ft/s. The flow loop is paired with an Endress&Hauser Coriolis mass flow meter and an Electromagnetic flow meter to provide verification from different flow meter technologies. This work advances the development of a comprehensive online monitoring platform for waste processing, offering significant potential for improving operational efficiency and safety. The findings support the mission acceleration at the Hanford Site by providing a robust tool for real-time monitoring and decision support. The results are poised to inform future upgrades and deployments across similar industrial processes.
