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Sample records for dwpf melter system

  1. Checkout and start-up of the integrated DWPF (Defense Waste Processing Facility) melter system

    SciTech Connect

    Smith, M.E.; Hutson, N.D.; Miller, D.H.; Morrison, J.; Shah, H.; Shuford, J.A.; Glascock, J.; Wurzinger, F.H.; Zamecnik, J.R.

    1989-11-11

    The Integrated DWPF Melter System (IDMS) is a one-ninth-scale demonstration of the Defense Waste Processing Facility (DWPF) feed preparation, melter, and off-gas systems. The IDMS will be the first engineering-scale melter system at SRL to process mercury and flowsheet levels of halides and sulfates. This report includes a summary of the IDMS program objectives, system and equipment descriptions, and detailed discussions of the system checkout and start-up. 10 refs., 44 figs., 20 tabs.

  2. Literature review: Assessment of DWPF melter and melter off-gas system lifetime

    SciTech Connect

    Reigel, M. M.

    2015-07-30

    A glass melter for use in processing radioactive waste is a challenging environment for the materials of construction (MOC) resulting from a combination of high temperatures, chemical attack, and erosion/corrosion; therefore, highly engineered materials must be selected for this application. The focus of this report is to review the testing and evaluations used in the selection of the Defense Waste Processing Facility (DWPF), glass contact MOC specifically the Monofrax® K-3 refractory and Inconel® 690 alloy. The degradation or corrosion mechanisms of these materials during pilot scale testing and in-service operation were analyzed over a range of oxidizing and reducing flowsheets; however, DWPF has primarily processed a reducing flowsheet (i.e., Fe2+/ΣFe of 0.09 to 0.33) since the start of radioactive operations. This report also discusses the materials selection for the DWPF off-gas system and the corrosion evaluation of these materials during pilot scale testing and non-radioactive operations of DWPF Melter #1. Inspection of the off-gas components has not been performed during radioactive operations with the exception of maintenance because of plugging.

  3. Literature review: Assessment of DWPF melter and melter off-gas system lifetime

    SciTech Connect

    Reigel, M.

    2015-07-30

    A glass melter for use in processing radioactive waste is a challenging environment for the materials of construction (MOC) resulting from a combination of high temperatures, chemical attack, and erosion/corrosion; therefore, highly engineered materials must be selected for this application. The focus of this report is to review the testing and evaluations used in the selection of the Defense Waste Processing Facility (DWPF), glass contact MOC specifically the Monofrax® K-3 refractory and Inconel® 690 alloy. The degradation or corrosion mechanisms of these materials during pilot scale testing and in-service operation were analyzed over a range of oxidizing and reducing flowsheets; however, DWPF has primarily processed a reducing flowsheet (i.e., Fe2+/ΣFe of 0.09 to 0.33) since the start of radioactive operations. This report also discusses the materials selection for the DWPF off-gas system and the corrosion evaluation of these materials during pilot scale testing and non-radioactive operations of DWPF Melter #1. Inspection of the off-gas components has not been performed during radioactive operations with the exception of maintenance because of plugging.

  4. Literature Review: Assessment of DWPF Melter and Melter Off-gas System Lifetime

    SciTech Connect

    Reigel, M.

    2015-07-30

    Testing to date for the MOC for the Hanford Waste Treatment and Immobilization Plant (WTP) melters is being reviewed with the lessons learned from DWPF in mind and with consideration to the changes in the flowsheet/feed compositions that have occurred since the original testing was performed. This information will be presented in a separate technical report that identifies any potential gaps for WTP processing.

  5. Integrated DWPF Melter System (IDMS) campaign report: Hanford Waste Vitrification Plan (HWVP) process demonstration

    SciTech Connect

    Hutson, N.D.

    1992-08-10

    Vitrification facilities are being developed worldwide to convert high-level nuclear waste to a durable glass form for permanent disposal. Facilities in the United States include the Department of Energy`s Defense Waste Processing Facility (DWPF) at the Savannah River Site, the Hanford Waste Vitrification Plant (HWVP) at the Hanford Site and the West Valley Demonstration Project (WVDP) at West Valley, NY. At each of these sites, highly radioactive defense waste will be vitrified to a stable borosilicate glass. The DWPF and WVDP are near physical completion while the HWVP is in the design phase. The Integrated DWPF Melter System (IDMS) is a vitrification test facility at the Savannah River Technology Center (SRTC). It was designed and constructed to provide an engineering-scale representation of the DWPF melter and its associated feed preparation and off-gas treatment systems. Because of the similarities of the DWPF and HWVP processes, the IDMS facility has also been used to characterize the processing behavior of a reference NCAW simulant. The demonstration was undertaken specifically to determine material balances, to characterize the evolution of offgas products (especially hydrogen), to determine the effects of noble metals, and to obtain general HWVP design data. The campaign was conducted from November, 1991 to February, 1992.

  6. The Behavior and Effects of the Noble Metals in the DWPF Melter System

    SciTech Connect

    Smith, M.E.; Bickford, D.F.

    1997-11-30

    Governments worldwide have committed to stabilization of high-level nuclear waste (HLW) by vitrification to a durable glass form for permanent disposal. All of these nuclear wastes contain the fission-product noble metals: ruthenium, rhodium, and palladium. SRS wastes also contain natural silver from iodine scrubbers. Closely associated with the noble metals are the fission products selenium and tellurium which are chemical analogs of sulfur and which combine with noble metals to influence their behavior and properties. Experience has shown that these melt insoluble metals and their compounds tend to settle to the floor of Joule-heated ceramic melters. In fact, almost all of the major research and production facilities have experienced some operational problem which can be associated with the presence of dense accumulations of these relatively conductive metals and/or their compounds. In most cases, these deposits have led to a loss of production capability, in some cases, to the point that melter operation could not continue. HLW nuclear waste vitrification facilities in the United States are the Department of Energy`s Defense Waste Processing Facility (DWPF) at the Savannah River Site, the planned Hanford Waste Vitrification Plant (HWVP) at the Hanford Site and the operating West Valley Demonstration Project (WVDP) at West Valley, NY. The Integrated DWPF Melter System (IDMS) is a vitrification test facility at the Savannah River Technology Center (SRTC). It was designed and constructed to provide an engineering-scale representation of the DWPF melter and its associated feed preparation and off-gas treatment systems. An extensive noble metals testing program was begun in 1990. The objectives of this task were to explore the effects of the noble metals on the DWPF melter feed preparation and waste vitrification processes. This report focuses on the vitrification portion of the test program.

  7. Nitric acid flowsheet with late wash PHA testing. Task Technical Plan, Integrated DWPF Melter System

    SciTech Connect

    Zamecnik, J.R.

    1993-10-28

    This Task Technical Plan outlines the activities to be conducted in the Integrated DWPF Melter System (IDMS) in ongoing support of the Defense Waste Processing Facility (DWPF) Chemical Process Cell (CPC) utilizing the Nitric Acid Flowsheet in the Sludge Receipt and Adjustment Tank (SRAT) and Precipitate Hydrolysis Aqueous (PHA) produced by the Late Wash Flowsheet. The IDMS facility is to be operated over a series of runs (2 to 4) using the Nitric Acid Flowsheet. The PHA will be produced with the Late Wash Flowsheet in the Precipitate Hydrolysis Experimental Facility (PHEF). All operating conditions shall simulate the expected DWPF operating conditions as closely as possible. The task objectives are to perform at least two IDMS runs with as many operating conditions as possible at nominal DWPF conditions. The major purposes of these runs are twofold: verify that the combined Late Wash and Nitric Acid flowsheets produce glass of acceptable quality without additional changes to process equipment, and determine the reproducibility of data from run to run. These runs at nominal conditions will be compared to previous runs made with PHA produced from the Late Wash flowsheet and with the Nitric Acid flowsheet in the SRAT (Purex 4 and Purex 5).

  8. Freeze and restart of the DWPF Scale Glass Melter

    SciTech Connect

    Choi, A.S.

    1989-07-31

    After over two years of successful demonstration of many design and operating concepts of the DWPF Melter system, the last Scale Glass Melter campaign was initiated on 6/9/88 and consisted of two parts; (1) simulation of noble metal buildup and (2) freeze and subsequent restart of the melter under various scenarios. The objectives were to simulate a prolonged power loss to major heating elements and to examine the characteristics of transient melter operations during a startup with a limited supply of lid heat. Experimental results indicate that in case of a total power loss to the lower electrodes such as due to noble metal deposition, spinel crystals will begin to form in the SRL 165 composite waste glass pool in 24 hours. The total lid heater power required to initiate joule heating was the same as that during slurry-feeding. Results of a radiative heat transfer analysis in the plenum indicate that under the identical operating conditions, the startup capabilities of the SGM and the DWPF Melter are quite similar, despite a greater lid heater to melt surface area ratio in the DWPF Melter.

  9. Maximum total organic carbon limit for DWPF melter feed

    SciTech Connect

    Choi, A.S.

    1995-03-13

    DWPF recently decided to control the potential flammability of melter off-gas by limiting the total carbon content in the melter feed and maintaining adequate conditions for combustion in the melter plenum. With this new strategy, all the LFL analyzers and associated interlocks and alarms were removed from both the primary and backup melter off-gas systems. Subsequently, D. Iverson of DWPF- T{ampersand}E requested that SRTC determine the maximum allowable total organic carbon (TOC) content in the melter feed which can be implemented as part of the Process Requirements for melter feed preparation (PR-S04). The maximum TOC limit thus determined in this study was about 24,000 ppm on an aqueous slurry basis. At the TOC levels below this, the peak concentration of combustible components in the quenched off-gas will not exceed 60 percent of the LFL during off-gas surges of magnitudes up to three times nominal, provided that the melter plenum temperature and the air purge rate to the BUFC are monitored and controlled above 650 degrees C and 220 lb/hr, respectively. Appropriate interlocks should discontinue the feeding when one or both of these conditions are not met. Both the magnitude and duration of an off-gas surge have a major impact on the maximum TOC limit, since they directly affect the melter plenum temperature and combustion. Although the data obtained during recent DWPF melter startup tests showed that the peak magnitude of a surge can be greater than three times nominal, the observed duration was considerably shorter, on the order of several seconds. The long surge duration assumed in this study has a greater impact on the plenum temperature than the peak magnitude, thus making the maximum TOC estimate conservative. Two models were used to make the necessary calculations to determine the TOC limit.

  10. CHARACTERIZATION OF DWPF MELTER OFF-GAS QUENCHER SAMPLE

    SciTech Connect

    Newell, J.

    2011-11-14

    The Savannah River National Laboratory (SRNL) recently received a deposit sample from the Melter Primary Off Gas System (POG) of the Defense Waste Processing Facility (DWPF). This sample was composed of material that had been collected while the quencher was in operation January 27, 2011 through March 31, 2011. DWPF requested, through a technical assistance request, characterization of the melter off-gas deposits by x-ray diffraction (XRD), scanning electron microscopy (SEM), and chemical analysis. The purpose of the Melter Off-Gas System is to reduce the amount of radioactive particles and mercury in the gases vented to the atmosphere. Gases emitted from the melter pass through the primary film cooler, quencher, Off-Gas Condensate Tank (OGCT), Steam Atomized Scrubbers (SAS), a condenser, a high efficiency mist eliminator, and a high efficiency particulate air filter, before being vented to the Process Vessel Vent System. The film coolers cool the gases leaving the melter vapor space from {approx}750 C to {approx}375 C, by introducing air and steam to the flow. In the next step, the quencher cools the gas to about 60 C by bringing the condensate from the OGCT in contact with the effluent (Figure 1). Most of the steam in the effluent is then condensed and the melter vapor space pressure is reduced. The purpose of the OGCT is to collect and store the condensate formed during the melter operation. Condensate from the OGCT is circulated to the SAS and atomized with steam. This atomized condensate is mixed with the off-gas to wet and join the particulate which is then removed in the cyclone. The next stage incorporates a chilled water condenser which separates the vapors and elemental mercury from the off-gas steam. Primary off-gas deposit samples from the DWPF melter have previously been analyzed. In 2003, samples from just past the film cooler, from the inlet of the quencher and inside the quencher were analyzed at SRNL. It was determined that the samples were a

  11. YIELD STRESS REDUCTION OF DWPF MELTER FEED SLURRIES

    SciTech Connect

    Stone, M; Michael02 Smith, M

    2006-12-28

    The Defense Waste Processing Facility (DWPF) at the Savannah River Site vitrifies High Level Waste for repository internment. The process consists of three major steps: waste pretreatment, vitrification, and canister decontamination/sealing. The HLW consists of insoluble metal hydroxides (primarily iron, aluminum, magnesium, manganese, and uranium) and soluble sodium salts (carbonate, hydroxide, nitrite, nitrate, sulfate). The pretreatment process acidifies the sludge with nitric and formic acids, adds the glass formers as glass frit, then concentrates the resulting slurry to approximately 50 weight percent (wt%) total solids. This slurry is fed to the joule-heated melter where the remaining water is evaporated followed by calcination of the solids and conversion to glass. The Savannah River National Laboratory (SRNL) is currently assisting DWPF efforts to increase throughput of the melter. As part of this effort, SRNL has investigated methods to increase the solids content of the melter feed to reduce the heat load required to complete the evaporation of water and allow more of the energy available to calcine and vitrify the waste. The process equipment in the facility is fixed and cannot process materials with high yield stresses, therefore increasing the solids content will require that the yield stress of the melter feed slurries be reduced. Changing the glass former added during pretreatment from an irregularly shaped glass frit to nearly spherical beads was evaluated. The evaluation required a systems approach which included evaluations of the effectiveness of beads in reducing the melter feed yield stress as well as evaluations of the processing impacts of changing the frit morphology. Processing impacts of beads include changing the settling rate of the glass former (which effects mixing and sampling of the melter feed slurry and the frit addition equipment) as well as impacts on the melt behavior due to decreased surface area of the beads versus frit

  12. Defining And Characterizing Sample Representativeness For DWPF Melter Feed Samples

    SciTech Connect

    Shine, E. P.; Poirier, M. R.

    2013-10-29

    statisticians used carefully thought out designs that systematically and economically provided plans for data collection from the DWPF process. Key shared features of the sampling designs used at DWPF and the Gy sampling methodology were the specification of a standard for sample representativeness, an investigation that produced data from the process to study the sampling function, and a decision framework used to assess whether the specification was met based on the data. Without going into detail with regard to the seven errors identified by Pierre Gy, as excellent summaries are readily available such as Pitard [1989] and Smith [2001], SRS engineers understood, for example, that samplers can be biased (Gy's extraction error), and developed plans to mitigate those biases. Experiments that compared installed samplers with more representative samples obtained directly from the tank may not have resulted in systematically partitioning sampling errors into the now well-known error categories of Gy, but did provide overall information on the suitability of sampling systems. Most of the designs in this report are related to the DWPF vessels, not the large SRS Tank Farm tanks. Samples from the DWPF Slurry Mix Evaporator (SME), which contains the feed to the DWPF melter, are characterized using standardized analytical methods with known uncertainty. The analytical error is combined with the established error from sampling and processing in DWPF to determine the melter feed composition. This composition is used with the known uncertainty of the models in the Product Composition Control System (PCCS) to ensure that the wasteform that is produced is comfortably within the acceptable processing and product performance region. Having the advantage of many years of processing that meets the waste glass product acceptance criteria, the DWPF process has provided a considerable amount of data about itself in addition to the data from many special studies. Demonstrating representative sampling

  13. Control of DWPF melter feed composition

    SciTech Connect

    Brown, K.G.; Edwards, R.E.; Postles, R.L.; Randall, C.T.

    1989-01-01

    The Defense Waste Processing Facility will be used to immobilize Savannah River Site high-level waste into a stable borosilicate glass for disposal in a geologic repository. Proper control of the melter feed composition in this facility is essential to the production of glass which meets product durability constraints dictated by repository regulations and facility processing constraints dictated by melter design. A technique has been developed which utilizes glass property models to determine acceptable processing regions based on the multiple constraints imposed on the glass product and to display these regions graphically. This system along with the batch simulation of the process is being used to form the basis for the statistical process control system for the facility.

  14. Control of DWPF melter feed composition

    SciTech Connect

    Brown, K.G.; Edwards, R.E.; Postles, R.L.; Randall, C.T.

    1989-12-31

    The Defense Waste Processing Facility will be used to immobilize Savannah River Site high-level waste into a stable borosilicate glass for disposal in a geologic repository. Proper control of the melter feed composition in this facility is essential to the production of glass which meets product durability constraints dictated by repository regulations and facility processing constraints dictated by melter design. A technique has been developed which utilizes glass property models to determine acceptable processing regions based on the multiple constraints imposed on the glass product and to display these regions graphically. This system along with the batch simulation of the process is being used to form the basis for the statistical process control system for the facility.

  15. Program plan: DWPF/HLWDP stirred Melter Program Plan

    SciTech Connect

    Smith, M.E.

    1994-02-28

    Slurry Fed Melters (SFM) have been developed in the United States, Europe, and Japan for the conversion of high-level radioactive waste (HLW) to borosilicate glass for permanent disposal. The newest design, the stirred melter, combines the high production rates and high glass quality features of the Joule-heated melters with the low-cost, compact, simple maintenance features of the pot melters. However, further engineering design and demonstrations are needed to operate the stirred melter on a large scale. This document outlines the program which develops a full scale stirred melter for the DWPF (240 pph), and provides a basis which will allow further scale-up of the technology for use in the Hanford High Level Waste Disposal Program (HLWDP) for up to four times the reference capacity.

  16. DEVELOPMENT OF AN ANTIFOAM TRACKING SYSTEM AS AN OPTION TO SUPPORT THE MELTER OFF-GAS FLAMMABILITY CONTROL STRATEGY AT THE DWPF

    SciTech Connect

    Edwards, T.; Lambert, D.

    2014-08-27

    . Sample calculations of the system are also included in this report. Please note that the system developed and documented in this report is intended as an alternative to the current, analytically-driven system being utilized by DWPF; the proposed system is not intended to eliminate the current system. Also note that the system developed in this report to track antifoam mass in the AMFT, SRAT, and SME will be applicable beyond just Sludge Batch 8. While the model used to determine acceptability of the SME product with respect to melter off-gas flammability controls must be reassessed for each change in sludge batch, the antifoam mass tracking methodology is independent of sludge batch composition and as such will be transferable to future sludge batches.

  17. DWPF Melter Glass Pump Implementation and Design Improvement

    SciTech Connect

    MICHAEL, SMITH

    2005-04-01

    In order to improve the melt rate of high level waste slurry feed being vitrified in the Savannah River Sites (SRS) Defense Waste Processing Facility (DWPF) Melter, a melter glass pump (pump 1) was installed in the DWPF Melter on February 10, 2004. The glass pump increased melt rate by generating a forced convection within the molten glass pool, thereby increasing the heat transfer from the molten glass to the unmolten feed cold cap that is on top of the glass pool. After operating for over four months, the pump was removed on June 22, 2004 due to indications that it had failed. The removed pump exhibited obvious signs of corrosion, had collapsed inward at the glass exit slots at the melt line, and was dog-legged in the same area. This lead to the pump being redesigned to improve its mechanical integrity (increased wall thickness and strength) while maintaining its hydraulic diameter as large as possible. The improved DWPF glass pump (pump 2) was installed on September 15, 2004. The impact of the new design on pump life, along with analysis of the glass pumps impact on melt rate in the DWPF Melter is discussed in this paper.

  18. Yield Stress Reduction of DWPF Melter Feed Slurries

    SciTech Connect

    Stone, M.E.; Smith, M.E.

    2007-07-01

    The Defense Waste Processing Facility (DWPF) at the Savannah River Site vitrifies High Level Waste for repository internment. The process consists of three major steps: waste pretreatment, vitrification, and canister decontamination/sealing. The HLW consists of insoluble metal hydroxides and soluble sodium salts. The pretreatment process acidifies the sludge with nitric and formic acids, adds the glass formers as glass frit, then concentrates the resulting slurry to approximately 50 weight percent (wt%) total solids. This slurry is fed to the joule-heated melter where the remaining water is evaporated followed by calcination of the solids and conversion to glass. The Savannah River National Laboratory (SRNL) is currently assisting DWPF efforts to increase throughput of the melter. As part of this effort, SRNL has investigated methods to increase the solids content of the melter feed to reduce the heat load required to complete the evaporation of water and allow more of the energy available to calcine and vitrify the waste. The process equipment in the facility is fixed and cannot process materials with high yield stresses, therefore increasing the solids content will require that the yield stress of the melter feed slurries be reduced. Changing the glass former added during pretreatment from an irregularly shaped glass frit to nearly spherical beads was evaluated. The evaluation required a systems approach which included evaluations of the effectiveness of beads in reducing the melter feed yield stress as well as evaluations of the processing impacts of changing the frit morphology. Processing impacts of beads include changing the settling rate of the glass former (which effects mixing and sampling of the melter feed slurry and the frit addition equipment) as well as impacts on the melt behavior due to decreased surface area of the beads versus frit. Beads were produced from the DWPF process frit by fire polishing. The frit was allowed to free fall through a flame

  19. DWPF Glass Melter Technology Manual: Volume 1

    SciTech Connect

    Iverson, D.C.

    1993-12-31

    This document details information about the design of a glass melter to be used at the Defense Waste Processing Facility located at the Savannah River Site. Topics include: melter overview, design basis, materials, vessel configuration, insulation, refractory configuration, electrical isolation, electrodes, riser and pour spout heater design, dome heaters, feed tubes, drain valves, differential pressure pouring, and melter test results. Information is conveyed using many diagrams and photographs.

  20. DWPF Glass Melter Technology Manual: Volume 4

    SciTech Connect

    Iverson, D.C.

    1993-12-31

    This document details information about the design of a glass melter to be used at the Defense Waste Processing Facility located at the Savannah River Plant. Information contained in this document consists solely of a machine drawing and parts list and purchase orders with specifications of equipment used in the development of the melter.

  1. Methods of Off-Gas Flammability Control for DWPF Melter Off-Gas System at Savannah River Site

    SciTech Connect

    Choi, A.S.; Iverson, D.C.

    1996-05-02

    Several key operating variables affecting off-gas flammability in a slurry-fed radioactive waste glass melter are discussed, and the methods used to prevent potential off-gas flammability are presented. Two models have played a central role in developing such methods. The first model attempts to describe the chemical events occurring during the calcining and melting steps using a multistage thermodynamic equilibrium approach, and it calculates the compositions of glass and calcine gases. Volatile feed components and calcine gases are fed to the second model which then predicts the process dynamics of the entire melter off-gas system including off-gas flammability under both steady state and various transient operating conditions. Results of recent simulation runs are also compared with available data

  2. DWPF Glass Melter Technology Manual: Volume 3

    SciTech Connect

    Iverson, D.C.

    1993-12-31

    This document details information about the design of a glass melter to be used at the Defense Waste Processing Facility located at the Savannah River Site. Topics discussed include: Information collected during testing, equipment, materials, design basis, feed tubes, and an evaluation of the performance of various components. Information is conveyed using many diagrams and photographs.

  3. Literature search for offsite data to improve the DWPF melter off-gas model

    SciTech Connect

    Daniel, W.E.

    2000-05-04

    This report documents the literature search performed and any relevant data that may help relax some of the constraints on the DWPF melter off-gas model. The objective of this task was to look for outside sources of technical data to help reduce some of the conservatism built in the DWPF melter off-gas model.

  4. Letter Report on the Issue of Noble Metals in the DWPF Melter

    SciTech Connect

    Hutson, N.D.

    2001-09-05

    This report presents some historical data from the radioactive operation of the DWPF melter. Some of the data seem to indication that the melter is displaying symptoms that may be linked to accumulation of noble metal or other conductive material on the melter floor. The complex and often competing effects of waste composition, glass pool temperatures, and operating conditions must also be considered.

  5. Preliminary Analysis of Species Partitioning in the DWPF Melter

    SciTech Connect

    Choi, A.; Kesterson, M.; Johnson, F.; McCabe, D.

    2015-07-15

    The work described in this report is preliminary in nature since its goal was to demonstrate the feasibility of estimating the off-gas entrainment rates from the Defense Waste Processing Facility (DWPF) melter based on a simple mass balance using measured feed and glass pour stream compositions and timeaveraged melter operating data over the duration of one canister-filling cycle. The only case considered in this study involved the SB6 pour stream sample taken while Canister #3472 was being filled over a 20-hour period on 12/20/2010, approximately three months after the bubblers were installed. The analytical results for that pour stream sample provided the necessary glass composition data for the mass balance calculations. To estimate the “matching” feed composition, which is not necessarily the same as that of the Melter Feed Tank (MFT) batch being fed at the time of pour stream sampling, a mixing model was developed involving three preceding MFT batches as well as the one being fed at that time based on the assumption of perfect mixing in the glass pool but with an induction period to account for the process delays involved in the calcination/fusion step in the cold cap and the melter turnover.

  6. NETEC COLD CRUCIBLE INDUCTION MELTER DEMONSTRATION FOR SRNL WITH SIMULATED SLUDGE BATCH 4 DWPF WASTE

    SciTech Connect

    Smith, M; Allan Barnes, A; Alexander Choi, A; James Marra, J

    2008-07-28

    Cold Crucible Induction Melter (CCIM) Technology is being considered as a possible next generation melter for the Defense Waste Processing Facility (DWPF). Initial and baseline demonstrations that vitrified a Sludge Batch 4 (SB4) simulant at a waste loading of 50 weight percent (versus about 38 weight percent in the current DWPF Melter) were performed by the Nuclear Engineering and Technology Institute (NETEC) in South Korea via a subcontract from the Washington Savannah River Company (WSRC). This higher waste loading was achieved by using a CCIM which can run at higher glass processing temperatures (1250 C and higher) than the current DWPF Melter (1150 C). Higher waste loadings would result in less canisters being filled and faster waste throughput at the DWPF. The main demonstration objectives were to determine the maximum melt rate/waste throughput for the NETEC CCIM with a Sludge Batch 4 simulant as well as determine the viability of this technology for use in the DWPF.

  7. Determination of process conditions for the spray nozzle for the DWPF melter off-gas HEME

    SciTech Connect

    Lee, L.

    1991-12-15

    The DWPF melter off-gas systems have High Efficiency Mist Eliminators (HEME) upstream of the High Efficiency Particulates Air filters (HEPA) to remove fine mist and particulates from the off-gas. To have an acceptable filter life and an efficient HEME operation, air atomized water is sprayed into the melter off-gas and onto the HEME surface. The water spray keeps the HEME wet, which dissolves the soluble particulates and enhances the HEME efficiency. DWPF Technical requested SRL to determine the conditions for the DWPF nozzle which will give complete atomization of water so that the HEME will operate efficiently. Since the air pressure and flow rate to generate the desired spray are not known before hand, an experiment was performed in two stages. The first stage involved preliminary tests which mapped out a general operating region for producing the desired spray pattern. Afterward, all the gages and meters were changed to suitable ranges for the conditions which generated an acceptable spray. This report summarizes the results and the conclusions of the second stage experiment.

  8. Recommendations for rheological testing and modelling of DWPF melter feed slurries

    SciTech Connect

    Shadday, M.A. Jr.

    1994-08-01

    The melter feed in the DWPF process is a non-Newtonian slurry. In the melter feed system and the sampling system, this slurry is pumped at a wide range of flow rates through pipes of various diameters. Both laminar and turbulent flows are encountered. Good rheology models of the melter feed slurries are necessary for useful hydraulic models of the melter feed and sampling systems. A concentric cylinder viscometer is presently used to characterize the stress/strain rate behavior of the melter feed slurries, and provide the data for developing rheology models of the fluids. The slurries exhibit yield stresses, and they are therefore modelled as Bingham plastics. The ranges of strain rates covered by the viscometer tests fall far short of the entire laminar flow range, and therefore hydraulic modelling applications of the present rheology models frequently require considerable extrapolation beyond the range of the data base. Since the rheology models are empirical, this cannot be done with confidence in the validity of the results. Axial pressure drop versus flow rate measurements in a straight pipe can easily fill in the rest of the laminar flow range with stress/strain rate data. The two types of viscometer tests would be complementary, with the concentric cylinder viscometer providing accurate data at low strain rates, near the yield point if one exists, and pipe flow tests providing data at high strain rates up to and including the transition to turbulence. With data that covers the laminar flow range, useful rheological models can be developed. In the Bingham plastic model, linear behavior of the shear stress as a function of the strain rate is assumed once the yield stress is exceeded. Both shear thinning and shear thickening behavior have been observed in viscometer tests. Bingham plastic models cannot handle this non-linear behavior, but a slightly more complicated yield/power law model can.

  9. Conceptual Methods for Decontamination and Decommissioning, Size Reduction, and Disposal of the DWPF Melter and Components

    SciTech Connect

    Smith, M.E.

    2001-06-15

    This report identifies potential methods for the disassembly, size reduction, and decontamination of large DWPF equipment. It specifically targets the DWPF Melter. Methods found to work on the melter should be easily applied to other equipment, as the melter is the most complex large-scale equipment that must be processed. It is also likely to be the most contaminated component as it could contain up to 16,000 pounds of HLW glass in it when it is shut down. This report also evaluates methods, equipment, and techniques that may be used. It also discusses possible dismantlement sequences that could be used as well as issues that need to be addressed. In addition, past experiences in dismantling and inspection of various ceramic-lined melters will be discussed.

  10. Nuclear criticality safety evaluation DWPF melter -- Batch 1

    SciTech Connect

    Williamson, T.G.

    1993-12-01

    The Savannah River Site (SRS) High Level Nuclear Waste will be vitrified in the Defense Waste Processing Facility (DWPF) for long term storage and disposal. This is a preliminary safety evaluation for the Melt Cell of the DWPF vitrification process for Batch 1 waste. This evaluation demonstrates that the material in the Melt cell remains subcritical for the contents of Batch 1 which contains uranium with less than 1% by weight U-235.

  11. Examination of DWPF Melter Materials After 8 Years of Service

    SciTech Connect

    Imrich, K.

    2003-04-29

    The first Defense Waste Processing Facility high level radioactive waste glass melter was successfully operated for eight years. Recent failure of melter heaters and decrease in glass production necessitated its removal. Prior to removing the melter from the facility, a remote in situ visual inspection of the refractory and Inconel(TM) 690 components was performed. The vapor space and glass contact refractory blocks were in excellent condition, showing little evidence of spalling or corrosion. Inconel 690 top head components and lid heaters in the vapor space were also in good condition, considering the service. Upper electrodes experienced significant deflection, which probably resulted from extended operation in excess of 1150 degrees C. Condition of the melter components examined during the remote visual inspection is summarized in this paper.

  12. Milliwave melter monitoring system

    DOEpatents

    Daniel, William E.; Woskov, Paul P.; Sundaram, Shanmugavelayutham K.

    2011-08-16

    A milliwave melter monitoring system is presented that has a waveguide with a portion capable of contacting a molten material in a melter for use in measuring one or more properties of the molten material in a furnace under extreme environments. A receiver is configured for use in obtaining signals from the melt/material transmitted to appropriate electronics through the waveguide. The receiver is configured for receiving signals from the waveguide when contacting the molten material for use in determining the viscosity of the molten material. Other embodiments exist in which the temperature, emissivity, viscosity and other properties of the molten material are measured.

  13. Analysis of the DWPF glass pouring system using neural networks

    SciTech Connect

    Calloway, T.B. Jr.; Jantzen, C.M.; Medich, L.; Spennato, N.

    1997-08-05

    Neural networks were used to determine the sensitivity of 39 selected Melter/Melter Off Gas and Melter Feed System process parameters as related to the Defense Waste Processing Facility (DWPF) Melter Pour Spout Pressure during the overall analysis and resolution of the DWPF glass production and pouring issues. Two different commercial neural network software packages were used for this analysis. Models were developed and used to determine the critical parameters which accurately describe the DWPF Pour Spout Pressure. The model created using a low-end software package has a root mean square error of {+-} 0.35 inwc (< 2% of the instrument`s measured range, R{sup 2} = 0.77) with respect to the plant data used to validate and test the model. The model created using a high-end software package has a R{sub 2} = 0.97 with respect to the plant data used to validate and test the model. The models developed for this application identified the key process parameters which contribute to the control of the DWPF Melter Pour Spout pressure during glass pouring operations. The relative contribution and ranking of the selected parameters was determined using the modeling software. Neural network computing software was determined to be a cost-effective software tool for process engineers performing troubleshooting and system performance monitoring activities. In remote high-level waste processing environments, neural network software is especially useful as a replacement for sensors which have failed and are costly to replace. The software can be used to accurately model critical remotely installed plant instrumentation. When the instrumentation fails, the software can be used to provide a soft sensor to replace the actual sensor, thereby decreasing the overall operating cost. Additionally, neural network software tools require very little training and are especially useful in mining or selecting critical variables from the vast amounts of data collected from process computers.

  14. Assessment of the impact of the next generation solvent on DWPF melter off-gas flammability

    SciTech Connect

    Daniel, W. E.

    2013-02-13

    An assessment has been made to evaluate the impact on the DWPF melter off-gas flammability of replacing the current solvent used in the Modular Caustic-Side Solvent Extraction Process Unit (MCU) process with the Next Generation Solvent (NGS-MCU) and blended solvent. The results of this study showed that the concentrations of nonvolatile carbon and hydrogen of the current solvent in the Slurry Mix Evaporator (SME) product would both be about 29% higher than their counterparts of the NGS-MCU and blended solvent in the absence of guanidine partitioning. When 6 ppm of guanidine (TiDG) was added to the effluent transfer to DWPF to simulate partitioning for the NGS-MCU and blended solvent cases and the concentration of Isopar{reg_sign} L in the effluent transfer was controlled below 87 ppm, the concentrations of nonvolatile carbon and hydrogen of the NGS-MCU and blended solvent were still about 12% and 4% lower, respectively, than those of the current solvent. It is, therefore, concluded that as long as the volume of MCU effluent transfer to DWPF is limited to 15,000 gallons per Sludge Receipt and Adjustment Tank (SRAT)/SME cycle and the concentration of Isopar{reg_sign} L in the effluent transfer is controlled below 87 ppm, using the current solvent assumption of 105 ppm Isopar{reg_sign} L or 150 ppm solvent in lieu of NGS-MCU or blended solvent in the DWPF melter off-gas flammability assessment is conservative for up to an additional 6 ppm of TiDG in the effluent due to guanidine partitioning. This report documents the calculations performed to reach this conclusion.

  15. MELTER OFF-GAS FLAMMABILITY ASSESSMENT FOR DWPF ALTERNATE REDUCTANT FLOWSHEET OPTIONS

    SciTech Connect

    Choi, A.

    2011-07-08

    Glycolic acid and sugar are being considered as potential candidates to substitute for much of the formic acid currently being added to the Defense Waste Processing Facility (DWPF) melter feed as a reductant. A series of small-scale melter tests were conducted at the Vitreous State Laboratory (VSL) in January 2011 to collect necessary data for the assessment of the impact of these alternate reductants on the melter off-gas flammability. The DM10 melter with a 0.021 m{sup 2} melt surface area was run with three different feeds which were prepared at SRNL based on; (1) the baseline formic/nitric acid flowsheet, (2) glycolic/formic/nitric acid flowsheet, and (3) sugar/formic/nitric acid flowsheet - these feeds will be called the baseline, glycolic, and sugar flowsheet feeds, respectively, hereafter. The actual addition of sugar to the sugar flowsheet feed was made at VSL before it was fed to the melter. For each feed, the DM10 was run under both bubbled (with argon) and non-bubbled conditions at varying melter vapor space temperatures. The goal was to lower its vapor space temperature from nominal 500 C to less than 300 C at 50 C increments and maintain steady state at each temperature at least for one hour, preferentially for two hours, while collecting off-gas data including CO, CO{sub 2}, and H{sub 2} concentrations. Just a few hours into the first test with the baseline feed, it was discovered that the DM10 vapor space temperature would not readily fall below 350 C simply by ramping up the feed rate as the test plan called for. To overcome this, ambient air was introduced directly into the vapor space through a dilution air damper in addition to the natural air inleakage occurring at the operating melter pressure of -1 inch H{sub 2}O. A detailed description of the DM10 run along with all the data taken is given in the report issued by VSL. The SRNL personnel have analyzed the DM10 data and identified 25 steady state periods lasting from 32 to 92 minutes for all

  16. Melter viewing system for liquid-fed ceramic melters

    SciTech Connect

    Westsik, J.H. Jr.; Brenden, B.B.

    1988-01-01

    Melter viewing systems are an integral component of the monitoring and control systems for liquid-fed ceramic melters. The Pacific Northwest Laboratory (PNL) has designed cameras for use with glass melters at PNL, the Hanford Waste Vitrification Plant (HWVP), and West Valley Demonstration Project (WVDP). This report is a compilation of these designs. Operating experiences with one camera designed for the PNL melter are discussed. A camera has been fabricated and tested on the High-Bay Ceramic Melter (HBCM) and the Pilot-Scale Ceramic Melter (PSCM) at PNL. The camera proved to be an effective tool for monitoring the cold cap formed as the feed pool developed on the molten glass surface and for observing the physical condition of the melter. Originally, the camera was built to operate using the visible light spectrum in the melter. It was later modified to operate using the infrared (ir) spectrum. In either configuration, the picture quality decreases as the size of the cold cap increases. Large cold caps cover the molten glass, reducing the amount of visible light and reducing the plenum temperatures below 600/sup 0/C. This temperature corresponds to the lowest level of blackbody radiation to which the video tube is sensitive. The camera has been tested in melter environments for about 1900 h. The camera has withstood mechanical shocks and vibrations. The cooling system in the camera has proved effective in maintaining the optical and electronic components within acceptable temperature ranges. 10 refs., 15 figs.

  17. On The Impact of Borescope Camera Air Purge on DWPF Melter Off-Gas Flammability

    SciTech Connect

    CHOI, ALEXANDER

    2004-07-22

    DWPF Engineering personnel requested that a new minimum backup film cooler air flow rate, which will meet the off-gas safety basis limits for both normal and seismic sludge-only operations, be calculated when the air purge to the borescope cameras is isolated from the melter. Specifically, it was requested that the latest calculations which were used to set the off-gas flammability safety bases for the sludge batch 2 and 3 feeds be revised, while maintaining all other process variables affecting off-gas flammability such as total organic carbon (TOC), feed rate, melter air purges, and vapor space temperature at their current respective maximum or minimum limits. Before attempting to calculate the new minimum backup film cooler air flow, some of the key elements of the combustion model were reviewed, and it was determined that the current minimum backup film cooler air flow of 233 lb/hr is adequate to satisfy the off-gas flammability safety bases for both normal and seismic operations i n the absence of any borescope camera air purge. It is, therefore, concluded that there is no need to revise the reference E-7 calculations. This conclusion is in essence based on the fact that the current minimum backup film cooler air flow was set to satisfy the minimum combustion air requirement under the worst-case operating scenario involving a design basis earthquake during which all the air purges not only to the borescope cameras but to the seal pot are presumed to be lost due to pipe ruptures. The minimum combustion air purge is currently set at 150 per cent of the stoichiometric air flow required to combust 3 times the normal flow of flammable gases. The DWPF control strategy has been that 100 per cent of the required minimum combustion air is to be provided by the controlled air purge through the backup film cooler alone.

  18. SRAT CHEMISTRY AND ACID CONSUMPTION DURING SIMULATED DWPF MELTER FEED PREPARATION

    SciTech Connect

    Koopman, D; David Best, D; Bradley Pickenheim, B

    2008-12-03

    Due to higher than expected hydrogen generation during the Tank 51-Sludge Batch 4 (SB4) qualification run, DWPF engineering requested the Savannah River National Laboratory (SRNL) to expand the ongoing catalytic hydrogen generation program. The work presented in this Technical Report was identified as part of SRNL/Liquid Waste Organization (LWO) meetings to define potential causes of catalytic hydrogen generation as well as from an external technical review panel commissioned to evaluate SRNL hydrogen related data and programs. New scope included improving the understanding of SRAT/SME process chemistry, particularly as it related to acid consumption and hydrogen generation. The expanded hydrogen program scope was covered under the technical task request (TTR): HLW-DWPF-TTR-2007-0016. A task technical and quality assurance plan (TT&QAP) was issued to cover focus areas raised in meetings with LWO plus a portion of the recommendations made by the review panel. A supporting analytical study plan was issued. It was also noted in the review of catalytic hydrogen generation that control of the DWPF acid stoichiometry was an important element in controlling hydrogen generation. A separate TTR was issued to investigate ways of improving the determination of the acid requirement during processing: HLWDWPF-TTR-0015. A separate TT&QAP was prepared for this task request. This report discusses some progress on this task related to developing alternative acid equations and to performing experimental work to supplement the existing database. Simulant preparation and preliminary flowsheet studies were already documented. The prior work produced a sufficient quantity of simulant for the hydrogen program and melter feed rheology testing. It also defined a suitable acid addition stoichiometry. The results presented in this report come from samples and process data obtained during sixteen 22-L SRAT/SME simulations that were performed in the second half of 2007 to produce eight SME

  19. CHARACTERIZATION OF DWPF MELTER OFF-GAS QUENCHER AND STEAM ATOMIZED SCRUBBER DEPOSIT SAMPLES

    SciTech Connect

    Zeigler, K; Ned Bibler, N

    2007-06-06

    This report summarizes the results from the characterization of deposits from the inlets of the primary off-gas Quencher and Steam Atomized Scrubber (SAS) in the Defense Waste Processing Facility (DWPF), as requested by a technical assistance request. DWPF requested elemental analysis and compound identification to help determine the potential causes for the substance formation. This information will be fed into Savannah River National Laboratory modeling programs to determine if there is a way to decrease the formation of the deposits. The general approach to the characterization of these samples included x-ray diffraction (XRD), scanning electron microscopy (SEM), and chemical analysis. The following conclusions are drawn from the analytical results found in this report: (1) The deposits are not high level waste glass from the DWPF melt pool based on comparison of the compositions of deposits to the composition of a sample of glass taken from the pour stream of the melter during processing of Sludge Batch 3. (2) Chemical composition results suggest that the deposits are probably a combination of sludge and frit particles entrained in the off-gas. (3) Gamma emitters, such as Co-60, Cs-137, Eu-154, Am-241, and Am-243 were detected in both the Quencher and SAS samples with Cs-137 having the highest concentration of the gamma emitters. (4) No evidence existed for accumulation of fissile material (U-233, U-235, and Pu-239) relative to Fe in either deposit. (5) XRD results indicated both samples were primarily amorphorous and contained some crystals of the iron oxides, hematite and magnetite (Fe{sub 2}O{sub 3} and Fe(Fe{sub 2}O{sub 4})), along with sodium nitrate (NaNO{sub 3}). The other main crystalline compound in the SAS deposit was mercurous chloride. The main crystalline compound in the Quencher deposit was a uranium oxide compound. These are all sludge components. (6) SEM analysis of the Quencher deposit revealed crystalline uranium compounds within the sample

  20. Evaluation of materials and surface treatments for the DWPF melter pour spout bellows protective liner

    SciTech Connect

    Imrich, K.J.; Bickford, D.F.; Wicks, G.G.

    1997-06-27

    A study was undertaken to evaluate a variety of materials and coatings for the DWPF pour spout bellows liner. The intent was to identify materials that would minimize or eliminate adherence of glass on the bellows liner wall and help minimize possible pluggage during glass pouring operations in DWPF. Glass has been observed adhering to the current bellow`s liner, which is made of 304L stainless steel. Materials were identified which successfully allowed molten glass to hit these surfaces and not adhere. Results of this study suggest that if these materials are used in the pouring system glass could still fall into the canister without appreciable plugging, even if an unstable glass stream is produced. The materials should next be evaluated under the most realistic DWPF conditions possible. Other findings of this study include the following: (1) increasing coupon thickness produced a favorable increase in the glass sticking temperature; (2) highly polished surfaces, with the exception of the oxygen-free copper coupon coated with Armoloy dense chromium, did not produce a significant improvement in the glass sticking temperature, increasing angle of contact of the coupon to the falling glass did not yield a significant performance improvement; (3) electroplating with gold and silver and various diffusion coatings did not produce a significant increase in the glass sticking temperature. However, they may provide added oxidation and corrosion resistance for copper and bronze liners. Boron nitride coatings delaminated immediately after contact with the molten glass.

  1. NOBLE METAL CHEMISTRY AND HYDROGEN GENERATION DURING SIMULATED DWPF MELTER FEED PREPARATION

    SciTech Connect

    Koopman, D

    2008-06-25

    Simulations of the Defense Waste Processing Facility (DWPF) Chemical Processing Cell vessels were performed with the primary purpose of producing melter feeds for the beaded frit program plus obtaining samples of simulated slurries containing high concentrations of noble metals for off-site analytical studies for the hydrogen program. Eight pairs of 22-L simulations were performed of the Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME) cycles. These sixteen simulations did not contain mercury. Six pairs were trimmed with a single noble metal (Ag, Pd, Rh, or Ru). One pair had all four noble metals, and one pair had no noble metals. One supporting 4-L simulation was completed with Ru and Hg. Several other 4-L supporting tests with mercury have not yet been performed. This report covers the calculations performed on SRNL analytical and process data related to the noble metals and hydrogen generation. It was originally envisioned as a supporting document for the off-site analytical studies. Significant new findings were made, and many previous hypotheses and findings were given additional support as summarized below. The timing of hydrogen generation events was reproduced very well within each of the eight pairs of runs, e.g. the onset of hydrogen, peak in hydrogen, etc. occurred at nearly identical times. Peak generation rates and total SRAT masses of CO{sub 2} and oxides of nitrogen were reproduced well. Comparable measures for hydrogen were reproduced with more variability, but still reasonably well. The extent of the reproducibility of the results validates the conclusions that were drawn from the data.

  2. The DWPF product composition control system at Savannah River: Statistical process control algorithm

    SciTech Connect

    Postles, R.L.; Brown, K.G.

    1991-01-01

    The DWPF Process batch-blends aqueous radwaste (PHA) with solid radwaste (Sludge) in a waste receipt vessel (the SRAT). The resulting SRAT-Batch is transferred to the next process vessel (the SME) and there blended with ground glass (Frit) to produce a batch of feed slurry. The SME-Batch is passed to a subsequent hold tank (the MFT) which feeds a Melter continuously. The Melter produces a molten glass wasteform which is poured into stainless steel canisters for cooling and, ultimately, shipment to and storage in a geologic Repository. The Repository will require that the glass wasteform be resistant to leaching by any underground water that might contact it. In addition, there are processing constraints on Viscosity and Liquidus Temperature of the melt. The Product Composition Control System (PCCS) is the system intended to ensure that the melt will be Processible and that the glass wasteform will be Acceptable. Within the PCCS, the SPC Algorithm is the device which guides control of the DWPF process. The SPC Algorithm is needed to control the multivariate DWPF process in the face of uncertainties (variances and covariances) which arise from this process and its supply, sampling, modeling, and measurement systems.

  3. The DWPF product composition control system at Savannah River: Statistical process control algorithm

    SciTech Connect

    Postles, R.L.; Brown, K.G.

    1991-12-31

    The DWPF Process batch-blends aqueous radwaste (PHA) with solid radwaste (Sludge) in a waste receipt vessel (the SRAT). The resulting SRAT-Batch is transferred to the next process vessel (the SME) and there blended with ground glass (Frit) to produce a batch of feed slurry. The SME-Batch is passed to a subsequent hold tank (the MFT) which feeds a Melter continuously. The Melter produces a molten glass wasteform which is poured into stainless steel canisters for cooling and, ultimately, shipment to and storage in a geologic Repository. The Repository will require that the glass wasteform be resistant to leaching by any underground water that might contact it. In addition, there are processing constraints on Viscosity and Liquidus Temperature of the melt. The Product Composition Control System (PCCS) is the system intended to ensure that the melt will be Processible and that the glass wasteform will be Acceptable. Within the PCCS, the SPC Algorithm is the device which guides control of the DWPF process. The SPC Algorithm is needed to control the multivariate DWPF process in the face of uncertainties (variances and covariances) which arise from this process and its supply, sampling, modeling, and measurement systems.

  4. Experimental Plan for the Cold Demonstration (Scoping Tests) of Glass Removal Methods from a DWPF Melter

    SciTech Connect

    Smith, M.E.

    2001-09-21

    SRS and WVDP currently do not have the capability to size reduce, decontaminate, classify, and dispose of large, failed, highly contaminated equipment. Tanks Focus Area Task 777 was developed to address this problem. The first activity for Task 777 is to develop and demonstrate techniques suitable for removing the solid HLW glass from HLW melters. This experimental plan describes the work that will be performed for this glass removal demonstration.

  5. Cylindrical Induction Melter Modicon Control System

    SciTech Connect

    Weeks, G.E.

    1998-04-01

    In the last several years an extensive R{ampersand}D program has been underway to develop a vitrification system to stabilize Americium (Am) and Curium (Cm) inventories at SRS. This report documents the Modicon control system designed for the 3 inch Cylindrical Induction Melter (CIM).

  6. Thermal effects of electrically conductive deposits in melter

    SciTech Connect

    Choi, I.G.; Bickford, D.F.; Carter, J.T.

    1992-01-01

    The radioactive waste processed by the Defense Waste Processing Facility melter at the Savannah river Site contains noble metal fission-products. Operation of waste-glass melters treating commercial power reactor wastes indicates that accumulation of noble metals on melter floors can lead to distortion of electric heating patterns, loss of power, and possible electrode damage. Changes in melter geometry have been developed in Japan and Germany to minimize these effects. The two existing melters for the US Department of Energy's Defense Waste Processing Facility were designed in 1982, before this effect was known or had been characterized. Modeling and pilot scale tests are being conducted in the Integrated DWPF melter system to determine if the effect is significant for melters processing defense wastes, and if the effect can be diagnosed and corrected without significant damage or changes to the melter design. This document provides a discussion of these tests.

  7. Thermal effects of electrically conductive deposits in melter

    SciTech Connect

    Choi, I.G.; Bickford, D.F.; Carter, J.T.

    1992-07-01

    The radioactive waste processed by the Defense Waste Processing Facility melter at the Savannah river Site contains noble metal fission-products. Operation of waste-glass melters treating commercial power reactor wastes indicates that accumulation of noble metals on melter floors can lead to distortion of electric heating patterns, loss of power, and possible electrode damage. Changes in melter geometry have been developed in Japan and Germany to minimize these effects. The two existing melters for the US Department of Energy`s Defense Waste Processing Facility were designed in 1982, before this effect was known or had been characterized. Modeling and pilot scale tests are being conducted in the Integrated DWPF melter system to determine if the effect is significant for melters processing defense wastes, and if the effect can be diagnosed and corrected without significant damage or changes to the melter design. This document provides a discussion of these tests.

  8. Crystallization In High Level Waste (HLW) Glass Melters: Operational Experience From The Savannah River Site

    SciTech Connect

    Fox, K. M.

    2014-02-27

    observed in any of the pour stream glass samples. Spinel was observed at the bottom of DWPF Melter 1 as a result of K-3 refractory corrosion. Issues have occurred with accumulation of spinel in the pour spout during periods of operation at higher waste loadings. Given that both DWPF melters were or have been in operation for greater than 8 years, the service life of the melters has far exceeded design expectations. It is possible that the DWPF liquidus temperature approach is conservative, in that it may be possible to successfully operate the melter with a small degree of allowable crystallization in the glass. This could be a viable approach to increasing waste loading in the glass assuming that the crystals are suspended in the melt and swept out through the riser and pour spout. Additional study is needed, and development work for WTP might be leveraged to support a different operating limit for the DWPF. Several recommendations are made regarding considerations that need to be included as part of the WTP crystal tolerant strategy based on the DWPF development work and operational data reviewed here. These include: Identify and consider the impacts of potential heat sinks in the WTP melter and glass pouring system; Consider the contributions of refractory corrosion products, which may serve to nucleate additional crystals leading to further accumulation; Consider volatilization of components from the melt (e.g., boron, alkali, halides, etc.) and determine their impacts on glass crystallization behavior; Evaluate the impacts of glass REDuction/OXidation (REDOX) conditions and the distribution of temperature within the WTP melt pool and melter pour chamber on crystal accumulation rate; Consider the impact of precipitated crystals on glass viscosity; Consider the impact of an accumulated crystalline layer on thermal convection currents and bubbler effectiveness within the melt pool; Evaluate the impact of spinel accumulation on Joule heating of the WTP melt pool; and

  9. IMPACT OF ELIMINATING MERCURY REMOVAL PRETREATMENT ON THE PERFORMANCE OF A HIGH LEVEL RADIOACTIVE WASTE MELTER OFFGAS SYSTEM

    SciTech Connect

    Zamecnik, J; Alexander Choi, A

    2009-03-17

    The Defense Waste Processing Facility at the Savannah River Site processes high-level radioactive waste from the processing of nuclear materials that contains dissolved and precipitated metals and radionuclides. Vitrification of this waste into borosilicate glass for ultimate disposal at a geologic repository involves chemically modifying the waste to make it compatible with the glass melter system. Pretreatment steps include removal of excess aluminum by dissolution and washing, and processing with formic and nitric acids to: (1) adjust the reduction-oxidation (redox) potential in the glass melter to reduce radionuclide volatility and improve melt rate; (2) adjust feed rheology; and (3) reduce by steam stripping the amount of mercury that must be processed in the melter. Elimination of formic acid pretreatment has been proposed to eliminate the production of hydrogen in the pretreatment systems; alternative reductants would be used to control redox. However, elimination of formic acid would result in significantly more mercury in the melter feed; the current specification is no more than 0.45 wt%, while the maximum expected prior to pretreatment is about 2.5 wt%. An engineering study has been undertaken to estimate the effects of eliminating mercury removal on the melter offgas system performance. A homogeneous gas-phase oxidation model and an aqueous phase model were developed to study the speciation of mercury in the DWPF melter offgas system. The model was calibrated against available experimental data and then applied to DWPF conditions. The gas-phase model predicted the Hg{sub 2}{sup 2-}/Hg{sup 2+} ratio accurately, but some un-oxidized Hg{sup 0} remained. The aqueous model, with the addition of less than 1 mM Cl{sub 2} showed that this remaining Hg{sup 0} would be oxidized such that the final Hg{sub 2}{sup 2+}/Hg{sup 2+} ratios matched the experimental data. The results of applying the model to DWPF show that due to excessive shortage of chloride, only 6% of

  10. Crystallization in high level waste (HLW) glass melters: Savannah River Site operational experience

    SciTech Connect

    Fox, K.

    2015-06-12

    This paper provides a review of the scaled melter testing that was completed for design input to the Defense Waste Processing Facility (DWPF) melter. Testing with prototype melters provided the data to define the DWPF operating limits to avoid bulk (volume) crystallization in the un-agitated DWPF melter and provided the data to distinguish between spinels generated by refractory corrosion versus spinels that precipitated from the HLW glass melt pool. A review of the crystallization observed with the prototype melters and the full scale DWPF melters (DWPF Melter 1 and DWPF Melter 2) is included. Examples of actual DWPF melter attainment with Melter 2 are given. The intent is to provide an overview of lessons learned, including some example data, that can be used to advance the development and implementation of an empirical model and operating limit for crystal accumulation for a waste treatment and immobilization plant.

  11. Melt rate predictions for slurry-fed glass melters

    SciTech Connect

    Freeman, C.J.

    1996-03-01

    Numerous bench-scale and pilot-scale tests have been conducted to support high-level waste vitrification projects within DOE. These projects include the Hanford Waste Vitrification Plant (HWP), the Defense Waste Processing Facility (DWPF), and the West Valley Demonstration Project (MNDP). Testing for these projects has investigated aspects of the vitrification process such as the pumpability of the slurry feed, melter processing rates, melter scale-up, and off-gas decontamination factors for feed constituents. The high costs for testing have generated interest in using modeling to predict major processing impacts on the vitrification systems from any given feed material. Important components required for such modeling include feed composition, feed rheology, melter glass temperature, melter geometry, and melter power configurations. I Some work has already been performed in modeling glass melters, but little attention has been given to feed composition (Routt 1982).

  12. MODELING THE IMPACT OF ELEVATED MERCURY IN DEFENSE WASTE PROCESSING FACILITY MELTER FEED ON THE MELTER OFF-GAS SYSTEM - PRELIMINARY REPORT

    SciTech Connect

    Zamecnik, J.; Choi, A.

    2009-03-25

    The Defense Waste Processing Facility (DWPF) is currently evaluating an alternative Chemical Process Cell (CPC) flowsheet to increase throughput. It includes removal of the steam-stripping step, which would significantly reduce the CPC processing time and lessen the sampling needs. However, its downside would be to send 100% of the mercury that come in with the sludge straight to the melter. For example, the new mercury content in the Sludge Batch 5 (SB5) melter feed is projected to be 25 times higher than that in the SB4 with nominal steam stripping of mercury. This task was initiated to study the impact of the worst-case scenario of zero-mercury-removal in the CPC on the DWPF melter off-gas system. It is stressed that this study is intended to be scoping in nature, so the results presented in this report are preliminary. In order to study the impact of elevated mercury levels in the feed, it is necessary to be able to predict how mercury would speciate in the melter exhaust under varying melter operating conditions. A homogeneous gas-phase oxidation model of mercury by chloride was developed to do just that. The model contains two critical parameters pertaining to the partitioning of chloride among HCl, Cl, Cl{sub 2}, and chloride salts in the melter vapor space. The values for these parameters were determined at two different melter vapor space temperatures by matching the calculated molar ratio of HgCl (or Hg{sub 2}Cl{sub 2}) to HgCl{sub 2} with those measured during the Experimental-Scale Ceramic Melter (ESCM) tests run at the Pacific Northwest National Laboratory (PNNL). The calibrated model was then applied to the SB5 simulant used in the earlier flowsheet study with an assumed mercury stripping efficiency of zero; the molar ratio of Cl-to-Hg in the resulting melter feed was only 0.4, compared to 12 for the ESCM feeds. The results of the model run at the indicated melter vapor space temperature of 650 C (TI4085D) showed that due to excessive shortage of

  13. MODELING THE IMPACT OF ELEVATED MERCURY IN DEFENSE WASTE PROCESSING FACILITY MELTER FEED ON THE MELTER OFF-GAS SYSTEM-PRELIMINARY REPORT

    SciTech Connect

    Zamecnik, J.; Choi, A.

    2010-08-18

    The Defense Waste Processing Facility (DWPF) is currently evaluating an alternative Chemical Process Cell (CPC) flowsheet to increase throughput. It includes removal of the steam-stripping step, which would significantly reduce the CPC processing time and lessen the sampling needs. However, its downside would be to send 100% of the mercury that comes in with the sludge straight to the melter. For example, the new mercury content in the Sludge Batch 5 (SB5) melter feed is projected to be 25 times higher than that in the SB4 with nominal steam stripping of mercury. This task was initiated to study the impact of the worst-case scenario of zero-mercury-removal in the CPC on the DWPF melter offgas system. It is stressed that this study is intended to be scoping in nature, so the results presented in this report are preliminary. In order to study the impact of elevated mercury levels in the feed, it is necessary to be able to predict how mercury would speciate in the melter exhaust under varying melter operating conditions. A homogeneous gas-phase oxidation model of mercury by chloride was developed to do just that. The model contains two critical parameters pertaining to the partitioning of chloride among HCl, Cl, Cl{sub 2}, and chloride salts in the melter vapor space. The values for these parameters were determined at two different melter vapor space temperatures by matching the calculated molar ratio of HgCl (or Hg{sub 2}Cl{sub 2}) to HgCl{sub 2} with those measured during the Experimental-Scale Ceramic Melter (ESCM) tests run at the Pacific Northwest National Laboratory (PNNL). The calibrated model was then applied to the SB5 simulant used in the earlier flowsheet study with an assumed mercury stripping efficiency of zero; the molar ratio of Cl-to-Hg in the resulting melter feed was only 0.4, compared to 12 for the ESCM feeds. The results of the model run at the indicated melter vapor space temperature of 650 C (TI4085D) showed that due to excessive shortage of

  14. Extending Fuzzy System Concepts for Control of a Vitrification Melter

    SciTech Connect

    Whitehouse, J.C.; Sorgel, W.; Garrison, A.; Schalkoff, R.J.

    1995-08-16

    Fuzzy systems provide a mathematical framework to capture uncertainty. The complete description of real, complex systems or situations often requires far more detail and information than could ever be obtained (or understood). Fuzzy approaches are an alternative technology for both system control and information processing and management. In this paper, we present the design of a fuzzy control system for a melter used in the vitrification of hazardous waste. Design issues, especially those related to melter shutdown and obtaining smooth control surfaces, are addressed. Several extensions to commonly-applied fuzzy techniques, notably adaptive defuzzification and modified rule structures are developed.

  15. Melt Rate Improvement for DWPF MB3: Melt Rate Furnace Testing

    SciTech Connect

    Stone, M.E.

    2001-07-24

    The Defense Waste Processing Facility (DWPF) would like to increase its canister production rate. The goal of this study is to improve the melt rate in DWPF specifically for Macrobatch 3. However, the knowledge gained may result in improved melting efficiencies translating to future DWPF macrobatches and in higher throughput for other Department of Energy's (DOE) melters. Increased melting efficiencies decrease overall operational costs by reducing the immobilization campaign time for a particular waste stream. For melt rate limited systems, a small increase in melting efficiency translates into significant hard dollar savings by reducing life cycle operational costs.

  16. Glass melter off-gas system

    DOEpatents

    Jantzen, Carol M.

    1997-01-01

    Apparatus and method for melting glass in a glass melter in such a way as to reduce deposition of particulates in the off-gas duct. Deposit accumulation is reduced by achieving an off-gas velocity above approximately 15 meters/second and an off-gas temperature as close as possible to, but not higher than, the glass softening point. Because the deposits are largely water-soluble, those that do form on the interior surface of the duct can be readily removed by injecting water or steam directly into the off-gas duct from its entrance or exit.

  17. Formic acid requirement for the Savannah River Site Defense Waste Processing Facility melter feed preparation

    SciTech Connect

    Hsu, C.W.

    1991-01-01

    The Westinghouse Savannah River Company (WSRC) will vitrify the high-level radioactive waste into a borosilicate glass wasteform using a slurry-fed, joule-heated melter. Formic acid is used to treat the sludge slurry for melter feed preparation. Both a minimum formate requirement and a maximum allowable formate level need to be established to adequately prepare the sludge for melter feed. The data from the Savannah River Laboratory (SRL) Scale Glass Melter (SGM), Integrated DWPF Melter System (IDMS), and research mini-melter runs were used for this purpose. The stoichiometry for major reactions during formic acid treatment was revised to reflect the more predominant chemical reactions and their yields. A minimum formic acid requirement was established according to this revised stoichiometry. Methods for determining the minimum level of formic acid were specified. An operating envelope that includes the maximum total formate level and the minimum nitrate levels, was also proposed. 5 refs., 3 figs., 4 tabs.

  18. Temperature control system for liquid-fed ceramic melters

    SciTech Connect

    Westsik, J.H. Jr.

    1986-10-01

    A temperature-feedback system has been developed for controlling electrical power to liquid-fed ceramic melters (LFCM). Software, written for a microcomputer-based data acquisition and process monitoring system, compares glass temperatures with a temperature setpoint and adjusts the electrical power accordingly. Included in the control algorithm are steps to reject failed thermocouples, spatially average the glass temperatures, smooth the averaged temperatures over time using a digital filter, and detect foaming in the glass. The temperature control system has proved effective during all phases of melter operation including startup, steady operation, loss of feed, and shutdown. This system replaces current, power, and resistance feedback control systems used previously in controlling the LFCM process.

  19. Remote Fiber Laser Cutting System for Dismantling Glass Melter - 13071

    SciTech Connect

    Mitsui, Takashi; Miura, Noriaki; Oowaki, Katsura; Kawaguchi, Isao; Miura, Yasuhiko; Ino, Tooru

    2013-07-01

    Since 2008, the equipment for dismantling the used glass melter has been developed in High-level Liquid Waste (HLW) Vitrification Facility in the Japanese Rokkasho Reprocessing Plant (RRP). Due to the high radioactivity of the glass melter, the equipment requires a fully-remote operation in the vitrification cell. The remote fiber laser cutting system was adopted as one of the major pieces of equipment. An output power of fiber laser is typically higher than other types of laser and so can provide high-cutting performance. The fiber laser can cut thick stainless steel and Inconel, which are parts of the glass melter such as casings, electrodes and nozzles. As a result, it can make the whole of the dismantling work efficiently done for a shorter period. Various conditions of the cutting test have been evaluated in the process of developing the remote fiber cutting system. In addition, the expected remote operations of the power manipulator with the laser torch have been fully verified and optimized using 3D simulations. (authors)

  20. Advanced Mixed Waste Treatment Project melter system preliminary design technical review meeting

    SciTech Connect

    Eddy, T.L.; Raivo, B.D.; Soelberg, N.R.; Wiersholm, O.

    1995-02-01

    The Idaho National Engineering Laboratory Advanced Mixed Waste Treatment Project sponsored a plasma are melter technical design review meeting to evaluate high-temperature melter system configurations for processing heterogeneous alpha-contaminated low-level radioactive waste (ALLW). Thermal processing experts representing Department of Energy contractors, the Environmental Protection Agency, and private sector companies participated in the review. The participants discussed issues and evaluated alternative configurations for three areas of the melter system design: plasma torch melters and graphite arc melters, offgas treatment options, and overall system configuration considerations. The Technical Advisory Committee for the review concluded that graphite arc melters are preferred over plasma torch melters for processing ALLW. Initiating involvement of stakeholders was considered essential at this stage of the design. For the offgas treatment system, the advisory committee raised the question whether to a use wet-dry or a dry-wet system. The committee recommended that the waste stream characterization, feed preparation, and the control system are essential design tasks for the high-temperature melter treatment system. The participants strongly recommended that a complete melter treatment system be assembled to conduct tests with nonradioactive surrogate waste material. A nonradioactive test bed would allow for inexpensive design and operational changes prior to assembling a system for radioactive waste treatment operations.

  1. Application of artificial intelligence to melter control: Realtime process advisor for the scale melter facility

    SciTech Connect

    Edwards, Jr, R E

    1988-01-01

    The Defense Waste Processing Facility (DWPF) at the Savannah River Plant (SRP) is currently under construction and when completed will process high-level radioactive waste into a borosilicate glass wasteform. This facility will consist of numerous batch chemical processing steps as well as the continuous operation of a joule-heated melter and its off-gas treatment system. A realtime process advisor system based on Artificial Intelligence (AI) techniques has been developed and is currently in use at the semiworks facility, which is operating a 2/3 scale of the DWPF joule-heated melter. The melter advisor system interfaces to the existing data collection and control system and monitors current operations of this facility. The advisor then provides advice to operators and engineers when it identifies process problems. The current system is capable of identifying process problems such as feed system pluggages and thermocouple failures and providing recommended actions. The system also provides facilities normally with distributed control systems. These include the ability to display process flowsheets, monitor alarm conditions, and check the status of process interlocks. 7 figs.

  2. Preliminary melter performance assessment report

    SciTech Connect

    Elliott, M.L.; Eyler, L.L.; Mahoney, L.A.; Cooper, M.F.; Whitney, L.D.; Shafer, P.J.

    1994-08-01

    The Melter Performance Assessment activity, a component of the Pacific Northwest Laboratory`s (PNL) Vitrification Technology Development (PVTD) effort, was designed to determine the impact of noble metals on the operational life of the reference Hanford Waste Vitrification Plant (HWVP) melter. The melter performance assessment consisted of several activities, including a literature review of all work done with noble metals in glass, gradient furnace testing to study the behavior of noble metals during the melting process, research-scale and engineering-scale melter testing to evaluate effects of noble metals on melter operation, and computer modeling that used the experimental data to predict effects of noble metals on the full-scale melter. Feed used in these tests simulated neutralized current acid waste (NCAW) feed. This report summarizes the results of the melter performance assessment and predicts the lifetime of the HWVP melter. It should be noted that this work was conducted before the recent Tri-Party Agreement changes, so the reference melter referred to here is the Defense Waste Processing Facility (DWPF) melter design.

  3. Evaluation Pilot-Scale Melter Systems for the Direct Vitrification Development Program

    SciTech Connect

    Mc Cray, Casey William; Thomson, Troy David

    2001-09-01

    This report documents the results of an evaluation conducted to identify a joule-heated melter system that could be installed in the Idaho Falls area in support of the Direct Vitrification Development Program. The relocation was to be completed by January 1, 2002, within a total budget of one million dollars. Coordination with the Department of Energy Tanks Focus Area identified five melters or melter systems that could potentially support the Direct Vitrification Development Program. Each unit was inspected and evaluated based on qualitative criteria such as availability, completeness of the system, contamination, scalability, materials of construction, facility requirements, and any unique features.

  4. DWPF corrosion study

    SciTech Connect

    Selby, C.L.

    1986-12-17

    Corrosion of candidate alloys for the DWPF SRAT, SME, and melter was tested in the large (1/3 scale) SRAT/SME, the 200th scale SRAT/SME, and the LSFM. Flat or twisted coupons with or without a weld bead and U-bend specimens (specimens bent into a ''U'' shape and bolted together at the ends to stress the bend area) were installed on racks that ensured electrical isolation to avoid galvanic effects. Teflon/reg sign/ washers isolated the low temperature exposure racks and ceramic washers isolated the high temperature exposure racks. Serrated washers simulated crevices, but crevice corrosion did not result. 9 refs., 9 tabs.

  5. Characterization of and waste acceptance radionuclide to be reported for the 2nd macro-batch of high-level waste sludge being vitrified in the DWPF melter

    SciTech Connect

    Fellinger, T.L.

    2000-01-26

    The Defense Waste Processing Facility (DWPF), at the Savannah River Site (SRS), is currently processing the second million gallon batch (Macro-Batch 2) of radioactive sludge slurry into a durable borosilicate glass for permanent geological disposal. To meet the reporting requirements as specified in the Department of Energy's Waste Acceptance Product Specifications (WAPS), for the final glass product, the nonradioactive and radioactive compositions must be provided for a Macro-Batch of material. In order to meet this requirement, sludge slurry samples from Macro-Batch 2 were analyzed in the Shielded Cells Facility of the Savannah River Technology Center (SRTC). This information is used to complete the necessary Production Records at DWPF so that the final glass product, resulting from Macro Batch 2, may be disposed of at a Federal Repository. This paper describes the results obtained from the analyses of the sludge slurry samples taken from Macro-Batch 2 to meet the reporting requirements of the WAPS. Twenty eight elements were identified for the nonradioactive composition and thirty one for the radioactive composition. The reportable radioisotopes range from C-14 to Cm-246.

  6. Final Report - Engineering Study for DWPF Bubblers, VSL-10R1770-1, Rev. 0, dated 12/22/10

    SciTech Connect

    Kruger, Albert A.; Joseph, I.; Matlack, K. S.; Kot, W. K.; Diener, G. A.; Pegg, I. L.; Callow, R. A.

    2013-11-13

    The objective of this work was to perform an engineering assessment of the impact of implementation of bubblers to improve mixing of the glass pool, and thereby increase throughput, in the Defense Waste Processing Facility (DWPF) on the melter and off-gas system. Most of the data used for this evaluation were from extensive melter tests performed on non-SRS feeds. This information was supplemented by more recent results on SRS HLW simulants that were tested on a melter system at VSL under contracts from ORP and SRR. Per the work scope, the evaluation focused on the following areas: Glass production rate; Corrosion of melter components; Power requirements; Pouring stability; Off-gas characteristics; Safety and flammability.

  7. Investigation of corrosion experienced in a spray calciner/ceramic melter vitrification system

    SciTech Connect

    Dierks, R.D.; Mellinger, G.B.; Miller, F.A.; Nelson, T.A.; Bjorklund, W.J.

    1980-08-01

    After periodic testing of a large-scale spray calciner/ceramic melter vitrification system over a 2-yr period, sufficient corrosion was noted on various parts of the vitrification system to warrant its disassembly and inspection. A majority of the 316 SS sintered metal filters on the spray calciner were damaged by chemical corrosion and/or high temperature oxidation. Inconel-601 portions of the melter lid were attacked by chlorides and sulfates which volatilized from the molten glass. The refractory blocks, making up the walls of the melter, were attacked by the waste glass. This attack was occurring when operating temperatures were >1200/sup 0/C. The melter floor was protected by a sludge layer and showed no corrosion. Corrosion to the Inconel-690 electrodes was minimal, and no corrosion was noted in the offgas treatment system downstream of the sintered metal filters. It is believed that most of the melter corrosion occurred during one specific operating period when the melter was operated at high temperatures in an attempt to overcome glass foaming behavior. These high temperatures resulted in a significant release of volatile elements from the molten glass, and also created a situation where the glass was very fluid and convective, which increased the corrosion rate of the refractories. Specific corrosion to the calciner components cannot be proven to have occurred during a specific time period, but the mechanisms of attack were all accelerated under the high-temperature conditions that were experienced with the melter. A review of the materials of construction has been made, and it is concluded that with controlled operating conditions and better protection of some materials of construction corrosion of these systems will not cause problems. Other melter systems operating under similar strenuous conditions have shown a service life of 3 yr.

  8. DWPF MATERIALS EVALUATION SUMMARY REPORT

    SciTech Connect

    Gee, T.; Chandler, G.; Daugherty, W.; Imrich, K.; Jankins, C.

    1996-09-12

    To better ensure the reliability of the Defense Waste Processing Facility (DWPF) remote canyon process equipment, a materials evaluation program was performed as part of the overall startup test program. Specific test programs included FA-04 ('Process Vessels Erosion/Corrosion Studies') and FA-05 (melter inspection). At the conclusion of field testing, Test Results Reports were issued to cover the various test phases. While these reports completed the startup test requirements, DWPF-Engineering agreed to compile a more detailed report which would include essentially all of the materials testing programs performed at DWPF. The scope of the materials evaouation programs included selected equipment from the Salt Process Cell (SPC), Chemical Process Cell (CPC), Melt Cell, Canister Decon Cell (CDC), and supporting facilities. The program consisted of performing pre-service baseline inspections (work completed in 1992) and follow-up inspections after completion of the DWPF cold chemical runs. Process equipment inspected included: process vessels, pumps, agitators, coils, jumpers, and melter top head components. Various NDE (non-destructive examination) techniques were used during the inspection program, including: ultrasonic testing (UT), visual (direct or video probe), radiography, penetrant testing (PT), and dimensional analyses. Finally, coupon racks were placed in selected tanks in 1992 for subsequent removal and corrosion evaluation after chemical runs.

  9. DWPF Sample Vial Insert Study-Statistical Analysis of DWPF Mock-Up Test Data

    SciTech Connect

    Harris, S.P.

    1997-09-18

    This report is prepared as part of Technical/QA Task Plan WSRC-RP-97-351 which was issued in response to Technical Task Request HLW/DWPF/TTR-970132 submitted by DWPF. Presented in this report is a statistical analysis of DWPF Mock-up test data for evaluation of two new analytical methods which use insert samples from the existing HydragardTM sampler. The first is a new hydrofluoric acid based method called the Cold Chemical Method (Cold Chem) and the second is a modified fusion method.Either new DWPF analytical method could result in a two to three fold improvement in sample analysis time.Both new methods use the existing HydragardTM sampler to collect a smaller insert sample from the process sampling system. The insert testing methodology applies to the DWPF Slurry Mix Evaporator (SME) and the Melter Feed Tank (MFT) samples.The insert sample is named after the initial trials which placed the container inside the sample (peanut) vials. Samples in small 3 ml containers (Inserts) are analyzed by either the cold chemical method or a modified fusion method. The current analytical method uses a HydragardTM sample station to obtain nearly full 15 ml peanut vials. The samples are prepared by a multi-step process for Inductively Coupled Plasma (ICP) analysis by drying, vitrification, grinding and finally dissolution by either mixed acid or fusion. In contrast, the insert sample is placed directly in the dissolution vessel, thus eliminating the drying, vitrification and grinding operations for the Cold chem method. Although the modified fusion still requires drying and calcine conversion, the process is rapid due to the decreased sample size and that no vitrification step is required.A slurry feed simulant material was acquired from the TNX pilot facility from the test run designated as PX-7.The Mock-up test data were gathered on the basis of a statistical design presented in SRT-SCS-97004 (Rev. 0). Simulant PX-7 samples were taken in the DWPF Analytical Cell Mock

  10. Draft letter report: Evaluation of the adaptability of the DWPF feed preparation system to the HWVP

    SciTech Connect

    Jones, E.O.; Peterson, M.E.

    1996-03-01

    This report evaluates the performance of the Defense Waste Processing Facility (DWPF) feed preparation System using Hanford Waste Vitrification Plant (HWVP) process criteria and feed properties. Included is a proposed test plan to verify performance of the equipment identified in the evaluation. The HWVP is being designed to vitrify high-level liquid defense waste currently stored in double shell tanks on the Hanford site. The following sections describe the background and objectives and the approach used in this evaluation.

  11. Tunable molten oxide pool assisted plasma-melter vitrification systems

    DOEpatents

    Titus, Charles H.; Cohn, Daniel R.; Surma, Jeffrey E.

    1998-01-01

    The present invention provides tunable waste conversion systems and apparatus which have the advantage of highly robust operation and which provide complete or substantially complete conversion of a wide range of waste streams into useful gas and a stable, nonleachable solid product at a single location with greatly reduced air pollution to meet air quality standards. The systems provide the capability for highly efficient conversion of waste into high quality combustible gas and for high efficiency conversion of the gas into electricity by utilizing a high efficiency gas turbine or an internal combustion engine. The solid product can be suitable for various commercial applications. Alternatively, the solid product stream, which is a safe, stable material, may be disposed of without special considerations as hazardous material. In the preferred embodiment, the arc plasma furnace and joule heated melter are formed as a fully integrated unit with a common melt pool having circuit arrangements for the simultaneous independently controllable operation of both the arc plasma and the joule heated portions of the unit without interference with one another. The preferred configuration of this embodiment of the invention utilizes two arc plasma electrodes with an elongated chamber for the molten pool such that the molten pool is capable of providing conducting paths between electrodes. The apparatus may additionally be employed with reduced use or without further use of the gases generated by the conversion process. The apparatus may be employed as a net energy or net electricity producing unit where use of an auxiliary fuel provides the required level of electricity production. Methods and apparatus for converting metals, non-glass forming waste streams and low-ash producing inorganics into a useful gas are also provided. The methods and apparatus for such conversion include the use of a molten oxide pool having predetermined electrical, thermal and physical

  12. Vitrification melter study

    SciTech Connect

    Jones, J.A.

    1995-04-01

    This report presents the results of a study performed to identify the most promising vitrification melter technologies that the Department of Energy (EM-50) might pursue with available funding. The primary focus was on plasma arc systems and graphite arc melters. The study was also intended to assist EM-50 in evaluating competing technologies, formulating effective technology strategy, developing focused technology development projects, and directing the work of contractors involved in vitrification melter development.

  13. Characteristics of dioxins and metals emission from radwaste plasma arc melter system.

    PubMed

    Yang, Hee-Chul; Kim, Joon-Hyung

    2004-11-01

    This study investigated the emission characteristics of PCDD/Fs and the partitioning of three heavy metals (Cd, Hg and Pb) and two radioactive metal surrogates (Co and Cs) in a radwaste plasma arc melter system. Typical mixtures of low-level radioactive wastes were simulated as the trial burn surrogate wastes. The emission of PCDD/Fs and the partitioning of the metals were strongly influenced by the feed waste stream and melter operating temperature, respectively. The emissions of PCDD/Fs, cadmium and lead were greatly enhanced when the polyvinyl chloride was included in the feed waste stream. Most of the nonvolatile cobalt partitioned into the glass. A significant quantity of cesium, cadmium and lead was vaporized during the highest melter temperature test. A lower melter temperature resulted in more cesium, cadmium and lead species remaining in the glass. The results of this study suggest that wet scrubbing as well as a low-temperature two-step fine filtration, or both of them together could not effectively capture the gas-phase or fine particle phase PCDD/Fs and mercury species. In order to effectively treat low-level radioactive waste streams, the tested high-temperature melter should include an adsorption system, which could collect the gas-phase PCDD/Fs and mercury species. PMID:15331269

  14. Maximum organic carbon limits at different melter feed rates (U)

    SciTech Connect

    Choi, A.S.

    1995-12-31

    This report documents the results of a study to assess the impact of varying melter feed rates on the maximum total organic carbon (TOC) limits allowable in the DWPF melter feed. Topics discussed include: carbon content; feed rate; feed composition; melter vapor space temperature; combustion and dilution air; off-gas surges; earlier work on maximum TOC; overview of models; and the results of the work completed.

  15. DWPF Macrobatch 2 Melt Rate Tests

    SciTech Connect

    Stone, M.E.

    2001-01-03

    The Defense Waste Processing Facility (DWPF) canister production rate must be increased to meet canister production goals. Although a number of factors exist that could potentially increase melt rate, this study focused on two: (1) changes in frit composition and (2) changes to the feed preparation process to alter the redox of the melter feed. These two factors were investigated for Macrobatch 2 (sludge batch 1B) utilizing crucible studies and a specially designed ''melt rate'' furnace. Other potential factors that could increase melt rate include: mechanical mixing via stirring or the use of bubblers, changing the power skewing to redistribute the power input to the melter, and elimination of heat loss (e.g. air in leakage). The melt rate testing in FY00 demonstrated that melt rate can be improved by adding a different frit or producing a much more reducing glass by the addition of sugar as a reductant. The frit that melted the fastest in the melt rate testing was Frit 165. A paper stud y was performed using the Product Composition Control System (PCCS) to determine the impact on predicted glass viscosity, liquidus, durability, and operating window if the frit was changed from Frit 200 to Frit 165. PCCS indicated that the window was very similar for both frits. In addition, the predicted viscosity of the frit 165 glass was 46 poise versus 84 poise for the Frit 200 glass. As a result, a change from Frit 200 to Frit 165 is expected to increase the melt rate in DWPF without decreasing waste loading.

  16. Selection of melter systems for the DOE/Industrial Center for Waste Vitrification Research

    SciTech Connect

    Bickford, D.F.

    1993-12-31

    The EPA has designated vitrification as the best developed available technology for immobilization of High-Level Nuclear Waste. In a recent federal facilities compliance agreement between the EPA, the State of Washington, and the DOE, the DOE agreed to vitrify all of the Low Level Radioactive Waste resulting from processing of High Level Radioactive Waste stored at the Hanford Site. This is expected to result in the requirement of 100 ton per day Low Level Radioactive Waste melters. Thus, there is increased need for the rapid adaptation of commercial melter equipment to DOE`s needs. DOE has needed a facility where commercial pilot scale equipment could be operated on surrogate (non-radioactive) simulations of typical DOE waste streams. The DOE/Industry Center for Vitrification Research (Center) was established in 1992 at the Clemson University Department of Environmental Systems Engineering, Clemson, SC, to address that need. This report discusses some of the characteristics of the melter types selected for installation of the Center. An overall objective of the Center has been to provide the broadest possible treatment capability with the minimum number of melter units. Thus, units have been sought which have broad potential application, and which had construction characteristics which would allow their adaptation to various waste compositions, and various operating conditions, including extreme variations in throughput, and widely differing radiological control requirements. The report discusses waste types suitable for vitrification; technical requirements for the application of vitrification to low level mixed wastes; available melters and systems; and selection of melter systems. An annotated bibliography is included.

  17. Control Loop Tuning and Surge Response for Hanford WTP Melter Offgas Systems

    SciTech Connect

    SMITH, FG III

    2004-06-14

    This report describes control loop tuning in models of the high level waste (HLW) melter offgas system, the low activity waste (LAW) melter offgas system and the HLW Pulse Jet Ventilation system and an assessment of the response to steam surges in both melter offgas systems. The three offgas systems were modeled using the Aspen Custom Modeler (ACM) software. The ACM models have been recently updated. Flowsheets of the system models used in this study are provided in Appendix D. To facilitate testing, these flowsheets represent somewhat simplified versions of the full models. For example, the HLW and LAW vessel ventilation systems have been represented as fixed air sources that provide a constant gas flow and specified air surges. Similarly, the six tanks and individual pulse-jet air sources in the HLW Pulse Jet Ventilation system are represented as a constant air source for control loop tuning purposes. The second LAW melter system has also been represented as a constant flow air source and several other simplifications such as removing HLW and LAW control interlocks, submerged bed scrubber bypass lines, and pressure relief valves have been made.

  18. DATA PACKET FOR THE FRIT 202-A11 SB3 GLASS SYSTEM A CANDIDATE FOR THE COLD CRUCIBLE INDUCTION MELTER DEMONSTRATION

    SciTech Connect

    Peeler, D; Kevin Fox, K; Tommy Edwards, T; David Best, D; Irene Reamer, I; Phyllis Workman, P

    2007-06-13

    A demonstration of the Cold Crucible Induction Melter (CCIM) technology is currently planned for the fall of 2007 to assess the potential for attaining higher waste throughputs as compared to joule heated melter technology. The CCIM demonstrations will be based on a Defense Waste Processing Facility (DWPF) waste slurry feed surrogate with a nominal operating temperature of approximately 1250 C (higher temperatures may be used). The waste slurry feed (nominally 45-50 weight percent solids) surrogate will be representative of Sludge Batch 3 (SB3) in order to allow a direct comparison to the DWPF joule heated melter performance during processing of this sludge waste. This pilot scale demonstration is being conducted to evaluate performance and to identify potential processing issues with the existing CCIM technology, and it will include characterization of the resultant glass product to ensure current product performance (durability) specifications are met. The information presented in this data packet provides a technical basis from which decisions regarding the melter demonstration can be made. More specifically, the results presented in this report provide technical data on the impact of waste loading (WL) on critical properties of interest--in particular, durability, liquidus temperature, and viscosity. All of the glasses of this study, regardless of heat treatment, were acceptable when their durabilities were compared to those of the Environmental Assessment (EA) glass. In general, as WL increases, the durabilities for the quenched versions of the glasses tend to decrease due to the changing composition of the glass. For the glasses subjected to the canister centerline cooling (ccc) regime, the durability response appears to be more non-linear as WL increases. At WLs less than 50%, X-ray diffraction (XRD) analysis indicates the potential for the presence of aegirine and/or nepheline crystalline phases, and when these phases are present, there is a decrease in the

  19. Durability of glasses vitrified from high copper feed in the 774 Research Melter

    SciTech Connect

    Andrews, M.K.

    1993-04-28

    Small scale crucible studies were performed by Schumacher to examine the effects of formate and nitrate on glass redox at high copper levels. The results of the crucible studies were used to determine the regions where copper precipitates in the glass. However, durability tests were not performed on the glass samples. Studies were performed in the 774 Research Melter using a simulated feed from the Purex 4 Campaign in the Integrated DWPF Melter System (IDMS). Three runs were performed with this simulated feed. The first used the feed as it was received to determine a baseline. The results from the second and third campaigns were compared to the baseline. The second run increased the copper concentration. The third increased the copper and formate concentrations. The purpose of these experiments was to investigate melter performance and glass durability using a feed with increased copper concentration. The Purex 4 feed did not contain the target amounts of sludge and Precipitate Hydrolysis Aqueous (PHA). Less than 20% of the feed slurry consisted of simulated sludge, making it a low waste-loading feed. The use of this feed with significantly more copper added than anticipated in the DWPF, showed no indication of copper precipitating in the melter. In addition, the glasses produced during the campaigns were more durable than the benchmark glass.

  20. Analysis of cascade impactor and EPA method 29 data from the americium/curium pilot melter system

    SciTech Connect

    Zamecnik, J.R.

    1997-11-01

    The offgas system of the Am/Cm pilot melter at TNX was characterized by measuring the particulate evolution using a cascade impactor and EPA Method 29. This sampling work was performed by John Harden of the Clemson Environmental Technologies Laboratory, under SCUREF Task SC0056. Elemental analyses were performed by the SRTC Mobile Laboratory.Operation of the Am/Cm melter with B2000 frit has resulted in deposition of PbO and boron compounds in the offgas system that has contributed to pluggage of the High Efficiency Mist Eliminator (HEME). Sampling of the offgas system was performed to quantify the amount of particulate in the offgas system under several sets of conditions. Particulate concentration and particle size distribution were measured just downstream of the melter pressure control air addition port and at the HEME inlet. At both locations, the particulate was measured with and without steam to the film cooler while the melter was idled at about 1450 degrees Celsius. Additional determinations were made at the melter location during feeding and during idling at 1150 degrees Celsius rather than 1450 degrees Celsius (both with no steam to the film cooler). Deposition of particulates upstream of the melter sample point may have, and most likely did occur in each run, so the particulate concentrations measured do no necessarily reflect the total particulate emission at the melt surface. However, the data may be used in a relative sense to judge the system performance.

  1. SCIX IMPACT ON DWPF CPC

    SciTech Connect

    Koopman, D.

    2011-07-14

    A program was conducted to systematically evaluate potential impacts of the proposed Small Column Ion Exchange (SCIX) process on the Defense Waste Processing Facility (DWPF) Chemical Processing Cell (CPC). The program involved a series of interrelated tasks. Past studies of the impact of crystalline silicotitanate (CST) and monosodium titanate (MST) on DWPF were reviewed. Paper studies and material balance calculations were used to establish reasonable bounding levels of CST and MST in sludge. Following the paper studies, Sludge Batch 10 (SB10) simulant was modified to have both bounding and intermediate levels of MST and ground CST. The SCIX flow sheet includes grinding of the CST which is larger than DWPF frit when not ground. Nominal ground CST was not yet available, therefore a similar CST ground previously in Savannah River National Laboratory (SRNL) was used. It was believed that this CST was over ground and that it would bound the impact of nominal CST on sludge slurry properties. Lab-scale simulations of the DWPF CPC were conducted using SB10 simulants with no, intermediate, and bounding levels of CST and MST. Tests included both the Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME) cycles. Simulations were performed at high and low acid stoichiometry. A demonstration of the extended CPC flowsheet was made that included streams from the site interim salt processing operations. A simulation using irradiated CST and MST was also completed. An extensive set of rheological measurements was made to search for potential adverse consequences of CST and MST and slurry rheology in the CPC. The SCIX CPC impact program was conducted in parallel with a program to evaluate the impact of SCIX on the final DWPF glass waste form and on the DWPF melter throughput. The studies must be considered together when evaluating the full impact of SCIX on DWPF. Due to the fact that the alternant flowsheet for DWPF has not been selected, this study did not

  2. The integrated melter off-gas treatment systems at the West Valley Demonstration Project

    SciTech Connect

    Vance, R.F.

    1991-12-01

    The West Valley Demonstration project was established by an act of Congress in 1980 to solidify the high level radioactive liquid wastes produced from operation of the Western New York Nuclear Services Center from 1966 to 1972. The waste will be solidified as borosilicate glass. This report describes the functions, the controlling design criteria, and the resulting design of the melter off-gas treatment systems.

  3. Impact Of Melter Internal Design On Off-Gas Flammability

    SciTech Connect

    Choi, A. S.; Lee, S. Y.

    2012-05-30

    The purpose of this study was to: (1) identify the more dominant design parameters that can serve as the quantitative measure of how prototypic a given melter is, (2) run the existing DWPF models to simulate the data collected using both DWPF and non-DWPF melter configurations, (3) confirm the validity of the selected design parameters by determining if the agreement between the model predictions and data is reasonably good in light of the design and operating conditions employed in each data set, and (4) run Computational Fluid Dynamics (CFD) simulations to gain new insights into how fluid mixing is affected by the configuration of melter internals and to further apply the new insights to explaining, for example, why the agreement is not good.

  4. Vitrification of simulated radioactive Rocky Flats plutonium containing ash residue with a Stir Melter System

    SciTech Connect

    Marra, J.C.; Kormanyos, K.R.; Overcamp, T.J.

    1996-10-01

    A demonstration trial has been completed in which a simulated Rocky Flats ash consisting of an industrial fly-ash material doped with cerium oxide was vitrified in an alloy tank Stir-Melter{trademark} System. The cerium oxide served as a substitute for plutonium oxide present in the actual Rocky Flats residue stream. The glass developed falls within the SiO{sub 2} + Al{sub 2}O{sub 3}/{Sigma}Alkali/B{sub 2}O{sub 3} system. The glass batch contained approximately 40 wt% of ash, the ash was modified to contain {approximately} 5 wt% CeO{sub 2} to simulate plutonium chemistry in the glass. The ash simulant was mixed with water and fed to the Stir-Melter as a slurry with a 60 wt% water to 40 wt% solids ratio. Glass melting temperature was maintained at approximately 1,050 C during the melting trials. Melting rates as functions of impeller speed and slurry feed rate were determined. An optimal melting rate was established through a series of evolutionary variations of the control variables` settings. The optimal melting rate condition was used for a continuous six hour steady state run of the vitrification system. Glass mass flow rates of the melter were measured and correlated with the slurry feed mass flow. Melter off-gas was sampled for particulate and volatile species over a period of four hours during the steady state run. Glass composition and durability studies were run on samples collected during the steady state run.

  5. CALCULATION OF DEMONSTRATION BULK VITRIFICATION SYSTEM MELTER INLEAKAGE AND OFF-GAS GENERATION RATE

    SciTech Connect

    MAY TH

    2008-04-16

    The River Protection Project (RPP) mission is to safely store, retrieve, treat, immobilize, and dispose of the Hanford Site tank waste. The Demonstration Bulk Vitrification System (DBVS) is a research and development project whose objective is to demonstrate the suitability of Bulk Vitrification treatment technology waste form for disposing of low-activity waste from the Tank Farms. The objective of this calculation is to determine the DBVS melter inleakage and off-gas generation rate based on full scale testing data from 38D. This calculation estimates the DBVS melter in leakage and gas generation rate based on test data. Inleakage is estimated before the melt was initiated, at one point during the melt, and at the end of the melt. Maximum gas generation rate is also estimated.

  6. LFCM (liquid-fed eramic melter) emission and off-gas system performance for feed component cesium

    SciTech Connect

    Goles, R.W.; Andersen, C.M.

    1986-09-01

    Except for volatile off-gas effluents, overall adequacy of the liquid-fed ceramic melter (LFCM) system depends most upon its effectiveness in dealing with cesium. However, the mechanism responsible for melter cesium losses has proved insensitive to many LFCM operating and processing conditions. As a result, variations in inleakage, plenum temperature, feeding rate and waste loading do not significantly influence melter cesium performance. Feed composition, specifically halogen content, is the only processing variable that has had a significant effect. Due to the submicron nature of LFCM-generated aerosols, melter disengagement design features are not expected to be particularly effective in reducing cesium emission rates. For the same reason, the cesium performance of conventional quench scrubbers is quite low, being dependent only upon the magnitude of melter entrainment losses. Although a deep bed washable filter has been effective in removing submicron aerosols from the process exhaust, high performance has only been achieved under dry operating conditions. The melter's idling state does not appear to place additional demands upon the off-gas treatment system.

  7. DWPF Development Plan. Revision 1

    SciTech Connect

    Holtzscheiter, E.W.

    1994-05-09

    The DWPF Development Plan is based on an evaluation process flowsheet and related waste management systems. The scope is shown in Figure 1 entitled ``DWPF Process Development Systems.`` To identify the critical development efforts, each system has been analyzed to determine: The identification of unresolved technology issues. A technology issue (TI) is one that requires basic development to resolve a previously unknown process or equipment problem and is managed via the Technology Assurance Program co-chaired by DWPF and SRTC. Areas that require further work to sufficiently define the process basis or technical operating envelop for DWPF. This activity involves the application of sound engineering and development principles to define the scope of work required to complete the technical data. The identification of the level of effort and expertise required to provide process technical consultation during the start-up and demonstration of this first of a kind plant.

  8. Melter Dismantlement

    SciTech Connect

    Richardson, BS

    2000-10-01

    The U.S. Department of Energy (DOE) has been utilizing vitrification processes to convert high-level radioactive waste forms into a stable glass for disposal in waste repositories. Vitrification facilities at the Savannah River Site (SRS) and at the West Valley Demonstration Project (WVDP) are converting liquid high level waste (HLW) by combining it with a glass-forming media to form a borosilicate glass, which will ensure safe long-term storage. Large, slurry fed melters, which are utilized for this process, were anticipated to have a finite life, on the order of two to three years, at which time they would have to be replaced using remote methods, due to the high radiation fields. In actuality the melters useable life span has, to date, have exceeded original life span estimates. Initial plans called for the removal of failed melters by placing the melter assembly into a container and storing in a concrete vault on the vitrification plant site pending size reduction, segregation, containerization, and shipment to appropriate storage facilities. Separate facilities for the processing of the failed melters currently do not exist. Options for handling these melters include (1) locating a facility to conduct the size reduction, characterization, and containerization as originally planned; (2) long-term storage or disposal of the complete melter assembly; and (3) attempting to refurbish the melter and to reuse the melter assembly. The focus of this report is to look at methods and issues pertinent to size reduction and/or melter refurbishment. In particular, removal of glass as a part of a refurbishment or for the purposes of reducing contamination levels (allowing for disposal of a greater proportion of the melter as low level waste) will be addressed.

  9. DWPF RECYCLE EVAPORATOR FLOWSHEET EVALUATION (U)

    SciTech Connect

    Stone, M

    2005-04-30

    The Defense Waste Processing Facility (DWPF) converts the high level waste slurries stored at the Savannah River Site into borosilicate glass for long-term storage. The vitrification process results in the generation of approximately five gallons of dilute recycle streams for each gallon of waste slurry vitrified. This dilute recycle stream is currently transferred to the H-area Tank Farm and amounts to approximately 1,400,000 gallons of effluent per year. Process changes to incorporate salt waste could increase the amount of effluent to approximately 2,900,000 gallons per year. The recycle consists of two major streams and four smaller streams. The first major recycle stream is condensate from the Chemical Process Cell (CPC), and is collected in the Slurry Mix Evaporator Condensate Tank (SMECT). The second major recycle stream is the melter offgas which is collected in the Off Gas Condensate Tank (OGCT). The four smaller streams are the sample flushes, sump flushes, decon solution, and High Efficiency Mist Eliminator (HEME) dissolution solution. These streams are collected in the Decontamination Waste Treatment Tank (DWTT) or the Recycle Collection Tank (RCT). All recycle streams are currently combined in the RCT and treated with sodium nitrite and sodium hydroxide prior to transfer to the tank farm. Tank Farm space limitations and previous outages in the 2H Evaporator system due to deposition of sodium alumino-silicates have led to evaluation of alternative methods of dealing with the DWPF recycle. One option identified for processing the recycle was a dedicated evaporator to concentrate the recycle stream to allow the solids to be recycled to the DWPF Sludge Receipt and Adjustment Tank (SRAT) and the condensate from this evaporation process to be sent and treated in the Effluent Treatment Plant (ETP). In order to meet process objectives, the recycle stream must be concentrated to 1/30th of the feed volume during the evaporation process. The concentrated stream

  10. REAL WASTE TESTING OF SLUDGE BATCH 5 MELTER FEED RHEOLOGY

    SciTech Connect

    Reboul, S.; Stone, M.

    2010-03-17

    Clogging of the melter feed loop at the Defense Waste Processing Facility (DWPF) has reduced the throughput of Sludge Batch 5 (SB5) processing. After completing a data review, DWPF attributed the clogging to the rheological properties of the Slurry Mix Evaporator (SME) project. The yield stress of the SB5 melter feed material was expected to be high, based on the relatively high pH of the SME product and the rheological results of a previous Chemical Process Cell (CPC) demonstration performed at the Savannah River National Laboratory (SRNL).

  11. Cold Crucible Induction Melter Testing at The Idaho National Laboratory for the Advanced Remediation Technologies Program

    SciTech Connect

    Jay Roach; Nick Soelberg; Mike Ancho; Eric Tchemitcheff; John Richardson

    2009-03-01

    AREVA Federal Services (AFS) is performing a multi-year, multi-phase Advanced Remediation Technologies (ART) project, sponsored by the U.S. Department of Energy (DOE), to evaluate the feasibility and benefits of replacing the existing joule-heated melter (JHM) used to treat high level waste (HLW) in the Defense Waste Processing Facility (DWPF) at the Savannah River Site with a cold crucible induction melter (CCIM). The AFS ART CCIM project includes several collaborators from AREVA subsidiaries, French companies, and DOE national laboratories. The Savannah River National Laboratory and the Commissariat a l’Energie Atomique (CEA) have performed laboratory-scale studies and testing to determine a suitable, high-waste-loading glass matrix. The Idaho National Laboratory (INL) and CEA are performing CCIM demonstrations at two different pilot scales to assess CCIM design and operation for treating SRS sludge wastes that are currently being treated in the DWPF. SGN is performing engineering studies to validate the feasibility of retrofitting CCIM technology into the DWPF Melter Cell. The long-term project plan includes more lab-testing, pilot- and large-scale demonstrations, and engineering activities to be performed during subsequent project phases. This paper provides preliminary results of tests using the engineering-scale CCIM test system located at the INL. The CCIM test system was operated continuously over a time period of about 58 hours. As the DWPF simulant feed was continuously fed to the melter, the glass level gradually increased until a portion of the molten glass was drained from the melter. The glass drain was operated semi-continuously because the glass drain rate was higher than the glass feedrate. A cold cap of unmelted feed was controlled by adjusting the feedrate and melter power levels to obtain the target molten glass temperatures with varying cold cap levels. Three test conditions were performed per the test plan, during which the melter was

  12. Literature review of arc/plasma, combustion, and joule-heated melter vitrification systems

    SciTech Connect

    Freeman, C.J.; Abrigo, G.P.; Shafer, P.J.; Merrill, R.A.

    1995-07-01

    This report provides reviews of papers and reports for three basic categories of melters: arc/plasma-heated melters, combustion-heated melters, and joule-heated melters. The literature reviewed here represents those publications which may lend insight to phase I testing of low-level waste vitrification being performed at the Hanford Site in FY 1995. For each melter category, information from those papers and reports containing enough information to determine steady-state mass balance data is tabulated at the end of each section. The tables show the composition of the feed processed, the off-gas measured via decontamination factors, gross energy consumptions, and processing rates, among other data.

  13. Operation of Bubblers in the Savannah River Site Defense Waste Processing Facility Melter - 12166

    SciTech Connect

    Hodges, Brandon C.; Iverson, Daniel C.; Diener, Glenn

    2012-07-01

    Savannah River Remediation (SRR) LLC acquired the liquid waste contract at the Savannah River Site (SRS) in the summer of 2009. In order to achieve the main goal of the contract, closing of High Level Waste (HLW) tanks, it was necessary to process more waste throughout the SRS liquid waste facilities. The Defense Waste Processing Facility (DWPF) would need to increase its production rate of radioactive waste glass filled canisters as a part of the plan to achieve this commitment. To attain the increased production rate, four bubblers were installed in the DWPF Melter in September 2010 to agitate the DWPF Melter glass pool. The four bubblers were designed to be installed in existing nozzles on the top-head of the DWPF Melter. The design and fabrication of the four (4) bubblers was accomplished through SRR critical subcontractor EnergySolutions LLC. In addition to the existing bubbler design, a new design concept has been approved and is in the process of fabrication. The new design will allow for the lower end (inside melter) of the bubbler to be replaced while the upper end (outside melter) of the bubbler is reused to minimize cost and waste at the DWPF. The bubblers have been operating in the DWPF Melter for approximately 1 year. The originally installed bubbler set was replaced in January 2011. The bubblers were visually examined once removed from the melter and showed minimal signs of wear. Material testing of the Inconel 690 is being performed to determine if the bubblers operational life can be extended. The use of the bubblers has changed the dynamics within the melter glass pool. This is shown through indications that the bubblers have increased the glass pool circulation. Overall, performance of the bubblers has been encouraging and the DWPF Melter has seen a significant improvement in its ability to process waste since the bubbler installation. The installation of the bubblers accomplished the goal of increasing the glass production capability of DWPF

  14. Characterization of high level nuclear waste glass samples following extended melter idling

    SciTech Connect

    Fox, K.

    2015-06-16

    The Savannah River Site Defense Waste Processing Facility (DWPF) melter was recently idled with glass remaining in the melt pool and riser for approximately three months. This situation presented a unique opportunity to collect and analyze glass samples since outages of this duration are uncommon. The objective of this study was to obtain insight into the potential for crystal formation in the glass resulting from an extended idling period. The results will be used to support development of a crystal-tolerant approach for operation of the high level waste melter at the Hanford Tank Waste Treatment and Immobilization Plant (WTP). Two glass pour stream samples were collected from DWPF when the melter was restarted after idling for three months. The samples did not contain crystallization that was detectible by X-ray diffraction. Electron microscopy identified occasional spinel and noble metal crystals of no practical significance. Occasional platinum particles were observed by microscopy as an artifact of the sample collection method. Reduction/oxidation measurements showed that the pour stream glasses were fully oxidized, which was expected after the extended idling period. Chemical analysis of the pour stream glasses revealed slight differences in the concentrations of some oxides relative to analyses of the melter feed composition prior to the idling period. While these differences may be within the analytical error of the laboratories, the trends indicate that there may have been some amount of volatility associated with some of the glass components, and that there may have been interaction of the glass with the refractory components of the melter. These changes in composition, although small, can be attributed to the idling of the melter for an extended period. The changes in glass composition resulted in a 70-100 °C increase in the predicted spinel liquidus temperature (TL) for the pour stream glass samples relative to the analysis of the melter feed prior to

  15. RECENT PROCESS IMPROVEMENTS TO INCREASE HLW THROUGHPUT AT THE DWPF

    SciTech Connect

    Herman, C

    2007-02-14

    The Savannah River Site's (SRS) Defense Waste Processing Facility (DWPF), the world's largest operating high level waste (HLW) vitrification plant, began stabilizing about 35 million gallons of SRS liquid radioactive waste by-product in 1996. The DWPF has since filled over 2000 canisters with about 4000 pounds of radioactive glass in each canister. In the past few years there have been several process and equipment improvements at the DWPF to increase the rate at which the waste can be stabilized. These improvements have either directly increased waste processing rates or have desensitized the process and therefore minimized process upsets and thus downtime. These improvements, which include glass former optimization, increased waste loading of the glass, the melter heated bellows liner, and glass surge protection software, will be discussed in this paper.

  16. ROLE OF MANGANESE REDUCTION/OXIDATION (REDOX) ON FOAMING AND MELT RATE IN HIGH LEVEL WASTE (HLW) MELTERS (U)

    SciTech Connect

    Jantzen, C; Michael Stone, M

    2007-03-30

    High-level nuclear waste is being immobilized at the Savannah River Site (SRS) by vitrification into borosilicate glass at the Defense Waste Processing Facility (DWPF). Control of the Reduction/Oxidation (REDOX) equilibrium in the DWPF melter is critical for processing high level liquid wastes. Foaming, cold cap roll-overs, and off-gas surges all have an impact on pouring and melt rate during processing of high-level waste (HLW) glass. All of these phenomena can impact waste throughput and attainment in Joule heated melters such as the DWPF. These phenomena are caused by gas-glass disequilibrium when components in the melter feeds convert to glass and liberate gases such as H{sub 2}O vapor (steam), CO{sub 2}, O{sub 2}, H{sub 2}, NO{sub x}, and/or N{sub 2}. During the feed-to-glass conversion in the DWPF melter, multiple types of reactions occur in the cold cap and in the melt pool that release gaseous products. The various gaseous products can cause foaming at the melt pool surface. Foaming should be avoided as much as possible because an insulative layer of foam on the melt surface retards heat transfer to the cold cap and results in low melt rates. Uncontrolled foaming can also result in a blockage of critical melter or melter off-gas components. Foaming can also increase the potential for melter pressure surges, which would then make it difficult to maintain a constant pressure differential between the DWPF melter and the pour spout. Pressure surges can cause erratic pour streams and possible pluggage of the bellows as well. For these reasons, the DWPF uses a REDOX strategy and controls the melt REDOX between 0.09 {le} Fe{sup 2+}/{summation}Fe {le} 0.33. Controlling the DWPF melter at an equilibrium of Fe{sup +2}/{summation}Fe {le} 0.33 prevents metallic and sulfide rich species from forming nodules that can accumulate on the floor of the melter. Control of foaming, due to deoxygenation of manganic species, is achieved by converting oxidized MnO{sub 2} or Mn

  17. Connecting section and associated systems concept for the spray calciner/in-can melter process

    SciTech Connect

    Petkus, L.L.; Gorton, P.S.; Blair, H.T.

    1981-06-01

    For a number of years, researchers at the Pacific Northwest Laboratory have been developing processes and equipment for converting high-level liquid wastes to solid forms. One of these processes is the Spray Calciner/In-Can Melter system. To immobilize high-level liquid wastes, this system must be operated remotely, and the calcine must be reliably conveyed from the calciner to the melting furnace. A concept for such a remote conveyance system was developed at the Pacific Northwest Laboratory, and equipment was tested under full-scale, nonradioactive conditions. This concept and the design of demonstration equipment are described, and the results of equipment operation during experimental runs of 7 d are presented. The design includes a connecting section and its associated systems - a canister sypport and alignment concept and a weight-monitoring system for the melting furnace. Overall, the runs demonstrated that the concept design is an acceptable method of connecting the two pieces of process equipment together. Although the connecting section has not been optimized in all areas of concern, it provides a first-generation design of a production-oriented system.

  18. Design of a mixing system for simulated high-level nuclear waste melter feed slurries

    SciTech Connect

    Peterson, M.E.; McCarthy, D.; Muhlstein, K.D.

    1986-03-01

    The Nuclear Waste Treatment Program development program consists of coordinated nonradioactive and radioactive testing combined with numerical modeling of the process to provide a complete basis for design and operation of a vitrification facility. The radioactive demonstration tests of equipment and processes are conducted before incorporation in radioactive pilot-scale melter systems for final demonstration. The mixing system evaluation described in this report was conducted as part of the nonradioactive testing. The format of this report follows the sequence in which the design of a large-scale mixing system is determined. The initial program activity was concerned with gaining an understanding of the theoretical foundation of non-Newtonian mixing systems. Section 3 of this report describes the classical rheological models that are used to describe non-Newtonian mixing systems. Since the results obtained here are only valid for the slurries utilized, Section 4, Preparation of Simulated Hanford and West Valley Slurries, describes how the slurries were prepared. The laboratory-scale viscometric and physical property information is summarized in Section 5, Laboratory Rheological Evaluations. The bench-scale mixing evaluations conducted to define the effects of the independent variables described above on the degree of mixing achieved with each slurry are described in Section 6. Bench-scale results are scaled-up to establish engineering design requirements for the full-scale mixing system in Section 7. 24 refs., 37 figs., 44 tabs.

  19. FEASIBILITY EVALUATION AND RETROFIT PLAN FOR COLD CRUCIBLE INDUCTION MELTER DEPLOYMENT IN THE DEFENSE WASTE PROCESSING FACILITY AT SAVANNAH RIVER SITE - 8118

    SciTech Connect

    Barnes, A; Dan Iverson, D; Brannen Adkins, B

    2007-11-15

    through a bottom drain, typically through a water-cooled slide valve that starts and stops the pour stream. To promote uniform temperature distribution and increase heat transfer to the slurry fed High Level Waste (HLW) sludge, the CCIM may be equipped with bubblers and/or water cooled mechanical agitators. The DWPF could benefit from use of CCIM technology, especially in light of our latest projections of waste volume to be vitrified. Increased waste loading and increased throughput could result in substantial life cycle cost reduction. In order to significantly surpass the waste throughput capability of the currently installed Joule Heated Melter, it may be necessary to install two 950 mm CCIMs in the DWPF Melt Cell. A cursory evaluation of system design requirements and modifications to the facility that may be required to support installation and operation of two 950 mm CCIMs was performed. Based on this evaluation, it appears technically feasible to position two CCIMs in the Melt Cell of the DWPF within the existing footprint of the current melter. Interfaces with support systems and controls including Melter Feed, Power, Melter Cooling Water, Melter Off-gas, and Canister Operations must be designed to support dual CCIM operations.

  20. Design features of the radioactive Liquid-Fed Ceramic Melter system

    SciTech Connect

    Holton, L.K. Jr.

    1985-06-01

    During 1983, the Pacific Northwest Laboratory (PNL), at the request of the Department of Energy (DOE), undertook a program with the principal objective of testing the Liquid-Fed Ceramic Melter (LFCM) process in actual radioactive operations. This activity, termed the Radioactive LFCM (RLFCM) Operations is being conducted in existing shielded hot-cell facilities in B-Cell of the 324 Building, 300 Area, located at Hanford, Washington. This report summarizes the design features of the RLFCM system. These features include: a waste preparation and feed system which uses pulse-agitated waste preparation tanks for waste slurry agitation and an air displacement slurry pump for transferring waste slurries to the LFCM; a waste vitrification system (LFCM) - the design features, design approach, and reasoning for the design of the LFCM are described; a canister-handling turntable for positioning canisters underneath the RLFCM discharge port; a gamma source positioning and detection system for monitoring the glass fill level of the product canisters; and a primary off-gas treatment system for removing the majority of the radionuclide contamination from the RLFCM off gas. 8 refs., 48 figs., 6 tabs.

  1. Noble Metals and Spinel Settling in High Level Waste Glass Melters

    SciTech Connect

    Sundaram, S. K.; Perez, Joseph M.

    2000-09-30

    In the continuing effort to support the Defense Waste Processing Facility (DWPF), the noble metals issue is addressed. There is an additional concern about the amount of noble metals expected to be present in the future batches that will be considered for vitrification in the DWPF. Several laboratory, as well as melter-scale, studies have been completed by various organizations (mainly PNNL, SRTC, and WVDP in the USA). This letter report statuses the noble metals issue and focuses at the settling of noble metals in melters.

  2. ART CCIM Phase II-A Off-Gas System Evaluation Test Plan

    SciTech Connect

    Nick Soelberg; Jay Roach

    2009-01-01

    This test plan defines testing to be performed using the Idaho National Laboratory (INL) engineering-scale cold crucible induction melter (CCIM) test system for Phase II-A of the Advanced Remediation Technologies (ART) CCIM Project. The multi-phase ART-CCIM Project is developing a conceptual design for replacing the joule-heated melter (JHM) used to treat high level waste (HLW) in the Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS) with a cold crucible induction melter. The INL CCIM test system includes all feed, melter off-gas control, and process control subsystems needed for fully integrated operation and testing. Testing will include operation of the melter system while feeding a non-radioactive slurry mixture prepared to simulate the same type of waste feed presently being processed in the DWPF. Process monitoring and sample collection and analysis will be used to characterize the off-gas composition and properties, and to show the fate of feed constituents, to provide data that shows how the CCIM retrofit conceptual design can operate with the existing DWPF off-gas control system.

  3. (a, n) Neutron Emission from DWPF Glass

    SciTech Connect

    Pellarin, D.J.

    2001-03-23

    In the Defense Waste Processing Facility (DWPF) of Savannah River Plant site waste will be immobilized in borosilicate glass. A knowledge of the neutron emission from DWPF glass is necessary to assess shielding requirements for the DWPF canister and to determine the response characteristics of the Neutron Transmission Glass Level Detection System. Excellent agreement was obtained between measured and calculated neutron emissions (yields) from Pu spiked black frit glasses using West's method of weighting components based on relative stopping power. The calculated values for the three glasses were 2-7 percent higher than measured. Calculations using a Nj Zj weighting method were 19-22 percent lower than measured. The good agreement between measurement and calculation using West's method lends confidence in its use to calculate the neutron source term for DWPF glass.

  4. DWPF GLASS BEADS AND GLASS FRIT TRANSPORT DEMONSTRATION

    SciTech Connect

    Adamson, D; Bradley Pickenheim, B

    2008-11-24

    DWPF is considering replacing irregularly shaped glass frit with spherical glass beads in the Slurry Mix Evaporator (SME) process to decrease the yield stress of the melter feed (a non-Newtonian Bingham Plastic). Pilot-scale testing was conducted on spherical glass beads and glass frit to determine how well the glass beads would transfer when compared to the glass frit. Process Engineering Development designed and constructed the test apparatus to aid in the understanding and impacts that spherical glass beads may have on the existing DWPF Frit Transfer System. Testing was conducted to determine if the lines would plug with the glass beads and the glass frit slurry and what is required to unplug the lines. The flow loop consisted of vertical and horizontal runs of clear PVC piping, similar in geometry to the existing system. Two different batches of glass slurry were tested: a batch of 50 wt% spherical glass beads and a batch of 50 wt% glass frit in process water. No chemicals such as formic acid was used in slurry, only water and glass formers. The glass beads used for this testing were commercially available borosilicate glass of mesh size -100+200. The glass frit was Frit 418 obtained from DWPF and is nominally -45+200 mesh. The spherical glass beads did not have a negative impact on the frit transfer system. The transferring of the spherical glass beads was much easier than the glass frit. It was difficult to create a plug with glass bead slurry in the pilot transfer system. When a small plug occurred from setting overnight with the spherical glass beads, the plug was easy to displace using only the pump. In the case of creating a man made plug in a vertical line, by filling the line with spherical glass beads and allowing the slurry to settle for days, the plug was easy to remove by using flush water. The glass frit proved to be much more difficult to transfer when compared to the spherical glass beads. The glass frit impacted the transfer system to the point

  5. DWPF recycle minimization: Brainstorming session

    SciTech Connect

    Jacobs, R.A.; Poirier, M.R.

    1993-10-12

    The recycle stream from the DWPF constitutes a major source of water addition to the High Level Waste evaporator system. As now designed, the entire flow of 3.5 to 6.5 gal/min (@ 25% and 75% attainment, respectively), or 2 gal/min during idling, flow to the 2H evaporator system (Tank 43). Substantial improvement in the HLW water balance and tank volume management is expected if the DWPF recycle to the HLW evaporator system can be significantly reduced. A task team has been appointed to study alternatives for reducing the flow to the HLW evaporator system and make recommendations for implementation and/or further study and evaluation. The brainstorming session detailed in this report was designed to produce the first cut options for the task team to further evaluate.

  6. DWPF Welder Parametric Study

    SciTech Connect

    Plodinec, M.J.

    1998-11-20

    After being filled with glass, DWPF canistered waste forms will be welded closed using an upset resistance welding process. This final closure weld must be leaktight, and must remain so during extended storage at SRS. As part of the DWPF Startup Test Program, a parametric study (DWPF-WP-24) has been performed to determine a range of welder operating parameters which will produce acceptable welds. The parametric window of acceptable welds defined by this study is 90,000 + 15,000 lb of force, 248,000 + 22,000 amps of current, and 95 + 15 cycles* for the time of application of the current.

  7. DWPF risk analysis summary

    SciTech Connect

    Shedrow, C.B.

    1990-10-01

    This document contains selected risk analysis data from Chapter 9 (Safety Analysis) of the Defense Waste Processing Facility Safety Analysis Report DWPF SAR and draft Addendum 1 to the Waste Tank Farms SAR. Although these data may be revised prior to finalization of the draft SAR and the draft addendum, they are presently the best available information and were therefore used in preparing the risk analysis portion of the DWPF Environmental Analysis (DWPF EA). This information has been extracted from those draft documents an approved under separate cover so that it can be used as reference material for the DWPF EA when it is placed in the public reading rooms. 9 refs., 4 tabs.

  8. GADOLINIUM SOLUBILITY AND VOLATILITY DURING DWPF PROCESSING

    SciTech Connect

    Reboul, S

    2008-01-30

    Understanding of gadolinium behavior, as it relates to potential neutron poisoning applications at the DWPF, has increased over the past several years as process specific data have been generated. Of primary importance are phenomena related to gadolinium solubility and volatility, which introduce the potential for gadolinium to be separated from fissile materials during Chemical Process Cell (CPC) and Melter operations. Existing data indicate that gadolinium solubilities under moderately low pH conditions can vary over several orders of magnitude, depending on the quantities of other constituents that are present. With respect to sludge batching processes, the gadolinium solubility appears to be highly affected by iron. In cases where the mass ratio of Fe:Gd is 300 or more, the gadolinium solubility has been observed to be low, one milligram per liter or less. In contrast, when the ratio of Fe:Gd is 20 or less, the gadolinium solubility has been found to be relatively high, several thousands of milligrams per liter. For gadolinium to serve as an effective neutron poison in CPC operations, the solubility needs to be limited to approximately 100 mg/L. Unfortunately, the Fe:Gd ratio that corresponds to this solubility limit has not been identified. Existing data suggest gadolinium and plutonium are not volatile during melter operations. However, the data are subject to inherent uncertainties preventing definitive conclusions on this matter. In order to determine if gadolinium offers a practical means of poisoning waste in DWPF operations, generation of additional data is recommended. This includes: Gd solubility testing under conditions where the Fe:Gd ratio varies from 50 to 150; and Gd and Pu volatility studies tailored to quantifying high temperature partitioning. Additional tests focusing on crystal aging of Gd/Pu precipitates should be pursued if receipt of gadolinium-poisoned waste into the Tank Farm becomes routine.

  9. FEASIBILITY EVALUATION AND RETROFIT PLAN FOR COLD CRUCIBLE INDUCTION MELTER DEPLOYMENT IN THE DEFENSE WASTE PROCESSING FACILITY AT SAVANNAH RIVER SITE 8118

    SciTech Connect

    Barnes, A; Dan Iverson, D; Brannen Adkins, B

    2008-02-06

    increase heat transfer to the slurry fed High Level Waste (HLW) sludge, the CCIM may be equipped with bubblers and/or water cooled mechanical agitators. The DWPF could benefit from use of CCIM technology, especially in light of our latest projections of waste volume to be vitrified. Increased waste loading and increased throughput could result in substantial life cycle cost reduction. In order to significantly surpass the waste throughput capability of the currently installed JHM, it may be necessary to install two 950 mm CCIMs in the DWPF Melt Cell. A cursory evaluation of system design requirements and modifications to the facility that may be required to support installation and operation of two 950 mm CCIMs was performed. Based on this evaluation, it appears technically feasible to position two CCIMs in the Melt Cell of the DWPF within the existing footprint of the current melter. Interfaces with support systems and controls including Melter Feed, Power, Melter Cooling Water, Melter Off-gas, and Canister Operations must be designed to support dual CCIM operations. This paper describes the CCIM technology and identifies technical challenges that must be addressed in order to implement CCIMs in the DWPF.

  10. Feasibility Evaluation and Retrofit Plan for Cold Crucible Induction Melter Deployment in the Defense Waste Processing Facility at Savannah River Site

    SciTech Connect

    Barnes, A.B.; Iverson, D.C.; Adkins, B.J.; Tchemitcheff, E.

    2008-07-01

    distribution and increase heat transfer to the slurry fed High Level Waste (HLW) sludge, the CCIM may be equipped with bubblers and/or water cooled mechanical agitators. The DWPF could benefit from use of CCIM technology, especially in light of our latest projections of waste volume to be vitrified. Increased waste loading and increased throughput could result in substantial life cycle cost reduction. In order to significantly surpass the waste throughput capability of the currently installed JHM, it may be necessary to install two 950 mm CCIMs in the DWPF Melt Cell. A cursory evaluation of system design requirements and modifications to the facility that may be required to support installation and operation of two 950 mm CCIMs was performed. Based on this evaluation, it appears technically feasible to position two CCIMs in the Melt Cell of the DWPF within the existing footprint of the current melter. Interfaces with support systems and controls including Melter Feed, Power, Melter Cooling Water, Melter Off-gas, and Canister Operations must be designed to support dual CCIM operations. This paper describes the CCIM technology and identifies technical challenges that must be addressed in order to implement CCIMs in the DWPF. (authors)

  11. TTP SR1-6-WT-31, Milestone C.3-2 Annual Report on Clemson/INEEL Melter Work

    SciTech Connect

    Bickford, D.F.

    1999-10-20

    This work is performed in collaboration with RL37WT31-C and ID77WT31-B. During the first two years of radioactive operation of the DWPF process, several areas for improvement in melter design have been identified. The continuing scope of this task is to address performance limitations and deficiencies identified by the user. SRS will design and test several configurations of the melter pour spout and associated equipment to improve consistency of performance and recommend design improvements.

  12. ANALYSIS OF DWPF SLUDGE BATCH 7A (MACROBATCH 8) POUR STREAM SAMPLES

    SciTech Connect

    Johnson, F.

    2012-05-01

    The Defense Waste Processing Facility (DWPF) began processing Sludge Batch 7a (SB7a), also referred to as Macrobatch 8 (MB8), in June 2011. SB7a is a blend of the heel of Tank 40 from Sludge Batch 6 (SB6) and the SB7a material that was transferred to Tank 40 from Tank 51. SB7a was processed using Frit 418. During processing of each sludge batch, the DWPF is required to take at least one glass sample to meet the objectives of the Glass Product Control Program (GPCP), which is governed by the DWPF Waste Compliance Plan, and to complete the necessary Production Records so that the final glass product may be disposed of at a Federal Repository. Three pour stream glass samples and two Melter Feed Tank (MFT) slurry samples were collected while processing SB7a. These additional samples were taken during SB7a to understand the impact of antifoam and the melter bubblers on glass redox chemistry. The samples were transferred to the Savannah River National Laboratory (SRNL) where they were analyzed. The following conclusions were drawn from the analytical results provided in this report: (1) The sum of oxides for the official SB7a pour stream glass is within the Product Composition Control System (PCCS) limits (95-105 wt%). (2) The average calculated Waste Dilution Factor (WDF) for SB7a is 2.3. In general, the measured radionuclide content of the official SB7a pour stream glass is in good agreement with the calculated values from the Tank 40 dried sludge results from the SB7a Waste Acceptance Program Specification (WAPS) sample. (3) As in previous pour stream samples, ruthenium and rhodium inclusions were detected by Scanning Electron Microscopy-Electron Dispersive Spectroscopy (SEM-EDS) in the official SB7a pour stream sample. (4) The Product Consistency Test (PCT) results indicate that the official SB7a pour stream glass meets the waste acceptance criteria for durability with a normalized boron release of 0.64 g/L, which is an order of magnitude less than the Environmental

  13. Melter Disposal Strategic Planning Document

    SciTech Connect

    BURBANK, D.A.

    2000-09-25

    This document describes the proposed strategy for disposal of spent and failed melters from the tank waste treatment plant to be built by the Office of River Protection at the Hanford site in Washington. It describes program management activities, disposal and transportation systems, leachate management, permitting, and safety authorization basis approvals needed to execute the strategy.

  14. Melter Technologies Assessment

    SciTech Connect

    Perez, J.M. Jr.; Schumacher, R.F.; Forsberg, C.W.

    1996-05-01

    The problem of controlling and disposing of surplus fissile material, in particular plutonium, is being addressed by the US Department of Energy (DOE). Immobilization of plutonium by vitrification has been identified as a promising solution. The Melter Evaluation Activity of DOE`s Plutonium Immobilization Task is responsible for evaluating and selecting the preferred melter technologies for vitrification for each of three immobilization options: Greenfield Facility, Adjunct Melter Facility, and Can-In-Canister. A significant number of melter technologies are available for evaluation as a result of vitrification research and development throughout the international communities for over 20 years. This paper describes an evaluation process which will establish the specific requirements of performance against which candidate melter technologies can be carefully evaluated. Melter technologies that have been identified are also described.

  15. High Level Waste Remote Handling Equipment in the Melter Cave Support Handling System at the Hanford Waste Treatment Plant

    SciTech Connect

    Bardal, M.A.; Darwen, N.J.

    2008-07-01

    Cold war plutonium production led to extensive amounts of radioactive waste stored in tanks at the Department of Energy's (DOE) Hanford site. Bechtel National, Inc. is building the largest nuclear Waste Treatment Plant in the world located at the Department of Energy's Hanford site to immobilize the millions of gallons of radioactive waste. The site comprises five main facilities; Pretreatment, High Level Waste vitrification, Low Active Waste vitrification, an Analytical Lab and the Balance of Facilities. The pretreatment facilities will separate the high and low level waste. The high level waste will then proceed to the HLW facility for vitrification. Vitrification is a process of utilizing a melter to mix molten glass with radioactive waste to form a stable product for storage. The melter cave is designated as the High Level Waste Melter Cave Support Handling System (HSH). There are several key processes that occur in the HSH cell that are necessary for vitrification and include: feed preparation, mixing, pouring, cooling and all maintenance and repair of the process equipment. Due to the cell's high level radiation, remote handling equipment provided by PaR Systems, Inc. is required to install and remove all equipment in the HSH cell. The remote handling crane is composed of a bridge and trolley. The trolley supports a telescoping tube set that rigidly deploys a TR 4350 manipulator arm with seven degrees of freedom. A rotating, extending, and retracting slewing hoist is mounted to the bottom of the trolley and is centered about the telescoping tube set. Both the manipulator and slewer are unique to this cell. The slewer can reach into corners and the manipulator's cross pivoting wrist provides better operational dexterity and camera viewing angles at the end of the arm. Since the crane functions will be operated remotely, the entire cell and crane have been modeled with 3-D software. Model simulations have been used to confirm operational and maintenance

  16. UNCERTAINTIES OF ANION AND TOC MEASUREMENTS AT THE DWPF LABORATORY

    SciTech Connect

    Edwards, T.

    2011-04-07

    The Savannah River Remediation (SRR) Defense Waste Processing Facility (DWPF) has identified a technical issue related to the amount of antifoam added to the Chemical Process Cell (CPC). Specifically, due to the long duration of the concentration and reflux cycles for the Sludge Receipt and Adjustment Tank (SRAT), additional antifoam has been required. The additional antifoam has been found to impact the melter flammability analysis as an additional source of carbon and hydrogen. To better understand and control the carbon and hydrogen contributors to the melter flammability analysis, SRR's Waste Solidification Engineering (WSE) has requested, via a Technical Task Request (TTR), that the Savannah River National Laboratory (SRNL) conduct an error evaluation of the measurements of key Slurry Mix Evaporator (SME) anions. SRNL issued a Task Technical and Quality Assurance Plan (TTQAP) [2] in response to that request, and the work reported here was conducted under the auspices of that TTQAP. The TTR instructs SRNL to conduct an error evaluation of anion measurements generated by the DWPF Laboratory using Ion Chromatography (IC) performed on SME samples. The anions of interest include nitrate, oxalate, and formate. Recent measurements of SME samples for these anions as well as measurements of total organic carbon (TOC) were provided to SRNL by DWPF Laboratory Operations (Lab OPS) personnel for this evaluation. This work was closely coordinated with the efforts of others within SRNL that are investigating the Chemical Process Cell (CPC) contributions to the melter flammability. The objective of that investigation was to develop a more comprehensive melter flammability control strategy that when implemented in DWPF will rely on process measurements. Accounting for the uncertainty of the measurements is necessary for successful implementation. The error evaluations conducted as part of this task will facilitate the integration of appropriate uncertainties for the

  17. An Ice Core Melter System for Continuous Major and Trace Chemical Analyses of a New Mt. Logan Summit Ice Core

    NASA Astrophysics Data System (ADS)

    Osterberg, E. C.; Handley, M. J.; Sneed, S. D.; Mayewski, P. A.; Kreutz, K. J.; Fisher, D. A.

    2004-12-01

    The ice core melter system at the University of Maine Climate Change Institute has been recently modified and updated to allow high-resolution (<1-2 cm ice/sample), continuous and coregistered sampling of ice cores, most notably the 2001 Mt. Logan summit ice core (187 m to bedrock), for analyses of 34 trace elements (Sr, Cd, Sb, Cs, Ba, Pb, Bi, U, As, Al, S, Ca, Ti, V, Cr, Mn, Fe, Co, Cu, Zn, REE suite) by inductively coupled plasma mass spectrometry (ICP-MS), 8 major ions (Na+, Ca2+, Mg2+, K+, Cl-, SO42-, NO3-, MSA) by ion chromatography (IC), stable water isotopes (δ 18O, δ D, d) and volcanic tephra. The UMaine continuous melter (UMCoM) system is housed in a dedicated clean room with HEPA filtered air. Standard clean room procedures are employed during melting. A Wagenbach-style continuous melter system has been modified to include a pure Nickel melthead that can be easily dismantled for thorough cleaning. The system allows melting of both ice and firn without wicking of the meltwater into unmelted core. Contrary to ice core melter systems in which the meltwater is directly channeled to online instruments for continuous flow analyses, the UMCoM system collects discrete samples for each chemical analysis under ultraclean conditions. Meltwater from the pristine innermost section of the ice core is split between one fraction collector that accumulates ICP-MS samples in acid pre-cleaned polypropylene vials under a class-100 HEPA clean bench, and a second fraction collector that accumulates IC samples. A third fraction collector accumulates isotope and tephra samples from the potentially contaminated outer portion of the core. This method is advantageous because an archive of each sample remains for subsequent analyses (including trace element isotope ratios), and ICP-MS analytes are scanned for longer intervals and in replicate. Method detection limits, calculated from de-ionized water blanks passed through the entire UMCoM system, are below 10% of average Mt

  18. NEXT GENERATION MELTER(S) FOR VITRIFICATION OF HANFORD WASTE STATUS AND DIRECTION

    SciTech Connect

    RAMSEY WG; GRAY MF; CALMUS RB; EDGE JA; GARRETT BG

    2011-01-13

    Vitrification technology has been selected to treat high-level waste (HLW) at the Hanford Site, the West Valley Demonstration Project and the Savannah River Site (SRS), and low activity waste (LAW) at Hanford. In addition, it may potentially be applied to other defense waste streams such as sodium bearing tank waste or calcine. Joule-heated melters (already in service at SRS) will initially be used at the Hanford Site's Waste Treatment and Immobilization Plant (WTP) to vitrify tank waste fractions. The glass waste content and melt/production rates at WTP are limited by the current melter technology. Significant reductions in glass volumes and mission life are only possible with advancements in melter technology coupled with new glass formulations. The Next Generation Melter (NGM) program has been established by the U.S. Department of Energy's (DOE's), Environmental Management Office of Waste Processing (EM-31) to develop melters with greater production capacity (absolute glass throughput rate) and the ability to process melts with higher waste fractions. Advanced systems based on Joule-Heated Ceramic Melter (JHCM) and Cold Crucible Induction Melter (CCIM) technologies will be evaluated for HLW and LAW processing. Washington River Protection Solutions (WRPS), DOE's tank waste contractor, is developing and evaluating these systems in cooperation with EM-31, national and university laboratories, and corporate partners. A primary NGM program goal is to develop the systems (and associated flowsheets) to Technology Readiness Level 6 by 2016. Design and testing are being performed to optimize waste glass process envelopes with melter and balance of plant requirements. A structured decision analysis program will be utilized to assess the performance of the competing melter technologies. Criteria selected for the decision analysis program will include physical process operations, melter performance, system compatibility and other parameters.

  19. FINAL REPORT TESTS ON THE DURAMELTER 1200 HLW PILOT MELTER SYSTEM USING AZ-101 HLW SIMULANTS VSL-02R0100-2 REV 1 2/17/03

    SciTech Connect

    KRUGER AA; MATLACK KS; KOT WK; BARDAKCI T; GONG W; D'ANGELO NA; SCHATZ TR; PEGG IL

    2011-12-29

    This document provides the final report on data and results obtained from a series of nine tests performed on the one-third scale DuraMelter{trademark} 1200 (DM1200) HLW Pilot Melter system that has been installed at VSL with an integrated prototypical off-gas treatment system. That system has replaced the DM1000 system that was used for HLW throughput testing during Part B1 [1]. Both melters have similar melt surface areas (1.2 m{sup 2}) but the DM1200 is prototypical of the present RPP-WTP HLW melter design whereas the DM1000 was not. These tests were performed under a corresponding RPP-WTP Test Specification and associated Test Plans. The nine tests reported here were preceded by an initial series of short-duration tests conducted to support the start-up and commissioning of this system. This report is a followup to the previously issued Preliminary Data Summary Reports. The DM1200 system was deployed for testing and confirmation of basic design, operability, flow sheet, and process control assumptions as well as for support of waste form qualification and permitting. These tests include data on processing rates, off-gas treatment system performance, recycle stream compositions, as well as process operability and reliability. Consequently, this system is a key component of the overall HLW vitrification development strategy. The primary objective of the present series of tests was to determine the effects of a variety of parameters on the glass production rate in comparison to the RPP-WTP HL W design basis of 400 kg/m{sup 2}/d. Previous testing on the DMIOOO system [1] concluded that achievement of that rate with simulants of projected WTP melter feeds (AZ-101 and C-106/AY-102) was unlikely without the use of bubblers. As part of those tests, the same feed that was used during the cold-commissioning of the West Valley Demonstration Project (WVDP) HLW vitrification system was run on the DM1000 system. The DM1000 tests reproduced the rates that were obtained at the

  20. Glass formulation requirements for DWPF coupled operations using crystalline silicotitanates

    SciTech Connect

    Harbour, J.R.; Andrews, M.K.

    1997-01-09

    The design basis DWPF flowsheet couples the vitrification of two waste streams: (1) a washed sludge and (2) a hydrolyzed sodium tetraphenylborate precipitate product, PHA. The PHA contains cesium-137 which had been precipitated from the tank supernate with sodium tetraphenylborate. Smaller amounts of strontium and plutonium adsorbed on sodium titanate are also present with the PHA feed. Currently, DWPF is running a sludge-only flowsheet while working towards solutions to the problems encountered with In Tank Precipitation (ITP). The sludge loading for the sludge-only flowsheet and for the anticipated coupled operations is 28 wt% on an oxide basis. For the coupled operation, it is essential to balance the treatment of the two waste streams such that no supernate remains after immobilization of all the sludge. An alternative to ITP and sodium titanate is the removal of Cs-137, Sr-90, and plutonium from the tank supernate by ion exchange using crystalline silicotitanate (CST). This material has been shown to effectively sorb these elements from the supernate. It is also known that CST sorbs plutonium. The loaded CST could then be immobilized with the sludge during vitrification. It has recently been demonstrated that CST loadings approaching 70 wt% for a CST-only glass can be achieved using a borosilicate glass formulation which can be processed by the DWPF melter. Initial efforts on coupled waste streams with simulated DWPF sludge show promise that a borosilicate glass formulation can incorporate both sludge and CST. This paper presents the bases for research efforts to develop a glass formulation which will incorporate sludge and CST at loadings appropriate for DWPF operation.

  1. RHEOLOGICAL AND ELEMENTAL ANALYSES OF SIMULANT SB5 SLURRY MIX EVAPORATOR-MELTER FEED TANK SLURRIES

    SciTech Connect

    Fernandez, A.

    2010-02-08

    The Defense Waste Processing Facility (DWPF) will complete Sludge Batch 5 (SB5) processing in fiscal year 2010. DWPF has experienced multiple feed stoppages for the SB5 Melter Feed Tank (MFT) due to clogs. Melter throughput is decreased not only due to the feed stoppage, but also because dilution of the feed by addition of prime water (about 60 gallons), which is required to restart the MFT pump. SB5 conditions are different from previous batches in one respect: pH of the Slurry Mix Evaporator (SME) product (9 for SB5 vs. 7 for SB4). Since a higher pH could cause gel formation, due in part to greater leaching from the glass frit into the supernate, SRNL studies were undertaken to check this hypothesis. The clogging issue is addressed by this simulant work, requested via a technical task request from DWPF. The experiments were conducted at Aiken County Technology Laboratory (ACTL) wherein a non-radioactive simulant consisting of SB5 Sludge Receipt and Adjustment Tank (SRAT) product simulant and frit was subjected to a 30 hour SME cycle at two different pH levels, 7.5 and 10; the boiling was completed over a period of six days. Rheology and supernate elemental composition measurements were conducted. The caustic run exhibited foaming once, after 30 minutes of boiling. It was expected that caustic boiling would exhibit a greater leaching rate, which could cause formation of sodium aluminosilicate and would allow gel formation to increase the thickness of the simulant. Xray Diffraction (XRD) measurements of the simulant did not detect crystalline sodium aluminosilicate, a possible gel formation species. Instead, it was observed that caustic conditions, but not necessarily boiling time, induced greater thickness, but lowered the leach rate. Leaching consists of the formation of metal hydroxides from the oxides, formation of boric acid from the boron oxide, and dissolution of SiO{sub 2}, the major frit component. It is likely that the observed precipitation of Mg

  2. TTP SR1-6-WT-31, Milestone C.3-2 annual report on Clemson/INEEL melter work. Revision 1

    SciTech Connect

    Bickford, D.F.

    1999-12-17

    This work is performed in collaboration with RL37WT31-C and ID77WT31-B. During the first two years of radioactive operation of the DWPF process, several areas for improvement in melter design have been identified. The continuing scope of this task is to address performance limitations and deficiencies identified by the user. SRS will design and test several configurations of the melter pour spout and associated equipment to improve consistency of performance and recommend design improvements.

  3. DWPF DECON FRIT SUPERNATE ANALYSIS

    SciTech Connect

    Peeler, D.; Crawford, C.

    2010-09-22

    of this study, it is recommended that DWPF re-evaluate the technical basis for the B WAC limit (the only component that exceeds the ETP WAC limit from the supernate analyses) or assess if a waiver or exception can be obtained for exceeding this limit. Given the possible dissolution of B, Li, Na, and Si into the supernate (due to dissolution of frit), DWPF may need to assess if the release of these frit components into the supernate are a concern for the disposal options being considered. It should be noted that the results of this study may not be representative of future decon frit solutions or sump/slurry solids samples. Therefore, future DWPF decisions regarding the possible disposal pathways for either the aqueous or solid portions of the Decon Frit system need to factor in the potential differences. More specifically, introduction of a different frit or changes to other DWPF flowsheet unit operations (e.g., different sludge batch or coupling with other process streams) may impact not only the results but also the conclusions regarding acceptability with respect to the ETF WAC limits.

  4. Canister disposition plan for the DWPF Startup Test Program

    SciTech Connect

    Harbour, J.R.; Payne, C.H.

    1990-01-01

    This report details the disposition of canisters and the canistered waste forms produced during the DWPF Startup Test Program. The six melter campaigns (DWPF Startup Tests FA-13, WP-14, WP-15, WP-16, WP-17, and FA-18) will produce 126 canistered waste forms. In addition, up to 20 additional canistered waste forms may be produced from glass poured during the transition between campaigns. In particular, this canister disposition plan (1) assigns (by alpha-numeric code) a specific canister to each location in the six campaign sequences, (2) describes the method of access for glass sampling on each canistered waste form, (3) describes the nature of the specific tests which will be carried out, (4) details which tests will be carried out on each canistered waste form, (5) provides the sequence of these tests for each canistered waste form, and (6) assigns a storage location for each canistered waste form. The tests are designed to provide evidence, as detailed in the Waste Form Compliance Plan (WCP[sup 1]), that the DWPF product will comply with the Waste Acceptance Product Specifications (WAPS[sup 2]). The WAPS must be met before the canistered waste form is accepted by DOE for ultimate disposal at the Federal Repository. The results of these tests will be included in the Waste Form Qualification Report (WQR).

  5. PRELIMINARY EVALUATION OF DWPF IMPACTS OF BORIC ACID USE IN CESIUM STRIP FOR SWPF AND MCU

    SciTech Connect

    Stone, M.

    2010-09-28

    A new solvent system is being evaluated for use in the Modular Caustic-Side Solvent Extraction Unit (MCU) and in the Salt Waste Processing Facility (SWPF). The new system includes the option to replace the current dilute nitric acid strip solution with boric acid. To support this effort, the impact of using 0.01M, 0.1M, 0.25M and 0.5M boric acid in place of 0.001M nitric acid was evaluated for impacts on the DWPF facility. The evaluation only covered the impacts of boric acid in the strip effluent and does not address the other changes in solvents (i.e., the new extractant, called MaxCalix, or the new suppressor, guanidine). Boric acid additions may lead to increased hydrogen generation during the SRAT and SME cycles as well as change the rheological properties of the feed. The boron in the strip effluent will impact glass composition and could require each SME batch to be trimmed with boric acid to account for any changes in the boron from strip effluent additions. Addition of boron with the strip effluent will require changes in the frit composition and could lead to changes in melt behavior. The severity of the impacts from the boric acid additions is dependent on the amount of boric acid added by the strip effluent. The use of 0.1M or higher concentrations of boric acid in the strip effluent was found to significantly impact DWPF operations while the impact of 0.01M boric acid is expected to be relatively minor. Experimental testing is required to resolve the issues identified during the preliminary evaluation. The issues to be addressed by the testing are: (1) Impact on SRAT acid addition and hydrogen generation; (2) Impact on melter feed rheology; (3) Impact on glass composition control; (4) Impact on frit production; and (5) Impact on melter offgas. A new solvent system is being evaluated for use in the Modular Caustic-Side Solvent Extraction Unit (MCU) and in the Salt Waste Processing Facility (SWPF). The new system includes the option to replace the

  6. Test plan for glass melter system technologies for vitrification of high-sodium content low-level radioactive liquid waste, Project No. RDD-43288

    SciTech Connect

    Higley, B.A.

    1995-03-15

    This document provides a test plan for the conduct of combustion fired cyclone vitrification testing by a vendor in support of the Hanford Tank Waste Remediation System, Low-Level Waste Vitrification Program. The vendor providing this test plan and conducting the work detailed within it is the Babcock & Wilcox Company Alliance Research Center in Alliance, Ohio. This vendor is one of seven selected for glass melter testing.

  7. DWPF welder parametric study

    SciTech Connect

    Eberhard, B.J.; Harbour, J.R.; Plodinec, M.J.

    1994-06-01

    As part of the DWPF Startup Test Program, a parametric study has been performed to determine a range of welder operating parameters which will produce acceptable final welds for canistered waste forms. The parametric window of acceptable welds defined by this study is 90,000 {plus_minus} 15,000 lb of force, 248,000 {plus_minus} 22,000 amps of current, and 95 {plus_minus} 15 cycles (@ 60 cops) for the time of application of the current.

  8. INSTALLATION OF BUBBLERS IN THE SAVANNAH RIVER SITED DEFENSE WASTE PROCESSING FACILITY MELTER

    SciTech Connect

    Smith, M.; Iverson, D.

    2010-12-08

    Savannah River Remediation (SRR) LLC assumed the liquid waste contract at the Savannah River Site (SRS) in the summer of 2009. The main contractual agreement was to close 22 High Level Waste (HLW) tanks in eight years. To achieve this aggressive commitment, faster waste processing throughout the SRS liquid waste facilities will be required. Part of the approach to achieve faster waste processing is to increase the canister production rate of the Defense Waste Processing Facility (DWPF) from approximately 200 canisters filled with radioactive waste glass per year to 400 canisters per year. To reach this rate for melter throughput, four bubblers were installed in the DWPF Melter in the late summer of 2010. This effort required collaboration between SRR, SRR critical subcontractor EnergySolutions, and Savannah River Nuclear Solutions, including the Savannah River National Laboratory (SRNL). The tasks included design and fabrication of the bubblers and related equipment, testing of the bubblers for various technical issues, the actual installation of the bubblers and related equipment, and the initial successful operation of the bubblers in the DWPF Melter.

  9. Oxygen enriched combustion system performance study. Phase 2: 100 percent oxygen enriched combustion in regenerative glass melters, Final report

    SciTech Connect

    Tuson, G.B.; Kobayashi, H.; Campbell, M.J.

    1994-08-01

    The field test project described in this report was conducted to evaluate the energy and environmental performance of 100% oxygen enriched combustion (100% OEC) in regenerative glass melters. Additional objectives were to determine other impacts of 100% OEC on melter operation and glass quality, and to verify on a commercial scale that an on-site Pressure Swing Adsorption oxygen plant can reliably supply oxygen for glass melting with low electrical power consumption. The tests constituted Phase 2 of a cooperative project between the United States Department of Energy, and Praxair, Inc. Phase 1 of the project involved market and technical feasibility assessments of oxygen enriched combustion for a range of high temperature industrial heating applications. An assessment of oxygen supply options for these applications was also performed during Phase 1, which included performance evaluation of a pilot scale 1 ton per day PSA oxygen plant. Two regenerative container glass melters were converted to 100% OEC operation and served as host sites for Phase 2. A 75 ton per day end-fired melter at Carr-Lowrey Glass Company in Baltimore, Maryland, was temporarily converted to 100% OEC in mid- 1990. A 350 tpd cross-fired melter at Gallo Glass Company in Modesto, California was rebuilt for permanent commercial operation with 100% OEC in mid-1991. Initially, both of these melters were supplied with oxygen from liquid storage. Subsequently, in late 1992, a Pressure Swing Adsorption oxygen plant was installed at Gallo to supply oxygen for 100% OEC glass melting. The particular PSA plant design used at Gallo achieves maximum efficiency by cycling the adsorbent beds between pressurized and evacuated states, and is therefore referred to as a Vacuum/Pressure Swing Adsorption (VPSA) plant.

  10. Thermal analysis of the failed equipment storage vault system

    SciTech Connect

    Jerrell, J.; Lee, S.Y.; Shadday, A.

    1995-07-01

    A storage facility for failed glass melters is required for radioactive operation of the Defense Waste Processing Facility (DWPF). It is currently proposed that the failed melters be stored in the Failed Equipment Storage Vaults (FESV`s) in S area. The FESV`s are underground reinforced concrete structures constructed in pairs, with adjacent vaults sharing a common wall. A failed melter is to be placed in a steel Melter Storage Box (MSB), sealed, and lowered into the vault. A concrete lid is then placed over the top of the FESV. Two melters will be placed within the FESV/MSB system, separated by the common wall. There is no forced ventilation within the vault so that the melter is passively cooled. Temperature profiles in the Failed Equipment Storage Vault Structures have been generated using the FLOW3D software to model heat conduction and convection within the FESV/MSB system. Due to complexities in modeling radiation with FLOW3D, P/THERMAL software has been used to model radiation using the conduction/convection temperature results from FLOW3D. The final conjugate model includes heat transfer by conduction, convection, and radiation to predict steady-state temperatures. Also, the FLOW3D software has been validated as required by the technical task request.

  11. Characterization and Dessolution Test results for the January 2005 DWPF Off Gas Condensate Tank Samples (U)

    SciTech Connect

    Fellinger, T

    2005-04-08

    The Off Gas Condensate Tank (OGCT) at the Defense Waste Processing Facility (DWPF) collects the condensate from the off-gas system of the melter. The condensate stream contains entrained solids that collect in the OGCT. Water from the OGCT is re-circulated to the Steam Atomized Scrubber and quencher and may provide a mechanism for re-introducing the particulates into the off-gas system. These particulates are thought to be responsible for plugging the downstream High Efficiency Mist Eliminator filters. Therefore, the OGCT needs to be periodically cleaned to remove the build-up of entrained solids. Currently, the OGCT is cleaned by adding nominally 12 wt% nitric acid with agitation to slurry the solids from the tank. Samples from the OGCT were sent to the Savannah River National Lab (SRNL) for characterization and to conduct tests to determine the optimum nitric acid concentration and residence time to allow more effective cleaning of the OGCT. This report summarizes the chemical and radionuclide results and the results from the nitric acid dissolution testing at 50% and 12% obtained for the OGCT sample.

  12. Tunable, self-powered integrated arc plasma-melter vitrification system for waste treatment and resource recovery

    DOEpatents

    Titus, Charles H.; Cohn, Daniel R.; Surma, Jeffrey E.

    1998-01-01

    The present invention provides a relatively compact self-powered, tunable waste conversion system and apparatus which has the advantage of highly robust operation which provides complete or substantially complete conversion of a wide range of waste streams into useful gas and a stable, nonleachable solid product at a single location with greatly reduced air pollution to meet air quality standards. The system provides the capability for highly efficient conversion of waste into high quality combustible gas and for high efficiency conversion of the gas into electricity by utilizing a high efficiency gas turbine or by an internal combustion engine. The solid product can be suitable for various commercial applications. Alternatively, the solid product stream, which is a safe, stable material, may be disposed of without special considerations as hazardous material. In the preferred embodiment of the invention, the arc plasma furnace and joule heated melter are formed as a fully integrated unit with a common melt pool having circuit arrangements for the simultaneous independently controllable operation of both the arc plasma and the joule heated portions of the unit without interference with one another. The preferred configuration of this embodiment of the invention utilizes two arc plasma electrodes with an elongated chamber for the molten pool such that the molten pool is capable of providing conducting paths between electrodes. The apparatus may additionally be employed with reduced or without further use of the gases generated by the conversion process. The apparatus may be employed as a self-powered or net electricity producing unit where use of an auxiliary fuel provides the required level of electricity production.

  13. DWPF COAL-CARBON WASTE ACCEPTANCE CRITERIA LIMIT EVALUATION BASED ON EXPERIMENTAL WORK (TANK 48 IMPACT STUDY)

    SciTech Connect

    Lambert, D.; Choi, A.

    2010-10-15

    This report summarizes the results of both experimental and modeling studies performed using Sludge Batch 10 (SB10) simulants and FBSR product from Tank 48 simulant testing in order to develop higher levels of coal-carbon that can be managed by DWPF. Once the Fluidized Bed Steam Reforming (FBSR) process starts up for treatment of Tank 48 legacy waste, the FBSR product stream will contribute higher levels of coal-carbon in the sludge batch for processing at DWPF. Coal-carbon is added into the FBSR process as a reductant and some of it will be present in the FBSR product as unreacted coal. The FBSR product will be slurried in water, transferred to Tank Farm and will be combined with sludge and washed to produce the sludge batch that DWPF will process. The FBSR product is high in both water soluble sodium carbonate and unreacted coal-carbon. Most of the sodium carbonate is removed during washing but all of the coal-carbon will remain and become part of the DWPF sludge batch. A paper study was performed earlier to assess the impact of FBSR coal-carbon on the DWPF Chemical Processing Cell (CPC) operation and melter off-gas flammability by combining it with SB10-SB13. The results of the paper study are documented in Ref. 7 and the key findings included that SB10 would be the most difficult batch to process with the FBSR coal present and up to 5,000 mg/kg of coal-carbon could be fed to the melter without exceeding the off-gas flammability safety basis limits. In the present study, a bench-scale demonstration of the DWPF CPC processing was performed using SB10 simulants spiked with varying amounts of coal, and the resulting seven CPC products were fed to the DWPF melter cold cap and off-gas dynamics models to determine the maximum coal that can be processed through the melter without exceeding the off-gas flammability safety basis limits. Based on the results of these experimental and modeling studies, the presence of coal-carbon in the sludge feed to DWPF is found to have

  14. Assessment of the impact of TOA partitioning on DWPF off-gas flammability

    SciTech Connect

    Daniel, W. E.

    2013-06-01

    An assessment has been made to evaluate the impact on the DWPF melter off-gas flammability of increasing the amount of TOA in the current solvent used in the Modular Caustic-Side Solvent Extraction Process Unit (MCU) process. The results of this study showed that the concentrations of nonvolatile carbon of the current solvent limit (150 ppm) in the Slurry Mix Evaporator (SME) product would be about 7% higher and the nonvolatile hydrogen would be 2% higher than the actual current solvent (126 ppm) with an addition of up to 3 ppm of TOA when the concentration of Isopar L in the effluent transfer is controlled below 87 ppm and the volume of MCU effluent transfer to DWPF is limited to 15,000 gallons per Sludge Receipt and Adjustment Tank (SRAT)/SME cycle. Therefore, the DWPF melter off-gas flammability assessment is conservative for up to an additional 3 ppm of TOA in the effluent based on these assumptions. This report documents the calculations performed to reach this conclusion.

  15. Analysis Of DWPF Sludge Batch 7a (Macrobatch 8) Pour Stream Samples

    SciTech Connect

    Johnson, F. C.; Pareizs, J. M.

    2012-10-24

    The Defense Waste Processing Facility (DWPF) began processing Sludge Batch 7a (SB7a), also referred to as Macrobatch 8 (MB8), in June 2011. SB7a is a blend of the heel of Tank 40 from Sludge Batch 6 (SB6) and the SB7a material that was transferred to Tank 40 from Tank 51. SB7a was processed using Frit 418. During processing of each sludge batch, the DWPF is required to take at least one glass sample to meet the objectives of the Glass Product Control Program (GPCP), which is governed by the DWPF Waste Compliance Plan, and to complete the necessary Production Records so that the final glass product may be disposed of at a Federal Repository. Three pour stream glass samples and two Melter Feed Tank (MFT) slurry samples were collected while processing SB7a. These additional samples were taken during SB7a to understand the impact of antifoam and the melter bubblers on glass redox chemistry. The samples were transferred to the Savannah River National Laboratory (SRNL) where they were analyzed.

  16. Off-gas chemistry study of melter feed by Springborn Laboratories. [Sludge-only and sludge-precipitate feed samples

    SciTech Connect

    Crow, K.R.

    1985-06-05

    The purpose of the off-gas chemistry study of melter feed samples was to support and help substantiate glass melter thermochemistry models developed for the DWPF. Both sludge-only and sludge-precipitate feed samples were analyzed. Each slurry sample was pyrolyzed at temperatures from 150 to 1000/sup 0/C in air and inert atmospheres, and the head space products were analyzed by chromatographic and mass spectrometric methods. Thermogravimetric, differential scanning calorimetric and Fourier transform infrared analyses were also performed on each sample. There were no unusually high exothermic reactions that would be cause for concern in the DWPF melter. Results for two types of sludge-precipitate feed were compared. One type contained simulated precipitate hydrolysis aqueous (PHA) product as fed to the SCM-2 melter. The second type contained PHA from the lab-scale acid hydrolysis reactor in 677-T. A major difference between the two types was a small, but distinct, presence of higher aromatics in gas from feed with reactor-produced PHA. This feed also evolved more CO and CO/sub 2/ than feed with simulated PHA at high pyrolytic temperatures (>750/sup 0/C). Recent analyses have identified the higher boiling aromatics in reactor-produced PHA as primarily diphenylamine and p-terphenyl. These compounds will be included in future PHA simulations that are fed to research melters. Under an inert atmosphere, benzene and phenol were the two most abundant organics evolved during pyrolysis of sludge-precipitate feed.

  17. DWPF COAL CARBON WASTE ACCEPTANCE CRITERIA LIMIT EVALUATION

    SciTech Connect

    Lambert, D.; Choi, A.

    2010-06-21

    A paper study was completed to assess the impact on the Defense Waste Processing Facility (DWPF)'s Chemical Processing Cell (CPC) acid addition and melter off-gas flammability control strategy in processing Sludge Batch 10 (SB10) to SB13 with an added Fluidized Bed Steam Reformer (FBSR) stream and two Salt Waste Processing Facility (SWPF) products (Strip Effluent and Actinide Removal Stream). In all of the cases that were modeled, an acid mix using formic acid and nitric acid could be achieved that would produce a predicted Reducing/Oxidizing (REDOX) Ratio of 0.20 Fe{sup +2}/{Sigma}Fe. There was sufficient formic acid in these combinations to reduce both the manganese and mercury present. Reduction of manganese and mercury are both necessary during Sludge Receipt and Adjustment Tank (SRAT) processing, however, other reducing agents such as coal and oxalate are not effective in this reduction. The next phase in this study will be experimental testing with SB10, FBSR, and both SWPF simulants to validate the assumptions in this paper study and determine whether there are any issues in processing these streams simultaneously. The paper study also evaluated a series of abnormal processing conditions to determine whether potential abnormal conditions in FBSR, SWPF or DWPF would produce melter feed that was too oxidizing or too reducing. In most of the cases that were modeled with one parameter at its extreme, an acid mix using formic acid and nitric acid could be achieved that would produce a predicted REDOX of 0.09-0.30 (target 0.20). However, when a run was completed with both high coal and oxalate, with minimum formic acid to reduce mercury and manganese, the final REDOX was predicted to be 0.49 with sludge and FBSR product and 0.47 with sludge, FBSR product and both SWPF products which exceeds the upper REDOX limit.

  18. ART CCIM PHASE II-A OFF-GAS SYSTEM EVALUATION TEST REPORT

    SciTech Connect

    Nick Soelberg

    2009-04-01

    AREVA Federal Services (AFS) is performing a multi-year, multi-phase Advanced Remediation Technologies (ART) project, sponsored by the U.S. Department of Energy (DOE), to evaluate the feasibility and benefits of replacing the existing joule-heated melter (JHM) used to treat high level waste (HLW) in the Defense Waste Processing Facility (DWPF) at the Savannah River Site with a cold crucible induction melter (CCIM). The AFS ART CCIM project includes several collaborators from AREVA subsidiaries, French companies, and DOE national laboratories. The Savannah River National Laboratory and the Commissariat a l’Energie Atomique (CEA) have performed laboratory-scale studies and testing to determine a suitable, high-waste-loading glass matrix. The Idaho National Laboratory (INL) and CEA are performing CCIM demonstrations at two different pilot scales to assess CCIM design and operation for treating SRS sludge wastes that are currently being treated in the DWPF. SGN is performing engineering studies to validate the feasibility of retrofitting CCIM technology into the DWPF Melter Cell. The long-term project plan includes more lab-testing, pilot- and large-scale demonstrations, and engineering activities to be performed during subsequent project phases. A simulant of the DWPF SB4 feed was successfully fed and melted in a small pilot-scale CCIM system during two test series. The OGSE tests provide initial results that (a) provide melter operating conditions while feeding a DWPF SB4 simulant feed, (b) determine the fate of feed organic and metal feed constituents and metals partitioning, and (c) characterize the melter off-gas source term to a downstream off-gas system. The INL CCIM test system was operated continuously for about 30 hours during the parametric test series, and for about 58 hours during the OGSE test. As the DWPF simulant feed was continuously fed to the melter, the glass level gradually increased until a portion of the molten glass was drained from the melter

  19. Final Report - Glass Formulation Development and Testing for DWPF High AI2O3 HLW Sludges, VSL-10R1670-1, Rev. 0, dated 12/20/10

    SciTech Connect

    Kruger, Albert A.; Pegg, I. L.; Kot, W. K.; Gan, H.; Matlack, K. S.

    2013-11-13

    The principal objective of the work described in this Final Report is to develop and identify glass frit compositions for a specified DWPF high-aluminum based sludge waste stream that maximizes waste loading while maintaining high production rate for the waste composition provided by ORP/SRS. This was accomplished through a combination of crucible-scale, vertical gradient furnace, and confirmation tests on the DM100 melter system. The DM100-BL unit was selected for these tests. The DM100-BL was used for previous tests on HLW glass compositions that were used to support subsequent tests on the HLW Pilot Melter. It was also used to process compositions with waste loadings limited by aluminum, bismuth, and chromium, to investigate the volatility of cesium and technetium during the vitrification of an HLW AZ-102 composition, to process glass formulations at compositional and property extremes, and to investigate crystal settling on a composition that exhibited one percent crystals at 963{degrees}C (i.e., close to the WTP limit). The same melter was selected for the present tests in order to maintain comparisons between the previously collected data. The tests provide information on melter processing characteristics and off-gas data, including formation of secondary phases and partitioning. Specific objectives for the melter tests are as follows: Determine maximum glass production rates without bubbling for a simulated SRS Sludge Batch 19 (SB19). Demonstrate a feed rate equivalent to 1125 kg/m{sup 2}/day glass production using melt pool bubbling. Process a high waste loading glass composition with the simulated SRS SB19 waste and measure the quality of the glass product. Determine the effect of argon as a bubbling gas on waste processing and the glass product including feed processing rate, glass redox, melter emissions, etc.. Determine differences in feed processing and glass characteristics for SRS SB19 waste simulated by the co-precipitated and direct

  20. Lid heater for glass melter

    DOEpatents

    Phillips, Terrance D.

    1993-01-01

    A glass melter having a lid electrode for heating the glass melt radiantly. The electrode comprises a series of INCONEL 690 tubes running above the melt across the melter interior and through the melter walls and having nickel cores inside the tubes beginning where the tubes leave the melter interior and nickel connectors to connect the tubes electrically in series. An applied voltage causes the tubes to generate heat of electrical resistance for melting frit injected onto the melt. The cores limit heat generated as the current passes through the walls of the melter. Nickel bus connection to the electrical power supply minimizes heat transfer away from the melter that would occur if standard copper or water-cooled copper connections were used between the supply and the INCONEL 690 heating tubes.

  1. Lid heater for glass melter

    DOEpatents

    Phillips, T.D.

    1993-12-14

    A glass melter having a lid electrode for heating the glass melt radiantly. The electrode comprises a series of INCONEL 690 tubes running above the melt across the melter interior and through the melter walls and having nickel cores inside the tubes beginning where the tubes leave the melter interior and nickel connectors to connect the tubes electrically in series. An applied voltage causes the tubes to generate heat of electrical resistance for melting frit injected onto the melt. The cores limit heat generated as the current passes through the walls of the melter. Nickel bus connection to the electrical power supply minimizes heat transfer away from the melter that would occur if standard copper or water-cooled copper connections were used between the supply and the INCONEL 690 heating tubes. 3 figures.

  2. ANALYSIS OF DWPF SLUDGE BATCH 6 (MACROBATCH 7) POUR STREAM GLASS SAMPLES

    SciTech Connect

    Johnson, F.

    2012-01-20

    The Defense Waste Processing Facility (DWPF) began processing Sludge Batch 6 (SB6), also referred to as Macrobatch 7 (MB7), in June 2010. SB6 is a blend of the heel of Tank 40 from Sludge Batch 5 (SB5), H-Canyon Np transfers and SB6 that was transferred to Tank 40 from Tank 51.1 SB6 was processed using Frit 418. Sludge is received into the DWPF Chemical Processing Cell (CPC) and is processed through the Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator Tank (SME). The treated sludge slurry is then transferred to the Melter Feed Tank (MFT) and fed to the melter. During processing of each sludge batch, the DWPF is required to take at least one glass sample to meet the objectives of the Glass Product Control Program (GPCP) and to complete the necessary Production Records so that the final glass product may be disposed of at a Federal Repository. The DWPF requested various analyses of radioactive glass samples obtained from the melter pour stream during processing of SB6 as well as reduction/oxidation (REDOX) analysis of MFT samples to determine the impact of Argon bubbling. Sample analysis followed the Task Technical and Quality Assurance Plan (TTQAP) and an Analytical Study Plan (ASP). Four Pour Stream (PS) glass samples and two MFT slurry samples were delivered to the Savannah River National Laboratory (SRNL) from the DWPF. Table 1-1 lists the sample information for each pour stream glass sample. SB6 PS3 (S03472) was selected as the official pour stream sample for SB6 and full analysis was requested. This report details the visual observations of the as-received SB6 PS No.3 glass sample as well as results for the chemical composition, Product Consistency Test (PCT), radionuclide content, noble metals, and glass density. REDOX results will be provided for all four pour stream samples and vitrified samples of MFT-558 and MFT-568A. Where appropriate, data from other pour stream samples will be provided.

  3. Energy Efficient Glass Melting - The Next Generation Melter

    SciTech Connect

    David Rue

    2008-03-01

    The objective of this project is to demonstrate a high intensity glass melter, based on the submerged combustion melting technology. This melter will serve as the melting and homogenization section of a segmented, lower-capital cost, energy-efficient Next Generation Glass Melting System (NGMS). After this project, the melter will be ready to move toward commercial trials for some glasses needing little refining (fiberglass, etc.). For other glasses, a second project Phase or glass industry research is anticipated to develop the fining stage of the NGMS process.

  4. Application of the Evacuated Canister System for Removing Residual Molten Glass From the West Valley Demonstration Project High-Level Waste Melter

    SciTech Connect

    May, Joseph J.; Dombrowski, David J.; Valenti, Paul J.; Houston, Helene M.

    2003-02-27

    The principal mission of the West Valley Demonstration Project (WVDP) is to meet a series of objectives defined in the West Valley Demonstration Project Act (Public Law 96-368). Chief among these is the objective to solidify liquid high-level waste (HLW) at the WVDP site into a form suitable for disposal in a federal geologic repository. In 1982, the Secretary of Energy formally selected vitrification as the technology to be used to solidify HLW at the WVDP. One of the first steps in meeting the HLW solidification objective involved designing, constructing and operating the Vitrification (Vit) Facility, the WVDP facility that houses the systems and subsystems used to process HLW into stainless steel canisters of borosilicate waste-glass that satisfy waste acceptance criteria (WAC) for disposal in a federal geologic repository. HLW processing and canister production began in 1996. The final step in meeting the HLW solidification objective involved ending Vit system operations and shut ting down the Vit Facility. This was accomplished by conducting a discrete series of activities to remove as much residual material as practical from the primary process vessels, components, and associated piping used in HLW canister production before declaring a formal end to Vit system operations. Flushing was the primary method used to remove residual radioactive material from the vitrification system. The inventory of radioactivity contained within the entire primary processing system diminished by conducting the flushing activities. At the completion of flushing activities, the composition of residual molten material remaining in the melter (the primary system component used in glass production) consisted of a small quantity of radioactive material and large quantities of glass former materials needed to produce borosilicate waste-glass. A special system developed during the pre-operational and testing phase of Vit Facility operation, the Evacuated Canister System (ECS), was

  5. Cold Crucible Induction Melter Technology: Results of Laboratory Directed Research and Development

    SciTech Connect

    Gombert, Dirk; Richardson, John Grant

    2001-09-01

    This report provides a review of cold crucible induction melter (CCIM) technology and presents summaries of alternatives and design issues associated with major system components. The objective in this report is to provide background systems level information relating to development and application of cold crucible induction-heated melter technology for radiological waste processing. Included is a detailed description of the bench-top melter system at the V. G. Khlopin Radium Institute currently being used for characterization testing

  6. Melter Glass Removal and Dismantlement

    SciTech Connect

    Richardson, BS

    2000-10-31

    The U.S. Department of Energy (DOE) has been using vitrification processes to convert high-level radioactive waste forms into a stable glass for disposal in waste repositories. Vitrification facilities at the Savannah River Site (SRS) and at the West Valley Demonstration Project (WVDP) are converting liquid high-level waste (HLW) by combining it with a glass-forming media to form a borosilicate glass, which will ensure safe long-term storage. Large, slurry fed melters, which are used for this process, were anticipated to have a finite life (on the order of two to three years) at which time they would have to be replaced using remote methods because of the high radiation fields. In actuality the melters useable life spans have, to date, exceeded original life-span estimates. Initial plans called for the removal of failed melters by placing the melter assembly into a container and storing the assembly in a concrete vault on the vitrification plant site pending size-reduction, segregation, containerization, and shipment to appropriate storage facilities. Separate facilities for the processing of the failed melters currently do not exist. Options for handling these melters include (1) locating a facility to conduct the size-reduction, characterization, and containerization as originally planned; (2) long-term storing or disposing of the complete melter assembly; and (3) attempting to refurbish the melter and to reuse the melter assembly. The focus of this report is to look at methods and issues pertinent to size-reduction and/or melter refurbishment in particular, removing the glass as a part of a refurbishment or to reduce contamination levels (thus allowing for disposal of a greater proportion of the melter as low level waste).

  7. DWPF GC FILTER ASSEMBLY SAMPLING AND ANALYSIS

    SciTech Connect

    Bannochie, C.; Imrich, K.

    2009-11-11

    On March 18, 2009 a Defense Waste Processing Facility (DWPF) GC Line Filter Assembly was received at the Savannah River National Laboratory (SRNL). This filter assembly was removed from operation following the completion of Sludge Batch 4 processing in the DWPF. Work on this sample was requested in a Technical Assistance Request. This document reports the pictures, observations, samples collected, and analytical results for the assembly. The assembly arrived at SRNL separated into its three component filters: high efficiency particulate air (HEPA)-1, HEPA-2, and a high efficiency mist evaporator (HEME). Each stage of the assembly's media was sampled and examined visually and by scanning electron microscopy (SEM). Solids built up in the filter housing following the first stage HEME, were dissolved in dilute nitric acid and analyzed by ICP-AES and the undissolved white solids were analyzed by x-ray diffraction (XRD). The vast majority of the material in each of the three stages of the DWPF GC Line Filter Assembly appears to be contaminated with a Hg compound that is {approx}59 wt% Hg on a total solids basis. The Hg species was identified by XRD analysis to contain a mixture of Hg{sub 4}(OH)(NO{sub 3}){sub 3} and Hg{sub 10}(OH){sub 4}(NO{sub 3}){sub 6}. Only in the core sample of the second stage HEPA, did this material appear to be completely covering portions of the filter media, possibly explaining the pressure drops observed by DWPF. The fact that the material migrates through the HEME filter and both HEPA filters, and that it was seen collecting on the outlet side of the HEME filter, would seem to indicate that these filters are not efficient at removing this material. Further SRAT off-gas system modeling should help determine the extent of Hg breakthrough past the Mercury Water Wash Tank (MWWT). The SRAT off-gas system has not been modeled since startup of the facility. Improvements to the efficiency of Hg stripping prior to the ammonia scrubber would seem to be

  8. Design and performance of a 100-kg/h, direct calcine-fed electric-melter system for nuclear-waste vitrification

    SciTech Connect

    Dierks, R.D.

    1980-11-01

    This report describes the physical characteristics of a ceramic-lined, joule-heated glass melter that is directly connected to the discharge of a spray calciner and is currently being used to study the vitrification of simulated nuclear-waste slurries. Melter performance characteristics and subsequent design improvements are described. The melter contains 0.24 m/sup 3/ of glass with a glass surface area of 0.76 m/sup 2/, and is heated by the flow of an alternating current (ranging from 600 to 1200 amps) between two Inconel-690 slab-type electrodes immersed in the glass at either end of the melter tank. The melter was maintained at operating temperature (900 to 1260/sup 0/C) for 15 months, and produced 62,000 kg of glass. The maximum sustained operating period was 122 h, during which glass was produced at the rate of 70 kg/h.

  9. LFCM (liquid-fed ceramic melter) vitrification technology: Quarterly progress report, October-December 1986

    SciTech Connect

    Brouns, R.A.; Allen, C.R.; Powell, J.A.

    1987-09-01

    This report describes the progress in developing, testing, applying, and documenting liquid-fed ceramic melter (LFCM) vitrification technology. Progress in the following technical subject areas during the first quarter of FY 1987 is discussed. Topics include melting process chemistry and glass development, feed preparation and transfer systems, melter systems, off-gas systems, canister filling and handling systems, and process/product modeling.

  10. LFCM (liquid-fed ceramic melter) vitrification technology: Quarterly progress report, July-September 1986

    SciTech Connect

    Burkholder, H.C.; Allen, C.R.; Andersen, C.M.; Bates, S.O.; Dierks, R.D.; Faletti, D.W.; Farnsworth, R.K.; Goles, R.W.; Kuhn, W.L.; Nakaoka, R.K.: Perez, J.M Jr.; Peters, R.D.; Peterson, M.E.; Pulsipher, B.A.; Reimus, P.W.

    1987-06-01

    Individual papers are processed separately for the data bases. This report documents progress on liquid-fed ceramic melter (LFCM) vitrification technology. Progress in melting process chemistry and glass development, feed preparation and transfer systems, melter systems, off-gas systems, and process/product modeling and control is discussed.

  11. FINAL REPORT START-UP AND COMMISSIONING TESTS ON THE DURAMELTER 1200 HLW PILOT MELTER SYSTEM USING AZ-101 HLW SIMULANTS VSL-01R0100-2 REV 0 1/20/03

    SciTech Connect

    KRUGER AA; MATLACK KS; KOT WK; BRANDYS M; WILSON CN; SCHATZ TR; GONG W; PEGG IL

    2011-12-29

    This document provides the final report on data and results obtained from commissioning tests performed on the one-third scale DuraMelter{trademark} 1200 (DM 1200) HLW Pilot Melter system that has been installed at VSL with an integrated prototypical off-gas treatment system. That system has replaced the DM1000 system that was used for HLW throughput testing during Part BI [1]. Both melters have similar melt surface areas (1.2 m{sup 2}) but the DM1200 is prototypical of the present RPP-WTP HLW melter design whereas the DM1000 was not. These tests were performed under a corresponding RPP-WTP Test Specification and associated Test Plan. This report is a followup to the previously issued Preliminary Data Summary Report. The DM1200 system will be used for testing and confirmation of basic design, operability, flow sheet, and process control assumptions as well as for support of waste form qualification and permitting. This will include data on processing rates, off-gas treatment system performance, recycle stream compositions, as well as process operability and reliability. Consequently, this system is a key component of the overall HLW vitrification development strategy. The results presented in this report are from the initial series of short-duration tests that were conducted to support the start-up and commissioning of this system prior to conducting the main body of development tests that have been planned for this system. These tests were directed primarily at system 'debugging,' operator training, and procedure refinement. The AZ-101 waste simulant and glass composition that was used for previous testing was selected for these tests.

  12. Canister disposition plan for the DWPF Startup Test Program. Revision 1

    SciTech Connect

    Harbour, J.R.; Payne, C.H.

    1990-12-31

    This report details the disposition of canisters and the canistered waste forms produced during the DWPF Startup Test Program. The six melter campaigns (DWPF Startup Tests FA-13, WP-14, WP-15, WP-16, WP-17, and FA-18) will produce 126 canistered waste forms. In addition, up to 20 additional canistered waste forms may be produced from glass poured during the transition between campaigns. In particular, this canister disposition plan (1) assigns (by alpha-numeric code) a specific canister to each location in the six campaign sequences, (2) describes the method of access for glass sampling on each canistered waste form, (3) describes the nature of the specific tests which will be carried out, (4) details which tests will be carried out on each canistered waste form, (5) provides the sequence of these tests for each canistered waste form, and (6) assigns a storage location for each canistered waste form. The tests are designed to provide evidence, as detailed in the Waste Form Compliance Plan (WCP{sup 1}), that the DWPF product will comply with the Waste Acceptance Product Specifications (WAPS{sup 2}). The WAPS must be met before the canistered waste form is accepted by DOE for ultimate disposal at the Federal Repository. The results of these tests will be included in the Waste Form Qualification Report (WQR).

  13. Vitrification of noble metals containing NCAW simulant with an engineering scale melter (ESM): Campaign report

    SciTech Connect

    Grunewald, W.; Roth, G.; Tobie, W.; Weisenburger, S.; Weiss, K.; Elliott, M.; Eyler, L.L.

    1996-03-01

    ESM has been designed as a 10th-scale model of the DWPF-type melter, currently the reference melter for nitrification of Hanford double shell tankwaste. ESM and related equipment have been integrated to the existing mockup vitrification plant VA-WAK at KfK. On June 2-July 10, 1992, a shakedown test using 2.61 m{sup 3} of NCAW (neutralized current acid waste) simulant without noble metals was performed. On July 11-Aug. 30, 1992, 14.23 m{sup 3} of the same simulant with nominal concentrations of Ru, Rh, and Pd were vitrified. Objective was to investigate the behavior of such a melter with respect to discharge of noble metals with routine glass pouring via glass overflow. Results indicate an accumulation of noble metals in the bottom area of the flat-bottomed ESM. About 65 wt% of the noble metals fed to the melter could be drained out, whereas 35 wt% accumulated in the melter, based on analysis of glass samples from glass pouring stream in to the canisters. After the melter was drained at the end of the campaign through a bottom drain valve, glass samples were taken from the residual bottom layer. The samples had significantly increased noble metals content (factor of 20-45 to target loading). They showed also a significant decrease of the specific electric resistance compared to bulk glass (factor of 10). A decrease of 10- 15% of the resistance between he power electrodes could be seen at the run end, but the total amount of noble metals accumulated was not yet sufficient enough to disturb the Joule heating of the glass tank severely.

  14. Letter report: Cold crucible melter assessment

    SciTech Connect

    Elliott, M.L.

    1996-03-01

    One of the activities of the PNL Vitrification Technology Development (PVTD) Project is to assist the Tank Waste Remediation Systems (TWRS) Program in determining which melter systems should be performance tested for potential implementation in the high-level waste (HLW) vitrification plant. The Richland Operations Office (RL) has recommended that the Cold Crucible Melter (CCM) be evaluated as a candidate ``next generation`` melter. As a result, the CCM System Evaluation cost account was established under the PVTD Project so that the CCM could be initially assessed on a high-priority basis. This letter report summarizes a brief initial review and assessment of the CCM. Using the recommendations made in this document, Westinghouse Hanford Company (WHC) and RL will make a decision regarding the urgency of performance testing the CCM. If the decision is favorable, a subcontract will be negotiated for performance testing of a CCM using Hanford HLW simulants in a pilot-scale facility. Because of the aggressive nature of the schedule, the CCM evaluation was not rigorous. The evaluation consisted of a literature review and interviews with proponents of the technology during a recent trip to France. This letter report summarizes the evaluation and makes recommendations regarding further work in this area.

  15. Induction melter apparatus

    DOEpatents

    Roach, Jay A [Idaho Falls, ID; Richardson, John G [Idaho Falls, ID; Raivo, Brian D [Idaho Falls, ID; Soelberg, Nicholas R [Idaho Falls, ID

    2008-06-17

    Apparatus and methods of operation are provided for a cold-crucible-induction melter for vitrifying waste wherein a single induction power supply may be used to effect a selected thermal distribution by independently energizing at least two inductors. Also, a bottom drain assembly may be heated by an inductor and may include an electrically resistive heater. The bottom drain assembly may be cooled to solidify molten material passing therethrough to prevent discharge of molten material therefrom. Configurations are provided wherein the induction flux skin depth substantially corresponds with the central longitudinal axis of the crucible. Further, the drain tube may be positioned within the induction flux skin depth in relation to material within the crucible or may be substantially aligned with a direction of flow of molten material within the crucible. An improved head design including four shells forming thermal radiation shields and at least two gas-cooled plenums is also disclosed.

  16. DWPF Recycle Evaporator Simulant Tests

    SciTech Connect

    Stone, M

    2005-04-05

    Testing was performed to determine the feasibility and processing characteristics of an evaporation process to reduce the volume of the recycle stream from the Defense Waste Processing Facility (DWPF). The concentrated recycle would be returned to DWPF while the overhead condensate would be transferred to the Effluent Treatment Plant. Various blends of evaporator feed were tested using simulants developed from characterization of actual recycle streams from DWPF and input from DWPF-Engineering. The simulated feed was evaporated in laboratory scale apparatus to target a 30X volume reduction. Condensate and concentrate samples from each run were analyzed and the process characteristics (foaming, scaling, etc) were visually monitored during each run. The following conclusions were made from the testing: Concentration of the ''typical'' recycle stream in DWPF by 30X was feasible. The addition of DWTT recycle streams to the typical recycle stream raises the solids content of the evaporator feed considerably and lowers the amount of concentration that can be achieved. Foaming was noted during all evaporation tests and must be addressed prior to operation of the full-scale evaporator. Tests were conducted that identified Dow Corning 2210 as an antifoam candidate that warrants further evaluation. The condensate has the potential to exceed the ETP WAC for mercury, silicon, and TOC. Controlling the amount of equipment decontamination recycle in the evaporator blend would help meet the TOC limits. The evaporator condensate will be saturated with mercury and elemental mercury will collect in the evaporator condensate collection vessel. No scaling on heating surfaces was noted during the tests, but splatter onto the walls of the evaporation vessels led to a buildup of solids. These solids were difficult to remove with 2M nitric acid. Precipitation of solids was not noted during the testing. Some of the aluminum present in the recycle streams was converted from gibbsite to

  17. FINAL REPORT MELTER TESTS WITH AZ-101 HLW SIMULANT USING A DURAMELTER 100 VITRIFICATION SYSTEM VSL-01R10N0-1 REV 1 2/25/02

    SciTech Connect

    KRUGER AA; MATLACK KS; KOT WK; PEGG IL

    2011-12-29

    This report provides data, analyses, and conclusions from a series of tests that were conducted at the Vitreous State Laboratory of The Catholic of America (VSL) to determine the processing rates that are achievable with AZ-101 HLW simulants and corresponding melter feeds on a DuraMelter 100 (DM100) vitrification system. One of the most critical pieces of information in determining the required size of the RPP-WTP HLW melter is the specific glass production rate in terms of the mass of glass that can be produced per unit area of melt surface per unit time. The specific glass production rate together with the waste loading (essentially, the ratio of waste-in to glass-out, which is determined from glass formulation activities) determines the melt area that is needed to achieve a given waste processing rate with due allowance for system availability. Tests conducted during Part B1 (VSL-00R2590-2) on the DM1000 vitrification system installed at the Vitreous State Laboratory of The Catholic University of America showed that, without the use of bubblers, glass production rates with AZ-101 and C-106/AY-102 simulants were significantly lower than the Project design basis rate of 0.4 MT/m{sup 2}/d. Conversely, three-fold increases over the design basis rate were demonstrated with the use of bubblers. Furthermore, an un-bubbled control test using a replica of the melter feed used in cold commissioning tests at West Valley reproduced the rates that were observed with that feed on the WVDP production melter. More recent tests conducted on the DM1200 system, which more closely represents the present RPP-WTP design, are in general agreement with these earlier results. Screening tests conducted on the DM10 system have provided good indications of the larger-scale processing rates with bubblers (for both HL W and LAW feeds) but significantly overestimated the DM1000 un-bubbled rate observed for C-106/AY-102 melter feeds. This behavior is believed to be a consequence of the role of

  18. Hanford Waste Vitrification program pilot-scale ceramic melter Test 23

    SciTech Connect

    Goles, R.W.; Nakaoka, R.K.

    1990-02-01

    The pilot-scale ceramic melter test, was conducted to determine the vitrification processing characteristics of simulated Hanford Waste Vitrification Plant process slurries and the integrated performance of the melter off-gas treatment system. Simulated melter feed was prepared and processed to produce glass. The vitrification system, achieved an on-stream efficiency of greater than 98%. The melter off-gas treatment system included a film cooler, submerged bed scrubber, demister, high-efficiency mist eliminator, preheater, and high-efficiency particulate air filter (HEPA). Evaluation of the off-gas system included the generation, nature, and capture efficiency of gross particulate, semivolatile, and noncondensible melter products. 17 refs., 48 figs., 61 tabs.

  19. Statistical analysis of the DWPF prototypic sampler

    SciTech Connect

    Postles, R.L.; Reeve, C.P.; Jenkins, W.J.; Bickford, D.F.

    1991-12-31

    The DWPF process will be controlled using assay measurements on samples of feed slurry. These slurries are radioactive, and thus will be sampled remotely. A Hydraguard{trademark} pump-driven sampler system will be used as the remote sampling device. A prototype Hydraguard{trademark} sampler has been studied in a full-scale mock-up of a DWPF process vessel. Two issues were of dominant interest: (1) what accuracy and precision can be provided by such a pump-driven sampler in the face of the slurry rheology; and, if the Hydraguard{trademark} sample accurately represents the slurry in its local area, (2) is the slurry homogeneous enough throughout for it to represent the entire vessel? To determine Hydraguard{trademark} Accuracy, a Grab Sampler of simpler mechanism was used as reference. This (Low) Grab Sampler was located as near to the intake port of the Hydraguard{trademark} as could be arranged. To determine Homogeneity, a second (High) Grab Sampler was located above the first. The data necessary to these determinations comes from the measurement system, so its important variables also affect the results. Thus, the design of the test involved not just Sampling variables, but also some of the Measurement variables as well. However, the main concern was the Sampler and not the Measurement System, so the test design included only such measurement variables as could not be circumvented (Vials, Dissolution Method, and Aliquoting). The test was executed by, or under the direct oversight of, expert technologists. It thus did not explore the many important particulars of ``routine`` plant operations (such as Remote Sample Preparation or Laboratory Shift Operation).

  20. Statistical analysis of the DWPF prototypic sampler

    SciTech Connect

    Postles, R.L.; Reeve, C.P.; Jenkins, W.J.; Bickford, D.F.

    1991-01-01

    The DWPF process will be controlled using assay measurements on samples of feed slurry. These slurries are radioactive, and thus will be sampled remotely. A Hydraguard{trademark} pump-driven sampler system will be used as the remote sampling device. A prototype Hydraguard{trademark} sampler has been studied in a full-scale mock-up of a DWPF process vessel. Two issues were of dominant interest: (1) what accuracy and precision can be provided by such a pump-driven sampler in the face of the slurry rheology; and, if the Hydraguard{trademark} sample accurately represents the slurry in its local area, (2) is the slurry homogeneous enough throughout for it to represent the entire vessel To determine Hydraguard{trademark} Accuracy, a Grab Sampler of simpler mechanism was used as reference. This (Low) Grab Sampler was located as near to the intake port of the Hydraguard{trademark} as could be arranged. To determine Homogeneity, a second (High) Grab Sampler was located above the first. The data necessary to these determinations comes from the measurement system, so its important variables also affect the results. Thus, the design of the test involved not just Sampling variables, but also some of the Measurement variables as well. However, the main concern was the Sampler and not the Measurement System, so the test design included only such measurement variables as could not be circumvented (Vials, Dissolution Method, and Aliquoting). The test was executed by, or under the direct oversight of, expert technologists. It thus did not explore the many important particulars of routine'' plant operations (such as Remote Sample Preparation or Laboratory Shift Operation).

  1. Graphite electrode arc melter demonstration Phase 2 test results

    SciTech Connect

    Soelberg, N.R.; Chambers, A.G.; Anderson, G.L.; O`Connor, W.K.; Oden, L.L.; Turner, P.C.

    1996-06-01

    Several U.S. Department of Energy organizations and the U.S. Bureau of Mines have been collaboratively conducting mixed waste treatment process demonstration testing on the near full-scale graphite electrode submerged arc melter system at the Bureau`s Albany (Oregon) Research Center. An initial test series successfully demonstrated arc melter capability for treating surrogate incinerator ash of buried mixed wastes with soil. The conceptual treatment process for that test series assumed that buried waste would be retrieved and incinerated, and that the incinerator ash would be vitrified in an arc melter. This report presents results from a recently completed second series of tests, undertaken to determine the ability of the arc melter system to stably process a wide range of {open_quotes}as-received{close_quotes} heterogeneous solid mixed wastes containing high levels of organics, representative of the wastes buried and stored at the Idaho National Engineering Laboratory (INEL). The Phase 2 demonstration test results indicate that an arc melter system is capable of directly processing these wastes and could enable elimination of an up-front incineration step in the conceptual treatment process.

  2. High Temperature Inspection System

    SciTech Connect

    Robinson, C.W.

    1999-01-26

    The Remote and Specialty Equipment Section (RSES) of the Savannah River Technology Center has developed a High Temperature Inspection System (HTIS) for remotely viewing the interior of the Defense Waste Processing Facility (DWPF) melter pour spout. The DWPF is a vitrification facility at the Savannah River Site where radioactive waste is processed, mixed and melted with glass frit in an electrically heated melter, and poured into canisters for long-term storage. The glass mixture is transferred from the melter to the canisters via the pour spout, a vertical interface between the melter and the canisters. During initial operation of the melter, problems were experienced with wicking of the glass stream to the sides of the pour spout resulting in pluggage of the pour spout. A removable insert was developed to eliminate the wicking problem. Routine cleaning of the pour spout and replacement of the insert requires that the pour spout interior be inspected on a regular basis. The HTIS was developed to perform the inspection. The HTIS provides two video images: one view for aligning the HTIS with the pour spout and the other for inspecting the pour spout wall condition and other surfaces. The HTIS is carried into the melter cell using an overhead crane and is remotely connected to the cell's telerobotic manipulator (TRM). An operator uses the TRM to insert the HTIS into the 2-inch (5.08 cm) diameter pour spout, rotate it 360 degrees, and then remove it. This application created many challenges for the inspection device, especially regarding size and temperature. The HTIS design allows the video cameras to stay below a safe operating temperature during use in the 1100 degrees C environment. Many devices are designed to penetrate a wall and extend into a heated chamber only a few inches, but the HTIS is inserted into the heated chamber 22 inches (55.88 cm). Other devices can handle the insertion length and small diameter, but they are not designed to handle the high

  3. Effect of melter residence time and temperature on Defense Waste Processing Facility glass durability

    SciTech Connect

    Cicero, C.A.

    1994-06-01

    The Defense Waste Processing Facility (DWPF) located at the Savannah River Site (SRS) in Aiken, South Carolina, is currently scheduled to vitrify more than 130 million liters of High Level Waste (HLW). The glass product that will be produced must meet certain specifications, as defined in the Waste Acceptance Product Specifications (WAPS), in order for the DWPF canistered waste forms to be sent to the Civilian Radioactive Waste Management System (repository). WAPS 1.3 requires that the DWPF produce a consistent product, which is better than the Environmental Assessment (EA) glass as measured by the B, Na, and Li release from the Product Consistency Test (PCT).

  4. Analysis of Sludge Batch 3 (Macrobatch4) DWPF Pour Stream Glass Sample for Canister s02312

    SciTech Connect

    Bannochie, C

    2005-09-01

    The Defense Waste Processing Facility (DWPF) began processing Sludge Batch 3 (SB3), Macrobatch 4 (MB4) in March 2004 as part of Sludge Receipt and Adjustment Tank (SRAT) Batch 272. Sludge Batch 3 is a blend of the contents Tank 40 remaining from Sludge Batch 2 (SB2), the sludge that was transferred to Tank 40 from Tank 51 and Canyon Np solution additions made directly to Tank 40. The sludge transferred from Tank 51 contained sludges from Tanks 7, 18 and 19 along with precipitated solutions of U, Pu/Gd and Am/Cm from the F and H Canyons. The blend of sludge from Tank 51, Tank 40, and the Canyon additions defines SB3 (or MB4). The sludge slurry is received into the DWPF Chemical Processing Cell (CPC) and is processed through the SRAT and Slurry Mix Evaporator (SME) Tank and fed to the melter. During the processing of each sludge batch, the DWPF is required to take at least one glass sample. This glass sample is taken to meet the objectives of the Glass Product Control Program and complete the necessary Production Records so that the final glass product may be disposed of at a Federal Repository. Two glass samples were obtained while pouring Canisters S02312 and S02315 which were sent to the Savannah River National Laboratory's (SRNL) Shielded Cells Facility. Sample S02312 was designated for analysis, while sample S02315 was designated for archival storage. This report contains the visual observations of the as-received glass sample, results for the density, chemical composition, the Product Consistency Test (PCT) and the calculated and measured radionuclide results needed for the Production Record for Canister S02312. The following conclusions were drawn from the examination of this DWPF pour stream glass sample: (1) The glass sample taken during the filling of DWPF Canister S02312 weighed 41.69 g and was generally dark and reflective. (2) Minor inclusions, on the order of 1 {micro}m in size, of noble metals were seen in the glass via contained scanning electron

  5. EVALUATION OF MIXING IN THE SLURRY MIX EVAPORATOR AND MELTER FEED TANK

    SciTech Connect

    MARINIK, ANDREW

    2004-08-01

    The Defense Waste Processing Facility (DWPF) vitrifies High Level radioactive Waste (HLW) currently stored in underground tanks at the Savannah River Site (SRS). The HLW currently being processed is a waste sludge composed primarily of metal hydroxides and oxides in caustic slurry. These slurries are typically characterized as Bingham Plastic fluids. The HLW undergoes a pretreatment process in the Chemical Process Cell (CPC) at DWPF. The processed HLW sludge is then transferred to the Sludge Receipt and Adjustment Tank (SRAT) where it is acidified with nitric and formic acid then evaporated to concentrate the solids. Reflux boiling is used to strip mercury from the waste and then the waste is transferred to the Slurry Mix Evaporator tank (SME). Glass formers are added as a frit slurry to the SME to prepare the waste for vitrification. This mixture is evaporated in the SME to the final concentration target. The frit slurry mixture is then transferred to the Melter Feed Tank (MFT) to be fed to the melter.

  6. Compilation of information on melter modeling

    SciTech Connect

    Eyler, L.L.

    1996-03-01

    The objective of the task described in this report is to compile information on modeling capabilities for the High-Temperature Melter and the Cold Crucible Melter and issue a modeling capabilities letter report summarizing existing modeling capabilities. The report is to include strategy recommendations for future modeling efforts to support the High Level Waste (HLW) melter development.

  7. LFCM (liquid-fed ceramic melter) processing characteristics of mercury

    SciTech Connect

    Goles, R.W.; Sevigny, G.J.; Andersen, C.M.

    1990-06-01

    An experimental-scale liquid-fed ceramic melter was used in a series of tests to evaluate the processing characteristics of mercury in simulated defense waste under various melter operating conditions. This solidification technology had no detectable capacity for incorporating mercury into its borosilicate, vitreous, product, and essentially all the mercury fed to the melter was lost to the off-gas system as gaseous effluent. An ejector venturi scrubber condensed and collected 97% of the mercury evolved from the melter. Chemically the condensed mercury effluent was composed entirely of chlorides, and except in a low-temperature test, mercury chlorides (Hg{sub 2}Cl{sub 2}) was the primary chloride formed. As a result, combined mercury accounted for most of the insoluble mass collected by the process quench scrubber. Although macroscopic quantities of elemental mercury were never observed in process secondary waste streams, finely divided and dispersed mercury that blackened all condensed Hg{sub 2}Cl{sub 2} residues was capable of saturating the quenched process exhaust with mercury vapor. However, the vapor pressure of mercury in the quenched melter exhaust was easily and predictably controlled with an off-gas stream chiller. 5 refs., 4 figs., 12 tabs.

  8. Characterization of DWPF recycle condensate materials

    SciTech Connect

    Bannochie, C. J.; Adamson, D. J.; King, W. D.

    2015-04-01

    A Defense Waste Processing Facility (DWPF) Recycle Condensate Tank (RCT) sample was delivered to the Savannah River National Laboratory (SRNL) for characterization with particular interest in the concentration of I-129, U-233, U-235, total U, and total Pu. Since a portion of Salt Batch 8 will contain DWPF recycle materials, the concentration of I-129 is important to understand for salt batch planning purposes. The chemical and physical characterizations are also needed as input to the interpretation of future work aimed at determining the propensity of the RCT material to foam, and methods to remediate any foaming potential. According to DWPF the Tank Farm 2H evaporator has experienced foaming while processing DWPF recycle materials. The characterization work on the RCT samples has been completed and is reported here.

  9. Measurement of DWPF glass viscosity - Final Report

    SciTech Connect

    Harbour, J.R.

    2000-02-17

    This report details the results of a scoping study funded by the Defense Waste Processing Facility (DWPF) for the measurement of melt viscosities for simulated glasses representative of Macrobatch 2 (Tank 42/51 feed).

  10. HWVP melter lifetime prediction letter

    SciTech Connect

    Eyler, L.L.; Mahoney, L.A.; Elliott, M.L.

    1996-03-01

    Preliminary predictions were made of the time to reach hypothesized operational limits of the HWVP melter due to build up of a noble metals sludge layer on the melter floor. Predictions were made with the TEMPEST computer program, Version T2.9h, for use in the MPA activity in the Pacific Northwest Laboratory`s (PNL) Hanford Waste Vitrification Plant (HWVP) Technology Development (PHTD) effort. The NWEST computer program (Trent and Eyler 1993) is a PNL-MA-70/Part 2 -- Good Practices Standard (QA Level III) research and development software tool.

  11. Technical bases for the DWPF testing program

    SciTech Connect

    Plodinec, M.J.

    1990-09-17

    The Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS) will be the first production facility in the United States for the immobilization of high-level nuclear waste. Production of DWPF canistered wasteforms will begin prior to repository licensing, so decisions on facility startup will have to be made before the final decisions on repository design are made. The Department of Energy's Office of Civilian Radioactive Waste Management (RW) has addressed this discrepancy by defining a Waste Acceptance Process. This process provides assurance that the borosilicate-glass wasteform, in a stainless-steel canister, produced by the DWPF will be acceptable for permanent storage in a federal repository. As part of this process, detailed technical specifications have been developed for the DWPF product. SRS has developed detailed strategies for demonstrating compliance with each of the Waste Acceptance Process specifications. An important part of the compliance is the testing which will be carried out in the DWPF. In this paper, the bases for each of the tests to be performed in the DWPF to establish compliance with the specifications are described, and the tests are detailed. The results of initial tests relating to characterization of sealed canisters are reported.

  12. Technical bases for the DWPF testing program

    SciTech Connect

    Plodinec, M.J.

    1990-09-17

    The Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS) will be the first production facility in the United States for the immobilization of high-level nuclear waste. Production of DWPF canistered wasteforms will begin prior to repository licensing, so decisions on facility startup will have to be made before the final decisions on repository design are made. The Department of Energy`s Office of Civilian Radioactive Waste Management (RW) has addressed this discrepancy by defining a Waste Acceptance Process. This process provides assurance that the borosilicate-glass wasteform, in a stainless-steel canister, produced by the DWPF will be acceptable for permanent storage in a federal repository. As part of this process, detailed technical specifications have been developed for the DWPF product. SRS has developed detailed strategies for demonstrating compliance with each of the Waste Acceptance Process specifications. An important part of the compliance is the testing which will be carried out in the DWPF. In this paper, the bases for each of the tests to be performed in the DWPF to establish compliance with the specifications are described, and the tests are detailed. The results of initial tests relating to characterization of sealed canisters are reported.

  13. Proposed commercial service for DC graphite melter

    SciTech Connect

    Desrosiers, A.E.; Trescot, J.; Wittle, J.K.

    1995-11-01

    The volume of mixed waste continues to increase with few options for its permanent disposal other than storage on site. This mixed waste is being generated by not only the Department of Energy at government sites but by the private sector in hospitals and at electrical utility sites. Bartlett Services, Inc. proposes to offer a service to treat these materials to both reduce the volume and stabilize the radionuclides in a vitrified material. This product will be formed in the DC Graphite Arc melters developed by Electro-Pyrolysis, Inc. and being offered for commercial design, sale and installation by Kennedy Van Saun. The process is a high temperature procedure which pyrolytically decomposes the organic portion of the waste to form clean hydrogen and carbon monoxide and solid carbon. The inorganic portion, containing the radioactive components, melts to produce a stable glass which is resistant to environmental leaching and will remain stable until the radioactivity has decreased to a safe level. Glasses produced with surrogate materials such as cesium and cerium have been shown to pass the Product Compatibility Test (PCT). The process being proposed for this treatment utilizes a sealed melter system having the capability of melting wastes containing both metallic and inorganic materials. This process, unlike joule heated melters, is capable of operating to temperatures of 1600{degrees}C or higher. Since the system is heated electrically, oxidation is not required to create the heat. Since the system is pyrolytic, relatively small quantities of gas are produced. These gases may have beneficial uses in producing chemicals or may be used as a clean fuel.

  14. Integration of the Uncertainties of Anion and TOC Measurements into the Flammability Control Strategy for Sludge Batch 8 at the DWPF

    SciTech Connect

    Edwards, T. B.

    2013-03-14

    The Savannah River National Laboratory (SRNL) has been working with the Savannah River Remediation (SRR) Defense Waste Processing Facility (DWPF) in the development and implementation of a flammability control strategy for DWPF’s melter operation during the processing of Sludge Batch 8 (SB8). SRNL’s support has been in response to technical task requests that have been made by SRR’s Waste Solidification Engineering (WSE) organization. The flammability control strategy relies on measurements that are performed on Slurry Mix Evaporator (SME) samples by the DWPF Laboratory. Measurements of nitrate, oxalate, formate, and total organic carbon (TOC) standards generated by the DWPF Laboratory are presented in this report, and an evaluation of the uncertainties of these measurements is provided. The impact of the uncertainties of these measurements on DWPF’s strategy for controlling melter flammability also is evaluated. The strategy includes monitoring each SME batch for its nitrate content and its TOC content relative to the nitrate content and relative to the antifoam additions made during the preparation of the SME batch. A linearized approach for monitoring the relationship between TOC and nitrate is developed, equations are provided that integrate the measurement uncertainties into the flammability control strategy, and sample calculations for these equations are shown to illustrate the impact of the uncertainties on the flammability control strategy.

  15. GLASS FORMULATION DEVELOPMENT TO SUPPORT MELTER TESTING TO DEMONSTRATE ENHANCED HIGH LEVEL WASTE THROUGHPUT

    SciTech Connect

    Marra, J; David Peeler, D; Tommy Edwards, T; Kevin Fox, K; Amanda Youchak, A; James Gillam, J

    2007-08-17

    The U.S. Department of Energy (DOE) is currently processing high-level waste (HLW) through a Joule-heated melter (JHM) at the Savannah River Site (SRS) and plans to vitrify HLW and Low activity waste (LAW) at the Hanford Site. Over the past few years at the DWPF, work has concentrated on increasing waste throughput. These efforts are continuing with an emphasis on high alumina content feeds. High alumina feeds have presented specific challenges for the JHM technology regarding the ability to increase waste loading yet still maintain product quality and adequate throughput. Alternatively, vitrification technology innovations are also being investigated as a means to increase waste throughput. The Cold Crucible Induction Melter (CCIM) technology affords the opportunity for higher vitrification process temperatures as compared to the current reference JHM technology. Higher process temperatures may allow for higher waste loading and higher melt rate. Glass formulation testing to support melter demonstration testing was recently completed. This testing was specifically aimed at high alumina concentration wastes. Glass composition property models were utilized as a guide for formulation development. Both CCIM and JHM testing will be conducted so glass formulation testing was targeted at both technologies with a goal to significantly increase waste loading without compromising product quality.

  16. DWPF FLOWSHEET STUDIES WITH SIMULANT TO DETERMINE THE IMPACT OF NEXT GENERATION SOLVENT ON THE CPC PROCESS AND GLASS FORMULATION

    SciTech Connect

    Newell, J.; Peeler, D.; Edwards, T.; Hay, M.; Stone, M.

    2011-06-29

    As a part of the Actinide Removal Process (ARP)/Modular Caustic Side Solvent Extraction Unit (MCU) Life Extension Project, a next generation solvent (NGS), a new strip acid, and modified monosodium titanate (mMST) will be deployed. The NGS is comprised of four components: 0.050 M MaxCalix (extractant), 0.50 M Cs-7SB (modifier), 0.003 M guanidine-LIX-79, with the balance ({approx}74 wt%) being Isopar{reg_sign} L. The strip acid will be changed from dilute nitric acid to dilute boric acid (0.01 M). Because of these changes, experimental testing with the next generation solvent and mMST was required to determine the impact of these changes in 512-S and Defense Waste Processing Facility (DWPF) operations, as well as Chemical Process Cell (CPC), glass formulation activities, and melter operations. Because of these changes, experimental testing with the next generation solvent and mMST is required to determine the impact of these changes. A Technical Task Request (TTR) was issued to support the assessments of the impact of the next generation solvent and mMST on the downstream DWPF flowsheet unit. The TTR identified five tasks to be investigated: (1) CPC Flowsheet Demonstration for NGS; (2) Solvent Stability for DWPF CPC Conditions; (3) Glass Formulation Studies; (4) Boron Volatility and Melt Rate; and (5) CPC Flowsheet Demonstration for mMST.

  17. HLW system plan - revision 2

    SciTech Connect

    Not Available

    1994-01-14

    The projected ability of the Tank Farm to support DWPF startup and continued operation has diminished somewhat since revision 1 of this Plan. The 13 month delay in DWPF startup, which actually helps the Tank Farm condition in the near term, was more than offset by the 9 month delay in ITP startup, the delay in the Evaporator startups and the reduction to Waste Removal funding. This Plan does, however, describe a viable operating strategy for the success of the HLW System and Mission, albeit with less contingency and operating flexibility than in the past. HLWM has focused resources from within the division on five near term programs: The three evaporator restarts, DWPF melter heatup and completion of the ITP outage. The 1H Evaporator was restarted 12/28/93 after a 9 month shutdown for an extensive Conduct of Operations upgrade. The 2F and 2H Evaporators are scheduled to restart 3/94 and 4/94, respectively. The RHLWE startup remains 11/17/97.

  18. LFCM (liquid-fed ceramic melter) vitrification technology: Quarterly progress report, January--March 1987

    SciTech Connect

    Brouns, R. A.; Allen, C. R.; Powell, J. A.

    1988-05-01

    This report is compiled by the Nuclear Waste Treatment Program and the Hanford Waste Vitrification Program at Pacific Northwest Laboratory to describe the progress in developing, testing, applying and documenting liquid-fed ceramic melter vitrification technology. Progress in the following technical subject areas during the second quarter of FY 1987 is discussed: melting process chemistry and glass development, feed preparation and transfer systems, melter systems, canister filling and handling systems, and process/product modeling. 23 refs., 14 figs., 10 tabs.

  19. High-Intensity Plasma Glass Melter Final Technical Report

    SciTech Connect

    Gonterman, J. Ronald; Weinstein, Michael A.

    2006-10-27

    The purpose of this project was to demonstrate the energy efficiency and reduced emissions that can be obtained with a dual torch DC plasma transferred arc-melting system. Plasmelt Glass Technologies, LLC was formed to solicit and execute the project, which utilize a full-scale test melter system. The system is similar to the one that was originally constructed by Johns Manville, but Plasmelt has added significant improvements to the torch design and melter system that has extended the original JM short torch lives. The original JM design has been shown to achieve melt rates 5 to 10 times faster than conventional gas or electric melting, with improved energy efficiency and reduced emissions. This project began on 7/28/2003 and ended 7/27/06. A laboratory scale melter was designed, constructed, and operated to conduct multiple experimental melting trials on various glass compositions. Glass quality was assessed. Although the melter design is generic and equally applicable to all sectors within the glass industry, the development of this melter has focused primarily on fiberglass with additional exploratory melting trials of frits, specialty, and minerals-melting applications. Throughput, energy efficiency, and glass quality have been shown to be heavily dependent on the selected glass composition. During this project, Plasmelt completed the proof-of-concept work in our Boulder, CO Lab to show the technical feasibility of this transferred-arc plasma melter. Late in the project, the work was focused on developing the processes and evaluating the economic viability of plasma melting aimed at the specific glasses of interest to specific client companies. Post project work is on going with client companies to address broader non-glass materials such as refractories and industrial minerals. Exploratory melting trials have been conducted on several glasses of commercial interest including: C-glass, E-glass, S-Glass, AR-Glass, B-glass, Lighting Glass, NE-Glass, and various

  20. Waste glass melter numerical and physical modeling

    SciTech Connect

    Eyler, L.L.; Peters, R.D.; Lessor, D.L.; Lowery, P.S.; Elliott, M.L.

    1991-10-01

    Results of physical and numerical simulation modeling of high-level liquid waste vitrification melters are presented. Physical modeling uses simulant fluids in laboratory testing. Visualization results provide insight into convective melt flow patterns from which information is derived to support performance estimation of operating melters and data to support numerical simulation. Numerical simulation results of several melter configurations are presented. These are in support of programs to evaluate melter operation characteristics and performance. Included are investigations into power skewing and alternating current electric field phase angle in a dual electrode pair reference design and bi-modal convective stability in an advanced design. 9 refs., 9 figs., 1 tab.

  1. The Impacts of Uranium and Thorium on the Defense Waste Processing Facility (DWPF) Viscosity Model

    SciTech Connect

    CAROL, JANTZEN

    2005-02-28

    The Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS) vitrifies high level liquid waste (HLLW) into borosilicate glass for stabilization and permanent disposal. The viscosity of the borosilicate glass melt as a function of temperature is the single most important variable affecting the melt rate and pour ability of the glass. The viscosity determines the rate of melting of the raw feed, the rate of glass bubble release (foaming and fining), the rate of homogenization, the adequacy of heat transfer, the devitrification rate, and thus, the quality (in terms of glass homogeneity) of the final glass product. If the viscosity is too low, excessive convection currents can occur during melting, increasing corrosion/erosion of the melter materials of construction (refractory and electrodes) and making control of the melter more difficult. The lowest glass viscosities allowed in the DWPF melter have, therefore, been determined to be approximately 20 poise. DWPF glasses must pour continuously into a large steel canister for ultimate storage in a geologic repository, but glasses with a viscosity greater than or equal to 500 poise do not readily pour. Moreover, too high a viscosity can reduce product quality by causing voids in the final glass. A conservative range of 20-110 poise at a melt temperature, Tmelt or Tm, of 1150 degrees C was, therefore, established for DWPF production. In summary, a uranium term is not needed in the DWPF viscosity model as long as the U3O8 concentrations of the glasses being melted are less than or equal to 5.76 wt percent, the maximum value examined in this study. The fact that a U-plus-6 term is not needed in the DWPF viscosity model is consistent with the fact that U-plus-6 has four bridging and two non-bridging oxygen bonds. Therefore, the impact of the number of bridging and non-bridging oxygens is approximately equal at U3O8 concentrations of less than or equal to 5.76 wt percent. Uranium may not have an impact at

  2. DWPF simulant CPC studies for SB8

    SciTech Connect

    Koopman, D. C.; Zamecnik, J. R.

    2013-06-25

    The Savannah River National Laboratory (SRNL) accepted a technical task request (TTR) from Waste Solidification Engineering to perform simulant tests to support the qualification of Sludge Batch 8 (SB8) and to develop the flowsheet for SB8 in the Defense Waste Processing Facility (DWPF). These efforts pertained to the DWPF Chemical Process Cell (CPC). Separate studies were conducted for frit development and glass properties (including REDOX). The SRNL CPC effort had two primary phases divided by the decision to drop Tank 12 from the SB8 constituents. This report focuses on the second phase with SB8 compositions that do not contain the Tank 12 piece. A separate report will document the initial phase of SB8 testing that included Tank 12. The second phase of SB8 studies consisted of two sets of CPC studies. The first study involved CPC testing of an SB8 simulant for Tank 51 to support the CPC demonstration of the washed Tank 51 qualification sample in the SRNL Shielded Cells facility. SB8-Tank 51 was a high iron-low aluminum waste with fairly high mercury and moderate noble metal concentrations. Tank 51 was ultimately washed to about 1.5 M sodium which is the highest wash endpoint since SB3-Tank 51. This study included three simulations of the DWPF Sludge Receipt and Adjustment Tank (SRAT) cycle and Slurry Mix Evaporator (SME) cycle with the sludge-only flowsheet at nominal DWPF processing conditions and three different acid stoichiometries. These runs produced a set of recommendations that were used to guide the successful SRNL qualification SRAT/SME demonstration with actual Tank 51 washed waste. The second study involved five SRAT/SME runs with SB8-Tank 40 simulant. Four of the runs were designed to define the acid requirements for sludge-only processing in DWPF with respect to nitrite destruction and hydrogen generation. The fifth run was an intermediate acid stoichiometry demonstration of the coupled flowsheet for SB8. These runs produced a set of processing

  3. FINAL REPORT REGULATORY OFF GAS EMISSIONS TESTING ON THE DM1200 MELTER SYSTEM USING HLW AND LAW SIMULANTS VSL-05R5830-1 REV 0 10/31/05

    SciTech Connect

    KRUGER AA; MATLACK KS; GONG W; BARDAKCI T; D'ANGELO NA; BRANDYS M; KOT WK; PEGG IL

    2011-12-29

    The operational requirements for the River Protection Project - Waste Treatment Plant (RPP-WTP) Low Activity Waste (LAW) and High Level Waste (HLW) melter systems, together with the feed constituents, impose a number of challenges to the off-gas treatment system. The system must be robust from the standpoints of operational reliability and minimization of maintenance. The system must effectively control and remove a wide range of solid particulate matter, acid mists and gases, and organic constituents (including those arising from products of incomplete combustion of sugar and organics in the feed) to concentration levels below those imposed by regulatory requirements. The baseline design for the RPP-WTP LAW primary off-gas system includes a submerged bed scrubber (SBS), a wet electrostatic precipitator (WESP), and a high efficiency particulate air (HEPA) filter. The secondary off-gas system includes a sulfur-impregnated activated carbon bed (AC-S), a thermal catalytic oxidizer (TCO), a single-stage selective catalytic reduction NOx treatment system (SCR), and a packed-bed caustic scrubber (PBS). The baseline design for the RPP-WTP HLW primary off-gas system includes an SBS, a WESP, a high efficiency mist eliminator (HEME), and a HEPA filter. The HLW secondary off-gas system includes a sulfur-impregnated activated carbon bed, a silver mordenite bed, a TCO, and a single-stage SCR. The one-third scale HLW DM1200 Pilot Melter installed at the Vitreous State Laboratory (VSL) was equipped with a prototypical off-gas train to meet the needs for testing and confirmation of the performance of the baseline off-gas system design. Various modifications have been made to the DM1200 system as the details of the WTP design have evolved, including the installation of a silver mordenite column and an AC-S column for testing on a slipstream of the off-gas flow; the installation of a full-flow AC-S bed for the present tests was completed prior to initiation of testing. The DM1200

  4. Supercritical water oxidation technology for DWPF

    SciTech Connect

    Carter, J.T.; Gentilucci, J.A.

    1992-02-07

    At the request of Mr. H.L. Brandt and others in the Savannah River Field Office High Level Waste Division office, DWPF, and SRL personnel have reviewed two potential applications for supercritical water oxidation technology in DWPF. The first application would replace the current hydrolysis process by destroying the organic fractions of the precipitated cesium / potassium tetraphenylborate slurry. The second application pertains to liquid benzene destruction. After a thorough evaluation the first application is not recommended. The second is ready to be tested if needed.

  5. Vitrification of Simulated LILW Using Induction Cold Crucible Melter Technology

    SciTech Connect

    Kim, C.W.; Park, J.K.; Shin, S.W.; Hwang, T.W.; Ha, J.H.; Song, M.J.

    2006-07-01

    Vitrification destroys hazardous organics, and immobilizes heavy metals and radioactive elements to form a chemically durable and highly leach-resistant vitrified form. The vitrification process provides exceptional volume reduction and is attractive for minimizing disposal volume. A pilot plant test using an induction Cold Crucible Melter (CCM) fitted with an off-gas treatment system (OGTS) has been conducted to vitrify a simulated low-and intermediate-level radioactive waste (LILW) generated from Korean nuclear power plants. The CCM process is based on the use of a water-cooled metallic structure assembled in sectors which is transparent to the electromagnetic field supplied by a high-frequency generator. A solidified glass layer because of the water-cooled structure of the CCM protects the structure against corrosion. By creating the solidified glass auto-crucible on the inner surface of the wall, corrosion damage to the steel in contact with the molten glass is prevented. In order to start-up the CCM, the glass frits were loaded in the CCM. The glass melting was initiated by heating of a short-circuited titanium ring in an electromagnetic field followed by ring burnout and incorporation of the titania in the glass frits. The melter has one drain that exits through the bottom. It is a direct bottom drain from the floor of the melt tank. It is sealed by the solidified glass layer and can be activated by removing the water cooling system. This drain is used if it is desired to drain the melter. The melter employs oxygen bubbling to promote mixing and to increase the melting rate. The bubblers are desired to produce a curtain of bubbles rising from the melter floor. In addition to mixing, the bubbling of oxygen tends to keep the melt well oxidized. The top of the melter is equipped with a number of ports. These provide access for feed, viewing, off-gas discharge, etc. The normal method of feeding is dry feeding through a feed pipe mounted through the top of the

  6. Research-scale melter test report

    SciTech Connect

    Cooper, M.F.; Elliott, M.L.; Eyler, L.L.; Freeman, C.J.; Higginson, J.J.; Mahoney, L.A.; Powell, M.R.

    1994-05-01

    The Melter Performance Assessment (MPA) activity in the Pacific Northwest Laboratory`s (PNL) Hanford Waste Vitrification Plant (HWVP) Technology Development (PHTD) effort is intended to determine the impact of noble metals on the operational life of the reference HWVP melter. As a part of this activity, a parametric melter test was completed using a Research-Scale Melter (RSM). The RSM is a small, approximately 1/100-scale melter, 6-in.-diameter, that allows rapid changing of process conditions and subsequent re-establishment of a steady-state condition. The test matrix contained nine different segments that varied the melter operating parameters (glass and plenum temperatures) and feed properties (oxide concentration, redox potential, and noble metal concentrations) so that the effects of these parameters on noble metal agglomeration on the melter floor could be evaluated. The RSM operated for 48 days and consumed 1,300 L of feed, equating to 153 tank turnovers. The run produced 531 kg of glass. During the latter portion of the run, the resistance between the electrodes decreased. Upon destructive examination of the melter, a layer of noble metals was found on the bottom. This was surprising because the glass residence time in the RSM is only 10% of the HWVP plant melter. The noble metals layer impacted the melter significantly. Approximately 1/3 of one paddle electrode was melted or corroded off. The cause is assumed to be localized heating from short circuiting of the electrode to the noble metal layer. The metal layer also removed approximately 1/2 in. of the refractory on the bottom of the melter. The mechanism for this damage is not presently known.

  7. Statistical Analysis of DWPF ARG-1 Data

    SciTech Connect

    Harris, S.P.

    2001-03-02

    A statistical analysis of analytical results for ARG-1, an Analytical Reference Glass, blanks, and the associated calibration and bench standards has been completed. These statistics provide a means for DWPF to review the performance of their laboratory as well as identify areas of improvement.

  8. Technical bases DWPF Late Washing Facility

    SciTech Connect

    Fish, D.L.; Landon, L.F.

    1992-08-10

    A task force recommended that the technical feasibility of a Late Wash' facility be assessed [1]. In this facility, each batch of tetraphenylborate slurry from Tank 49 would be given a final wash to reduce the concentrations of nitrite and radiolysis products to acceptable levels. Laboratory-scale studies have demonstrated that d the nitrite content of the slurry fed to DWPF is reduced to 0.01 M or less (and at least a 4X reduction in concentration of the soluble species is attained), (1) the need for HAN during hydrolysis is eliminated (eliminating the production of ammonium ion during hydrolysis), (2) hydrolysis may be done with a catalyst concentration that will not exceed the copper solubility in glass and (3) the non-polar organic production during hydrolysis is significantly reduced. The first phase of an aggressive research and development program has been completed and all test results obtained to date support the technical feasibility of Late Washing. Paralleling this research and development effort is an aggressive design study directed by DWPF to scope and cost retrofitting the Auxiliary Pump Pit (APP) to enable performing a final wash of each batch of precipitate slurry before R is transferred into the DWPF Soft Processing Cell (SPC). An initial technical bases for the Late Wash Facility was transmitted to DWPF on June 15, 1992. Research and development activities are continuing directed principally at optimization of the cross-f low fitter decontamination methodology and pilot-scale validation of the recommended benzene stripping metodology.

  9. Development of an advanced gas-fired mineral-wool melter. Annual report, January-December 1988

    SciTech Connect

    Vereecke, F.J.; Thekdi, A.C.

    1989-06-01

    A gas-fired mineral-wool melter was designed to provide a melting technology option to the existing coke-fired cupola melters used by the mineral wool industry. Over the past few years, mineral-wool producers have been increasingly pressured to reduce their level of pollutant gaseous emissions. Including the fuel consumption for an afterburner required with a cupola melter, the direct production costs for fuel currently range from $32 to $44 per ton of melted product; dependent on the effectiveness of a heat-recovery system. The estimated direct fuel cost for a gas-fired mineral-wool melter could be as low as $16 per ton. The configuration of the prototype melter contributes to the energy savings because waste heat is reclaimed by preheating the feedstock in a counterflow shaft. Besides the beneficial decrease in energy costs, the proposed gas-fired melter will virtually eliminate carbon monoxide and unburned hydrocarbon emissions as well as substantially reduce emissions of hydrogen sulfide. Finally, with an improved capability to process the melted product at a controlled temperature and flow rate, the gas-fired melter should improve the overall quality of the mineral fiber product compared to the state-of-the-art coke-fired cupola melter.

  10. Cold Crucible Induction Melter (CCIM) Demonstration Using a Representative Savannah River Site Sludge Simulant On the Large-Size Pilot Platform at the CEA-Marcoule

    SciTech Connect

    Girold, C.; Delaunay, M.; Dussossoy, J.L.; Lacombe, J.; Iverson, D.; Do Quang, R.; Tchemitcheff, E.; Veyer, C.

    2008-07-01

    The cold-crucible induction melter technology (CCIM) is considered worldwide for industrial implementation to overcome the current limits of high level waste vitrification technologies and to answer future challenges such as: new or difficult sludge compositions, need for improving waste loading, need for high temperatures, and corrosive effluents. More particularly, this technology is being considered for implementation at the US DOE Savannah River site to increase the rate of waste processing while reducing the number of HLW canisters to be produced through increased waste loading and improved waste throughput. A collaborative program involving AREVA, CEA (French Atomic Energy Commission), SRNL (Savannah River National Laboratory) and WSRC (Washington Savannah River Company) has thus been initiated in 2007 to demonstrate vitrification with waste loadings on the order of 50% (versus the current DWPF waste loading of about 35%) with a PUREX-type waste composition (high Fe{sub 2}O{sub 3} composition), and to perform two pilot-scale runs on the large size platform equipped with a 650 mm diameter CCIM at the CEA Marcoule. The objectives of the demonstrations were 1) to show the feasibility of processing a representative SRS sludge surrogate using continuous slurry feeding, 2) to produce a glass that would meet the acceptance specifications with an increased waste loading when compared to what is presently achieved at the DWPF, and 3) achieve improved waste throughputs. This presentation describes the platform and the very encouraging results obtained from the demonstration performed at temperatures, specific throughputs and waste loadings that overcome current DWPF limits. Results from the initial exploratory run and second demonstration run include 1) production of a glass product that achieved the targeted glass composition that was more durable than the standard Environmental Assessment (EA) glass, 2) successful slurry feeding of the CCIM, and 3) promising waste

  11. Examination Of Sulfur Measurements In DWPF Sludge Slurry And SRAT Product Materials

    SciTech Connect

    Bannochie, C. J.; Wiedenman, B. J.

    2012-11-29

    Savannah River National Laboratory (SRNL) was asked to re-sample the received SB7b WAPS material for wt. % solids, perform an aqua regia digestion and analyze the digested material by inductively coupled plasma - atomic emission spectroscopy (ICP-AES), as well as re-examine the supernate by ICP-AES. The new analyses were requested in order to provide confidence that the initial analytical subsample was representative of the Tank 40 sample received and to replicate the S results obtained on the initial subsample collected. The ICP-AES analyses for S were examined with both axial and radial detection of the sulfur ICP-AES spectroscopic emission lines to ascertain if there was any significant difference in the reported results. The outcome of this second subsample of the Tank 40 WAPS material is the first subject of this report. After examination of the data from the new subsample of the SB7b WAPS material, a team of DWPF and SRNL staff looked for ways to address the question of whether there was in fact insoluble S that was not being accounted for by ion chromatography (IC) analysis. The question of how much S is reaching the melter was thought best addressed by examining a DWPF Slurry Mix Evaporator (SME) Product sample, but the significant dilution of sludge material, containing the S species in question, that results from frit addition was believed to add additional uncertainty to the S analysis of SME Product material. At the time of these discussions it was believed that all S present in a Sludge Receipt and Adjustment Tank (SRAT) Receipt sample would be converted to sulfate during the course of the SRAT cycle. A SRAT Product sample would not have the S dilution effect resulting from frit addition, and hence, it was decided that a DWPF SRAT Product sample would be obtained and submitted to SRNL for digestion and sample preparation followed by a round-robin analysis of the prepared samples by the DWPF Laboratory, F/H Laboratories, and SRNL for S and sulfate. The

  12. SUMMARY REPORT ON POTENTIAL IMPACTS OF SMALL COLUMN ION EXCHANGE ON DWPF GLASS FORMULATION

    SciTech Connect

    Fox, K.; Edwards, T.; Johnson, F.

    2011-04-27

    This report summarizes a large amount of experimental work completed to identify the potential impacts of material from Small Column Ion Exchange (SCIX) on glass formulation at the Defense Waste Processing Facility (DWPF). The results show no significant issues with the predicted values of chemical durability and viscosity using the current Product Composition Control System (PCCS) models when the SCIX components are added to projected DWPF glass compositions. No modifications to the viscosity and durability models appear to be necessary at this time in order to incorporate the SCIX streams at DWPF. It is recommended that the Savannah River National Laboratory (SRNL) continue to verify the durability and viscosity models as the projected compositions for DWPF processing evolve. It is also recommended that the data generated thus far be reviewed and a determination be made as to how best to extend the validation ranges of the durability and viscosity models. The liquidus temperatures for the experimental glasses are also reported and discussed in this report. The results show that the measured or estimated (based on measured data) liquidus temperature values for the glasses with SCIX components added are consistently higher than those predicted by the current model. Therefore, the PCCS liquidus temperature model will need to be modified in order to incorporate the SCIX streams at DWPF. It is recommended that SRNL carry out full measurements of the liquidus temperatures for those KT-series glasses where estimates have been made. These data should then be used to support an evaluation of whether a refitting of the liquidus temperature model coefficients will be sufficient to correctly predict the liquidus temperature of glasses containing the SCIX components (particularly higher TiO{sub 2} concentrations), or whether additional modifications to the model are required. While there are prediction issues with the current liquidus temperature model, they are not at this

  13. INTEGRATED DM 1200 MELTER TESTING OF HLW C-106/AY-102 COMPOSITION USING BUBBLERS VSL-03R3800-1 REV 0 9/15/03

    SciTech Connect

    KRUGER AA; MATLACK KS; GONG W; BARDAKCI T; D'ANGELO NA; KOT WK; PEGG IL

    2011-12-29

    This report documents melter and off-gas performance results obtained on the DM1200 HLW Pilot Melter during processing of simulated HLW C-106/AY-102 feed. The principal objectives of the DM1200 melter testing were to determine the achievable glass production rates for simulated HLW C-106/AY-102 feed; determine the effect of bubbling rate on production rate; characterize melter off-gas emissions; characterize the performance of the prototypical off-gas system components as well as their integrated performance; characterize the feed, glass product, and off-gas effluents; and to perform pre- and post test inspections of system components.

  14. GTS Duratek, Phase I Hanford low-level waste melter tests: 100-kg melter offgas report

    SciTech Connect

    Eaton, W.C.

    1995-11-01

    A multiphase program was initiated in 1994 to test commercially available melter technologies for the vitrification of the low-level waste (LLW) stream from defense wastes stored in underground tanks at the Hanford Site in southeastern Washington State. Phase 1 of the melter demonstration tests using simulated LLW was completed during fiscal year 1995. This document is the 100-kg melter offgas report on testing performed by GTS Duratek, Inc., in Columbia, Maryland. GTS Duratek (one of the seven vendors selected) was chosen to demonstrate Joule heated melter technology under WHC subcontract number MMI-SVV-384215. The document contains the complete offgas report on the 100-kg melter as prepared by Parsons Engineering Science, Inc. A summary of this report is also contained in the GTS Duratek, Phase I Hanford Low-Level Waste Melter Tests: Final Report (WHC-SD-WM-VI-027).

  15. Cold-Crucible Induction Melter Design and Development

    SciTech Connect

    Gombert, Dirk; Richardson, John R.

    2003-03-15

    The international process for immobilization of high-activity waste from aqueous fuel reprocessing is vitrification. In the United States joule-heated melter technology has been implemented at West Valley and the Savannah River Site, but improved melter concepts are sought to bring down the costs of processing. The cold-crucible induction melter (CCIM) design is being evaluated for many applications, including radioactive wastes because it eliminates many materials and operating constraints inherent in the baseline technology. The cold-crucible design is also smaller, less expensive, and generates much less waste for ultimate disposal. In addition, it should allow a much more flexible operating envelope, which will be crucial if the heterogeneous wastes at the U.S. Department of Energy (DOE) reprocessing sites are to be vitrified.A joule-heated melter operates by passing current between water-cooled electrodes through a molten pool in a refractory-lined chamber. This design is inherently limited by susceptibility of materials to corrosion and melting. In addition, redox conditions and free metal content have exacerbated materials problems or lead to electrical short-circuiting causing failures in developmental DOE melters. In contrast, the CCIM design is based on inductive coupling of a water-cooled high-frequency electrical coil with the glass, causing eddy currents that produce heat and mixing.While significant marketing claims have been made by technology suppliers and developers, little data is available for engineering and economic evaluation of the technology, and no facilities are available in the United States to support testing. In addition to verifying the capabilities of the technology, further development can exploit opportunities for optimization through better understanding of the electromagnetic thermal phenomena intrinsic to the cold-crucible melter. Induction frequency, applied power, and coil and crucible configuration are all related but

  16. DWPF Simulant CPC Studies For SB8

    SciTech Connect

    Newell, J. D.

    2013-09-25

    Prior to processing a Sludge Batch (SB) in the Defense Waste Processing Facility (DWPF), flowsheet studies using simulants are performed. Typically, the flowsheet studies are conducted based on projected composition(s). The results from the flowsheet testing are used to 1) guide decisions during sludge batch preparation, 2) serve as a preliminary evaluation of potential processing issues, and 3) provide a basis to support the Shielded Cells qualification runs performed at the Savannah River National Laboratory (SRNL). SB8 was initially projected to be a combination of the Tank 40 heel (Sludge Batch 7b), Tank 13, Tank 12, and the Tank 51 heel. In order to accelerate preparation of SB8, the decision was made to delay the oxalate-rich material from Tank 12 to a future sludge batch. SB8 simulant studies without Tank 12 were reported in a separate report.1 The data presented in this report will be useful when processing future sludge batches containing Tank 12. The wash endpoint target for SB8 was set at a significantly higher sodium concentration to allow acceptable glass compositions at the targeted waste loading. Four non-coupled tests were conducted using simulant representing Tank 40 at 110-146% of the Koopman Minimum Acid requirement. Hydrogen was generated during high acid stoichiometry (146% acid) SRAT testing up to 31% of the DWPF hydrogen limit. SME hydrogen generation reached 48% of of the DWPF limit for the high acid run. Two non-coupled tests were conducted using simulant representing Tank 51 at 110-146% of the Koopman Minimum Acid requirement. Hydrogen was generated during high acid stoichiometry SRAT testing up to 16% of the DWPF limit. SME hydrogen generation reached 49% of the DWPF limit for hydrogen in the SME for the high acid run. Simulant processing was successful using previously established antifoam addition strategy. Foaming during formic acid addition was not observed in any of the runs. Nitrite was destroyed in all runs and no N2O was detected

  17. Product/Process (P/P) Models For The Defense Waste Processing Facility (DWPF): Model Ranges And Validation Ranges For Future Processing

    SciTech Connect

    Jantzen, C.; Edwards, T.

    2015-09-25

    Radioactive high level waste (HLW) at the Savannah River Site (SRS) has successfully been vitrified into borosilicate glass in the Defense Waste Processing Facility (DWPF) since 1996. Vitrification requires stringent product/process (P/P) constraints since the glass cannot be reworked once it is poured into ten foot tall by two foot diameter canisters. A unique “feed forward” statistical process control (SPC) was developed for this control rather than statistical quality control (SQC). In SPC, the feed composition to the DWPF melter is controlled prior to vitrification. In SQC, the glass product would be sampled after it is vitrified. Individual glass property-composition models form the basis for the “feed forward” SPC. The models transform constraints on the melt and glass properties into constraints on the feed composition going to the melter in order to guarantee, at the 95% confidence level, that the feed will be processable and that the durability of the resulting waste form will be acceptable to a geologic repository.

  18. Materials performance in a high-level radioactive waste vitrification system

    SciTech Connect

    Imrich, K.J.; Chandler, G.T.

    1996-06-17

    The Defense Waste Processing Facility (DWPF) is a Department of Energy Facility designed to vitrify highly radioactive waste. An extensive materials evaluation program has been completed on key components in the DWPF after twelve months of operation using nonradioactive simulated wastes. Results of the visual inspections of the feed preparation system indicate that the system components, which were fabricated from Hastelloy C-276, should achieve their design lives. Significant erosion was observed on agitator blades that process glass frit slurries; however, design modifications should mitigate the erosion. Visual inspections of the DWPF melter top head and off gas components, which were fabricated from Inconel 690, indicated that varying degrees of degradation occurred. Most of the components will perform satisfactorily for their two year design life. The components that suffered significant attack were the borescopes, primary film cooler brush, and feed tubes. Changes in the operation of the film cooler brush and design modifications to the feed tubes and borescopes is expected to extend their service lives to two years. A program to investigate new high temperature engineered materials and alloys with improved oxidation and high temperature corrosion resistance will be initiated.

  19. Burst Test Qualification Analysis of DWPF Canister-Plug Weld

    SciTech Connect

    Gupta, N.K.; Gong, Chung

    1995-02-01

    The DWPF canister closure system uses resistance welding for sealing the canister nozzle and plug to ensure leak tightness. The welding group at SRTC is using the burst test to qualify this seal weld in lieu of the shear test in ASME B&PV Code, Section IX, paragraph QW-196. The burst test is considered simpler and more appropriate than the shear test for this application. Although the geometry, loading and boundary conditions are quite different in the two tests, structural analyses show similarity in the failure mode of the shear test in paragraph QW-196 and the burst test on the DWPF canister nozzle Non-linear structural analyses are performed using finite element techniques to study the failure mode of the two tests. Actual test geometry and realistic stress strain data for the 304L stainless steel and the weld material are used in the analyses. The finite element models are loaded until failure strains are reached. The failure modes in both tests are shear at the failure points. Based on these observations, it is concluded that the use of a burst test in lieu of the shear test for qualifying the canister-plug weld is acceptable. The burst test analysis for the canister-plug also yields the burst pressures which compare favorably with the actual pressure found during burst tests. Thus, the analysis also provides an estimate of the safety margins in the design of these vessels.

  20. DWPF SMECT PVV SAMPLE CHARACTERIZATION AND REMEDIATION

    SciTech Connect

    Bannochie, C.; Crawford, C.

    2013-06-18

    On April 2, 2013, a solid sample of material collected from the Defense Waste Processing Facility’s Process Vessel Vent (PVV) jumper for the Slurry Mix Evaporator Condensate Tank (SMECT) was received at the Savannah River National Laboratory (SRNL). DWPF has experienced pressure spikes within the SMECT and other process vessels which have resulted in processing delays while a vacuum was re-established. Work on this sample was requested in a Technical Assistance Request (TAR). This document reports the results of chemical and physical property measurements made on the sample, as well as insights into the possible impact to the material using DWPF’s proposed remediation methods. DWPF was interested in what the facility could expect when the material was exposed to either 8M nitric acid or 90% formic acid, the two materials they have the ability to flush through the PVV line in addition to process water once the line is capped off during a facility outage.

  1. Liquidus Temperature Data for DWPF Glass

    SciTech Connect

    GF Piepel; JD Vienna; JV Crum; M Mika; P Hrma

    1999-05-21

    This report provides new liquidus temperature (TL) versus composition data that can be used to reduce uncertainty in TL calculation for DWPF glass. According to the test plan and test matrix design PNNL has measured TL for 53 glasses within and just outside of the current DWPF processing composition window. The TL database generated under this task will directly support developing and enhancing the current TL process-control model. Preliminary calculations have shown a high probability of increasing HLW loading in glass produced at the SRS and Hanford. This increase in waste loading will decrease the lifecycle tank cleanup costs by decreasing process time and the volume of waste glass produced.

  2. Organics Characterization Of DWPF Alternative Reductant Simulants, Glycolic Acid, And Antifoam 747

    SciTech Connect

    White, T. L.; Wiedenman, B. J.; Lambert, D. P.; Crump, S. L.; Fondeur, F. F.; Papathanassiu, A. E.; Kot, W. K.; Pegg, I. L.

    2013-10-01

    The present study examines the fate of glycolic acid and other organics added in the Chemical Processing Cell (CPC) of the Defense Waste Processing Facility (DWPF) as part of the glycolic alternate flowsheet. Adoption of this flowsheet is expected to provide certain benefits in terms of a reduction in the processing time, a decrease in hydrogen generation, simplification of chemical storage and handling issues, and an improvement in the processing characteristics of the waste stream including an increase in the amount of nitrate allowed in the CPC process. Understanding the fate of organics in this flowsheet is imperative because tank farm waste processed in the CPC is eventually immobilized by vitrification; thus, the type and amount of organics present in the melter feed may affect optimal melt processing and the quality of the final glass product as well as alter flammability calculations on the DWPF melter off gas. To evaluate the fate of the organic compounds added as the part of the glycolic flowsheet, mainly glycolic acid and antifoam 747, samples of simulated waste that was processed using the DWPF CPC protocol for tank farm sludge feed were generated and analyzed for organic compounds using a variety of analytical techniques at the Savannah River National Laboratory (SRNL). These techniques included Ion Chromatography (IC), Gas Chromatography-Mass Spectrometry (GC-MS), Inductively Coupled Plasma-Atomic Emission Spectroscopy (ICP-AES), and Nuclear Magnetic Resonance (NMR) Spectroscopy. A set of samples were also sent to the Catholic University of America Vitreous State Laboratory (VSL) for analysis by NMR Spectroscopy at the University of Maryland, College Park. Analytical methods developed and executed at SRNL collectively showed that glycolic acid was the most prevalent organic compound in the supernatants of Slurry Mix Evaporator (SME) products examined. Furthermore, the studies suggested that commercially available glycolic acid contained minor amounts

  3. Rheological Modifier Testing with DWPF Process Slurries

    SciTech Connect

    MICHAEL, STONE

    2004-02-01

    Rheological modification agents were tested on simulated SRAT and SME products to determine if a suitable agent could be found for the DWPF process slurries. The agents tested were dispersants that lower the rheological properties of slurries by preventing agglomerization. Dolapix CE64, an ethylene glycol, and Disperse-Ayd W28, a polyacrylate, were the most effective dispersants tested. Further evaluation and testing should be performed on Dolapix CE64 and Disperse-Ayd W28 to determine if implementation is possible in DWPF. The initial phase of future work will include optimization of the rheology modifier by the Illinois Institute of Technology (IIT) and development of a maximum concentration limit for the rheology modifiers. IIT has been commissioned to evaluate the properties of these chemicals to determine if the chemical makeup can be optimized to enhance the properties of these modifiers. An initial concentration limit based upon the DWPF flammability limit and other constraints should be calculated to determine the potential downstream impacts.

  4. DWPF waste form compliance plan (Draft Revision)

    SciTech Connect

    Plodinec, M.J.; Marra, S.L.

    1991-12-31

    The Department of Energy currently has over 100 million liters of high-level radioactive waste in storage at the Savannah River Site (SRS). In the late 1970`s, the Department of Energy recognized that there were significant safety and cost advantages associated with immobilizing the high-level waste in a stable solid form. Several alternative waste forms were evaluated in terms of product quality and reliability of fabrication. This evaluation led to a decision to build the Defense Waste Processing Facility (DWPF) at SRS to convert the easily dispersed liquid waste to borosilicate glass. In accordance with the NEPA (National Environmental Policy Act) process, an Environmental Impact Statement was prepared for the facility, as well as an Environmental Assessment of the alternative waste forms, and issuance of a Record of Decision (in December, 1982) on the waste form. The Department of Energy, recognizing that start-up of the DWPF would considerably precede licensing of a repository, instituted a Waste Acceptance Process to ensure that these canistered waste forms would be acceptable for eventual disposal at a federal repository. This report is a revision of the DWPF compliance plan.

  5. DWPF waste form compliance plan (Draft Revision)

    SciTech Connect

    Plodinec, M.J.; Marra, S.L.

    1991-01-01

    The Department of Energy currently has over 100 million liters of high-level radioactive waste in storage at the Savannah River Site (SRS). In the late 1970's, the Department of Energy recognized that there were significant safety and cost advantages associated with immobilizing the high-level waste in a stable solid form. Several alternative waste forms were evaluated in terms of product quality and reliability of fabrication. This evaluation led to a decision to build the Defense Waste Processing Facility (DWPF) at SRS to convert the easily dispersed liquid waste to borosilicate glass. In accordance with the NEPA (National Environmental Policy Act) process, an Environmental Impact Statement was prepared for the facility, as well as an Environmental Assessment of the alternative waste forms, and issuance of a Record of Decision (in December, 1982) on the waste form. The Department of Energy, recognizing that start-up of the DWPF would considerably precede licensing of a repository, instituted a Waste Acceptance Process to ensure that these canistered waste forms would be acceptable for eventual disposal at a federal repository. This report is a revision of the DWPF compliance plan.

  6. ENHANCED DOE HIGH LEVEL WASTE MELTER THROUGHPUT STUDIES: SRNL GLASS SELECTION STRATEGY

    SciTech Connect

    Raszewski, F; Tommy Edwards, T; David Peeler, D

    2008-01-23

    The Department of Energy has authorized a team of glass formulation and processing experts at the Savannah River National Laboratory (SRNL), the Pacific Northwest National Laboratory (PNNL), and the Vitreous State Laboratory (VSL) at Catholic University of America to develop a systematic approach to increase high level waste melter throughput (by increasing waste loading with minimal or positive impacts on melt rate). This task is aimed at proof-of-principle testing and the development of tools to improve waste loading and melt rate, which will lead to higher waste throughput. Four specific tasks have been proposed to meet these objectives (for details, see WSRC-STI-2007-00483): (1) Integration and Oversight, (2) Crystal Accumulation Modeling (led by PNNL)/Higher Waste Loading Glasses (led by SRNL), (3) Melt Rate Evaluation and Modeling, and (4) Melter Scale Demonstrations. Task 2, Crystal Accumulation Modeling/Higher Waste Loading Glasses is the focus of this report. The objective of this study is to provide supplemental data to support the possible use of alternative melter technologies and/or implementation of alternative process control models or strategies to target higher waste loadings (WLs) for the Defense Waste Processing Facility (DWPF)--ultimately leading to higher waste throughputs and a reduced mission life. The glass selection strategy discussed in this report was developed to gain insight into specific technical issues that could limit or compromise the ability of glass formulation efforts to target higher WLs for future sludge batches at the Savannah River Site (SRS). These technical issues include Al-dissolution, higher TiO{sub 2} limits and homogeneity issues for coupled-operations, Al{sub 2}O{sub 3} solubility, and nepheline formation. To address these technical issues, a test matrix of 28 glass compositions has been developed based on 5 different sludge projections for future processing. The glasses will be fabricated and characterized based on

  7. ISOLOK VALVE ACCEPTANCE TESTING FOR DWPF SME SAMPLING PROCESS

    SciTech Connect

    Edwards, T.; Hera, K.; Coleman, C.; Jones, M.; Wiedenman, B.

    2011-12-05

    Evaluation of the Defense Waste Processing Facility (DWPF) Chemical Process Cell (CPC) cycle time identified several opportunities to improve the CPC processing time. Of the opportunities, a focus area related to optimizing the equipment and efficiency of the sample turnaround time for DWPF Analytical Laboratory was identified. The Mechanical Systems & Custom Equipment Development (MS&CED) Section of the Savannah River National Laboratory (SRNL) evaluated the possibility of using an Isolok{reg_sign} sampling valve as an alternative to the Hydragard{reg_sign} valve for taking process samples. Previous viability testing was conducted with favorable results using the Isolok sampler and reported in SRNL-STI-2010-00749 (1). This task has the potential to improve operability, reduce maintenance time and decrease CPC cycle time. This report summarizes the results from acceptance testing which was requested in Task Technical Request (TTR) HLW-DWPF-TTR-2010-0036 (2) and which was conducted as outlined in Task Technical and Quality Assurance Plan (TTQAP) SRNL-RP-2011-00145 (3). The Isolok to be tested is the same model which was tested, qualified, and installed in the Sludge Receipt Adjustment Tank (SRAT) sample system. RW-0333P QA requirements apply to this task. This task was to qualify the Isolok sampler for use in the DWPF Slurry Mix Evaporator (SME) sampling process. The Hydragard, which is the current baseline sampling method, was used for comparison to the Isolok sampling data. The Isolok sampler is an air powered grab sampler used to 'pull' a sample volume from a process line. The operation of the sampler is shown in Figure 1. The image on the left shows the Isolok's spool extended into the process line and the image on the right shows the sampler retracted and then dispensing the liquid into the sampling container. To determine tank homogeneity, a Coliwasa sampler was used to grab samples at a high and low location within the mixing tank. Data from the two locations

  8. Failure Analysis of a Pilot Scale Melter

    SciTech Connect

    Imrich, K J

    2001-09-14

    Failure of the pilot-scale test melter resulted from severe overheating of the Inconel 690 jacketed molybdenum electrode. Extreme temperatures were required to melt the glass during this campaign because the feed material contained a very high waste loading.

  9. Melter development needs assessment for RWMC buried wastes

    SciTech Connect

    Donaldson, A.D.; Carpenedo, R.J.; Anderson, G.L.

    1992-02-01

    This report presents a survey and initial assessment of the existing state-of-the-art melter technology necessary to thermally treat (stabilize) buried TRU waste, by producing a highly leach resistant glass/ceramic waste form suitable for final disposal. Buried mixed transuranic (TRU) waste at the Idaho National Engineering Laboratory (INEL) represents an environmental hazard requiring remediation. The Environmental Protection Agency (EPA) placed the INEL on the National Priorities List in 1989. Remediation of the buried TRU-contaminated waste via the CERCLA decision process is required to remove INEL from the National Priorities List. A Waste Technology Development (WTD) Preliminary Systems Design and Thermal Technologies Screening Study identified joule-heated and plasma-heated melters as the most probable thermal systems technologies capable of melting the INEL soil and waste to produce the desired final waste form (Iron-Enriched Basalt (IEB) glass/ceramic). The work reported herein then surveys the state of existing melter technology and assesses it within the context of processing INEL buried TRU wastes and contaminated soils. Necessary technology development work is recommended.

  10. Melter development needs assessment for RWMC buried wastes

    SciTech Connect

    Donaldson, A.D.; Carpenedo, R.J.; Anderson, G.L.

    1992-02-01

    This report presents a survey and initial assessment of the existing state-of-the-art melter technology necessary to thermally treat (stabilize) buried TRU waste, by producing a highly leach resistant glass/ceramic waste form suitable for final disposal. Buried mixed transuranic (TRU) waste at the Idaho National Engineering Laboratory (INEL) represents an environmental hazard requiring remediation. The Environmental Protection Agency (EPA) placed the INEL on the National Priorities List in 1989. Remediation of the buried TRU-contaminated waste via the CERCLA decision process is required to remove INEL from the National Priorities List. A Waste Technology Development (WTD) Preliminary Systems Design and Thermal Technologies Screening Study identified joule-heated and plasma-heated melters as the most probable thermal systems technologies capable of melting the INEL soil and waste to produce the desired final waste form [Iron-Enriched Basalt (IEB) glass/ceramic]. The work reported herein then surveys the state of existing melter technology and assesses it within the context of processing INEL buried TRU wastes and contaminated soils. Necessary technology development work is recommended.

  11. Supercritical water oxidation technology for DWPF. [Defense Waste Processing Facility (DWPF)

    SciTech Connect

    Carter, J.T.; Gentilucci, J.A.

    1992-02-07

    At the request of Mr. H.L. Brandt and others in the Savannah River Field Office High Level Waste Division office, DWPF, and SRL personnel have reviewed two potential applications for supercritical water oxidation technology in DWPF. The first application would replace the current hydrolysis process by destroying the organic fractions of the precipitated cesium / potassium tetraphenylborate slurry. The second application pertains to liquid benzene destruction. After a thorough evaluation the first application is not recommended. The second is ready to be tested if needed.

  12. Operating an induction melter apparatus

    DOEpatents

    Roach, Jay A.; Richardson, John G.; Raivo, Brian D.; Soelberg, Nicholas R.

    2006-01-31

    Apparatus and methods of operation are provided for a cold-crucible-induction melter for vitrifying waste wherein a single induction power supply may be used to effect a selected thermal distribution by independently energizing at least two inductors. Also, a bottom drain assembly may be heated by an inductor and may include an electrically resistive heater. The bottom drain assembly may be cooled to solidify molten material passing therethrough to prevent discharge of molten material therefrom. Configurations are provided wherein the induction flux skin depth substantially corresponds with the central longitudinal axis of the crucible. Further, the drain tube may be positioned within the induction flux skin depth in relation to material within the crucible or may be substantially aligned with a direction of flow of molten material within the crucible. An improved head design including four shells forming thermal radiation shields and at least two gas-cooled plenums is also disclosed.

  13. Inorganic analyses of volatilized and condensed species within prototypic Defense Waste Processing Facility (DWPF) canistered waste

    SciTech Connect

    Jantzen, C.M.

    1992-06-30

    The high-level radioactive waste currently stored in carbon steel tanks at the Savannah River Site (SRS) will be immobilized in a borosilicate glass in the Defense Waste Processing Facility (DWPF). The canistered waste will be sent to a geologic repository for final disposal. The Waste Acceptance Preliminary Specifications (WAPS) require the identification of any inorganic phases that may be present in the canister that may lead to internal corrosion of the canister or that could potentially adversely affect normal canister handling. During vitrification, volatilization of mixed (Na, K, Cs)Cl, (Na, K, Cs){sub 2}SO{sub 4}, (Na, K, Cs)BF{sub 4}, (Na, K){sub 2}B{sub 4}O{sub 7} and (Na,K)CrO{sub 4} species from glass melt condensed in the melter off-gas and in the cyclone separator in the canister pour spout vacuum line. A full-scale DWPF prototypic canister filled during Campaign 10 of the SRS Scale Glass Melter was sectioned and examined. Mixed (NaK)CI, (NaK){sub 2}SO{sub 4}, (NaK) borates, and a (Na,K) fluoride phase (either NaF or Na{sub 2}BF{sub 4}) were identified on the interior canister walls, neck, and shoulder above the melt pour surface. Similar deposits were found on the glass melt surface and on glass fracture surfaces. Chromates were not found. Spinel crystals were found associated with the glass pour surface. Reference amounts of the halides and sulfates were found retained in the glass and the glass chemistry, including the distribution of the halides and sulfates, was homogeneous. In all cases where rust was observed, heavy metals (Zn, Ti, Sn) from the cutting blade/fluid were present indicating that the rust was a reaction product of the cutting fluid with glass and heat sensitized canister or with carbon-steel contamination on canister interior. Only minimal water vapor is present so that internal corrosion of the canister, will not occur.

  14. Measurement of the volatility and glass transition temperatures of glasses produced during the DWPF startup test program

    SciTech Connect

    Marra, J.C.; Harbour, J.R.

    1995-10-18

    The Defense Waste Processing Facility (DWPF) will immobilize high-level radioactive waste currently stored in underground tanks at the Savannah River Site by incorporating the waste into a glass matrix. The molten waste glass will be poured into stainless steel canisters which will be welded shut to produce the final waste form. One specification requires that any volatiles produced as a result of accidentally heating the waste glass to the glass transition temperature be identified. Glass samples from five melter campaigns, run as part of the DWPF Startup Test Program, were analyzed to determine glass transition temperatures and to examine the volatilization (by weight loss). Glass transition temperatures (T{sub g}) for the glasses, determined by differential scanning calorimetry (DSC), ranged between 445 C and 474 C. Thermogravimetric analysis (TGA) scans showed that no overall weight loss occurred in any of the glass samples when heated to 500 C. Therefore, no volatility will occur in the final glass product when heated up to 500 C.

  15. Chemical compatibility of DWPF canistered waste forms. Revision 1

    SciTech Connect

    Harbour, J.R.

    1993-06-25

    The Waste Acceptance Preliminary Specifications (WAPS) require that the contents of the canistered waste form are compatible with one another and the stainless steel canister. The canistered waste form is a closed system comprised of a stainless steel vessel containing waste glass, air, and condensate. This system will experience a radiation field and an elevated temperature due to radionuclide decay. This report discusses possible chemical reactions, radiation interactions, and corrosive reactions within this system both under normal storage conditions and after exposure to temperatures up to the normal glass transition temperature, which for DWPF waste glass will be between 440 and 460{degrees}C. Specific conclusions regarding reactions and corrosion are provided. This document is based on the assumption that the period of interim storage prior to packaging at the federal repository may be as long as 50 years.

  16. Nitric acid-formic acid compatibility in DWPF

    SciTech Connect

    Eibling, R.E.

    1992-10-20

    The addition of the Nitric Acid Flowsheet to the DWPF feed preparation process introduces nitric acid into a vessel which will subsequently receive a formic acid solution. The combination of these two acids suggests that a denitration reaction might occur. This memorandum reviews the conditions under which a denitration reaction is possible and compares these conditions to DWPF operating conditions.

  17. GLYCOLIC-NITRIC ACID FLOWSHEET DEMONSTRATION OF THE DWPF CHEMICAL PROCESSING CELL WITH MATRIX SIMULANTS AND SUPERNATE

    SciTech Connect

    Lambert, D.; Stone, M.; Newell, J.; Best, D.

    2012-05-07

    Savannah River Remediation (SRR) is evaluating changes to its current DWPF flowsheet to improve processing cycle times. This will enable the facility to support higher canister production while maximizing waste loading. Higher throughput is needed in the CPC since the installation of the bubblers into the melter has increased melt rate. Due to the significant maintenance required for the DWPF gas chromatographs (GC) and the potential for production of flammable quantities of hydrogen, reducing or eliminating the amount of formic acid used in the CPC is being developed. Earlier work at Savannah River National Laboratory has shown that replacing formic acid with an 80:20 molar blend of glycolic and formic acids has the potential to remove mercury in the SRAT without any significant catalytic hydrogen generation. This report summarizes the research completed to determine the feasibility of processing without formic acid. In earlier development of the glycolic-formic acid flowsheet, one run (GF8) was completed without formic acid. It is of particular interest that mercury was successfully removed in GF8, no formic acid at 125% stoichiometry. Glycolic acid did not show the ability to reduce mercury to elemental mercury in initial screening studies, which is why previous testing focused on using the formic/glycolic blend. The objective of the testing detailed in this document is to determine the viability of the nitric-glycolic acid flowsheet in processing sludge over a wide compositional range as requested by DWPF. This work was performed under the guidance of Task Technical and Quality Assurance Plan (TT and QAP). The details regarding the simulant preparation and analysis have been documented previously.

  18. GLYCOLIC-NITRIC ACID FLOWSHEET DEMONSTRATION OF THE DWPF CHEMICAL PROCESS CELL WITH SLUDGE AND SUPERNATE SIMULANTS

    SciTech Connect

    Lambert, D.; Stone, M.; Newell, J.; Best, D.; Zamecnik, J.

    2012-08-28

    Savannah River Remediation (SRR) is evaluating changes to its current Defense Waste Processing Facility (DWPF) flowsheet to improve processing cycle times. This will enable the facility to support higher canister production while maximizing waste loading. Higher throughput is needed in the Chemical Process Cell (CPC) since the installation of the bubblers into the melter has increased melt rate. Due to the significant maintenance required for the DWPF gas chromatographs (GC) and the potential for production of flammable quantities of hydrogen, reducing or eliminating the amount of formic acid used in the CPC is being developed. Earlier work at Savannah River National Laboratory has shown that replacing formic acid with an 80:20 molar blend of glycolic and formic acids has the potential to remove mercury in the SRAT without any significant catalytic hydrogen generation. This report summarizes the research completed to determine the feasibility of processing without formic acid. In earlier development of the glycolic-formic acid flowsheet, one run (GF8) was completed without formic acid. It is of particular interest that mercury was successfully removed in GF8, no formic acid at 125% stoichiometry. Glycolic acid did not show the ability to reduce mercury to elemental mercury in initial screening studies, which is why previous testing focused on using the formic/glycolic blend. The objective of the testing detailed in this document is to determine the viability of the nitric-glycolic acid flowsheet in processing sludge over a wide compositional range as requested by DWPF. This work was performed under the guidance of Task Technical and Quality Assurance Plan (TT&QAP). The details regarding the simulant preparation and analysis have been documented previously.

  19. Bench-scale arc melter for R&D in thermal treatment of mixed wastes

    SciTech Connect

    Kong, P.C.; Grandy, J.D.; Watkins, A.D.; Eddy, T.L.; Anderson, G.L.

    1993-05-01

    A small dc arc melter was designed and constructed to run bench-scale investigations on various aspects of development for high-temperature (1,500-1,800{degrees}C) processing of simulated transuranic-contaminated waste and soil located at the Radioactive Waste Management Complex (RWMC). Several recent system design and treatment studies have shown that high-temperature melting is the preferred treatment. The small arc melter is needed to establish techniques and procedures (with surrogates) prior to using a similar melter with the transuranic-contaminated wastes in appropriate facilities at the site. This report documents the design and construction, starting and heating procedures, and tests evaluating the melter`s ability to process several waste types stored at the RWMC. It is found that a thin graphite strip provides reliable starting with initial high current capability for partially melting the soil/waste mixture. The heating procedure includes (1) the initial high current-low voltage mode, (2) a low current-high voltage mode that commences after some slag has formed and arcing dominates over the receding graphite conduction path, and (3) a predominantly Joule heating mode during which the current can be increased within the limits to maintain relatively quiescent operation. Several experiments involving the melting of simulated wastes are discussed. Energy balance, slag temperature, and electrode wear measurements are presented. Recommendations for further refinements to enhance its processing capabilities are identified. Future studies anticipated with the arc melter include waste form processing development; dissolution, retention, volatilization, and collection for transuranic and low-level radionuclides, as well as high vapor pressure metals; electrode material development to minimize corrosion and erosion; refractory corrosion and/or skull formation effects; crucible or melter geometry; metal oxidation; and melt reduction/oxidation (redox) conditions.

  20. Final Report - Testing of Optimized Bubbler Configuration for HLW Melter VSL-13R2950-1, Rev. 0, dated 6/12/2013

    SciTech Connect

    Kruger, Albert A.; Pegg, I. L.; Callow, R. A.; Joseph, I.; Matlack, K. S.; Kot, W. K.

    2013-11-13

    The principal objective of this work was to determine the glass production rate increase and ancillary effects of adding more bubbler outlets to the current WTP HLW melter baseline. This was accomplished through testing on the HLW Pilot Melter (DM1200) at VSL. The DM1200 unit was selected for these tests since it was used previously with several HLW waste streams including the four tank wastes proposed for initial processing at Hanford. This melter system was also used for the development and optimization of the present baseline WTP HLW bubbler configuration for the WTP HLW melter, as well as for MACT testing for both HLW and LAW. Specific objectives of these tests were to: Conduct DM1200 melter testing with the baseline WTP bubbling configuration and as augmented with additional bubblers. Conduct DM1200 melter testing to differentiate the effects of total bubbler air flow and bubbler distribution on glass production rate and cold cap formation. Collect melter operating data including processing rate, temperatures at a variety of locations within the melter plenum space, melt pool temperature, glass melt density, and melter pressure with the baseline WTP bubbling configuration and as augmented with additional bubblers. Collect melter exhaust samples to compare particulate carryover for different bubbler configurations. Analyze all collected data to determine the effects of adding more bubblers to the WTP HLW melter to inform decisions regarding future lid re-designs. The work used a high aluminum HLW stream composition defined by ORP, for which an appropriate simulant and high waste loading glass formulation were developed and have been previously processed on the DM1200.

  1. EVALUATION OF THE IMPACT OF THE DEFENSE WASTE PROCESSING FACILITY (DWPF) LABORATORY GERMANIUM OXIDE USE ON RECYCLE TRANSFERS TO THE H-TANK FARM

    SciTech Connect

    Jantzen, C.; Laurinat, J.

    2011-08-15

    When processing High Level Waste (HLW) glass, the Defense Waste Processing Facility (DWPF) cannot wait until the melt or waste glass has been made to assess its acceptability, since by then no further changes to the glass composition and acceptability are possible. Therefore, the acceptability decision is made on the upstream feed stream, rather than on the downstream melt or glass product. This strategy is known as 'feed forward statistical process control.' The DWPF depends on chemical analysis of the feed streams from the Sludge Receipt and Adjustment Tank (SRAT) and the Slurry Mix Evaporator (SME) where the frit plus adjusted sludge from the SRAT are mixed. The SME is the last vessel in which any chemical adjustments or frit additions can be made. Once the analyses of the SME product are deemed acceptable, the SME product is transferred to the Melter Feed Tank (MFT) and onto the melter. The SRAT and SME analyses have been analyzed by the DWPF laboratory using a 'Cold Chemical' method but this dissolution did not adequately dissolve all the elemental components. A new dissolution method which fuses the SRAT or SME product with cesium nitrate (CsNO{sub 3}), germanium (IV) oxide (GeO{sub 2}) and cesium carbonate (Cs{sub 2}CO{sub 3}) into a cesium germanate glass at 1050 C in platinum crucibles has been developed. Once the germanium glass is formed in that fusion, it is readily dissolved by concentrated nitric acid (about 1M) to solubilize all the elements in the SRAT and/or SME product for elemental analysis. When the chemical analyses are completed the acidic cesium-germanate solution is transferred from the DWPF analytic laboratory to the Recycle Collection Tank (RCT) where the pH is increased to {approx}12 M to be released back to the tank farm and the 2H evaporator. Therefore, about 2.5 kg/yr of GeO{sub 2}/year will be diluted into 1.4 million gallons of recycle. This 2.5 kg/yr of GeO{sub 2} may increase to 4 kg/yr when improvements are implemented to attain

  2. COMSOL MULTIPHYSICS MODEL FOR DWPF CANISTER FILLING

    SciTech Connect

    Kesterson, M.

    2011-03-31

    The purpose of this work was to develop a model that can be used to predict temperatures of the glass in the Defense Waste Processing Facility (DWPF) canisters during filling and cooldown. Past attempts to model these processes resulted in large (>200K) differences in predicted temperatures compared to experimentally measured temperatures. This work was therefore intended to also generate a model capable of reproducing the experimentally measured trends of the glass/canister temperature during filling and subsequent cooldown of DWPF canisters. To accomplish this, a simplified model was created using the finite element modeling software COMSOL Multiphysics which accepts user defined constants or expressions to describe material properties. The model results were compared to existing experimental data for validation. A COMSOL Multiphysics model was developed to predict temperatures of the glass within DWPF canisters during filling and cooldown. The model simulations and experimental data were in good agreement. The largest temperature deviations were {approx}40 C for the 87inch thermocouple location at 3000 minutes and during the initial cooldown at the 51 inch location occurring at approximately 600 minutes. Additionally, the model described in this report predicts the general trends in temperatures during filling and cooling observed experimentally. However, the model was developed using parameters designed to fit a single set of experimental data. Therefore, Q-loss is not currently a function of pour rate and pour temperature. Future work utilizing the existing model should include modifying the Q-loss term to be variable based on flow rate and pour temperature. Further enhancements could include eliminating the Q-loss term for a user defined convection where Navier-Stokes does not need to be solved in order to have convection heat transfer.

  3. Defense Waste Processing Facility: Report of task force on options to mitigate the effect of nitrite on DWPF operations

    SciTech Connect

    Randall, D.; Marek, J.C.

    1992-03-01

    The possibility of accumulating ammonium nitrate (an explosive) as well as organic compounds in the DWPF Chemical Processing Cell Vent System was recently discovered. A task force was therefore organized to examine ways to avoid this potential hazard. Of thirty-two processing/engineering options screened, the task force recommended five options, deemed to have the highest technical certainty, for detailed development and evaluation: Radiolysis of nitrite in the tetraphenylborate precipitate slurry feed in a new corrosion-resistant facility. Construction of a Late Washing Facility for precipitate washing before transfer to the DWPF; Just-in-Time'' precipitation; Startup Workaround by radiolysis of nitrite in the existing corrosion-resistant Pump Pit tanks; Ammonia venting and organics separation in the DWPF; and, Estimated costs and schedules are included in this report.

  4. Cold-Crucible Design Parameters for Next Generation HLW Melters

    SciTech Connect

    Gombert, D.; Richardson, J.; Aloy, A.; Day, D.

    2002-02-26

    The cold-crucible induction melter (CCIM) design eliminates many materials and operating constraints inherent in joule-heated melter (JHM) technology, which is the standard for vitrification of high-activity wastes worldwide. The cold-crucible design is smaller, less expensive, and generates much less waste for ultimate disposal. It should also allow a much more flexible operating envelope, which will be crucial if the heterogeneous wastes at the DOE reprocessing sites are to be vitrified. A joule-heated melter operates by passing current between water-cooled electrodes through a molten pool in a refractory-lined chamber. This design is inherently limited by susceptibility of materials to corrosion and melting. In addition, redox conditions and free metal content have exacerbated materials problems or lead to electrical short-circuiting causing failures in DOE melters. In contrast, the CCIM design is based on inductive coupling of a water-cooled high-frequency electrical coil with the glass, causing eddycurrents that produce heat and mixing. A critical difference is that inductance coupling transfers energy through a nonconductive solid layer of slag coating the metal container inside the coil, whereas the jouleheated design relies on passing current through conductive molten glass in direct contact with the metal electrodes and ceramic refractories. The frozen slag in the CCIM design protects the containment and eliminates the need for refractory, while the corrosive molten glass can be the limiting factor in the JH melter design. The CCIM design also eliminates the need for electrodes that typically limit operating temperature to below 1200 degrees C. While significant marketing claims have been made by French and Russian technology suppliers and developers, little data is available for engineering and economic evaluation of the technology, and no facilities are available in the US to support testing. A currently funded project at the Idaho National Engineering

  5. Arc melter demonstration baseline test results

    SciTech Connect

    Soelberg, N.R.; Chambers, A.G.; Anderson, G.L.; Oden, L.L.; O`Connor, W.K.; Turner, P.C.

    1994-07-01

    This report describes the test results and evaluation for the Phase 1 (baseline) arc melter vitrification test series conducted for the Buried Waste Integrated Demonstration program (BWID). Phase 1 tests were conducted on surrogate mixtures of as-incinerated wastes and soil. Some buried wastes, soils, and stored wastes at the INEL and other DOE sites, are contaminated with transuranic (TRU) radionuclides and hazardous organics and metals. The high temperature environment in an electric arc furnace may be used to process these wastes to produce materials suitable for final disposal. An electric arc furnace system can treat heterogeneous wastes and contaminated soils by (a) dissolving and retaining TRU elements and selected toxic metals as oxides in the slag phase, (b) destroying organic materials by dissociation, pyrolyzation, and combustion, and (c) capturing separated volatilized metals in the offgas system for further treatment. Structural metals in the waste may be melted and tapped separately for recycle or disposal, or these metals may be oxidized and dissolved into the slag. The molten slag, after cooling, will provide a glass/ceramic final waste form that is homogeneous, highly nonleachable, and extremely durable. These features make this waste form suitable for immobilization of TRU radionuclides and toxic metals for geologic timeframes. Further, the volume of contaminated wastes and soils will be substantially reduced in the process.

  6. DWPF FLOWSHEET STUDIES WITH SIMULANTS TO DETERMINE MCU SOLVENT BUILD-UP IN CONTINOUS RUNS

    SciTech Connect

    Lambert, D; Frances Williams, F; S Crump, S; Russell Eibling, R; Thomas02 White, T; David Best, D

    2006-05-25

    The Actinide Removal Process (ARP) facility and the Modular Caustic Side Solvent Extraction Unit (MCU) are scheduled to begin processing salt waste in fiscal year 2007. A portion of the streams generated in these salt processing facilities will be transferred to the Defense Waste Processing Facility (DWPF) to be incorporated in the glass matrix. Before the streams are introduced, a combination of impact analyses and research and development studies must be performed to quantify the impacts on DWPF processing. The Process Science & Engineering (PS&E) section of the Savannah River National Laboratory (SRNL) was requested via Technical Task Request (TTR) HLW/DWPF/TTR-2004-0031 to evaluate the impacts on DWPF processing. Simulant Chemical Process Cell (CPC) flowsheet studies have been performed using previous composition and projected volume estimates for the ARP sludge/monosodium titanate (MST) stream. Initial MCU incorporation testing for the DWPF flowsheet indicated unacceptable levels of Isopar{reg_sign}L were collecting in the Sludge Receipt and Adjustment Tank (SRAT) condenser system and unanticipated quantities of modifier were carrying over into the SRAT condenser system. This work was performed as part of Sludge Batch 4 (SB4) flowsheet testing and was reported by Baich et al. Due to changes in the flammability control strategy for DWPF for salt processing, the incorporation strategy for ARP changed and additional ARP flowsheet tests were necessary to validate the new processing strategy. The last round of ARP testing included the incorporation of the MCU stream and identified potential processing issues with the MCU solvent. The identified issues included the potential carry-over and accumulation of the MCU solvent components in the CPC condensers and in the recycle stream to the Tank Farm. Solvent retention in the DWPF condensers contradicts the DWPF solvent control strategy. Therefore, DWPF requested SRNL to perform additional MCU flowsheet studies to better

  7. HLW Melter Control Strategy Without Visual Feedback VSL-12R2500-1 Rev 0

    SciTech Connect

    Kruger, A A.; Joseph, Innocent; Matlack, Keith S.; Callow, Richard A.; Abramowitz, Howard; Pegg, Ian L.; Brandys, Marek; Kot, Wing K.

    2012-11-13

    Plans for the treatment of high level waste (HL W) at the Hanford Tank Waste Treatment and Immobilization Plant (WTP) are based upon the inventory of the tank wastes, the anticipated performance of the pretreatment processes, and current understanding of the capability of the borosilicate glass waste form [I]. The WTP HLW melter design, unlike earlier DOE melter designs, incorporates an active glass bubbler system. The bubblers create active glass pool convection and thereby improve heat and mass transfer and increase glass melting rates. The WTP HLW melter has a glass surface area of 3.75 m{sup 2} and depth of ~ 1.1 m. The two melters in the HLW facility together are designed to produce up to 7.5 MT of glass per day at 100% availability. Further increases in HL W waste processing rates can potentially be achieved by increasing the melter operating temperature above 1150°C and by increasing the waste loading in the glass product. Increasing the waste loading also has the added benefit of decreasing the number of canisters for storage.

  8. Baseline tests for arc melter vitrification of INEL buried wastes. Volume II: Baseline test data appendices

    SciTech Connect

    Oden, L.L.; O`Conner, W.K.; Turner, P.C.; Soelberg, N.R.; Anderson, G.L.

    1993-11-19

    This report presents field results and raw data from the Buried Waste Integrated Demonstration (BWID) Arc Melter Vitrification Project Phase 1 baseline test series conducted by the Idaho National Engineering Laboratory (INEL) in cooperation with the U.S. Bureau of Mines (USBM). The baseline test series was conducted using the electric arc melter facility at the USBM Albany Research Center in Albany, Oregon. Five different surrogate waste feed mixtures were tested that simulated thermally-oxidized, buried, TRU-contaminated, mixed wastes and soils present at the INEL. The USBM Arc Furnace Integrated Waste Processing Test Facility includes a continuous feed system, the arc melting furnace, an offgas control system, and utilities. The melter is a sealed, 3-phase alternating current (ac) furnace approximately 2 m high and 1.3 m wide. The furnace has a capacity of 1 metric ton of steel and can process as much as 1,500 lb/h of soil-type waste materials. The surrogate feed materials included five mixtures designed to simulate incinerated TRU-contaminated buried waste materials mixed with INEL soil. Process samples, melter system operations data and offgas composition data were obtained during the baseline tests to evaluate the melter performance and meet test objectives. Samples and data gathered during this program included (a) automatically and manually logged melter systems operations data, (b) process samples of slag, metal and fume solids, and (c) offgas composition, temperature, velocity, flowrate, moisture content, particulate loading and metals content. This report consists of 2 volumes: Volume I summarizes the baseline test operations. It includes an executive summary, system and facility description, review of the surrogate waste mixtures, and a description of the baseline test activities, measurements, and sample collection. Volume II contains the raw test data and sample analyses from samples collected during the baseline tests.

  9. The corrosion behavior of DWPF glasses

    SciTech Connect

    Ebert, W.L.; Bates, J.K.

    1995-06-01

    The authors analyzed the corroded surfaces of reference glasses developed for the Defense Waste Processing Facility (DWPF) to characterize their corrosion behavior. The corrosion mechanism of nuclear waste glasses must be known in order to provide source terms describing radionuclide release for performance assessment calculations. Different DWPF reference glasses were corroded under conditions that highlighted various aspects of the corrosion process and led to different extents of corrosion. The glasses corroded by similar mechanisms, and a phenomenological description of their corrosion behavior is presented here. The initial leaching of soluble glass components results in the formation of an amorphous gel layer on the glass surface. The gel layer is a transient phase that transforms into a layer of clay crystallites, which equilibrates with the solution as corrosion continues. The clay layer does not act as a barrier to either water penetration or glass dissolution, which continues beneath it, and may eventually separate from the glass. Solubility limits for glass components may be established by the eventual precipitation of secondary phases; thus, corrosion of the glass becomes controlled by the chemical equilibrium between the solution and the assemblage of secondary phases. In effect, the solution is an intermediate phase through which the glass transforms to an energetically more favorable assemblage of phases. Implications regarding the prediction of long-term glass corrosion behavior are discussed.

  10. Glass sampling program during DWPF Integrated Cold Runs

    SciTech Connect

    Plodinec, M.J.

    1990-03-30

    The described glass sampling program is designed to achieve two objectives: To demonstrate Defense Waste Processing Facility (DWPF) ability to control and verify the radionuclide release properties of the glass product; To confirm DWPF's readiness to obtain glass samples during production, and SRL's readiness to analyze and test those samples remotely. The DWPF strategy for control of the radionuclide release properties of the glass product, and verification of its acceptability are described in this report. The basic approach of the test program is then defined.

  11. Glass sampling program during DWPF Integrated Cold Runs. Revision 1

    SciTech Connect

    Plodinec, M.J.

    1990-03-30

    The described glass sampling program is designed to achieve two objectives: To demonstrate Defense Waste Processing Facility (DWPF) ability to control and verify the radionuclide release properties of the glass product; To confirm DWPF`s readiness to obtain glass samples during production, and SRL`s readiness to analyze and test those samples remotely. The DWPF strategy for control of the radionuclide release properties of the glass product, and verification of its acceptability are described in this report. The basic approach of the test program is then defined.

  12. Control of radioactive waste-glass melters

    SciTech Connect

    Bickford, D.F. ); Hrma, P. ); Bowan, B.W. II )

    1990-01-01

    Slurries of simulated high level radioactive waste and glass formers have been isothermally reacted and analyzed to identify the sequence of the major chemical reactions in waste vitrification, their effect on glass production rate, and the development of leach resistance. Melting rates of waste batches have been increased by the addition of reducing agents (formic acid, sucrose) and nitrates. The rate increases are attributable in part to exothermic reactions which occur at critical stages in the vitrification process. Nitrates must be balanced by adequate reducing agents to avoid the formation of persistent foam, which would destabilize the melting process. The effect of foaming on waste glass production rates is analyzed, and melt rate limitations defined for waste-glass melters, based upon measurable thermophysical properties. Minimum melter residence times required to homogenize glass and assure glass quality are much smaller than those used in current practice. Thus, melter size can be reduced without adversely affecting glass quality. Physical chemistry and localized heat transfer of the waste-glass melting process are examined, to refine the available models for predicting and assuring glass production rate. It is concluded that the size of replacement melters and future waste processing facilities can be significantly decreased if minimum heat transfer requirements for effective melting are met by mechanical agitation. A new class of waste glass melters has been designed, and proof of concept tests completed on simulated High Level Radioactive Waste slurry. Melt rates have exceeded 155 kg m{sup {minus}2} h{sup {minus}1} with slurry feeds (32 lb ft{sup {minus}2} h{sup {minus}1}), and 229 kg kg m{sup {minus}2} h{sup {minus}1} with dry feed (47 lb ft{sup {minus}2} h{sup {minus}1}). This is about 8 times the melt rate possible in conventional waste- glass melters of the same size. 39 refs., 5 figs., 9 tabs.

  13. IMPACT OF SMALL COLUMN ION EXCHANGE STREAMS ON DWPF GLASS FORMULATION MELT RATE STUDIES

    SciTech Connect

    Fox, K.; Miller, D.; Koopman, D.

    2011-04-26

    This study was undertaken to evaluate the potential impacts of the Small Column Ion Exchange (SCIX) streams - particularly the addition of Monosodium Titanate (MST) and Crystalline Silicotitanate (CST) - on the melt rate of simulated feed for the Defense Waste Processing Facility (DWPF). Additional MST was added to account for contributions from the Salt Waste Processing Facility (SWPF). The Savannah River National Laboratory (SRNL) Melt Rate Furnace (MRF) was used to evaluate four melter feed compositions: two with simulated SCIX and SWPF material and two without. The Slurry-fed Melt Rate Furnace (SMRF) was then used to compare two different feeds: one with and one without bounding concentrations of simulated SCIX and SWPF material. Analyses of the melter feed materials confirmed that they met their targeted compositions. Four feeds were tested in triplicate in the MRF. The linear melt rates were determined by using X-ray computed tomography to measure the height of the glass formed along the bottom of the beakers. The addition of the SCIX and SWPF material reduced the average measured melt rate by about 10% in MRF testing, although there was significant scatter in the data. Two feeds were tested in the SMRF. It was noted that the ground CST alone (ground CST with liquid in a bucket) was extremely difficult to resuspend during preparation of the feed with material from SCIX and SWPF. This feed was also more difficult to pump than the material without MST and CST due to settling occurring in the melter feed line, although the yield stress of both feeds was high relative to the DWPF design basis. Steady state feeding conditions were maintained for about five hours for each feed. There was a reduction in the feed and pour rates of approximately 15% when CST and MST were added to the feed, although there was significant scatter in the data. Analysis of samples collected from the SMRF pour stream showed that the composition of the glass changed as expected when MST and

  14. Experimental Plan for Crystal Accumulation Studies in the WTP Melter Riser

    SciTech Connect

    Miller, D.; Fowley, M.

    2015-04-28

    This experimental plan defines crystal settling experiments to be in support of the U.S. Department of Energy – Office of River Protection crystal tolerant glass program. The road map for development of crystal-tolerant high level waste glasses recommends that fluid dynamic modeling be used to better understand the accumulation of crystals in the melter riser and mechanisms of removal. A full-scale version of the Hanford Waste Treatment and Immobilization Plant (WTP) melter riser constructed with transparent material will be used to provide data in support of model development. The system will also provide a platform to demonstrate mitigation or recovery strategies in off-normal events where crystal accumulation impedes melter operation. Test conditions and material properties will be chosen to provide results over a variety of parameters, which can be used to guide validation experiments with the Research Scale Melter at the Pacific Northwest National Laboratory, and that will ultimately lead to the development of a process control strategy for the full scale WTP melter. The experiments described in this plan are divided into two phases. Bench scale tests will be used in Phase 1 (using the appropriate solid and fluid simulants to represent molten glass and spinel crystals) to verify the detection methods and analytical measurements prior to their use in a larger scale system. In Phase 2, a full scale, room temperature mockup of the WTP melter riser will be fabricated. The mockup will provide dynamic measurements of flow conditions, including resistance to pouring, as well as allow visual observation of crystal accumulation behavior.

  15. Technical information report: Plasma melter operation, reliability, and maintenance analysis

    SciTech Connect

    Hendrickson, D.W.

    1995-03-14

    This document provides a technical report of operability, reliability, and maintenance of a plasma melter for low-level waste vitrification, in support of the Hanford Tank Waste Remediation System (TWRS) Low-Level Waste (LLW) Vitrification Program. A process description is provided that minimizes maintenance and downtime and includes material and energy balances, equipment sizes and arrangement, startup/operation/maintence/shutdown cycle descriptions, and basis for scale-up to a 200 metric ton/day production facility. Operational requirements are provided including utilities, feeds, labor, and maintenance. Equipment reliability estimates and maintenance requirements are provided which includes a list of failure modes, responses, and consequences.

  16. THERMAL ANALYSIS OF WASTE GLASS MELTER FEEDS

    SciTech Connect

    KRUGER AA; HRMA PR; POKORNY R; PIERCE DA

    2011-10-21

    Melter feeds for high-level nuclear waste (HLW) typically contain a large number of constituents that evolve gas on heating, Multiple gas-evolving reactions are both successive and simultaneous, and include the release of chemically bonded water, reactions of nitrates with organics, and reactions of molten salts with solid silica. Consequently, when a sample of a HLW feed is subjected to thermogravimetric analysis (TGA), the rate of change of the sample mass reveals multiple overlapping peaks. In this study, a melter feed, formulated for a simulated high-alumina HLW to be vitrified in the Waste Treatment and Immobilization Plant, currently under construction at the Hanford Site in Washington State, USA, was subjected to TGA. In addition, a modified melter feed was prepared as an all-nitrate version of the baseline feed to test the effect of sucrose addition on the gas-evolving reactions. Activation energies for major reactions were determined using the Kissinger method. The ultimate aim of TGA studies is to obtain a kinetic model of the gas-evolving reactions for use in mathematical modeling of the cold cap as an element of the overall model of the waste-glass melter. In this study, we focused on computing the kinetic parameters of individual reactions without identifying their actual chemistry, The rough provisional model presented is based on the first-order kinetics.

  17. Parametric testing of a DWPF borosilicate glass

    SciTech Connect

    Bazan, F.; Rego, J.

    1985-01-18

    A series of tests have been performed to characterize the chemical stability of a DWPF borosilicate glass sample as part of the Waste Package Task of the NNWSI Project. This material was prepared at the Savannah River Laboratory for the purpose of testing the 165-frit matrix doped with a simulated non-radioactive waste. All tests were conducted at 90{sup 0}C using deionized water and J-13 water (a tuffaceous formation groundwater). In the deionized water tests, both monoliths and crushed glass were tested at various ratios of surface area of the sample to volume of water in order to compare leach rates for different sample geometries or leaching times. Effects on the leach rates due to the presence of crushed tuff and stainless steel material were also investigated in the tests with J-13 water. 4 references, 2 figures, 4 tables.

  18. GLASS FORMULATION DEVELOPMENT AND TESTING FOR COLD CRUCIBLE INDUCTION MELTER (CCIM) ADVANCED REMEDIATION TECHNOLOGIES DEMONSTRATION PROJECT - 9208

    SciTech Connect

    Marra, J; Amanda Billings, A; David Peeler, D; Michael Stone, M; Tommy Edwards, T

    2008-08-27

    Over the past few years, Cold Crucible Induction Melter (CCIM) demonstrations have been completed using SRS sludge batches 2, 3 and 4 (SB2, SB3 and SB4) simulant compositions. These campaigns demonstrated the ability of the CCIM to effectively produce quality glasses at high waste loadings. The current Advanced Remediation Technology (ART) Phase II-A Project is aimed at demonstrating the CCIM technology under representative DWPF flowsheet conditions and to demonstrate extended operations of the melter. A glass composition development effort was completed to identify and recommend a frit composition and sludge batch 4 (SB4) simulant waste loading target for subsequent ART-Phase II-A CCIM demonstration testing. Based on the results of the glass formulation testing, it was recommended that the Frit 503-R6 composition (B{sub 2}O{sub 3} = 14 wt %; Li{sub 2}O = 9 wt %; Na{sub 2}O = 3 wt %; and SiO{sub 2} = 74 wt %) be utilized for the demonstration. Furthermore, a waste loading of 46 wt % was recommended. The recommended frit and waste loading would produce a glass with acceptable durability with a liquidus temperature adequately below the 1250 C nominal CCIM operating temperature. This frit composition and waste loading was found to result in a glass that met CCIM processing requirements for viscosity, electrical conductivity and thermal conductivity. The recommended frit and waste loading level should also provide a buffer for sludge product compositional variation to support the Phase II-A CCIM demonstration.

  19. Performance test report for the 1000 kg melter

    SciTech Connect

    Eaton, W.C.

    1995-11-01

    A multiphase program was initiated in 1994 to test commercially available melter technologies for the vitrification of the low-level waste (LLW) stream from defense wastes stored in underground tanks at the Hanford Site in southeastern Washington State. Phase 1 of the melter demonstration tests using simulated LLW was completed during fiscal year 1995. This document is the 100 kg melter offgas report on testing performed by GTS Duratek Inc., in Columbia, Maryland. GTS Duratek (one of the seven vendors selected) was chosen to demonstrate Joule heated melter technology under WHC subcontract number MMI-SVV- 384215. The document contains the complete offgas report on the 100 kg melter as prepared by Parsons Engineering Science, Inc. A summary of this report is also contained in the ``GTS Duratek, Phase 1 Hanford Low-Level Waste Melter Tests: Final Report`` (WHC-SD-VI-027).

  20. DWPF Recycle Evaporator Shielded Cells Testing

    SciTech Connect

    Fellinger, T. L.; Herman, D. T.; Stone, M.E

    2005-07-01

    Testing was performed to determine the feasibility and processing characteristics of evaporation of actual Defense Waste Processing Facility (DWPF) recycle material. Samples of the Off Gas Condensate Tank (OGCT) and Slurry Mix Evaporator Condensate Tank (SMECT) were transferred from DWPF to the Savannah River National Lab (SRNL) Shielded Cells and blended with De-Ionized (DI) water and a small amount of Slurry Mix Evaporator (SME) product. A total of 3000 mL of this feed was concentrated to approximately 90 mL during a semi-batch evaporation test of approximately 17 hours. One interruption occurred during the run when the feed tube developed a split and was replaced. Samples of the resulting condensate and concentrate were collected and analyzed. The resulting analysis of the condensate was compared to the Waste Acceptance Criteria (WAC) limits for the F/H Effluent Treatment Plant (ETP). Results from the test were compared to previous testing using simulants and OLI modeling. Conclusions from this work included the following: (1) The evaporation of DWPF recycle to achieve a 30X concentration factor was successfully demonstrated. The feed blend of OGCT and SMECT material was concentrated from 3000 mL to approximately 90 mL during testing, a concentration of approximately 33X. (2) Foaming was observed during the run. Dow Corning 2210 antifoam was added seven times throughout the run at 100 parts per million (ppm) per addition. The addition of this antifoam was very effective in reducing the foam level, but the impact diminished over time and additional antifoam was required every 2 to 3 hours during the run. (3) No scale or solids formed on the evaporator vessel, but splatter was observed in the headspace of the evaporator vessel. No scaling formed on the stainless steel thermocouple. (4) The majority of the analytes met the F/H ETP WAC. However, the detection limits for selected species (Sr-90, Pu-238, Pu-240, Am-243, and Cm-244) exceeded the ETP WAC limits. (5) I

  1. Melter Throughput Enhancements for High-Iron HLW

    SciTech Connect

    Kruger, A. A.; Gan, Hoa; Joseph, Innocent; Pegg, Ian L.; Matlack, Keith S.; Chaudhuri, Malabika; Kot, Wing

    2012-12-26

    This report describes work performed to develop and test new glass and feed formulations in order to increase glass melting rates in high waste loading glass formulations for HLW with high concentrations of iron. Testing was designed to identify glass and melter feed formulations that optimize waste loading and waste processing rate while meeting all processing and product quality requirements. The work included preparation and characterization of crucible melts to assess melt rate using a vertical gradient furnace system and to develop new formulations with enhanced melt rate. Testing evaluated the effects of waste loading on glass properties and the maximum waste loading that can be achieved. The results from crucible-scale testing supported subsequent DuraMelter 100 (DM100) tests designed to examine the effects of enhanced glass and feed formulations on waste processing rate and product quality. The DM100 was selected as the platform for these tests due to its extensive previous use in processing rate determination for various HLW streams and glass compositions.

  2. Recirculation bubbler for glass melter apparatus

    DOEpatents

    Guerrero, Hector; Bickford, Dennis

    2007-06-05

    A gas bubbler device provides enhanced recirculation of molten glass within a glass melter apparatus. The bubbler device includes a tube member disposed within a pool of molten glass contained in the melter. The tube member includes a lower opening through which the molten glass enters and upper slots disposed close to (above or below) the upper surface of the pool of molten glass and from which the glass exits. A gas (air) line is disposed within the tube member and extends longitudinally thereof. A gas bubble distribution device, which is located adjacent to the lower end of the tube member and is connected to the lower end of the gas line, releases gas through openings therein so as to produce gas bubbles of a desired size in the molten glass and in a distributed pattern across the tube member.

  3. SLUDGE WASHING AND DEMONSTRATION OF THE DWPF FLOWSHEET IN THE SRNL SHIELDED CELLS FOR SLUDGE BATCH 6 QUALIFICATION

    SciTech Connect

    Pareizs, J.; Pickenheim, B.; Bannochie, C.; Billings, A.; Bibler, N.; Click, D.

    2010-10-01

    below the DWPF target with 750 g of steam per g of mercury. However, rheological properties did not improve and were above the design basis. Hydrogen generation rates did not exceed DWPF limits during the SRAT and Slurry Mix Evaporator (SME) cycles. However, hydrogen generation during the SRAT cycle approached the DWPF limit. The glass fabricated with the Tank 51 SB6 SME product and Frit 418 was acceptable with respect to chemical durability as measured by the Product Consistency Test (PCT). The PCT response was also predictable by the current durability models of the DWPF Product Composition Control System (PCCS). It should be noted, however, that in the first attempt to make glass from the SME product, the contents of the fabrication crucible foamed over. This may be a result of the SME product's REDOX (Reduction/Oxidation - Fe{sup 2+}/{Sigma}Fe) of 0.08 (calculated from SME product analytical results). The following are recommendations drawn from this demonstration. In this demonstration, at the request of DWPF, SRNL caustic boiled the SRAT contents prior to acid addition to remove water (to increase solids concentration). During the nearly five hours of caustic boiling, 700 ppm of antifoam was required to control foaming. SRNL recommends that DWPF not caustic boil/concentrate SRAT receipt prior to acid addition until further studies can be performed to provide a better foaming control strategy or a new antifoam is developed for caustic boiling. Based on this set of runs and a recently completed demonstration with the SB6 Waste Acceptance Product Specifications (WAPS) sample, it is recommended that DWPF not add formic acid at the design addition rate of two gallons per minute for this sludge batch. A longer acid addition time appears to be helpful in allowing slower reaction of formic acid with the sludge and possibly decreases the chance of a foam over during acid addition.

  4. Application of hydration thermodynamics to control of the DWPF process

    SciTech Connect

    Plodinec, M.J.

    1990-01-01

    The Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS) will incorporate the radioactivity in the 130 million liters of high-level nuclear waste at SRS in a stable borosilicate glass. Glass product specifications requite control of processing parameters to ensure glass durability. A model of glass durability, based on hydration thermodynamics, has been used at SRS to aid in formulation of waste glasses; to explain the relative durability of different glasses under identical test conditions (MCC-1 test ); and to explain the effects of changing test conditions on the observed durability of a given glass. This model has now been modified for use in control of the DWPF. It provides a tool which relates glass durability to parameters which can be controlled in the DWPF process. It provides a tool which relates glass durability to parameters which can be controlled in the DWPF process, primarily chemical composition. In this paper, the model is presented, and its projected role in control of the DWPF process is described.

  5. Building 774A mini-melter restoration

    SciTech Connect

    Mensink, D.L.

    1989-04-14

    Large scale mechanical improvements were made on the 100th scale glass melter in building 774A following a shutdown in November, 1988. The circumstances regarding that shutdown were reported by P.M. Allen in DPST-89-345. By request, the Mechanical Development Group assumed responsibility for the work on SRL Service order DS-87042. This report describes the changes which were made, their purpose, and observations as to their effectiveness after approximately 4 weeks of operating with the improvements in-place. Recommendations for further improving the equipment are also noted. The old melter design, now superseded, is documented in drawings ST5-23838 through ST5-23847. As-built drawing arrangements and details for the new work is shown in drawings SK5-6191-LD through SK5-6197-LD. Other design details are referenced in the drawings which were developed for the new shielded cells Research Melter, ST5-25111 through ST5-25124.

  6. Physical and numerical modeling of Joule-heated melters

    NASA Astrophysics Data System (ADS)

    Eyler, L. L.; Skarda, R. J.; Crowder, R. S., III; Trent, D. S.; Reid, C. R.; Lessor, D. L.

    1985-10-01

    The Joule-heated ceramic-lined melter is an integral part of the high level waste immobilization process under development by the US Department of Energy. Scaleup and design of this waste glass melting furnace requires an understanding of the relationships between melting cavity design parameters and the furnace performance characteristics such as mixing, heat transfer, and electrical requirements. Developing empirical models of these relationships through actual melter testing with numerous designs would be a very costly and time consuming task. Additionally, the Pacific Northwest Laboratory (PNL) has been developing numerical models that simulate a Joule-heated melter for analyzing melter performance. This report documents the method used and results of this modeling effort. Numerical modeling results are compared with the more conventional, physical modeling results to validate the approach. Also included are the results of numerically simulating an operating research melter at PNL. Physical Joule-heated melters modeling results used for qualiying the simulation capabilities of the melter code included: (1) a melter with a single pair of electrodes and (2) a melter with a dual pair (two pairs) of electrodes. The physical model of the melter having two electrode pairs utilized a configuration with primary and secondary electrodes. The principal melter parameters (the ratio of power applied to each electrode pair, modeling fluid depth, electrode spacing) were varied in nine tests of the physical model during FY85. Code predictions were made for five of these tests. Voltage drops, temperature field data, and electric field data varied in their agreement with the physical modeling results, but in general were judged acceptable.

  7. Physical and numerical modeling of Joule-heated melters

    SciTech Connect

    Eyler, L.L.; Skarda, R.J.; Crowder, R.S. III; Trent, D.S.; Reid, C.R.; Lessor, D.L.

    1985-10-01

    The Joule-heated ceramic-lined melter is an integral part of the high level waste immobilization process under development by the US Department of Energy. Scaleup and design of this waste glass melting furnace requires an understanding of the relationships between melting cavity design parameters and the furnace performance characteristics such as mixing, heat transfer, and electrical requirements. Developing empirical models of these relationships through actual melter testing with numerous designs would be a very costly and time consuming task. Additionally, the Pacific Northwest Laboratory (PNL) has been developing numerical models that simulate a Joule-heated melter for analyzing melter performance. This report documents the method used and results of this modeling effort. Numerical modeling results are compared with the more conventional, physical modeling results to validate the approach. Also included are the results of numerically simulating an operating research melter at PNL. Physical Joule-heated melters modeling results used for qualiying the simulation capabilities of the melter code included: (1) a melter with a single pair of electrodes and (2) a melter with a dual pair (two pairs) of electrodes. The physical model of the melter having two electrode pairs utilized a configuration with primary and secondary electrodes. The principal melter parameters (the ratio of power applied to each electrode pair, modeling fluid depth, electrode spacing) were varied in nine tests of the physical model during FY85. Code predictions were made for five of these tests. Voltage drops, temperature field data, and electric field data varied in their agreement with the physical modeling results, but in general were judged acceptable. 14 refs., 79 figs., 17 tabs.

  8. THE IMPACT OF THE MCU LIFE EXTENSION SOLVENT ON DWPF GLASS FORMULATION EFFORTS

    SciTech Connect

    Peeler, D; Edwards, T

    2011-03-24

    As a part of the Actinide Removal Process (ARP)/Modular Caustic Side Solvent Extraction Unit (MCU) Life Extension Project, a next generation solvent (NG-CSSX), a new strip acid, and modified monosodium titanate (mMST) will be deployed. The strip acid will be changed from dilute nitric acid to dilute boric acid (0.01 M). Because of these changes, experimental testing with the next generation solvent and mMST is required to determine the impact of these changes in 512-S operations as well as Chemical Process Cell (CPC), Defense Waste Processing Facility (DWPF) glass formulation activities, and melter operations at DWPF. To support programmatic objectives, the downstream impacts of the boric acid strip effluent (SE) to the glass formulation activities and melter operations are considered in this study. More specifically, the impacts of boric acid additions to the projected SB7b operating windows, potential impacts to frit production temperatures, and the potential impact of boron volatility are evaluated. Although various boric acid molarities have been reported and discussed, the baseline flowsheet used to support this assessment was 0.01M boric acid. The results of the paper study assessment indicate that Frit 418 and Frit 418-7D are robust to the implementation of the 0.01M boric acid SE into the SB7b flowsheet (sludge-only or ARP-added). More specifically, the projected operating windows for the nominal SB7b projections remain essentially constant (i.e., 25-43 or 25-44% waste loading (WL)) regardless of the flowsheet options (sludge-only, ARP added, and/or the presence of the new SE). These results indicate that even if SE is not transferred to the Sludge Receipt and Adjustment Tank (SRAT), there would be no need to add boric acid (from a trim tank) to compositionally compensate for the absence of the boric acid SE in either a sludge-only or ARP-added SB7b flowsheet. With respect to boron volatility, the Measurement Acceptability Region (MAR) assessments also

  9. Defense waste processing facility (DWPF) environmental dosimetry data

    SciTech Connect

    Marter, W.L.; Bauer, L.R.

    1990-04-09

    The original Environmental Impact Statement for the DWPF was issued in 1982. Since that time, estimated releases of radioactivity to the environment have changed because of the DWPF process. In addition, the methodology for calculating offsite doses from routine releases has changed. In anticipation of a potential supplement to the 1982 EIS, current dosimetry methodology has been used to estimate offsite doses from the current as-constructed estimate of radioactivity releases. Offsite doses have also been calculated for the radioactivity release data published in the 1982 EIS using current dosimetry methodology. The two data sets may therefore be used to compare the estimated original and current impacts. This memorandum documents the results of the offsite dose calculations for routine operation of the DWPF. Also included is a brief description of methodology and parameters used in the calculations. 8 refs., 2 figs., 10 tabs.

  10. The DWPF strategy for producing an acceptable product

    SciTech Connect

    Goldston, W.T.; Plodinec, M.J.

    1991-12-31

    The Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS) will convert the 130 million liters of high-level nuclear waste at SRS into stable borosilicate glass. Production of canistered waste forms by the DWPF is scheduled to begin well before submission of the license application for the first repository. The Department of Energy has defined waste acceptance specifications to ensure that DWPF canistered waste forms will be acceptable for eventual disposal. To ensure that canistered waste forms meet those specifications, a program is being carried out to qualify the waste form and those aspects of the production process which affect product quality. This program includes: Pre-production qualification testing of simulated and actual waste forms; Disciplined demonstrations of the ability to produce an acceptable product during startup testing; and Application of a rigorous product control program during production.

  11. The DWPF strategy for producing an acceptable product

    SciTech Connect

    Goldston, W.T.; Plodinec, M.J.

    1991-01-01

    The Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS) will convert the 130 million liters of high-level nuclear waste at SRS into stable borosilicate glass. Production of canistered waste forms by the DWPF is scheduled to begin well before submission of the license application for the first repository. The Department of Energy has defined waste acceptance specifications to ensure that DWPF canistered waste forms will be acceptable for eventual disposal. To ensure that canistered waste forms meet those specifications, a program is being carried out to qualify the waste form and those aspects of the production process which affect product quality. This program includes: Pre-production qualification testing of simulated and actual waste forms; Disciplined demonstrations of the ability to produce an acceptable product during startup testing; and Application of a rigorous product control program during production.

  12. High-temperature vitrification of Hanford residual-liquid waste in a continuous melter

    SciTech Connect

    Barnes, S.M.

    1980-04-01

    Over 270 kg of high-temperature borosilicate glass have been produced in a series of three short-term tests in the High-Temperature Ceramic Melter vitrification system at PNL. The glass produced was formulated to vitrify simulated Hanford residual-liquid waste. The tests were designed to (1) demonstrate the feasibility of utilizing high-temperature, continuous-vitrification technology for the immobilization of the residual-liquid waste, (2) test the airlift draining technique utilized by the high-temperature melter, (3) compare glass produced in this process to residual-liquid glass produced under laboratory conditions, (4) investigate cesium volatility from the melter during waste processing, and (5) determine the maximum residual-liquid glass production rate in the high-temperature melter. The three tests with the residual-liquid composition confirmed the viability of the continuous-melting vitrification technique for the immobilization of this waste. The airlift draining technique was demonstrated in these tests and the glass produced from the melter was shown to be less porous than the laboratory-produced glass. The final glass produced from the second test was compared to a glass of the same composition produced under laboratory conditions. The comparative tests found the glasses to be indistinguishable, as the small differences in the test results fell within the precision range of the characterization testing equipment. The cesium volatility was examined in the final test. This examination showed that 0.44 wt % of the cesium (assumed to be cesium oxide) was volatilized, which translates to a volatilization rate of 115 mg/cm/sup 2/-h.

  13. Redox control of electric melters with complex feed compositions. Part II: preliminary limits for radioactive waste melters

    SciTech Connect

    Bickford, D F; Diemer, Jr, R B; Iverson, D C

    1985-01-01

    Melter redox control is necessary for safe and continued melter operation. A combination of feed composition control, melter operational controls and monitors, and periodic determination of product glass redox state is sufficient to meet operating and safety requirements. Mossbauer spectroscopy, or other methods which determine the Fe(II)/Fe(III) ratio of the glass product, can be used to determine the oxidation state of the glass and thereby assess operating conditions. Slightly reducing conditions can eliminate radio-Ru volatility by suppressing the formation of RuO4. Reducing conditions also limit foaming resulting from the release of oxygen as transition metal oxides are dissolved in the melt. The calcination and partial combustion of organic compounds in the melter feed generates combustible mixtures of CO, H2 and benzene. The organics must be essentially completely incinerated to avoid the accumulation of combustible offgas mixtures, and prevent fouling of the equipment by soot and tars. Operation of the melter plenum above the autoignition temperature, metering in of purge air in excess of that required for complete combustion, and dilution by water vapor from reacted feed all preclude this occurrence in the melter. Prevention of dangerous offgas compositions after water vapor removal is assured by combustion in the melter, the addition of dilution air, and by continuous monitoring by % Lower Explosive Limit meters. Melter reducing power must be restricted to prevent formation of molten sulfides or selenides in the melter, and to prevent carburization and sulfidation attack of Inconel-690 melter components. Control of average oxygen partial pressure in the melter plenum is insufficient to assure prevention of localized attack of Inconel-690. An additional requirement is therefore necessary, that no soot or tarry substances be deposited on the Inconel-690.

  14. Defense Waste Processing Facility: Report of task force on options to mitigate the effect of nitrite on DWPF operations. Savannah River Site 200-S Area

    SciTech Connect

    Randall, D.; Marek, J.C.

    1992-03-01

    The possibility of accumulating ammonium nitrate (an explosive) as well as organic compounds in the DWPF Chemical Processing Cell Vent System was recently discovered. A task force was therefore organized to examine ways to avoid this potential hazard. Of thirty-two processing/engineering options screened, the task force recommended five options, deemed to have the highest technical certainty, for detailed development and evaluation: Radiolysis of nitrite in the tetraphenylborate precipitate slurry feed in a new corrosion-resistant facility. Construction of a Late Washing Facility for precipitate washing before transfer to the DWPF; ``Just-in-Time`` precipitation; Startup Workaround by radiolysis of nitrite in the existing corrosion-resistant Pump Pit tanks; Ammonia venting and organics separation in the DWPF; and, Estimated costs and schedules are included in this report.

  15. DWPF DECON FRIT: SUMP AND SLURRY SOLIDS ANALYSIS

    SciTech Connect

    Crawford, C.; Peeler, D.; Click, D.

    2010-10-20

    The Savannah River National Laboratory (SRNL) has been requested to perform analyses on samples of the Defense Waste Processing Facility (DWPF) decon frit slurry (i.e., supernate samples and sump solid samples). Four 1-L liquid slurry samples were provided to SRNL by Savannah River Remediation (SRR) from the 'front-end' decon activities. Additionally, two 1-L sump solids samples were provided to SRNL for compositional and physical analysis. In this report, the physical and chemical characterization results of the slurry solids and sump solids are reported. Crawford et al. (2010) provide the results of the supernate analysis. The results of the sump solids are reported on a mass basis given the samples were essentially dry upon receipt. The results of the slurry solids were converted to a volume basis given approximately 2.4 grams of slurry solids were obtained from the {approx}4 liters of liquid slurry sample. Although there were slight differences in the analytical results between the sump solids and slurry solids the following general summary statements can be made. Slight differences in the results are also captured for specific analysis. (1) Physical characterization - (a) SEM/EDS analysis suggested that the samples were enriched in Li and Si (B and Na not detectable using the current EDS system) which is consistent with two of the four principle oxides of Frit 418 (B{sub 2}O{sub 3}, Na{sub 2}O, Li{sub 2}O and SiO{sub 2}). (b) SEM/EDS analysis also identified impurities which were elementally consistent with stainless steel (i.e., Fe, Ni, Cr contamination). (c) XRD results indicated that the sump solids samples were amorphous which is consistent with XRD results expected for a Frit 418 based sample. (d) For the sump solids, SEM/EDS analysis indicated that the particle size of the sump solids were consistent with that of an as received Frit 418 sample from a current DWPF vendor. (e) For the slurry solids, SEM/EDS analysis indicated that the particle size range

  16. Preliminary Dynamic Modeling of the Hanford Waste Treatment Plant Melter Offgas

    SciTech Connect

    Smith, F.G. III

    2001-09-21

    This report documents preliminary versions of the models that include the components of the offgas systems from the melters through the exhaust stacks and the vessel ventilation systems. The models consider only the two major chemical species in the offgas stream: air and steam or water vapor. Model mass and energy balance calculations are designed to show the dynamic behavior of gas pressure and flow throughout the offgas systems in response to transient driving forces.

  17. Baseline tests for arc melter vitrification of INEL buried wastes. Volume 1: Facility description and summary data report

    SciTech Connect

    Oden, L.L.; O`Connor, W.K.; Turner, P.C.; Soelberg, N.R.; Anderson, G.L.

    1993-11-19

    This report presents field results and raw data from the Buried Waste Integrated Demonstration (BWID) Arc Melter Vitrification Project Phase 1 baseline test series conducted by the Idaho National Engineering Laboratory (INEL) in cooperation with the U.S. Bureau of Mines (USBM). The baseline test series was conducted using the electric arc melter facility at the USBM Albany Research Center in Albany, Oregon. Five different surrogate waste feed mixtures were tested that simulated thermally-oxidized, buried, TRU-contaminated, mixed wastes and soils present at the INEL. The USBM Arc Furnace Integrated Waste Processing Test Facility includes a continuous feed system, the arc melting furnace, an offgas control system, and utilities. The melter is a sealed, 3-phase alternating current (ac) furnace approximately 2 m high and 1.3 m wide. The furnace has a capacity of 1 metric ton of steel and can process as much as 1,500 lb/h of soil-type waste materials. The surrogate feed materials included five mixtures designed to simulate incinerated TRU-contaminated buried waste materials mixed with INEL soil. Process samples, melter system operations data and offgas composition data were obtained during the baseline tests to evaluate the melter performance and meet test objectives. Samples and data gathered during this program included (a) automatically and manually logged melter systems operations data, (b) process samples of slag, metal and fume solids, and (c) offgas composition, temperature, velocity, flowrate, moisture content, particulate loading and metals content. This report consists of 2 volumes: Volume I summarizes the baseline test operations. It includes an executive summary, system and facility description, review of the surrogate waste mixtures, and a description of the baseline test activities, measurements, and sample collection. Volume II contains the raw test data and sample analyses from samples collected during the baseline tests.

  18. Final Report - Glass Formulation Development and DM10 Melter Testing with ORP LAW Glasses, VSL-09R1510-2, Rev. 0, dated 6/12/09

    SciTech Connect

    Kruger, Albert A.; Pegg, I. L.; Matlack, K. S.; Joseph, I.; Muller, I. S.; Gong, W.

    2013-11-13

    The principal objective of the work described in this Final Report is to extend the glass formulation methodology developed in the earlier work by development of acceptable glass compositions for four LAW compositions specified by ORP that cover the range of sulfate to sodium and potassium to sodium ratios expected in Hanford LAW. The glass formulations were designed to exclude titanium and iron as glass former additives, while tin and vanadium as glass former additives were evaluated for beneficial effects in increasing waste loading in the glasses. This was accomplished through a combination of crucible-scale tests and tests on the DM10 melter system. This melter is the most efficient melter platform for screening glass compositions over a wide range of sulfate concentrations and therefore was selected for the present tests. The current tests provide information on melter processing characteristics and off-gas data, including sulfur incorporation and partitioning.

  19. Melt Rate Improvement for DWPF MB3: Sugar Addition Test

    SciTech Connect

    Stone, M.E.

    2001-06-20

    In order to meet certain production goals, the Defense Waste Processing Facility (DWPF) has focused on implementing a more temporally efficient method of waste vitrification. Changes in frit composition and alterations in the feed preparation process were investigated to determine if melt rate could be improved. The addition of sugar as an alternative reductant to formic acid was investigated for Macrobatch 3 (MB3).

  20. Chronic toxicity evaluation of simulated DWPF effluent to Ceriodaphnia dubia

    SciTech Connect

    Not Available

    1990-04-01

    A 7-Day Full Series Chronic Toxicity test was conducted April 13--20, 1990, for the Savannah River Site to assess the chronic toxicity of Simulated defense waste processing facility (DWPF) effluent to Ceriodaphnia dubia. The simulated effluented consisted of Sodium Nitrate, Sodium Oxalate, Sodium Formate, and Corros. Inib.

  1. Technical bases DWPF Late Washing Facility. Revision 1

    SciTech Connect

    Fish, D.L.; Landon, L.F.

    1992-08-10

    A task force recommended that the technical feasibility of a ``Late Wash` facility be assessed [1]. In this facility, each batch of tetraphenylborate slurry from Tank 49 would be given a final wash to reduce the concentrations of nitrite and radiolysis products to acceptable levels. Laboratory-scale studies have demonstrated that d the nitrite content of the slurry fed to DWPF is reduced to 0.01 M or less (and at least a 4X reduction in concentration of the soluble species is attained), (1) the need for HAN during hydrolysis is eliminated (eliminating the production of ammonium ion during hydrolysis), (2) hydrolysis may be done with a catalyst concentration that will not exceed the copper solubility in glass and (3) the non-polar organic production during hydrolysis is significantly reduced. The first phase of an aggressive research and development program has been completed and all test results obtained to date support the technical feasibility of Late Washing. Paralleling this research and development effort is an aggressive design study directed by DWPF to scope and cost retrofitting the Auxiliary Pump Pit (APP) to enable performing a final wash of each batch of precipitate slurry before R is transferred into the DWPF Soft Processing Cell (SPC). An initial technical bases for the Late Wash Facility was transmitted to DWPF on June 15, 1992. Research and development activities are continuing directed principally at optimization of the cross-f low fitter decontamination methodology and pilot-scale validation of the recommended benzene stripping metodology.

  2. IMPACTS OF SMALL COLUMN ION EXCHANGE STREAMS ON DWPF GLASS FORMULATION KT07-SERIES GLASS COMPOSITIONS

    SciTech Connect

    Fox, K.; Edwards, T.

    2011-01-12

    . The measured PCT responses were well predicted by the current DWPF Product Composition Control System (PCCS) durability models. The measured viscosity values for each KT07-series glass were acceptable for DWPF processing and were well predicted by the current PCCS model. Overall, the results show that the inclusion of relatively high concentrations of noble metals (in terms of expected values for a DWPF sludge batch) had no significant impact on the properties and performance of these glass compositions. There were no significant differences in the measured properties when compared to those of the KT04-series glasses, which did not contain noble metals. Liquidus temperature measurements are still underway and there may be an impact of the noble metals on those measurements. However, no adverse effects were noted in terms of crystallization after slow cooling. At the completion of these studies, all of the data generated will be reviewed with regard to the applicability of the DWPF PCCS models and recommendations will be made as to whether the validation ranges of the current models can be extended, or whether some or all of the models need to be refit to allow for the incorporation of the SCIX streams. As changes are made to the projected sludge compositions and the volume of the SCIX material, additional evaluations should be performed.

  3. Feed process studies: Research-Scale Melter

    SciTech Connect

    Whittington, K.F.; Seiler, D.K.; Luey, J.; Vienna, J.D.; Sliger, W.A.

    1996-09-01

    In support of a two-phase approach to privatizing the processing of hazardous and radioactive waste at Hanford, research-scale melter (RSM) experiments were conducted to determine feed processing characteristics of two potential privatization Phase 1 high-level waste glass formulations and to determine if increased Ag, Te, and noble metal amounts would have bad effects. Effects of feed compositions and process conditions were examined for processing rate, cold cap behavior, off-gas, and glass properties. The 2 glass formulations used were: NOM-2 with adjusted waste loading (all components except silica and soda) of 25 wt%, and NOM-3 (max waste loaded glass) with adjusted waste loading of 30 wt%. The 25 wt% figure is the minimum required in the privatization Request for Proposal. RSM operated for 19 days (5 runs). 1010 kg feed was processed, producing 362 kg glass. Parts of runs 2 and 3 were run at 10 to 30 degrees above the nominal temperature 1150 C, with the most significant processing rate increase in run 3. Processing observations led to the choice of NOM-3 for noble metal testing in runs 4 and 5. During noble metal testing, processing rates fell 50% from baseline. Destructive analysis showed that a layer of noble metals and noble metal oxides settled on the floor of the melter, leading to current ``channeling`` which allowed the top section to cool, reducing production rates.

  4. Test Plan: Phase 1, Hanford LLW melter tests, GTS Duratek, Inc.

    SciTech Connect

    Eaton, W.C.

    1995-06-14

    This document provides a test plan for the conduct of vitrification testing by a vendor in support of the Hanford Tank Waste Remediation System (TWRS) Low-Level Waste (LLW) Vitrification Program. The vendor providing this test plan and conducting the work detailed within it [one of seven selected for glass melter testing under Purchase Order MMI-SVV-384215] is GTS Duratek, Inc., Columbia, Maryland. The GTS Duratek project manager for this work is J. Ruller. This test plan is for Phase I activities described in the above Purchase Order. Test conduct includes melting of glass with Hanford LLW Double-Shell Slurry Feed waste simulant in a DuraMelter{trademark} vitrification system.

  5. FINAL REPORT INTEGRATED DM1200 MELTER TESTING USING AZ 102 AND C 106/AY-102 HLW SIMULANTS: HLW SIMULANT VERIFICATION VSL-05R5800-1 REV 0 6/27/05

    SciTech Connect

    KRUGER AA; MATLACK KS; GONG W; BARDAKCI T; D'ANGELO NA; BRANDYS M; KOT WK; PEGG IL

    2011-12-29

    The principal objectives of the DM1200 melter tests were to determine the effects of feed rheology, feed solid content, and bubbler configuration on glass production rate and off-gas system performance while processing the HLW AZ-101 and C-106/AY-102 feed compositions; characterize melter off-gas emissions; characterize the performance of the prototypical off-gas system components, as well as their integrated performance; characterize the feed, glass product, and off-gas effluents; and perform pre- and post test inspections of system components. The specific objectives (including test success criteria) of this testing, along with how each objective was met, are outlined in a table. The data provided in this Final Report address the impacts of HLW melter feed rheology on melter throughput and validation of the simulated HLW melter feeds. The primary purpose of this testing is to further validate/verify the HLW melter simulants that have been used for previous melter testing and to support their continued use in developing melter and off-gas related processing information for the Project. The primary simulant property in question is rheology. Simulants and melter feeds used in all previous melter tests were produced by direct addition of chemicals; these feed tend to be less viscous than rheological the upper-bound feeds made from actual wastes. Data provided here compare melter processing for the melter feed used in all previous DM100 and DM1200 tests (nominal melter feed) with feed adjusted by the feed vendor (NOAH Technologies) to be more viscous, thereby simulating more closely the upperbounding feed produced from actual waste. This report provides results of tests that are described in the Test Plan for this work. The Test Plan is responsive to one of several test objectives covered in the WTP Test Specification for this work; consequently, only part of the scope described in the Test Specification was addressed in this particular Test Plan. For the purpose of

  6. Vitrification Demonstration with Argentine Ion Exchange Material in the Stir-Melter

    SciTech Connect

    Cicero-Herman, C.A.

    2002-06-28

    The Savannah River Technology Center (SRTC) is investigating the viability of vitrification treatment of Argentine ion exchange material as part of a Department of Energy (DOE) - Office of Science and Technology Development Task Plan. Bench-scale studies were performed by the SRTC to define the necessary vitrification process for this material. However, the process had to be demonstrated in a melter system before vitrification could be considered a viable treatment option.

  7. Report - Melter Testing of New High Bismuth HLW Formulations VSL-13R2770-1

    SciTech Connect

    Kruger, Albert A.; Pegg, I. L.; Kot, W. K.; Gan, H.; Matlack, K. S.

    2013-11-13

    The primary objective of the work described was to test two glasses formulated for a high bismuth waste stream on the DM100 melter system. Testing was designed to determine processing characteristics and production rates, assess the tendency for foaming, and confirm glass properties. The glass compositions tested were previously developed to maintain high waste loadings and processing rates while suppressing the foaming observed in previous tests

  8. SULFATE SOLUBILITY LIMIT VERIFICATION FOR DWPF SLUDGE BATCH 7A

    SciTech Connect

    Billings, A.

    2011-04-19

    During processing at the Defense Waste Processing Facility (DWPF), high sulfate concentrations in the feed are a concern to DWPF as it can lead to the formation of a detrimental, sulfate-rich, molten salt phase on the surface of the glass melt pool. To avoid these issues, a sulfate concentration limit was implemented into the Product Composition Control System (PCCS). Related to SB7a frit development efforts, the Savannah River National Laboratory (SRNL) assessed the viability of using the current 0.6 wt % SO{sub 4}{sup 2-} limit set for SB6 (in glass) and the possibility of increasing the SO{sub 4}{sup 2-} solubility limit in PCCS to account for anticipated sulfur concentrations, targeted waste loadings, and inclusion of secondary streams (e.g., Actinide Removal Process (ARP)) with two recommended frits (Frit 418 and Frit 702) for SB7a processing. For a nominal SB7a blend with a 63 inch SB6 heel remaining in Tank 40 (projection SB7a-63), a 0.60 wt% SO{sub 4}{sup 2-} in glass limit was determined for waste loadings of 34 wt% up to 40 wt% with Frit 418 based on crucible melts with batched chemicals. SRNL also examined the inclusion of ARP for the same blending scenario (SB7a-63-ARP) with Frit 418 and at least a 0.6 wt% SO{sub 4}{sup 2-} level, and waste loadings of 34 wt% to 40 wt% were also acceptable. When a visible yellow and/or white sulfate salt layer was visible on the surface of any cooled glass, it was assumed to have surpassed the solubility limit of SO{sub 4}{sup 2-} for that particular composition. All of the glasses fabricated at these concentrations did not exhibit a sulfate rich salt layer on the surface of the glass melt and retained the majority of the batched SO{sub 4}{sup 2-}. At higher levels of SO{sub 4}{sup 2-} 'spiked' into the projected sludge compositions over the aforementioned interval of waste loadings, with Frit 418, low viscosity sulfur layers were observed on the surface of glass melts which confirm exceeding the solubility limit. The

  9. Final Report - Glass Formulation Testing to Increase Sulfate Volatilization from Melter, VSL-04R4970-1, Rev. 0, dated 2/24/05

    SciTech Connect

    Kruger, Albert A.; Matlack, K. A.; Pegg, I. L.; Gong, W.

    2013-11-13

    The principal objectives of the DM100 and DM10 tests were to determine the impact of four different organics and one inorganic feed additive on sulfate volatilization and to determine the sulfur partitioning between the glass and the off-gas system. The tests provided information on melter processing characteristics and off-gas data including sulfur incorporation and partitioning. A series of DM10 and DM100 melter tests were conducted using a LAW Envelope A feed. The testing was divided into three parts. The first part involved a series of DM10 melter tests with four different organic feed additives: sugar, polyethylene glycol (PEG), starch, and urea. The second part involved two confirmatory 50-hour melter tests on the DM100 using the best combination of reductants and conditions based on the DM10 results. The third part was performed on the DM100 with feeds containing vanadium oxide (V{sub 2}O{sub 5}) as an inorganic additive to increase sulfur partitioning to the off-gas. Although vanadium oxide is not a reductant, previous testing has shown that vanadium shows promise for partitioning sulfur to the melter exhaust, presumably through its known catalytic effect on the SO{sub 2}/SO{sub 3} reaction. Crucible-scale tests were conducted prior to the melter tests to confirm that the glasses and feeds would be processable in the melter and that the glasses would meet the waste form (ILAW) performance requirements. Thus, the major objectives of these tests were to: Perform screening tests on the DM10 followed by tests on the DM100-WV system using a LAW -Envelope A feed with four organic additives to assess their impact on sulfur volatilization. Perform tests on the DM100-WV system using a LAW -Envelope A feed containing vanadium oxide to assess its impact on sulfur volatilization. Determine feed processability and product quality with the above additives. Collect melter emissions data to determine the effect of additives on sulfur partitioning and melter emissions

  10. DWPF CATALYTIC HYDROGEN GENERATION PROGRAM - REVIEW OF CURRENT STATUS

    SciTech Connect

    Koopman, D.

    2009-07-10

    Significant progress has been made in the past two years in improving the understanding of acid consumption and catalytic hydrogen generation during the Defense Waste Processing Facility (DWPF) processing of waste sludges in the Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME). This report reviews issues listed in prior internal reviews, describes progress with respect to the recommendations made by the December 2006 external review panel, and presents a summary of the current understanding of catalytic hydrogen generation in the DWPF Chemical Process Cell (CPC). Noble metals, such as Pd, Rh, and Ru, are historically known catalysts for the conversion of formic acid into hydrogen and carbon dioxide. Rh, Ru, and Pd are present in the DWPF SRAT feed as by-products of thermal neutron fission of {sup 235}U in the original waste. Rhodium appears to become most active for hydrogen as the nitrite ion concentration becomes low (within a factor of ten of the Rh concentration). Prior to hydrogen generation, Rh is definitely active for nitrite destruction to N{sub 2}O and potentially active for nitrite to NO formation. These reactions are all consistent with the presence of a nitro-Rh complex catalyst, although definite proof for the existence of this complex during Savannah River Site (SRS) waste processing does not exist. Ruthenium does not appear to become active for hydrogen generation until nitrite destruction is nearly complete (perhaps less nitrite than Ru in the system). Catalytic activity of Ru during nitrite destruction is significantly lower than that of either Rh or Pd. Ru appears to start activating as Rh is deactivating from its maximum catalytic activity for hydrogen generation. The slow activation of the Ru, as inferred from the slow rate of increase in hydrogen generation that occurs after initiation, may imply that some species (perhaps Ru itself) has some bound nitrite on it. Ru, rather than Rh, is primarily responsible for the

  11. WASTE GLASS MELTER PROCESS MONITORING WITH MILLIMETER WAVES

    EPA Science Inventory

    Millimeter-wave technologies can provide novel and reliable online monitoring capability for many important parameters inside nuclear waste glass melters, including temperature, emissivity, density, and viscosity. The physical and analytical basis for millimeter-wave monitoring o...

  12. Energy-Efficient Glass Melting - Next Generation Melter

    SciTech Connect

    2006-08-01

    This factsheet describes an R&D project focused on an oxy-gas-fired submerged combustion melter for glass industry that offers decreased operating and capital costs, decreased energy use, simple design, and high reliability.

  13. Thermal Cycling on Fatigue Failure of the Plutonium Vitrification Melter

    SciTech Connect

    Jordan, Jeffrey; Gorczyca, Jennifer

    2009-02-11

    One method for disposition of excess plutonium is vitrification into cylindrical wasteforms. Due to the hazards of working with plutonium, the vitrification process must be carried out remotely in a shielded environment. Thus, the equipment must be easily maintained. With their simple design, induction melters satisfy this criterion, making them ideal candidates for plutonium vitrification. However, due to repeated heating and cooling cycles and differences in coefficients of thermal expansion of contacting materials fatigue failure of the induction melter is of concern. Due to the cost of the melter, the number of cycles to failure is critical. This paper presents a method for determining the cycles to failure for an induction melter by using the results from thermal and structural analyses as input to a fatigue failure model.

  14. MASBAL: A computer program for predicting the composition of nuclear waste glass produced by a slurry-fed ceramic melter

    SciTech Connect

    Reimus, P.W.

    1987-07-01

    This report is a user's manual for the MASBAL computer program. MASBAL's objectives are to predict the composition of nuclear waste glass produced by a slurry-fed ceramic melter based on a knowledge of process conditions; to generate simulated data that can be used to estimate the uncertainty in the predicted glass composition as a function of process uncertainties; and to generate simulated data that can be used to provide a measure of the inherent variability in the glass composition as a function of the inherent variability in the feed composition. These three capabilities are important to nuclear waste glass producers because there are constraints on the range of compositions that can be processed in a ceramic melter and on the range of compositions that will be acceptable for disposal in a geologic repository. MASBAL was developed specifically to simulate the operation of the West Valley Component Test system, a commercial-scale ceramic melter system that will process high-level nuclear wastes currently stored in underground tanks at the site of the Western New York Nuclear Services Center (near West Valley, New York). The program is flexible enough, however, to simulate any slurry-fed ceramic melter system. 4 refs., 16 figs., 5 tabs.

  15. Corrosion experience with a slurry-fed ceramic melter

    SciTech Connect

    Barnes, S.M.; Sevigny, G.J.; Goles, R.W.

    1982-03-01

    This report presents the findings of an investigation into the long-term performance of construction materials for joule-heated, ceramic-lined melters. The materials investigated include: the glass contact refractories, the melter electrodes, and the process off-gas containment materials. The corrosion rate and mechanism for these materials are presented. The report also includes the initial corrosion data from testing of improved effluent containment materials.

  16. 2. VIEW OF THE MICROWAVE MELTER DEVELOPED BY THE RESEARCH ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    2. VIEW OF THE MICROWAVE MELTER DEVELOPED BY THE RESEARCH AND DEVELOPMENT GROUP LOCATED IN BUILDING 701. THE MICROWAVE MELTER TRANSFORMED WASTE INTO A VITREOUS GLASS-LIKE SUBSTANCE, IMMOBILIZING THE WASTE, SO THAT IT COULD BE SHIPPED OFF SITE FOR DISPOSAL. (1/31/91) - Rocky Flats Plant, Design Laboratory, Northwest quadrant of Plant, between buildings 776-777 & 771, Golden, Jefferson County, CO

  17. High-Level Waste Melter Study Report

    SciTech Connect

    Perez Jr, Joseph M; Bickford, Dennis F; Day, Delbert E; Kim, Dong-Sang; Lambert, Steven L; Marra, Sharon L; Peeler, David K; Strachan, Denis M; Triplett, Mark B; Vienna, John D; Wittman, Richard S

    2001-07-13

    At the Hanford Site in Richland, Washington, the path to site cleanup involves vitrification of the majority of the wastes that currently reside in large underground tanks. A Joule-heated glass melter is the equipment of choice for vitrifying the high-level fraction of these wastes. Even though this technology has general national and international acceptance, opportunities may exist to improve or change the technology to reduce the enormous cost of accomplishing the mission of site cleanup. Consequently, the U.S. Department of Energy requested the staff of the Tanks Focus Area to review immobilization technologies, waste forms, and modifications to requirements for solidification of the high-level waste fraction at Hanford to determine what aspects could affect cost reductions with reasonable long-term risk. The results of this study are summarized in this report.

  18. NEXT GENERATION MELTER OPTIONEERING STUDY - INTERIM REPORT

    SciTech Connect

    GRAY MF; CALMUS RB; RAMSEY G; LOMAX J; ALLEN H

    2010-10-19

    The next generation melter (NOM) development program includes a down selection process to aid in determining the recommended vitrification technology to implement into the WTP at the first melter change-out which is scheduled for 2025. This optioneering study presents a structured value engineering process to establish and assess evaluation criteria that will be incorporated into the down selection process. This process establishes an evaluation framework that will be used progressively throughout the NGM program, and as such this interim report will be updated on a regular basis. The workshop objectives were achieved. In particular: (1) Consensus was reached with stakeholders and technology providers represented at the workshop regarding the need for a decision making process and the application of the D{sub 2}0 process to NGM option evaluation. (2) A framework was established for applying the decision making process to technology development and evaluation between 2010 and 2013. (3) The criteria for the initial evaluation in 2011 were refined and agreed with stakeholders and technology providers. (4) The technology providers have the guidance required to produce data/information to support the next phase of the evaluation process. In some cases it may be necessary to reflect the data/information requirements and overall approach to the evaluation of technology options against specific criteria within updated Statements of Work for 2010-2011. Access to the WTP engineering data has been identified as being very important for option development and evaluation due to the interface issues for the NGM and surrounding plant. WRPS efforts are ongoing to establish precisely data that is required and how to resolve this Issue. It is intended to apply a similarly structured decision making process to the development and evaluation of LAW NGM options.

  19. Toward acceptance of DWPF glass at a Federal Repository

    SciTech Connect

    Plodinec, M.J.; Stevens, W.R. III; Hacker, B.A.; Baxter, R.G.

    1987-01-01

    Construction of the nations's first facility to immobilize defense high-level nuclear waste, the Defense Waste Processing Facility (DWPF) at the Savannah River Plant, is scheduled to be completed soon. The Department of Energy's Office of Civilian Radioactive Waste Management (OCRWM) has set up a Waste Acceptance Process to provide reasonable assurance that the waste glass produced in the DWPF will be acceptable for permanent storage in a federal repository. As part of this process, detailed specifications have been developed for the waste glass itself, the canister which will contain the waste glass, the sealed canister after it is filled with waste glass, and quality assurance of the product. Savannah River has developed a detailed strategy for demonstrating compliance with each of the specifications, which is documented in a Waste Compliance Plan (WCP). In this paper, the compliance strategy, and progress in implementing the WCP are presented. 12 refs., 3 figs.

  20. The product consistency test for the DWPF wasteform

    SciTech Connect

    Jantzen, C.M.; Bibler, N.E.

    1990-12-31

    The preliminary specifications on the glass wasteform to be produced by the Defense Waste Processing Facility (DWPF) require extensive characterization of the glass product both before actual production begins and then during production. To aid in this characterization, a leach test was needed that was easily reproducible, could be performed remotely on highly radioactive samples, and could yield results rapidly. Several standard leach tests were examined with a variety of test configurations. Using existing tests as a starting point, the DWPF Product Consistency Test (PCT) was developed in which crushed glass samples are exposed to 90{degrees}C deionized water for seven days. Based on extensive testing, including a seven-laboratory round robin and confirmatory testing with radioactive samples, the PCT is very reproducible, yields reliable results rapidly, and can be performed in shielded cell facilities with radioactive samples.

  1. The product consistency test for the DWPF wasteform

    SciTech Connect

    Jantzen, C.M.; Bibler, N.E.

    1990-01-01

    The preliminary specifications on the glass wasteform to be produced by the Defense Waste Processing Facility (DWPF) require extensive characterization of the glass product both before actual production begins and then during production. To aid in this characterization, a leach test was needed that was easily reproducible, could be performed remotely on highly radioactive samples, and could yield results rapidly. Several standard leach tests were examined with a variety of test configurations. Using existing tests as a starting point, the DWPF Product Consistency Test (PCT) was developed in which crushed glass samples are exposed to 90{degrees}C deionized water for seven days. Based on extensive testing, including a seven-laboratory round robin and confirmatory testing with radioactive samples, the PCT is very reproducible, yields reliable results rapidly, and can be performed in shielded cell facilities with radioactive samples.

  2. Development of Alternative Rheological Measurements for DWPF Slurry Samples (U)

    SciTech Connect

    Koopman, D. c.

    2005-09-01

    Rheological measurements are used to evaluate the fluid dynamic behavior of Defense Waste Processing Facility, DWPF, slurry samples. Measurements are currently made on non-radioactive simulant slurries using two state-of-the-art rheometers located at the Aiken County Technical Laboratory, ACTL. Measurements are made on plant samples using a rheometer in the Savannah River National Laboratory, SRNL, Shielded Cells facility. Low activity simulants or plant samples can be analyzed using a rheometer located in a radioactive hood in SRNL. Variations in the rheology of SB2 simulants impacted the interpretation of results obtained in a number of related studies. A separate rheological study was initiated with the following four goals: (1) Document the variations seen in the simulant slurries, both by a review of recent data, and by a search for similar samples for further study. (2) Attempt to explain the variations in rheological behavior, or, failing that, reduce the number of possible causes. In particular, to empirically check for rheometer-related variations. (3) Exploit the additional capabilities of the rheometers by developing new measurement methods to study the simulant rheological properties in new ways. (4) Formalize the rheological measurement process for DWPF-related samples into a series of protocols. This report focuses on the third and fourth goals. The emphasis of this report is on the development and formalization of rheological measurement methods used to characterize DWPF slurry samples. The organization is by rheological measurement method. Progress on the first two goals was documented in a concurrent technical report, Koopman (2005). That report focused on the types and possible causes of unusual rheological behavior in simulant slurry samples. It was organized by the sample being studied. The experimental portion of this study was performed in the period of March to April 2004. A general rheology protocol for routine DWPF slurry samples, Koopman

  3. Melt Rate Improvement for DWPF MB3: Crucible Studies

    SciTech Connect

    Lorier, T.H.

    2001-06-15

    The objective of this research is to evaluate the melting behavior of Macrobatch 3 (MB3) for the Defense Waste Processing Facility (DWPF). This study focuses on the manipulation of the frit composition in order to enhance the melting rate of MB3, without sacrificing the quality of the final glass form. The goal is to find the proper frit composition so the development of this insulating layer is averted.

  4. Spray Calciner/In-Can Melter high-level waste solidification technical manual

    SciTech Connect

    Larson, D.E.

    1980-09-01

    This technical manual summarizes process and equipment technology developed at Pacific Northwest Laboratory over the last 20 years for vitrification of high-level liquid waste by the Spray Calciner/In-Can Melter process. Pacific Northwest Laboratory experience includes process development and demonstration in laboratory-, pilot-, and full-scale equipment using nonradioactive synthetic wastes. Also, laboratory- and pilot-scale process demonstrations have been conducted using actual high-level radioactive wastes. In the course of process development, more than 26 tonnes of borosilicate glass have been produced in 75 canisters. Four of these canisters contained radioactive waste glass. The associated process and glass chemistry is discussed. Technology areas described include calciner feed treatment and techniques, calcination, vitrification, off-gas treatment, glass containment (the canister), and waste glass chemistry. Areas of optimization and site-specific development that would be needed to adapt this base technology for specific plant application are indicated. A conceptual Spray Calciner/In-Can Melter system design and analyses are provided in the manual to assist prospective users in evaluating the process for plant application, to provide equipment design information, and to supply information for safety analyses and environmental reports. The base (generic) technology for the Spray Calciner/In-Can Melter process has been developed to a point at which it is ready for plant application.

  5. DWPF STARTUP FRIT VISCOSITY MEASUREMENT ROUND ROBIN RESULTS

    SciTech Connect

    Crum, Jarrod V.; Edwards, Tommy B.; Russell, Renee L.; Workman, Phyllis J.; Schweiger, Michael J.; Schumacher, Ray F.; Smith, Donald E.; Peeler, David K.; Vienna, John D.

    2012-07-31

    A viscosity standard is needed to replace the National Institute of Standards and Technology (NIST) glasses currently being used to calibrate viscosity measurement equipment. The current NIST glasses are either unavailable or less than ideal for calibrating equipment to measure the viscosity of high-level waste glasses. This report documents the results of a viscosity round robin study conducted on the Defense Waste Processing Facility (DWPF) startup frit. DWPF startup frit was selected because its viscosity-temperature relationship is similar to most DWPF and Hanford high-level waste glass compositions. The glass underwent grinding and blending to homogenize the large (100 lb) batch. Portions of the batch were supplied to the laboratories (named A through H) for viscosity measurements following a specified temperature schedule with a temperature range of 1150 C to 950 C and with an option to measure viscosity at lower temperatures if their equipment was capable of measuring at the higher viscosities. Results were used to fit the Vogel-Tamman-Fulcher and Arrhenius equations to viscosity as a function of temperature for the entire temperature range of 460 C through 1250 C as well as the limited temperature interval of approximately 950 C through 1250 C. The standard errors for confidence and prediction were determined for the fitted models.

  6. U.S. Bureau of Mines, phase I Hanford low-level waste melter tests: Melter offgas report

    SciTech Connect

    Eaton, W.C.

    1995-10-27

    A multiphase program was initiated in 1994 to test commercially available melter technologies for the vitrification of the low-level waste (LLW) stream from defense wastes stored in underground tanks at the Hanford Site in southeastern Washington State. Phase 1 of the melter demonstration tests using simulated LLW was completed during fiscal year 1995. This document is the melter offgas report on testing performed by the U.S. Department of the Interior, Bureau of Mines, Albany Research Center in Albany, Oregon. The Bureau of Mines (one of the seven vendors selected) was chosen to demonstrate carbon electrode melter technology (also called carbon arc or electric arc) under WHC subcontract number MMI-SVV-384216. The document contains the complete offgas report for the first 24-hour melter test (WHC-1) as prepared by Entropy Inc. A summary of this report is also contained in the``U.S. Bureau of Mines, Phase 1 Hanford Low-Level Waste Melter Tests: Final Report`` (WHC-SD-WM-VI-030).

  7. Physical Modeling of a Glass Melter Designed for Vitrification of Defense Waste

    SciTech Connect

    Routt, K.R.

    2001-08-29

    The theoretical relationships necessary to design, operate, and interpret data from a physical model of a glass melter are presented in this paper and applied, as an example, to an actual glass melter operated at the Savannah River Plant.

  8. Power distribution for an Am/Cm bushing melter

    SciTech Connect

    Gong, C.; Hardy, B.J.

    1996-12-31

    Decades of nuclear material production at the Savannah River Site (SRS) has resulted in the generation of large quantities of the isotopes Am{sup 243} and Cm{sup 244}. Currently, the Am and Cm isotopes are stored as a nitric acid solution in a tank. The Am and Cm isotopes have great commercial value but must be transferred to ORNL for processing. The nitric acid solution contains other isotopes and is intensely radioactive, which makes storage a problem and precludes shipment in the liquid form. In order to stabilize the material for onsite storage and to permit transport the material from SRS to ORNL, it has been proposed that the Am and Cm be separated from other isotopes in the solution and vitrified. Vitrification will be effected by depositing a liquid feed stream containing the isotopes in solution, together with a stream of glass frit, onto the top of a molten glass pool in a melter. The glass is non-conducting and the melter is a Platinum/Rhodium alloy vessel which is heated by passing an electric current through it. Because most of the power is required to evaporate the liquid feed at the top of the glass pool, power demands differ for the upper and lower parts of the melter. In addition, the melter is batch fed so that the local power requirements vary with time. In order to design a unique split power supply, which ensures adequate local power delivery, an analysis of the melter power distribution was performed with the ABAQUS finite element code. ABAQUS was used to calculate the electric potential and current density distributions in the melter for a variety of current and potential boundary conditions. The results of the calculation were compared with test data and will be used to compute power densities for input to a computational fluid dynamics model for the melter.

  9. SLURRY MIX EVAPORATOR BATCH ACCEPTABILITY AND TEST CASES OF THE PRODUCT COMPOSITION CONTROL SYSTEM WITH THORIUM AS A REPORTABLE ELEMENT

    SciTech Connect

    Edwards, T.

    2010-10-07

    The Defense Waste Processing Facility (DWPF), which is operated by Savannah River Remediation, LLC (SRR), has recently begun processing Sludge Batch 6 (SB6) by combining it with Frit 418 at a nominal waste loading (WL) of 36%. A unique feature of the SB6/Frit 418 glass system, as compared to the previous glass systems processed in DWPF, is that thorium will be a reportable element (i.e., concentrations of elemental thorium in the final glass product greater than 0.5 weight percent (wt%)) for the resulting wasteform. Several activities were initiated based upon this unique aspect of SB6. One of these was an investigation into the impact of thorium on the models utilized in DWPF's Product Composition and Control System (PCCS). While the PCCS is described in more detail below, for now note that it is utilized by Waste Solidification Engineering (WSE) to evaluate the acceptability of each batch of material in the Slurry Mix Evaporator (SME) before this material is passed on to the melter. The evaluation employs models that predict properties associated with processability and product quality from the composition of vitrified samples of the SME material. The investigation of the impact of thorium on these models was conducted by Peeler and Edwards [1] and led to a recommendation that DWPF can process the SB6/Frit 418 glass system with ThO{sub 2} concentrations up to 1.8 wt% in glass. Questions also arose regarding the handling of thorium in the SME batch acceptability process as documented by Brown, Postles, and Edwards [2]. Specifically, that document is the technical bases of PCCS, and while Peeler and Edwards confirmed the reliability of the models, there is a need to confirm that the current implementation of DWPF's PCCS appropriately handles thorium as a reportable element. Realization of this need led to a Technical Task Request (TTR) prepared by Bricker [3] that identified some specific SME-related activities that the Savannah River National Laboratory (SRNL) was

  10. IMPACTS OF SMALL COLUMN ION EXCHANGE STREAMS ON DWPF GLASS FORMULATION: KT05- AND KT06-SERIES GLASS COMPOSITIONS

    SciTech Connect

    Fox, K.; Edwards, T.

    2011-01-03

    This report is the second in a series of studies of the impacts of the addition of Crystalline Silicotitanate (CST) and Monosodium Titanate (MST) from the Small Column Ion Exchange (SCIX) process on the Defense Waste Processing Facility (DWPF) glass waste form and the applicability of the DWPF process control models. The KT05-series glasses were selected, fabricated, and characterized to further study glass compositions where iron titanate crystals had been previously found to form. The intent was to better understand the mechanisms and compositions that favored the formation of crystals containing titanium. Formation of these crystalline phases was confirmed. Increased Na{sub 2}O concentrations had little if any impact on reducing the propensity for the formation of the iron titanate crystalline phases. Other physical properties of these glasses were not measured since the intent was to focus on crystallization. Additional studies are suggested to investigate the potential impacts of Al{sub 2}O{sub 3} and K{sub 2}O on crystallization in glasses with high TiO{sub 2} concentrations. The KT06-series glasses were selected, fabricated, and characterized to further study glass compositions that, while broader than the current projections for DWPF feeds with SCIX material, are potential candidates for future processing (i.e., the compositions are acceptable for processing by the Product Composition Control System (PCCS) with the exception of the current TiO{sub 2} concentration constraint). The chemical compositions of these glasses matched well with the target values. The chemical durabilities of all the glasses were acceptable relative to the Environmental Assessment (EA) benchmark. Minor crystallization was identified in some of the slowly cooled glasses, although this crystallization did not impact chemical durability. Several of the KT06-series compositions had durability values that, while acceptable, were not accurately predicted by the current durability models

  11. CST Melter Feed Characterization in Support of the 1999 and 2000 Thermal Fluids Lab Hydragard Testing

    SciTech Connect

    Koopman, D.C.

    2001-06-07

    The Immobilization Technology Section measured properties of the melter feed simulants used in the 1999 and 2000 Hydragard sample loop tests. These tests used simulated Sludge Batch 1B (Macrobatch 2) melter feeds. The melter feeds were characterized for wt. percent total and insoluble solids, pH, composition, particle size distribution, and rheology.

  12. DWPF SIMULANT CPC STUDIES FOR SB7B

    SciTech Connect

    Koopman, D.

    2011-11-01

    Lab-scale DWPF simulations of Sludge Batch 7b (SB7b) processing were performed. Testing was performed at the Savannah River National Laboratory - Aiken County Technology Laboratory (SRNL-ACTL). The primary goal of the simulations was to define a likely operating window for acid stoichiometry for the DWPF Sludge Receipt and Adjustment Tank (SRAT). In addition, the testing established conditions for the SRNL Shielded Cells qualification simulation of SB7b-Tank 40 blend, supported validation of the current glass redox model, and validated the coupled process flowsheet at the nominal acid stoichiometry. An acid window of 105-140% by the Koopman minimum acid (KMA) equation (107-142% DWPF Hsu equation) worked for the sludge-only flowsheet. Nitrite was present in the SRAT product for the 105% KMA run at 366 mg/kg, while SME cycle hydrogen reached 94% of the DWPF Slurry Mix Evaporator (SME) cycle limit in the 140% KMA run. The window was determined for sludge with added caustic (0.28M additional base, or roughly 12,000 gallons 50% NaOH to 820,000 gallons waste slurry). A suitable processing window appears to be 107-130% DWPF acid equation for sludge-only processing allowing some conservatism for the mapping of lab-scale simulant data to full-scale real waste processing including potentially non-conservative noble metal and mercury concentrations. This window should be usable with or without the addition of up to 7,000 gallons of caustic to the batch. The window could potentially be wider if caustic is not added to SB7b. It is recommended that DWPF begin processing SB7b at 115% stoichiometry using the current DWPF equation. The factor could be increased if necessary, but changes should be made with caution and in small increments. DWPF should not concentrate past 48 wt.% total solids in the SME cycle if moderate hydrogen generation is occurring simultaneously. The coupled flowsheet simulation made more hydrogen in the SRAT and SME cycles than the sludge-only run with the

  13. One-dimensional cold cap model for melters with bubblers

    DOE PAGESBeta

    Pokorny, Richard; Hilliard, Zachary J.; Dixon, Derek R.; Schweiger, Michael J.; Guillen, Donna P.; Kruger, Albert A.; Hrma, Pavel

    2015-07-28

    The rate of glass production during vitrification in an all-electrical melter greatly impacts the cost and schedule of nuclear waste treatment and immobilization. The feed is charged to the melter on the top of the molten glass, where it forms a layer of reacting and melting material, called the cold cap. During the final stages of the batch-to-glass conversion process, gases evolved from reactions produce primary foam, the growth and collapse of which controls the glass production rate. The mathematical model of the cold cap was revised to include functional representation of primary foam behavior and to account for themore » dry cold cap surface. The melting rate is computed as a response to the dependence of the primary foam collapse temperature on the heating rate and melter operating conditions, including the effect of bubbling on the cold cap bottom and top surface temperatures. The simulation results are in good agreement with experimental data from laboratory-scale and pilot-scale melter studies. Lastly, the cold cap model will become part of the full three-dimensional mathematical model of the waste glass melter.« less

  14. One-dimensional cold cap model for melters with bubblers

    SciTech Connect

    Pokorny, Richard; Hilliard, Zachary J.; Dixon, Derek R.; Schweiger, Michael J.; Guillen, Donna P.; Kruger, Albert A.; Hrma, Pavel

    2015-07-28

    The rate of glass production during vitrification in an all-electrical melter greatly impacts the cost and schedule of nuclear waste treatment and immobilization. The feed is charged to the melter on the top of the molten glass, where it forms a layer of reacting and melting material, called the cold cap. During the final stages of the batch-to-glass conversion process, gases evolved from reactions produce primary foam, the growth and collapse of which controls the glass production rate. The mathematical model of the cold cap was revised to include functional representation of primary foam behavior and to account for the dry cold cap surface. The melting rate is computed as a response to the dependence of the primary foam collapse temperature on the heating rate and melter operating conditions, including the effect of bubbling on the cold cap bottom and top surface temperatures. The simulation results are in good agreement with experimental data from laboratory-scale and pilot-scale melter studies. Lastly, the cold cap model will become part of the full three-dimensional mathematical model of the waste glass melter.

  15. Final Report - Effects of High Spinel and Chromium Oxide Crystal Contents on Simulated HLW Vitrification in DM100 Melter Tests, VSL-09R1520-1, Rev. 0, dated 6/22/09

    SciTech Connect

    Kruger, Albert A.; Matlack, K. S.; Kot, W.; Pegg, I. L.; Chaudhuri, M.; Lutze, W.

    2013-11-13

    The principal objective of the work was to evaluate the effects of spinel and chromium oxide particles on WTP HLW melter operations and potential impacts on melter life. This was accomplished through a combination of crucible-scale tests, settling and rheological tests, and tests on the DM100 melter system. Crucible testing was designed to develop and identify HLW glass compositions with high waste loadings that exhibit formation of crystalline spinel and/or chromium oxide phases up to relatively high crystal contents (i.e., > 1 vol%). Characterization of crystal settling and the effects on melt rheology was performed on the HLW glass formulations. Appropriate candidate HLW glass formulations were selected, based on characterization results, to support subsequent melter tests. In the present work, crucible melts were formulated that exhibit up to about 4.4 vol% crystallization.

  16. Density of simulated americium/curium melter feed solution

    SciTech Connect

    Rudisill, T.S.

    1997-09-22

    Vitrification will be used to stabilize an americium/curium (Am/Cm) solution presently stored in F-Canyon for eventual transport to Oak Ridge National Laboratory and use in heavy isotope production programs. Prior to vitrification, a series of in-tank oxalate precipitation and nitric/oxalic acid washes will be used to separate these elements and lanthanide fission products from the bulk of the uranium and metal impurities present in the solution. Following nitric acid dissolution and oxalate destruction, the solution will be denitrated and evaporated to a dissolved solids concentration of approximately 100 g/l (on an oxide basis). During the Am/Cm vitrification, an airlift will be used to supply the concentrated feed solution to a constant head tank which drains through a filter and an in-line orifice to the melter. Since the delivery system is sensitive to the physical properties of the feed, a simulated solution was prepared and used to measure the density as a function of temperature between 20 to 70{degrees} C. The measured density decreased linearly at a rate of 0.0007 g/cm3/{degree} C from an average value of 1.2326 g/cm{sup 3} at 20{degrees} C to an average value of 1.1973g/cm{sup 3} at 70{degrees} C.

  17. Low NOx at low cost for glass melters

    SciTech Connect

    1996-06-01

    A major goal of the natural gas industry is developing new industrial technologies that reduce NO{sub x} emissions without sacrificing productivity and product quality. With the development of Oxygen Enriched Air Staging (OEAS), the industry is reaching that goal. OEAS is a retrofit air staging technology for regenerative glass melting furnaces. The patented OEAS process uses oxygen-enriched air-staged combustion to reduce NO{sub x} with minimal furnace modification and no impact on furnace operation or glass quality. In endport furnaces, a portion of the hot combustion air is removed from the firing side regenerator prior to the burner location. This produces an oxygen-deficient flame which results in reduced NO{sub x}. Then, oxygen-enriched air is injected into the furnace at strategic locations downstream of the flame. This acts as a secondary oxidant and effectively combusts any unburned hydrocarbons or carbon monoxide within the melter without forming additional NO{sub x}. Several variations of the system were also developed by the project team. These include using ambient or hot air entrained by oxygen or compressed air, or using air supplied by blowers, with or without oxygen as the secondary oxidant. These variations have also produced NO{sub x} reductions.

  18. Analysis Of The Sludge Batch 7b (Macrobatch 9) DWPF Pour Stream Glass Sample

    SciTech Connect

    Johnson, F. C.; Crawford, C. L.; Pareizs, J. M.

    2013-11-18

    The Defense Waste Processing Facility (DWPF) began processing Sludge Batch 7b (SB7b), also referred to as Macrobatch 9 (MB9), in January 2012. SB7b is a blend of the heel of Tank 40 from Sludge Batch 7a (SB7a) and the SB7b material that was transferred to Tank 40 from Tank 51. SB7b was processed using Frit 418. During processing of each sludge batch, the DWPF is required to take at least one glass sample to meet the objectives of the Glass Product Control Program (GPCP), which is governed by the DWPF Waste Form Compliance Plan, and to complete the necessary Production Records so that the final glass product may be disposed of at a Federal Repository. Two pour stream glass samples were collected while processing SB7b. The samples were transferred to the Savannah River National Laboratory (SRNL) where one was analyzed and the other was archived. The following conclusions were drawn from the analytical results provided in this report: The sum of oxides for the official SB7b pour stream glass is within the Product Composition Control System (PCCS) limits (95-105 wt%); The average calculated Waste Dilution Factor (WDF) for SB7b is 2.3. In general, the measured radionuclide content of the official SB7b pour stream glass is in good agreement with the calculated values from the Tank 40 dried sludge results from the SB7b Waste Acceptance Program Specification (WAPS) sample; As in previous pour stream samples, ruthenium and rhodium inclusions were detected by Scanning Electron Microscopy-Electron Dispersive Spectroscopy (SEM-EDS) in the SB7b pour stream sample; The Product Consistency Test (PCT) results indicate that the official SB7b pour stream glass meets the waste acceptance criteria for durability with a normalized boron release of 0.8 g/L, which is an order of magnitude less than the Environmental Assessment (EA) glass; The measured density of the SB7b pour stream glass was 2.70 g/cm{sup 3}; The Fe{sup 2+}/ΣFe ratio of the SB7b pour stream samples was 0.07.

  19. Gaseous and particulate emissions from a DC arc melter.

    PubMed

    Overcamp, Thomas J; Speer, Matthew P; Griner, Stewart J; Cash, Douglas M

    2003-01-01

    Tests treating soils contaminated with metal compounds and radionuclide surrogates were conducted in a DC arc melter. The soil melted, and glassy or ceramic waste forms with a separate metal phase were produced. Tests were run in the melter plenum with either air or N2 purge gases. In addition to nitrogen, the primary emissions of gases were CO2, CO, oxygen, methane, and oxides of nitrogen (NO(x)). Although the gas flow through the melter was low, the particulate concentrations ranged from 32 to 145 g/m3. Cerium, a nonradioactive surrogate for plutonium and uranium, was not enriched in the particulate matter (PM). The PM was enriched in cesium and highly enriched in lead. PMID:12568249

  20. Response of a glass melter to steam explosion

    SciTech Connect

    Yau, W F; Durant, W S

    1984-01-01

    As part of the safety assessment in the design of the glass melter for large-scale immobilization of high-level radioactive wastes, structural considerations of the containment shell include its dynamic responses to abnormal loading conditions such as that caused by a steam explosion. The postulated steam explosion, conservatively given an energy content equivalent to 13 pounds of TNT, is capable of exerting sudden pressures greater than 300 psi but less than 410 psi on the melter wall. By use of thin-shell theory, the equations of motion satisfying the discontinuity conditions at junctions of shells with different curvatures are solved analytically. Results of stress analysis ensure elastic responses of the containment structure of the melter. 6 references, 3 figures, 1 table.

  1. Melter performance during surrogate vitrification campaigns at the DOE/Industrial Center for Vitrification Research at Clemson University

    SciTech Connect

    Marra, J.C.; Overcamp, T.J.

    1995-10-05

    This report summarizes the results from seven melter campaigns performed at the DOE/Industrial Center for Vitrification Research at Clemson University. A brief description of the EnVitco EV-16 Joule heated glass melter and the Stir-Melter WV-0.25 stirred melter are included for reference. The report discusses each waste stream examined, glass formulations developed and utilized, specifics relating to melter operation, and a synopsis of the results from the campaigns. A `lessons learned` section is included for each melter to emphasize repeated processing problems and identify parameters which are considered extremely important to successful melter operation

  2. Earth melter with rubble walls and method of use

    DOEpatents

    Chapman, Chris C.

    1998-01-01

    The present invention is an improvement to the earth melter described and claimed in U.S. Pat. No. 5,443,618. The improvement is the use of rubble for retaining walls. More specifically, the retaining walls rest on ground level and extend above ground level piling rubble around a melt zone. A portion of the melter may be below grade wherein sidewalls are formed by the relatively undisturbed native soil or rock, and the rubble may be used as a backfill liner for the below grade sidewalls.

  3. Final examination of IDMS corrosion coupons

    SciTech Connect

    Imrich, K.J.; Jenkins, C.F.

    1993-09-16

    The metallurgical examination of corrosion coupons removed from the Integrated DWPF Melter System (IDMS) was performed as part of the IDMS Materials Evaluation Program. The findings and conclusions of the evaluation program are presented in this report.

  4. Evaluation of liquid-fed ceramic melter scale-up correlations

    SciTech Connect

    Koegler, S.S.; Mitchell, S.J.

    1988-08-01

    This study was conducted to determine the parameters governing factors of scale for liquid-fed ceramic melters (LFCMs) in order to design full-scale melters using smaller-scale melter data. Results of melter experiments conducted at Pacific Northwest Laboratory (PNL) and Savannah River Laboratory (SRL) are presented for two feed compositions and five different liquid-fed ceramic melters. The melter performance data including nominal feed rate and glass melt rate are correlated as a function of melter surface area. Comparisons are made between the actual melt rate data and melt rates predicted by a cold cap heat transfer model. The heat transfer model could be used in scale-up calculations, but insufficient data are available on the cold cap characteristics. Experiments specifically designed to determine heat transfer parameters are needed to further develop the model. 17 refs.

  5. Stabilizing distressed glass furnace melter crowns

    SciTech Connect

    1997-08-01

    Before the advent of pump casting, hot patching a melter or regenerator crown was extremely time and labor intensive. During these installations, known to many as the bucket brigade, the slurry was mixed on floor level and hauled in 50--65 lb batches up to 100 ft to the top of the crown. Today, in a single shift, a crew of seven can accomplish what took two days and a crew of {approximately}25 in the past. The first application of pump-casting zircon patch occurred on the AZS crown of an insulation-wool-glass furnace. For this application, 23 in. of insulating firebrick had to be removed to gain access to the fused AZS surface. The zircon patch was applied by pumping the mix from floor level up {approximately}60 ft to the crown by means of a concrete pump. Postmortems were performed on samples from two of the gas-fired TV-panel-glass furnaces. These postmortems were performed to determine if alterations occurred on the hot face of exposed zircon patch and, if so, how much alteration did occur. There was no destructive alteration because of alkali penetration into the patch. In fact, only trace amounts of lead, barium and strontium were detected, no further than 1 in. from the hot face. There was slight loss of P{sub 2}O{sub 5} on the hot face because of migration of phosphate toward the cold face, but it did not decrease the integrity of the patch. The dissociation of zircon was <3% baddelyite detected, all within an in. of the hot face.

  6. DC Graphite Arc Melter for vitrification of low-level waste

    SciTech Connect

    Desrosiers, A.E.; Wilver, P.J.; Wittle, J.K.

    1996-10-01

    The volume of mixed waste continues to increase with few options for its permanent disposal other than storage on site. This mixed waste is being generated by not only the Department of Energy at government sites but by the private sector in hospitals and at electrical utility sites. Bartlett Services, Inc. proposes to offer a service to treat these materials to both reduce the volume and stabilize the radionuclides in a vitrified material. This product will be formed in the DC Graphite Arc Melters developed by Electro-Pyrolysis, Inc. and being offered for commercial design, sale and installation by Svedala Industries, Pyro Division. The process is a high temperature procedure which pyrolytically decomposes the organic portion of the waste to form clean hydrogen and carbon monoxide and solid carbon. The inorganic portion, containing the radioactive components, melts to produce a stable glass which is resistant to environmental leaching and will remain stable until the radioactivity has decreased to a safe level. Glasses produced with surrogate materials such as cesium and cerium have been shown to pass the Product Compatibility Test (PCT). The process being proposed for this treatment utilizes a sealed melter system having the capability of melting wastes containing both metallic and inorganic materials. This process, unlike joule heated melters, is capable of operating to temperatures of 1600{degrees}C or higher. Since the system is heated electrically, oxidation is not required to create the heat. Since the system is pyrolytic, relatively small quantities of gas are produced. These gases may have beneficial uses in producing chemicals or may be used as a clean fuel.

  7. DC graphite arc melter for vitrification of low-level waste

    SciTech Connect

    Desrosiers, A.E.; Wilver, P.; Wittle, J.K.

    1996-03-01

    The volume of mixed waste continues to increase with few options for its permanent disposal other than storage on site. This mixed waste is being generated by not only the Department of Energy at government sites but by the private sector in hospitals and at electrical utility sites. Bartlett Services, Inc. proposes to offer a service to treat these materials to both reduce the volume and stabilize the radionuclides in a vitrified material. This product will be formed in the DC Graphite Arc melters developed by Electro-Pyrolysis, Inc. and being offered for commercial design, sale and installation by Svedala Industries, Pyro Division. The process is a high temperature procedure which pyrolytically decomposes the organic portion of the waste to form clean hydrogen and carbon monoxide and solid carbon. The inorganic portion, containing the radioactive components, melts to produce a stable glass which is resistant to environmental leaching and will remain stable until the radioactivity has decreased to a safe level. Glasses produced with surrogate materials such as cesium and cerium have been shown to pass the Product Compatibility Test (PCT). The process being proposed for this treatment utilizes a sealed melter system having the capability of melting wastes containing both metallic and inorganic materials. This process, unlike joule heated melters, is capable of operating to temperatures of 1600{degrees} C or higher. Since the system is heated electrically, oxidation is not required to create the heat. Since the system is pyrolytic, relatively small quantities of gas are produced. These gases may have beneficial uses in producing chemicals or may be used as a clean fuel.

  8. Evaluation of the DWPF Cold Chem Dissolution Method with Tank 7 and Tank 51 Radioactive Sludge

    SciTech Connect

    Click, D.R.

    2004-03-11

    Dissolution experiments were conducted on radioactive sludge from Tank 7, before transfer of the contents of Tank 7 to Tank 51, and the subsequent sludge in Tank 51 to evaluate the effectiveness of the DWPF Cold Chem Method. The DWPF Cold Chem Method is a room temperature dissolution method (DWPF Cold Chem Method) used in the DWPF on the Slurry Receipt and Adjustment Tank (SRAT) samples in preparation for instrumental analysis. Four types of dissolutions experiments were carried out, the DWPF Cold Chem Method, hot aqua regia, sodium peroxide fusion and hot HF-HNO3. The hot HF-HNO3 digestion is modified version of the DWPF method that incorporates a heating step. The hot aqua regia and sodium peroxide fusion digestions were included as reference digestions. The resulting solutions from all the sludge digestions were analyzed by ICP-ES (Inductively Coupled Plasma Emission Spectroscopy). Visual observations and ICP-ES results were used to evaluate the effectiveness of the DWPF Cold Chem by comparison to the hot aqua regia, sodium peroxide fusion and the hot HF-HNO3 digestions. The data and experimental observations support the following conclusions: The DWPF Cold Chem Method seemed to be effective at dissolving initial species of radioactive sludge, but concurrent precipitation of insoluble mixed-metal fluoride salts was observed in both the Tank 7 and Tank 51 Cold Chem digestion solutions. Complete dissolution, by visual observation, was achieved with a modified hot HF-HNO3 digestion. This was done as an alternative to the DWPF room-temperature acid dissolution.

  9. Equipment experience in a radioactive LFCM (liquid-fed ceramic melter) vitrification facility

    SciTech Connect

    Holton, L.K. Jr.; Dierks, R.D.; Sevigny, G.J.; Goles, R.W.; Surma, J.E.; Thomas, N.M.

    1986-11-01

    Since October 1984, the Pacific Northwest Laboratory (PNL) has operated a pilot-scale radioactive liquid-fed ceramic melter (RLFCM) vitrification process in shielded manipulator hot cells. This vitrification facility is being operated for the Department of Energy (DOE) to remotely test vitrification equipment components in a radioactive environment and to develop design and operation data that can be applied to production-scale projects. This paper summarizes equipment and process experience obtained from the operations of equipment systems for waste feeding, waste vitrification, canister filling, canister handling, and vitrification off-gas treatment.

  10. MODELING OF SPINEL SETTLING IN WASTE GLASS MELTER

    EPA Science Inventory

    The topic of this multi-institutional bi-national research is the formation and settling of spinel, the most common crystalline phase that precipitates in molten high-level waste HLW) glass. For the majority of HLW streams, spinel formation in the HLW melter limits the waste fra...

  11. Glass Formulation for Next Generation Cold Crucible Induction Melter

    SciTech Connect

    Kim, Dong-Sang; Schweiger, Michael J.; Vienna, John D.; Johnson, Fabienne; Marra, James C.; Peeler, David K.; Smith, Gary L.

    2011-12-21

    Transformational melter technologies are being considered to support mission acceleration within the U.S. Department of Energy (DOE) complex. New glass formulations are required to take full advantage of the next generation melters, for example, the cold crucible induction melter (CCIM). The key advantage of CCIM technology over current reference technologies is its capability to provide higher processing temperatures, which can lead to an increased waste throughput rate by achieving higher waste loadings and by increasing the feed processing rate. Various waste compositions within the DOE complex were evaluated to determine their potential for successfully demonstrating the unique advantages of the CCIM technology. Glass formulations that satisfy a set of constraints for product quality and assumed CCIM processing conditions were developed for two Hanford waste streams, AZ-101 high-level waste (HLW) and AN-105 low-activity waste (LAW). Three glasses selected for AZ-101 HLW have waste loadings of 40, 42.5, and 45 wt%. The 45-wt% waste loading corresponds to a 22% increase from 37 wt%, which is the maximum expected waste loading based on the current reference formulation. One glass selected for AN-105 LAW has a waste loading of 31.3 wt% at 24 wt% Na2O in glass, which is a 14% increase from the current reference formulation maximum of 21 wt% Na2O. These four glasses are planned for scaled melter tests for initial demonstration of the CCIM technologies for Hanford wastes.

  12. Glass melter assembly for the Hanford Waste Vitrification Plant

    SciTech Connect

    Chen, A.E.; Russell, A.; Shah, K.R.; Kalia, J.

    1993-01-01

    The Hanford Waste Vitrification Plant (HWVP) is designed to solidify high level radioactive waste by converting it into stable borosilicate after mixing with glass frit and water. The heart of this conversion process takes place in the glass melter. The life span of the existing melter is limited by the possible premature failure of the heater assembly, which is not remotely replaceable, in the riser and pour spout. A goal of HWVP Project is to design remotely replaceable riser and pour spout heaters so that the useful life of the melter can be prolonged. The riser pour spout area is accessible only by the canyon crane and impact wrench. It is also congested with supporting frame members, service piping, electrode terminals, canister positioning arm and other various melter components. The visibility is low and the accessibility is limited. The problem is further compounded by the extreme high temperature in the riser core and the electrical conductive nature of the molten glass that flows through it.

  13. Hydrogen generation during treatment of simulated high-level radioactive waste with formic acid

    SciTech Connect

    Ritter, J.A.; Zamecnik, J.R.; Hsu, C.W.

    1992-01-01

    The Integrated Defense Waste Processing Facility (DWPF) Melter System (IDMS), operated by the Savannah River Laboratory, is a one-fifth scale pilot facility used in support of the start-up and operation of the Department of Energy's DWPF. Five IDMS runs determined the effect of the presence of noble metals in HLW sludge on the H{sub 2} generation rate during the preparation of melter feed with formic acid. Overall, the results clearly showed that H{sub 2} generation in the DWPF SRAT could, at times, exceed the lower flammable limit of H{sub 2} in air (4 vol%), depending on such factors as offgas generation and air inleakage of the DWPF vessels. Therefore, the installation of a forced air purge system and H{sub 2} monitors were recommended to the DWPF to control the generation of H{sub 2} during melter feed preparation by fuel dilution.

  14. Hydrogen generation during treatment of simulated high-level radioactive waste with formic acid

    SciTech Connect

    Ritter, J.A.; Zamecnik, J.R.; Hsu, C.W.

    1992-05-01

    The Integrated Defense Waste Processing Facility (DWPF) Melter System (IDMS), operated by the Savannah River Laboratory, is a one-fifth scale pilot facility used in support of the start-up and operation of the Department of Energy`s DWPF. Five IDMS runs determined the effect of the presence of noble metals in HLW sludge on the H{sub 2} generation rate during the preparation of melter feed with formic acid. Overall, the results clearly showed that H{sub 2} generation in the DWPF SRAT could, at times, exceed the lower flammable limit of H{sub 2} in air (4 vol%), depending on such factors as offgas generation and air inleakage of the DWPF vessels. Therefore, the installation of a forced air purge system and H{sub 2} monitors were recommended to the DWPF to control the generation of H{sub 2} during melter feed preparation by fuel dilution.

  15. ELIMINATION OF THE CHARACTERIZATION OF DWPF POUR STREAM SAMPLE AND THE GLASS FABRICATION AND TESTING OF THE DWPF SLUDGE BATCH QUALIFICATION SAMPLE

    SciTech Connect

    Amoroso, J.; Peeler, D.; Edwards, T.

    2012-05-11

    A recommendation to eliminate all characterization of pour stream glass samples and the glass fabrication and Product Consistency Test (PCT) of the sludge batch qualification sample was made by a Six-Sigma team chartered to eliminate non-value-added activities for the Defense Waste Processing Facility (DWPF) sludge batch qualification program and is documented in the report SS-PIP-2006-00030. That recommendation was supported through a technical data review by the Savannah River National Laboratory (SRNL) and is documented in the memorandums SRNL-PSE-2007-00079 and SRNL-PSE-2007-00080. At the time of writing those memorandums, the DWPF was processing sludge-only waste but, has since transitioned to a coupled operation (sludge and salt). The SRNL was recently tasked to perform a similar data review relevant to coupled operations and re-evaluate the previous recommendations. This report evaluates the validity of eliminating the characterization of pour stream glass samples and the glass fabrication and Product Consistency Test (PCT) of the sludge batch qualification samples based on sludge-only and coupled operations. The pour stream sample has confirmed the DWPF's ability to produce an acceptable waste form from Slurry Mix Evaporator (SME) blending and product composition/durability predictions for the previous sixteen years but, ultimately the pour stream analysis has added minimal value to the DWPF's waste qualification strategy. Similarly, the information gained from the glass fabrication and PCT of the sludge batch qualification sample was determined to add minimal value to the waste qualification strategy since that sample is routinely not representative of the waste composition ultimately processed at the DWPF due to blending and salt processing considerations. Moreover, the qualification process has repeatedly confirmed minimal differences in glass behavior from actual radioactive waste to glasses fabricated from simulants or batch chemicals. In contrast, the

  16. Impact of the next generation solvent on DWPF CPC processing

    SciTech Connect

    Newell, J. D.

    2013-02-21

    As part of the Actinide Removal Process (ARP)/Modular Caustic-side Solvent Extraction Unit (MCU) Life Extension Project, a next generation solvent (NGS) and new strip acid will be deployed. Processing will begin with a blend of the current solvent and the NGS. Compositional changes in the NGS solvent and blending with the current solvent require review of previously performed work to determine if additional experimental work is required to address any impacts to the Defense Waste Processing Facility (DWPF) Chemical Process Cell (CPC). The composition change involved the substitution of the N,N’-dicyclohexyl-N”-isotridecylguanidine LIX® 79 guanidine suppressor with N,N’,N”-tris (3,7-dimethyloctyl) guanidine (TiDG) guanidine suppressor. The Savannah River National Laboratory (SRNL) was requested by DWPF to evaluate any impacts to offgas generation, solvent buildup or carryover, chemical, thermal, and radiolytic stability of the blended and pure TiDG based NGS. Previous work has been performed by SRNL to evaluate impacts to CPC processing using the next generation solvent containing LIX® 79 suppressor with boric acid strip effluent. Based on previous experimental work and current literature, the following conclusions are made for processing in the CPC: No mechanism for a change in the catalytic hydrogen evolution in the CPC was identified for the NGS TiDG based solvent; The transition from the LIX® 79 based suppressor to the TiDG based suppressor is not expected to have any impact on solvent or Isopar® L accumulation; Transitioning from the current solvent to the TiDG based NGS is not expected to have an impact on solvent carryover or partitioning; No changes to the chemical stability of the solvent in the CPC process are expected; No changes to the thermal stability of the solvent in the CPC process are expected; A “worst case” scenario was examined in which all of the hydrogen atoms from the TiDG based NGS and blended solvent form hydrogen gas in the

  17. DEVELOPMENT OF REMOTE HANFORD CONNECTOR GASKET REPLACEMENT TOOLING FOR DWPF

    SciTech Connect

    Krementz, D.; Coughlin, Jeffrey

    2009-05-05

    The Defense Waste Processing Facility (DWPF) requested the Savannah River National Laboratory (SRNL) to develop tooling and equipment to remotely replace gaskets in mechanical Hanford connectors to reduce personnel radiation exposure as compared to the current hands-on method. It is also expected that radiation levels will continually increase with future waste streams. The equipment is operated in the Remote Equipment Decontamination Cell (REDC), which is equipped with compressed air, two master-slave manipulators (MSM's) and an electro-mechanical manipulator (EMM) arm for operation of the remote tools. The REDC does not provide access to electrical power, so the equipment must be manually or pneumatically operated. The MSM's have a load limit at full extension of ten pounds, which limited the weight of the installation tool. In order to remotely replace Hanford connector gaskets several operations must be performed remotely, these include: removal of the spent gasket and retaining ring (retaining ring is also called snap ring), loading the new snap ring and gasket into the installation tool and installation of the new gasket into the Hanford connector. SRNL developed and tested tools that successfully perform all of the necessary tasks. Removal of snap rings from horizontal and vertical connectors is performed by separate air actuated retaining ring removal tools and is manipulated in the cell by the MSM. In order install a new gasket, the snap ring loader is used to load a new snap ring into a groove in the gasket installation tool. A new gasket is placed on the installation tool and retained by custom springs. An MSM lifts the installation tool and presses the mounted gasket against the connector block. Once the installation tool is in position, the gasket and snap ring are installed onto the connector by pneumatic actuation. All of the tools are located on a custom work table with a pneumatic valve station that directs compressed air to the desired tool and

  18. A STATISTICAL REVIEW OF DWPF LABORATORY MEASUREMENTS GENERATED DURING THE PROCESSING OF BATCHES 300 THROUGH 356

    SciTech Connect

    Edwards, T

    2006-08-31

    In this report, the Statistical Consulting Section (SCS) of the Savannah River National Laboratory (SRNL) provides summaries and comparisons of composition measurements for glass samples that were generated during the processing of batches 300 through 356 at the Defense Waste Processing Facility (DWPF). These analyses, which include measurements of samples from the Sludge Receipt and Adjustment Tank (SRAT) and the Slurry Mix Evaporator (SME) as well as samples of glass standards, were provided to SCS by the DWPF Laboratory (DWPF Lab) of Waste Laboratory Services. The comparisons made by SCS were extensive given that these data allowed for contrasts between preparation methods and between the two spectrometers that are currently in use at the DWPF Lab. In addition to general comparisons, specific questions that were posed in the Technical Task Request (TTR) behind this effort were addressed in this report.

  19. Tank 11H Analytical Results as Input to DWPF Sludge Batch 4

    SciTech Connect

    CHRISTOPHER, BANNOCHIE

    2004-09-01

    SRNL was requested by DWPF to conduct analyses on dissolved samples of Tank 11H material in preparation for DWPF processing. Two separate samples of Tank 11H were pulled during Tank Farm slurry and transfer operations. These samples have been designated Tank 11 - Sample 1 and Tank 11 - Sample 2. Aliquots of each slurry sample were digested in HNO3/HF and analyzed by inductively coupled plasma - atomic emission spectroscopy, inductively coupled plasma - mass spectrometry, and cold vapor - atomic absorption spectroscopy.

  20. Evaluation of Crystalline Silicotitanate and Self-Assembled Monolayers on Mesoporous Support for Cesium and Mercury Removal from DWPF Recycle

    SciTech Connect

    Oji, L.N.

    1999-11-05

    The affinities for cesium and mercury ions contained in DWPF recycle simulants and Tank-22H waste have been evaluated using Crystalline Silicotitanate (CST) and Self-Assembled Monolayers on Mesoporous Support (SAMMS) ion-exchange materials, respectively. Results of the performance evaluations of CST on the uptake of cesium with simulants and actual DWPF recycle samples (Tank 22H) indicate that, in practice, this inorganic ion-exchange material can be used to remove radioactive cesium from the DWPF recycle. SAMMS material showed little or no affinity for mercury from highly alkaline DWPF waste. However, at near neutral conditions (DWPF simulant solution pH adjusted to 7), SAMMS was found to have a significant affinity for mercury. Conventional Duolite/256 ion exchange material showed an increase in affinity for mercury with increase in DWPF recycle simulant pH. Duolite/256 GT-73 also had a high batch distribution coefficient for mercury uptake from actual Tank 22H waste.

  1. REPORTABLE RADIONUCLIDES IN DWPF SLUDGE BATCH 7A (MACROBATCH 8)

    SciTech Connect

    Reboul, S.; Diprete, D.; Click, D.; Bannochie, C.

    2011-12-20

    The Waste Acceptance Product Specifications (WAPS) 1.2 require that the waste producer 'shall report the curie inventory of radionuclides that have half-lives longer than 10 years and that are, or will be, present in concentrations greater than 0.05 percent of the total inventory for each waste type indexed to the years 2015 and 3115.' As part of the strategy to meet WAPS 1.2, the Defense Waste Processing Facility (DWPF) will report for each waste type all radionuclides that have half-lives longer than 10 years and contribute greater than 0.01 percent of the total curie inventory from the time of production through the 1100 year period from 2015 through 3115. The initial list of radionuclides to be reported is based on the design-basis glass identified in the Waste Form Compliance Plan (WCP) and Waste Form Qualification Report. However, it is required that the list be expanded if other radionuclides with half-lives greater than 10 years are identified that meet the 'greater than 0.01% of the curie inventory' criterion. Specification 1.6 of the WAPS, International Atomic Energy Agency Safeguards Reporting for High Level Waste (HLW), requires that the ratio by weights of the following uranium and plutonium isotopes be reported: U-233, U-234, U-235, U-236, and U-238; and Pu-238, Pu-239, Pu-240, Pu-241, and Pu-242. Therefore, the complete list of reportable radionuclides must also include these sets of U and Pu isotopes - and the U and Pu isotopic mass distributions must be identified. The DWPF receives HLW sludge slurry from Savannah River Site (SRS) Tank 40. For Sludge Batch 7a (SB7a), the waste in Tank 40 contained a blend of the heel from Sludge Batch 6 (SB6) and the Sludge Batch 7 (SB7) material transferred to Tank 40 from Tank 51. This sludge blend is also referred to as Macrobatch 8. Laboratory analyses of a Tank 40 sludge sample were performed to quantify the concentrations of pertinent radionuclides in the SB7a waste. Subsequently, radiological decay and in

  2. ACCELERATED PROCESSING OF SB4 AND PREPARATION FOR SB5 PROCESSING AT DWPF

    SciTech Connect

    Herman, C

    2008-12-01

    The Defense Waste Processing Facility (DWPF) initiated processing of Sludge Batch 4 (SB4) in May 2007. SB4 was the first DWPF sludge batch to contain significant quantities of HM or high Al sludge. Initial testing with SB4 simulants showed potential negative impacts to DWPF processing; therefore, Savannah River National Laboratory (SRNL) performed extensive testing in an attempt to optimize processing. SRNL's testing has resulted in the highest DWPF production rates since start-up. During SB4 processing, DWPF also began incorporating waste streams from the interim salt processing facilities to initiate coupled operations. While DWPF has been processing SB4, the Liquid Waste Organization (LWO) and the SRNL have been preparing Sludge Batch 5 (SB5). SB5 has undergone low-temperature aluminum dissolution to reduce the mass of sludge for vitrification and will contain a small fraction of Purex sludge. A high-level review of SB4 processing and the SB5 preparation studies will be provided.

  3. COMSOL MULTIPHYSICS MODEL FOR DWPF CANISTER FILLING, REVISION 1

    SciTech Connect

    Kesterson, M.

    2011-09-08

    This revision is an extension of the COMSOL Multiphysics model previously developed and documented to simulate the temperatures of the glass during pouring a Defense Waste Processing Facility (DWPF) canister. In that report the COMSOL Multiphysics model used a lumped heat loss term derived from experimental thermocouple data based on a nominal pour rate of 228 lbs./hr. As such, the model developed using the lumped heat loss term had limited application without additional experimental data. Therefore, the COMSOL Multiphysics model was modified to simulate glass pouring and subsequent heat input which, replaced the heat loss term in the initial model. This new model allowed for changes in flow geometry based on pour rate as well as the ability to increase and decrease flow and stop and restart flow to simulate varying process conditions. A revised COMSOL Multiphysics model was developed to predict temperatures of the glass within DWPF canisters during filling and cooldown. The model simulations and experimental data were in good agreement. The largest temperature deviations were {approx} 40 C for the 87 inch thermocouple location at 3000 minutes and during the initial cool down at the 51 inch location occurring at approximately 600 minutes. Additionally, the model described in this report predicts the general temperature trends during filling and cooling as observed experimentally. The revised model incorporates a heat flow region corresponding to the glass pouring down the centerline of the canister. The geometry of this region is dependent on the flow rate of the glass and can therefore be used to see temperature variations for various pour rates. The equations used for this model were developed by comparing simulation output to experimental data from a single pour rate. Use of the model will predict temperature profiles for other pour rates but the accuracy of the simulations is unknown due to only a single flow rate comparison.

  4. Description of DWPF reference waste form and canister

    SciTech Connect

    Not Available

    1981-06-01

    This document describes the reference waste form and canister for the Defense Waste Processing Facility (DWPF). The facility is planned for location at the Savannah River Plant in Aiken, SC, and is scheduled for construction authorization during FY-1983. The reference canister is fabricated of 24-in.-OD 304L stainless steel pipe with a dished bottom, domed head, and lifting and welding flanges on the head neck. The overall canister length is 9 ft 10 in., with a wall thickness of 3/8-in. (schedule 20 pipe). The canister length was selected to reduce equipment cell height in the DWPF to a practical size. The canister diameter was selected to ensure that a filled canister with its shipping cask could be accommodated on a legal-weight truck. The overall dimensions and weight appear to be generally compatible with preliminary assessments of repository requirements. The reference waste form is borosilicate glass containing approximately 28 wt % sludge oxides with the balance glass frit. Borosilicate glass was chosen because of its high resistance to leaching by water, its relatively high solubility for nuclides found in the sludge, and its reasonably low melting temperature. The glass frit contains approximately 58% SiO/sub 2/ and 15% B/sub 2/O/sub 3/. This composition results in a low average leachability in the waste form of approximately 5 x 10/sup -9/ g/cm/sup 2/-day based on /sup 137/Cs over 365 days in 25/sup 0/C water. The canister is filled with 3260 lb of glass which occupies about 85% of the free canister volume. The filled canister will generate approximately 425 watts when filled with oxides from 5-year-old sludge and 15-year-old supernate from the Stage 1 and Stage 2 processes. The radionuclide content of the canister is about 150,000 curies, with a radiation level of 2 x 10/sup 4/ rem/hour at 1 cm.

  5. Multiphase, multi-electrode Joule heat computations for glass melter and in situ vitrification simulations

    SciTech Connect

    Lowery, P.S.; Lessor, D.L.

    1991-02-01

    Waste glass melter and in situ vitrification (ISV) processes represent the combination of electrical thermal, and fluid flow phenomena to produce a stable waste-from product. Computational modeling of the thermal and fluid flow aspects of these processes provides a useful tool for assessing the potential performance of proposed system designs. These computations can be performed at a fraction of the cost of experiment. Consequently, computational modeling of vitrification systems can also provide and economical means for assessing the suitability of a proposed process application. The computational model described in this paper employs finite difference representations of the basic continuum conservation laws governing the thermal, fluid flow, and electrical aspects of the vitrification process -- i.e., conservation of mass, momentum, energy, and electrical charge. The resulting code is a member of the TEMPEST family of codes developed at the Pacific Northwest Laboratory (operated by Battelle for the US Department of Energy). This paper provides an overview of the numerical approach employed in TEMPEST. In addition, results from several TEMPEST simulations of sample waste glass melter and ISV processes are provided to illustrate the insights to be gained from computational modeling of these processes. 3 refs., 13 figs.

  6. Advanced waste form and melter development for treatment of troublesome high-level wastes

    SciTech Connect

    Marra, James; Kim, Dong -Sang; Maio, Vincent

    2015-09-02

    A number of waste components in US defense high level radioactive wastes (HLW) have proven challenging for current Joule heated ceramic melter (JHCM) operations and have limited the ability to increase waste loadings beyond already realized levels. Many of these "troublesome" waste species cause crystallization in the glass melt that can negatively impact product quality or have a deleterious effect on melter processing. Recent efforts at US Department of Energy laboratories have focused on understanding crystallization behavior within HLW glass melts and investigating approached to mitigate the impacts of crystallization so that increases in waste loading can be realized. Advanced glass formulations have been developed to highlight the unique benefits of next-generation melter technologies such as the Cold Crucible Induction Melter (CCIM). Crystal-tolerant HLW glasses have been investigated to allow sparingly soluble components such as chromium to crystallize in the melter but pass out of the melter before accumulating.

  7. GTS Duratek, phase I Hanford low-level waste melter tests: Final report

    SciTech Connect

    Eaton, W.C.

    1995-10-26

    A multiphase program was initiated in 1994 to test commercially available melter technologies for the vitrification of the low-level waste (LLW) stream from defense waste stored in underground tanks at the Hanford Site in southeastern Washington State. Phase 1 of the melter demonstration tests using simulated LLW was completed during fiscal year 1995. This document is the final report on testing performed by GTS Duratek Inc. in Columbia, Maryland. GTS Duratek (one of the seven vendors selected) was chosen to demonstrate Joule heated melter technology under WHC subcontract number MMI-SVV-384215. The report contains description of the tests, observations, test data and some analysis of the data as it pertains to application of this technology for LLW vitrification. The document also contains summaries of the melter offgas reports issued as separate documents for the 100 kg melter (WHC-SD-WM-VI-028) and for the 1000 kg melter (WHC-SD-WM-VI-029).

  8. Geochemical simulation of dissolution of West Valley and DWPF [Defense Waste Product Facility] glasses in J-13 water at 90{sup 0}C.

    SciTech Connect

    Bruton, C.J.

    1987-11-01

    Dissolution of West Valley and Defense Waste Product Facility (DWPF) glasses in J-13 water at 90{sup 0}C at the candidate Yucca Mountain, Nevada repository was simulated using the EQ3/6 computer code package. The objectives of the study were to attempt to predict the concentrations of radionuclides and other glass components in solution resulting from glass dissolution, and to identify potential precipitates that sequester glass components. Modified projected inventories of 10,000 year-old West Valley and DWPF SRL-165 frit glasses were used as starting glass compositions. J-13 water was considered to be representative of groundwater at Yucca Mountain. A total of 10 grams of each glass was assumed to dissolve congruently into a kilogram of J-13 water in a closed system. No inhibitions to precipitation, except for crystalline SiO{sub 2} polymorphs, were assumed to exist. Radiolysis and materials interactions were not considered. Simulation results predict that radionuclides and other glass components precipitate predominantly in the form of oxides and hydroxides, together with carbonates, silicates and phosphates. Precipitates appear to be effective in limiting the concentrations of radionuclides and other elements in solution. The general compositional trends in precipitates and solution chemistry are the same in the West Valley and DWPF simulations, except for variations arising from differences in glass chemistry. 20 refs., 7 figs., 3 tabs.

  9. MATRIX 1 RESULTS OF THE FY07 ENHANCED DOE HIGH-LEVEL WASTE MELTER THROUGHPUT STUDIES AT SRNL

    SciTech Connect

    Raszewski, F; Tommy Edwards, T; David Peeler, D

    2008-09-23

    High-level waste (HLW) throughput (i.e., the amount of waste processed per unit time) is a function of two critical parameters: waste loading (WL) and melt rate. For the Waste Treatment and Immobilization Plant (WTP) at the Hanford Site and the Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS), increasing HLW throughput would significantly reduce the overall mission life cycle costs for the Department of Energy (DOE). It has been proposed that a team of glass formulation and processing experts at the Pacific Northwest National Laboratory (PNNL), Savannah River National Laboratory (SRNL), and Vitreous State Laboratory (VSL) at Catholic University of America develop a systematic approach to increase HLW throughput (by increasing WL with minimal or positive impacts on melt rate). Programmatically, this task is aimed at proof-of-principle testing and the development of tools to improve waste loading and melt rate, which will lead to higher waste throughput. The following four specific tasks have been proposed to meet this programmatic objective: (1) Integration and Oversight, (2) Crystal Accumulation Modeling (led by PNNL)/Higher Waste Loading Glasses (led by SRNL), (3) Melt Rate Evaluation and Modeling, and (4) Melter Scale Demonstrations. The details of these tasks can be found in the associated task plan WSRC-STI-2007-00483. The current study is focused on Task 2 (crystal accumulation modeling and higher waste loading glasses) and involves glass formulation and physical property testing by both PNNL and SRNL (as defined in the PNNL and SRNL test plans). The intent of this report is to document the chemical composition and Product Consistency Test (PCT) results and statistical analysis of PNNL's Test Matrix 1 glasses. Note that this document is only a compilation of the data collected by SRNL for PNNL's glasses in support of this task and no conclusions will be drawn.

  10. BEHAVIOR OF MERCURY DURING DWPF CHEMICAL PROCESS CELL PROCESSING

    SciTech Connect

    Zamecnik, J.; Koopman, D.

    2012-04-09

    retention of mercury in the slurry. Both recovery of mercury in the offgas system and removal (segregation + recovery) from the slurry correlate with slurry consistency. Higher slurry consistency results in better retention of Hg in the slurry (less segregation) and better recovery in the offgas system, but the relationships of recovery and retention with consistency are sludge dependent. Some correlation with slurry yield stress and acid stoichiometry was also found. Better retention of mercury in the slurry results in better recovery in the offgas system because the mercury in the slurry is stripped more easily than the segregated mercury at the bottom of the vessel. Although better retention gives better recovery, the time to reach a particular slurry mercury content (wt%) is longer than if the retention is poorer because the segregation is faster. The segregation of mercury is generally a faster process than stripping. The stripping factor (mass of water evaporated per mass of mercury stripped) of mercury at the start of boiling were found to be less than 1000 compared to the assumed design basis value of 750 (the theoretical factor is 250). However, within two hours, this value increased to at least 2000 lb water per lb Hg. For runs with higher mercury recovery in the offgas system, the stripping factor remained around 2000, but runs with low recovery had stripping factors of 4000 to 40,000. DWPF data shows similar trends with the stripping factor value increasing during boiling. These high values correspond to high segregation and low retention of mercury in the sludge. The stripping factor for a pure Hg metal bead in water was found to be about 10,000 lb/lb. About 10-36% of the total Hg evaporated in a SRAT cycle was refluxed back to the SRAT during formic acid addition and boiling. Mercury is dissolved as a result of nitric acid formation from absorption of NO{sub x}. The actual solubility of dissolved mercury in the acidic condensate is about 100 times higher than

  11. DM100 AND DM1200 MELTER TESTING WITH HIGH WASTE LOADING GLASS FORMULATIONS FOR HANFORD HIGH-ALUMINUM HLW STREAMS

    SciTech Connect

    KRUGER AA; MATLACK KS; KOT WK; PEGG IL; JOSEPH I

    2009-12-30

    This Test Plan describes work to support the development and testing of high waste loading glass formulations that achieve high glass melting rates for Hanford high aluminum high level waste (HLW). In particular, the present testing is designed to evaluate the effect of using low activity waste (LAW) waste streams as a source of sodium in place ofchemical additives, sugar or cellulose as a reductant, boehmite as an aluminum source, and further enhancements to waste processing rate while meeting all processing and product quality requirements. The work will include preparation and characterization of crucible melts in support of subsequent DuraMelter 100 (DM 100) tests designed to examine the effects of enhanced glass formulations, glass processing temperature, incorporation of the LAW waste stream as a sodium source, type of organic reductant, and feed solids content on waste processing rate and product quality. Also included is a confirmatory test on the HLW Pilot Melter (DM1200) with a composition selected from those tested on the DM100. This work builds on previous work performed at the Vitreous State Laboratory (VSL) for Department of Energy's (DOE's) Office of River Protection (ORP) to increase waste loading and processing rates for high-iron HLW waste streams as well as previous tests conducted for ORP on the same waste composition. This Test Plan is prepared in response to an ORP-supplied statement of work. It is currently estimated that the number of HLW canisters to be produced in the Hanford Tank Waste Treatment and Immobilization Plant (WTP) is about 12,500. This estimate is based upon the inventory ofthe tank wastes, the anticipated performance of the sludge treatment processes, and current understanding of the capability of the borosilicate glass waste form. The WTP HLW melter design, unlike earlier DOE melter designs, incorporates an active glass bubbler system. The bubblers create active glass pool convection and thereby improve heat transfer and

  12. Materials and design experience in a slurry-fed electric glass melter

    SciTech Connect

    Barnes, S.M.; Larson, D.E.

    1981-08-01

    The design of a slurry-fed electric gas melter and an examination of the performance and condition of the construction materials were completed. The joule-heated, ceramic-lined melter was constructed to test the applicability of materials and processes for high-level waste vitrification. The developmental Liquid-Fed Ceramic Melter (LFCM) was operated for three years with simulated high-level waste and was subjected to conditions more severe than those expected for a nuclear waste vitrification plant.

  13. FRIT SELECTION TO SUPPORT STEKLO METALLICHESKIE KONSTRUKTSII MELTER TESTING WITH SRNL FEEDS

    SciTech Connect

    Fox, K; James Gillam, J; Tommy Edwards, T; David Peeler, D

    2007-07-26

    Four frits were developed for possible use in melter testing with V.G. Khlopin Radium Institute's Steklo Metallicheskie Konstruktsii (SMK) melter. The frits were selected using Measurement Acceptability Region (MAR) assessments of an array of frit formulations and two Sludge Batch 5 (SB5) flowsheets, one with the anticipated effect of the implementation of Al-dissolution and one without. Test glasses were fabricated in the laboratory to verify that the property and performance models used to select the frits were applicable to the frit/sludge systems of interest. Each of the four frits was tested with each of the two sludges at two different waste loadings, for a total of 16 test glasses. Each glass was both quenched and subjected to the canister centerline cooled (CCC) thermal profile. Samples of each glass were examined for crystallization by X-ray diffraction (XRD) and durability using the Product Consistency Test (PCT). The quenched version of each glass appeared amorphous by visual observations, although XRD results indicated a small amount of crystallization in four of the quenched glasses. Visual observations identified surface crystallization on the CCC versions of all 16 glasses. Three of the 35% waste loading (WL), CCC glasses were found to contain trevorite (a spinel) by XRD, and all of the 40% WL CCC glasses were found to contain trevorite. Nepheline was not observed in any of the test glasses, which is consistent with model predictions.

  14. Characterization of Ceramic Material Produced From a Cold Crucible Induction Melter Test

    SciTech Connect

    Amoroso, J.; Marra, J.

    2015-04-30

    This report summarizes the results from characterization of samples from a melt processed surrogate ceramic waste form. Completed in October of 2014, the first scaled proof of principle cold crucible induction melter (CCIM) test was conducted to process a Fe-hollandite-rich titanate ceramic for treatment of high level nuclear waste. X-ray diffraction, electron microscopy, inductively coupled plasma-atomic emission spectroscopy (and inductively coupled plasma-mass spectroscopy for Cs), and product consistency tests were used to characterize the CCIM material produced. Core samples at various radial locations from the center of the CCIM were taken. These samples were also sectioned and analyzed vertically. Together, the various samples were intended to provide an indication of the homogeneity throughout the CCIM with respect to phase assemblage, chemical composition, and chemical durability. Characterization analyses confirmed that a crystalline ceramic with desirable phase assemblage was produced from a melt using a CCIM. Hollandite and zirconolite were identified in addition to possible highly-substituted pyrochlore and perovskite. Minor phases rich in Fe, Al, or Cs were also identified. Remarkably only minor differences were observed vertically or radially in the CCIM material with respect to chemical composition, phase assemblage, and durability. This recent CCIM test and the resulting characterization in conjunction with demonstrated compositional improvements support continuation of CCIM testing with an improved feed composition and improved melter system.

  15. Evaluation of melter technologies for vitrification of Hanford site low-level tank waste - phase 1 testing summary report

    SciTech Connect

    Wilson, C.N., Westinghouse Hanford

    1996-06-27

    Following negotiation of the fourth amendment to the Tri- Party Agreement for Hanford Site cleanup, commercially available melter technologies were tested during 1994 and 1995 for vitrification of the low-level waste (LLW) stream to be derived from retrieval and pretreatment of the radioactive defense wastes stored in 177 underground tanks. Seven vendors were selected for Phase 1 testing to demonstrate vitrification of a high-sodium content liquid LLW simulant. The tested melter technologies included four Joule-heated melters, a carbon electrode melter, a combustion melter, and a plasma melter. Various dry and slurry melter feed preparation processes also were tested. The technologies and Phase 1 testing results were evaluated and a preliminary technology down-selection completed. This report describes the Phase 1 LLW melter vendor testing and the tested technologies, and summarizes the testing results and the preliminary technology recommendations.

  16. EVALUATION OF REQUIREMENTS FOR THE DWPF HIGHER CAPACITY CANISTER

    SciTech Connect

    Miller, D.; Estochen, E.; Jordan, J.; Kesterson, M.; Mckeel, C.

    2014-08-05

    The Defense Waste Processing Facility (DWPF) is considering the option to increase canister glass capacity by reducing the wall thickness of the current production canister. This design has been designated as the DWPF Higher Capacity Canister (HCC). A significant decrease in the number of canisters processed during the life of the facility would be achieved if the HCC were implemented leading to a reduced overall reduction in life cycle costs. Prior to implementation of the change, Savannah River National Laboratory (SRNL) was requested to conduct an evaluation of the potential impacts. The specific areas of interest included loading and deformation of the canister during the filling process. Additionally, the effect of the reduced wall thickness on corrosion and material compatibility needed to be addressed. Finally the integrity of the canister during decontamination and other handling steps needed to be determined. The initial request regarding canister fabrication was later addressed in an alternate study. A preliminary review of canister requirements and previous testing was conducted prior to determining the testing approach. Thermal and stress models were developed to predict the forces on the canister during the pouring and cooling process. The thermal model shows the HCC increasing and decreasing in temperature at a slightly faster rate than the original. The HCC is shown to have a 3°F ΔT between the internal and outer surfaces versus a 5°F ΔT for the original design. The stress model indicates strain values ranging from 1.9% to 2.9% for the standard canister and 2.5% to 3.1% for the HCC. These values are dependent on the glass level relative to the thickness transition between the top head and the canister wall. This information, along with field readings, was used to set up environmental test conditions for corrosion studies. Small 304-L canisters were filled with glass and subjected to accelerated environmental testing for 3 months. No evidence of

  17. Assessment of the Impact of a New Guanidine Suppressor In NGS on F/H Laboratory Analyses For DWPF and Saltstone MCU Transfers

    SciTech Connect

    Bannochie, C. J.

    2013-04-29

    Implementation of the Next Generation Solvent (NGS) in the Modular Caustic-Side Solvent Extraction Unit (MCU) will now proceed with a new suppressor compound, 1,2,3-tris(3,7-dimethyloctyl)guanidine (TiDG), replacing the originally planned suppressor for NGS, 1,3-dicyclohexyl-2-(11-methyldodecyl) guanidine (DCiTG). The Savannah River National Laboratory (SRNL) was tasked with evaluating the potential impact to F/H Laboratory analyses supporting the Defense Waste Processing Facility (DWPF) Waste Acceptance Criteria (WAC) used to qualify transfers of MCU Strip Effluent (SE) into the facility and the Saltstone WAC used to qualify transfers of Tank 50 containing Decontaminated Salt Solution (DSS) from MCU into Saltstone. This assigned scope is covered by a Task Technical and Quality Assurance Plan (TTQAP). Previous impact evaluations were conducted when the DCiTG suppressor was planned for NGS and concluded that there was no impact to either the determination of MCU SE pH nor the analysis of Isopar® L carryover in the MCU SE and DSS streams. SRNL reported on this series of cross-check studies between the SRNL and F/H Laboratories. The change in suppressor from DCiTG to TiDG in the NGS should not impact the measurement of Isopar® L or pH in SE or DSS necessary to satisfy DWPF and Saltstone WAC (Tank 50) criteria, respectively. A statistical study of the low bias observed in Isopar® L measurements in both SRNL and F/H Laboratories may be necessary now that the final NGS composition is fixed in order to quantify the low bias so that a proper correction can be applied to measurements critical to the DWPF and Saltstone WACs. Depending upon the final DWPF WAC requirement put in place for SE pH, it could become necessary to implement an alternative ICP-AES measurement of boron. The current blended solvent system testing in SRNL should address any impacts to Isopar® L carryover into either the DSS or the SE. It is recommended that SRNL monitor the current blended solvent

  18. Statistical process control applied to the liquid-fed ceramic melter process

    SciTech Connect

    Pulsipher, B.A.; Kuhn, W.L.

    1987-09-01

    In this report, an application of control charts to the apparent feed composition of a Liquid-Fed Ceramic Melter (LFCM) is demonstrated by using results from a simulation of the LFCM system. Usual applications of control charts require the assumption of uncorrelated observations over time. This assumption is violated in the LFCM system because of the heels left in tanks from previous batches. Methods for dealing with this problem have been developed to create control charts for individual batches sent to the feed preparation tank (FPT). These control charts are capable of detecting changes in the process average as well as changes in the process variation. All numbers reported in this document were derived from a simulated demonstration of a plausible LFCM system. In practice, site-specific data must be used as input to a simulation tailored to that site. These data directly affect all variance estimates used to develop control charts. 64 refs., 3 figs., 2 tabs.

  19. Review of Catalytic Hydrogen Generation in the Defense Waste Processing Facility (DWPF) Chemical Processing Cell

    SciTech Connect

    Koopman, D. C.

    2004-12-31

    This report was prepared to fulfill the Phase I deliverable for HLW/DWPF/TTR-98-0018, Rev. 2, ''Hydrogen Generation in the DWPF Chemical Processing Cell'', 6/4/2001. The primary objective for the preliminary phase of the hydrogen generation study was to complete a review of past data on hydrogen generation and to prepare a summary of the findings. The understanding was that the focus should be on catalytic hydrogen generation, not on hydrogen generation by radiolysis. The secondary objective was to develop scope for follow-up experimental and analytical work. The majority of this report provides a summary of past hydrogen generation work with radioactive and simulated Savannah River Site (SRS) waste sludges. The report also includes some work done with Hanford waste sludges and simulants. The review extends to idealized systems containing no sludge, such as solutions of sodium formate and formic acid doped with a noble metal catalyst. This includes general information from the literature, as well as the focused study done by the University of Georgia for the SRS. The various studies had a number of points of universal agreement. For example, noble metals, such as Pd, Rh, and Ru, catalyze hydrogen generation from formic acid and formate ions, and more acid leads to more hydrogen generation. There were also some points of disagreement between different sources on a few topics such as the impact of mercury on the noble metal catalysts and the identity of the most active catalyst species. Finally, there were some issues of potential interest to SRS that apparently have not been systematically studied, e.g. the role of nitrite ion in catalyst activation and reactivity. The review includes studies covering the period from about 1924-2002, or from before the discovery of hydrogen generation during simulant sludge processing in 1988 through the Shielded Cells qualification testing for Sludge Batch 2. The review of prior studies is followed by a discussion of proposed

  20. Review of Statistical Analyses Resulting from Performance of HLDWD- DWPF-005

    SciTech Connect

    Beck, R.S.

    1997-09-29

    The Engineering Department at the Defense Waste Processing Facility (DWPF) has reviewed two reports from the Statistical Consulting Section (SCS) involving the statistical analysis of test results for analysis of small sample inserts (references 1{ampersand}2). The test results cover two proposed analytical methods, a room temperature hydrofluoric acid preparation (Cold Chem) and a sodium peroxide/sodium hydroxide fusion modified for insert samples (Modified Fusion). The reports support implementation of the proposed small sample containers and analytical methods at DWPF. Hydragard sampler valve performance was typical of previous results (reference 3). Using an element from each major feed stream. lithium from the frit and iron from the sludge, the sampler was determined to deliver a uniform mixture in either sample container.The lithium to iron ratios were equivalent for the standard 15 ml vial and the 3 ml insert.The proposed method provide equivalent analyses as compared to the current methods. The biases associated with the proposed methods on a vitrified basis are less than 5% for major elements. The sum of oxides for the proposed method compares favorably with the sum of oxides for the conventional methods. However, the average sum of oxides for the Cold Chem method was 94.3% which is below the minimum required recovery of 95%. Both proposed methods, cold Chem and Modified Fusion, will be required at first to provide an accurate analysis which will routinely meet the 95% and 105% average sum of oxides limit for Product Composition Control System (PCCS).Issued to be resolved during phased implementation are as follows: (1) Determine calcine/vitrification factor for radioactive feed; (2) Evaluate covariance matrix change against process operating ranges to determine optimum sample size; (3) Evaluate sources for low sum of oxides; and (4) Improve remote operability of production versions of equipment and instruments for installation in 221-S.The specifics of

  1. Application of hydration thermodynamics to control of the DWPF process. Revision 1

    SciTech Connect

    Plodinec, M.J.

    1990-12-31

    The Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS) will incorporate the radioactivity in the 130 million liters of high-level nuclear waste at SRS in a stable borosilicate glass. Glass product specifications requite control of processing parameters to ensure glass durability. A model of glass durability, based on hydration thermodynamics, has been used at SRS to aid in formulation of waste glasses; to explain the relative durability of different glasses under identical test conditions (MCC-1 test ); and to explain the effects of changing test conditions on the observed durability of a given glass. This model has now been modified for use in control of the DWPF. It provides a tool which relates glass durability to parameters which can be controlled in the DWPF process. It provides a tool which relates glass durability to parameters which can be controlled in the DWPF process, primarily chemical composition. In this paper, the model is presented, and its projected role in control of the DWPF process is described.

  2. FINAL REPORT. SETTLING OF SPINEL IN A HIGH-LEVEL WASTE GLASS MELTER

    EPA Science Inventory

    The research on spinel settling in the high-level waste (HLW) glass melter was conducted to assist HLW retrieval, glass formulation, feed preparation, and melter design and operation for minimum-risk and minimum-cost vitrification of HLW at Hanford and other DOE sites. The main r...

  3. Vitrification of Cesium-Laden Organic Ion Exchange Resin in a Stirred Melter

    SciTech Connect

    Cicero-Herman, C.A; Sargent, T.N.; Overcamp, T.J.; Bickford, D.F.

    1997-07-09

    The goal of this research was a feasibility study for vitrifying the organic ion exchange resin in a stirred-tank melter. Tests were conducted to determine the fate of cesium including the feed, exit glass, and offgas streams and to assess any impact of feeding the resin on the melter or its performance.

  4. Erosion Modeling Analysis For Modified DWPF SME Tank

    SciTech Connect

    LEE, SI

    2004-05-03

    In support of an erosion evaluation for the modified cooling coil guide and its supporting structure in the DWPF SME vessel, a computational model was developed to identify potential sites of high erosion using the same methodology established by previous work. The erosion mechanism identified in the previous work was applied to the evaluation of high erosion locations representative of the actual flow process in the modified coil guide of the SME vessel, abrasive erosion which occurs by high wall shear of viscous liquid. The results show that primary locations of the highest erosion due to the abrasive wall erosion are at the leading edge of the guide, external surface of the insert plate, the tank floor next to the insert plate of the coil guide support, and the upstream lead-in plate. The present modeling results show a good comparison between the original and the modified cases in terms of high erosion sites, as well as the degree of erosion and the calculated shear stress. Wall she ar of the tank floor is reduced by about 30 per cent because of the new coil support plate. Calculations for the impeller speed lower than 103 rpm in the SME showed similar erosion patterns but significantly reduced wall shear stresses and reduced overall erosion. Comparisons of the 103 rpm results with SME measurements indicated that no significant erosion of the tank floor in the SME is to be expected. Thus, it is recommended that the agitator speed of SME does not exceed 103 rpm.

  5. SULFATE SOLUBILITY LIMIT VERIFICATION FOR DWPF SLUDGE BATCH 7B

    SciTech Connect

    Fox, K.

    2011-10-03

    the targeted values. The results for the SB7b glasses fabricated with Frit 418 showed an apparent trend of increasing sulfate retention with increasing Na{sub 2}O additions to the 5/25/11 sludge projection. This trend appears contradictory to other recent studies of sulfate retention in Defense Waste Processing Facility (DWPF) type glasses. Additional apparent contradictions to this trend were found in the data collected in the present study. Overall, the results for the SB7b sulfate study glasses with Frit 418 and the 5/25/11 projection with Na{sub 2}O additions showed that subtle changes in this complex glass composition impacted the degree of sulfate retention. These results do however provide confidence that a 0.6 wt % sulfate limit in glass is warranted for Frit 418 with the SB7b compositions evaluated in this study. The results for the SB7b glasses fabricated with Frit 702 are consistent with those of the previous SB7a study in that Frit 702 allowed for higher sulfate retention as compared to Frit 418 for the same sludge compositions. It is recommended that the DWPF implement a sulfate concentration limit of 0.6 wt % in glass for SB7b processing with Frit 418. If a higher than projected sulfate concentration is measured when SB7b processing begins (i.e., if a sulfate concentration higher than 0.6 wt % becomes necessary to achieve targeted waste loadings), DWPF should consider a transition to Frit 702. The sulfate limit could likely be raised to 0.8 wt % by transitioning to this frit. However, if DWPF considers transitioning from Frit 418 to Frit 702, additional glasses should be fabricated to confirm this higher limit due to the issues with incorrect B{sub 2}O{sub 3} concentrations for some of the glasses made with Frit 702 in this study. There are several factors other than sulfate retention that must also be carefully considered prior to changing frit compositions.

  6. Effect of Bubbles and Silica Dissolution on Melter Feed Rheology during Conversion to Glass

    SciTech Connect

    Marcial, Jose; Chun, Jaehun; Hrma, Pavel R.; Schweiger, Michael J.

    2014-10-21

    As the nuclear waste glass melter feed is converted to molten glass, the feed becomes a continuous glass-forming melt where dissolving refractory constituents are suspended together with numerous gas bubbles. Knowledge of mechanical properties of the reacting melter feed is crucial for understanding the feed-to-glass conversion as it occurs during melting. We studied the melter feed viscosity during heating and correlated it with volume fractions of dissolving quartz particles and gas phase. The measurements were performed with a rotating spindle rheometer on the melter feed heated at 5 K/min, starting at several different temperatures. The effects of undissolved quartz particles, gas bubbles, and compositional inhomogeneity on the melter feed viscosity were determined by fitting a linear relationship between log viscosity and volume fractions of suspended phases.

  7. Calculation of DWPF Canister Decay Heat for Sludge Macro-Batches 1B to 9

    SciTech Connect

    Choi, A. S.

    1999-04-27

    The rates of heat generation of DWPF glass canisters due to radioactive decay have been estimated for the remaining nine macro-batches of sludge feed. The estimated decay heat ranged from 177.5 Watts for each Macro-batch 1B canister to 498.4 Watts for each Macro-batch 8 canister. These projections are based on the HLW radionuclide inventory data available as of 4/1/98, and do not reflect further decay since then. It was assumed that each DWPF glass canister would also contain a nominal quantity of salt waste based on the reference coupled feed flowsheet. Issue of this report successfully closes a recent technical assistance request (HLW/DWPF-TAR-990003).

  8. Erosion Modeling Analysis For DWPF MFT/SME Tanks

    SciTech Connect

    LEE, SI

    2004-05-03

    This report presents the application of computational fluid dynamics (CFD) methods to qualitative estimate of the erosion phenomena expected in the actual Slurry Mixer Evaporator (SME) and MFT (Melter Feed Tank) process facilities by calculating erosion drivers. Using the transport equations governing the slurry flow, two erosion mechanisms were considered to evaluate high erosion sites and to investigate the primary cause of erosion damage for the modeling domain representative of the actual mixing process in the SME/MFT vessels. One of the two erosion mechanisms is the abrasive erosion which is worn by high wall shear of viscous liquid or by continuous contact or low-angle collision of the moving solids with rough surface, and the other is the chip-off erosion which is mainly governed by high-angle impingement of particles. Ductile wall material such as stainless steel is damaged by wall mechanism when particles are impinged on the ductile surface of the present coil guide geometry with wide-open space and no closed- and curved-flow path. The previous results show that the primary locations of high erosion due to particle impingement are at the occurrence of sudden change of flow direction, sudden contraction, and flow obstruction.

  9. Material compatibility evaluation for DWPF nitric-glycolic acid-literature review

    SciTech Connect

    Mickalonis, J.; Skidmore, E.

    2013-06-01

    Glycolic acid is being evaluated as an alternative for formic and nitric acid in the DWPF flowsheet. Demonstration testing and modeling for this new flowsheet has shown that glycolic acid and glycolate has a potential to remain in certain streams generated during the production of the nuclear waste glass. A literature review was conducted to assess the impact of glycolic acid on the corrosion of the materials of construction for the DWPF facility as well as facilities downstream which may have residual glycolic acid and glycolates present. The literature data was limited to solutions containing principally glycolic acid.

  10. Modeling an RF Cold Crucible Induction Heated Melter with Subsidence

    SciTech Connect

    Grant L. Hawkes

    2004-07-01

    A method to reduce radioactive waste volume that includes melting glass in a cold crucible radio frequency induction heated melter has been investigated numerically. The purpose of the study is to correlate the numerical investigation with an experimental apparatus that in the above mentioned melter. Unique to this model is the subsidence of the glass as it changes from a powder to molten glass and drastically changes density. A model has been created that couples the magnetic vector potential (real and imaginary) to a transient startup of the melter process. This magnetic field is coupled to the mass, momentum, and energy equations that vary with time and position as the melt grows. The coupling occurs with the electrical conductivity of the glass as it rises above the melt temperature of the glass and heat is generated. Natural convection within the molten glass helps determine the shape of the melt as it progresses in time. An electromagnetic force is also implemented that is dependent on the electrical properties and frequency of the coil. This study shows the progression of the melt shape with time along with temperatures, power input, velocities and magnetic vector potential. Coupled to all of this is a generator that will be used for this lab sized experiment. The coupling with the 60 kW generator occurs with the impedance of the melt as it progresses and changes with time. A power controller has been implemented that controls the primary coil current depending on the power that is induced into the molten glass region.

  11. Integrated Pilot Plant for a Large Cold Crucible Induction Melter

    SciTech Connect

    Do Quang, R.; Jensen, A.; Prod'homme, A.; Fatoux, R.; Lacombe, J.

    2002-02-26

    COGEMA has been vitrifying high-level liquid waste produced during nuclear fuel reprocessing on an industrial scale for over 20 years, with two main objectives: containment of the long lived fission products and reduction of the final volume of waste. Research performed by the French Atomic Energy Commission (CEA) in the 1950s led to the selection of borosilicate glass as the most suitable containment matrix for waste from spent nuclear fuel and to the development of the induction melter technology. This was followed by the commissioning of the Marcoule Vitrification Facility (AVM) in 1978. The process was implemented at a larger scale in the late 1980s in the R7 and T7 facilities of the La Hague reprocessing plant. COGEMA facilities have produced more than 11,000 high level glass canisters, representing more than 4,500 metric tons of glass and 4.5 billion curies. To further improve the performance of the vitrification lines in the R7 and T7 facilities, the CEA and COGEMA have been developing the Cold Crucible Melter (CCM) technology since the 1980s. This technology benefits from the 20 years of COGEMA HLW vitrification experience and ensures a virtually unlimited equipment service life and extensive flexibility in dealing with different types of waste. The high specific power directly transferred by induction to the melt allows high operating temperatures without any impact on the process equipment. In addition, the mechanical stirring of the melter significantly reduces operating constraints. COGEMA is already providing the CCM technology to international customers for nuclear and non-nuclear applications and plans to implement it in the La Hague vitrification plant for the vitrification of highly concentrated and corrosive solutions produced by uranium/molybdenum fuel reprocessing. The paper presents the CCM project that led to the building and start-up of this evolutionary and flexible pilot plant. It also describes the plant's technical characteristics and

  12. Technical Exchange on Improved Design and Performance of High Level Waste Melters - Final Report

    SciTech Connect

    SK Sundaram; ML Elliott; D Bickford

    1999-11-19

    SIA Radon is responsible for management of low- and intermediate-level radioactive waste (LILW) produced in Central Russia. In cooperation with Minatom organizations Radon carries out R and D programs on treatment of simulated high level waste (HLW) as well. Radon scientists deal with a study of materials for LILW, HLW, and Nuclear Power Plants (NPP) wastes immobilization, and development and testing of processes and technologies for waste treatment and disposal. Radon is mostly experienced in LILW vitrification. This experience can be carried over to HLW vitrification especially in field of melting systems. The melter chosen as a basic unit for the vitrification plant is a cold crucible. Later on Radon experience in LILW vitrification as well as our results on simulated HLW vitrification are briefly described.

  13. Resistance heater for use in a glass melter

    DOEpatents

    Routt, K.R.; Porter, M.A.

    1984-01-01

    A resistance heating element that includes: a resistance heating medium of a mixture of electrically conductive and insulative particles in powdered form mixed together in predetermined proportions to achieve a given resistivity; a hollow outer electrode surrounding the resistance heating medium; and an inner electrode coaxially disposed within said outer electrode. In its preferred embodiments, the electrically conductive powder is selected from the group consisting essentially of graphite, Inconel alloy, molybdenum, nichrome alloy and stainless steel, while the insulator powder is silicon dioxide or alumina. The resistance heating element, being resistant to damage from mechanical shock and corrosion at elevated temperatures, is used in a glass melter.

  14. PHYSICAL CHARACTERIZATION OF VITREOUS STATE LABORATORY AY102/C106 AND AZ102 HIGH LEVEL WASTE MELTER FEED SIMULANTS (U)

    SciTech Connect

    Hansen, E

    2005-03-31

    The objective of this task is to characterize and report specified physical properties and pH of simulant high level waste (HLW) melter feeds (MF) processed through the scaled melters at Vitreous State Laboratories (VSL). The HLW MF simulants characterized are VSL AZ102 straight hydroxide melter feed, VSL AZ102 straight hydroxide rheology adjusted melter feed, VSL AY102/C106 straight hydroxide melter feed, VSL AY102/C106 straight hydroxide rheology adjusted melter feed, and Savannah River National Laboratory (SRNL) AY102/C106 precipitated hydroxide processed sludge blended with glass former chemicals at VSL to make melter feed. The physical properties and pH were characterized using the methods stated in the Waste Treatment Plant (WTP) characterization procedure (Ref. 7).

  15. Laboratory optimization tests of technetium decontamination of Hanford Waste Treatment Plant low activity waste melter off-gas condensate simulant

    SciTech Connect

    Taylor-Pashow, Kathryn M.L.; McCabe, Daniel J.

    2015-11-01

    The Hanford Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) vitrification facility will generate an aqueous condensate recycle stream (LAW Off-Gas Condensate) from the off-gas system. The baseline plan for disposition of this stream is to send it to the WTP Pretreatment Facility, where it will be blended with LAW, concentrated by evaporation and recycled to the LAW vitrification facility again. Alternate disposition of this stream would eliminate recycling of problematic components, and would enable simplified operation of the LAW melter and the Pretreatment Facilities. Eliminating this stream from recycling within WTP would also decrease the LAW vitrification mission duration and quantity of glass waste.

  16. Compilation of information on modeling of inductively heated cold crucible melters

    SciTech Connect

    Lessor, D.L.

    1996-03-01

    The objective of this communication, Phase B of a two-part report, is to present information on modeling capabilities for inductively heated cold crucible melters, a concept applicable to waste immobilization. Inductively heated melters are those in which heat is generated using coils around, rather than electrodes within, the material to be heated. Cold crucible or skull melters are those in which the melted material is confined within unmelted material of the same composition. This phase of the report complements and supplements Phase A by Loren Eyler, specifically by giving additional information on modeling capabilities for the inductively heated melter concept. Eyler discussed electrically heated melter modeling capabilities, emphasizing heating by electrodes within the melt or on crucible walls. Eyler also discussed requirements and resources for the computational fluid dynamics, heat flow, radiation effects, and boundary conditions in melter modeling; the reader is referred to Eyler`s discussion of these. This report is intended for use in the High Level Waste (HLW) melter program at Hanford. We sought any modeling capabilities useful to the HLW program, whether through contracted research, code license for operation by Department of Energy laboratories, or existing codes and modeling expertise within DOE.

  17. IMPACTS OF SMALL COLUMN ION EXCHANGE STREAMS ON DWPF GLASS FORMULATION: KT08, KT09, AND KT10-SERIES GLASS COMPOSITIONS

    SciTech Connect

    Fox, K.; Edwards, T.

    2011-04-26

    well predicted by the DWPF model. No unexpected issues were encountered when uranium and thorium were added to the glasses with SCIX components. Increased Al{sub 2}O{sub 3} concentrations were not successful in preventing the formation of iron titanate crystals in the KT09-series glasses. Increased K{sub 2}O concentrations were successful in hindering the formation of iron titanates in some of the glasses after the canister centerline cooled (CCC) heat treatment. However, this result did not apply to all of the CCC versions of the glasses, indicating a compositional dependence of this effect. In addition, high concentrations of K{sub 2}O have been shown to hinder the ability of the DWPF durability and viscosity models to predict the performance of these glasses. The usefulness of increased K{sub 2}O concentrations in preventing the formation of iron titanates may therefore be limited. Further characterization was not performed for the KT09-series glasses since the type of crystallization formed was the characteristic of interest for these compositions. All of the KT10-series glasses were XRD amorphous, regardless of heat treatment. Chemical composition measurements showed that the glasses met the targeted concentrations for each oxide. In general, the measured PCT responses of the KT10-series glasses were well predicted by the DWPF models. The measured, normalized release values for silicon for some of the glasses fell above the 95% confidence interval for the predicted values; however, the PCT responses for these glasses remain considerably lower than that of the benchmark Environmental Assessment (EA) glass. The viscosities of the KT10-series glasses were generally well predicted by the DWPF model. The next step in this study will be to compile all of the data developed and further compare the measured properties and performance with those predicted by the current DWPF Product Composition Control System (PCCS) models. Recommendations will then be made as to which

  18. Self-cleaning feed distributing delivery device for glass melters

    SciTech Connect

    Mensink, D.L.

    1991-01-16

    This invention consists of a self cleaning, plug resistant, adjustable parameter feed distributing and delivery apparatus for a glass melter comprising a housing with a passage therethrough for a glass slurry, a cold finger within the passage for creating a dispersion patten of the slurry, a movable slotted tube for controlling the confluence of air propellant and slurry in the passage, and a plurality of ribs that extend through the slots in the slotted tube to urge the slurry forward if it becomes stuck or resists forward movement. Coolant passages in the housing and the cold finger maintain the slurry temperature below that of the melter plenum. The cold finger is axially movable to adjust the dispersion patten to the desired consistency. Other design features of size can be applied for use in situations requiring different parameters of patten, particle size, rate, feed consistencies. The device utilizes air as both a propellant and a surface cleansing mechanism. Other fluids may be used as propellants where process compatibility requires.

  19. Self-cleaning feed distributing delivery device for glass melters

    DOEpatents

    Mensink, Daniel L.

    1992-01-01

    A self cleaning, plug resistant, adjustable parameter feed distributing and delivery apparatus for a glass melter comprising a housing with a passage therethrough for a glass slurry, a cold finger within the passage for creating a dispersion pattern of the slurry, a movable slotted tube for controlling the confluence of air propellant and slurry in the passage, and a plurality of ribs that extend through the slots in the slotted tube to urge the slurry forward if it becomes stuck or resists forward movement. Coolant passages in the housing and the cold finger maintain the slurry temperature below that of the melter plenum. The cold finger is axially movable to adjust the dispersion pattern to the desired consistency. Other design features of size can be applied for use in situations requiring different parameters of pattern, particle size, rate, and feed consistencies. The device utilizes air as both a propellant and a surface cleansing mechanism. Other fluids may be used as propellants where process compatibility requires.

  20. HWVP NCAW melter feed rheology FY 1993 testing and analyses: Letter report

    SciTech Connect

    Smith, P.A.

    1996-03-01

    The Hanford Waste Vitrification Plant (HWVP) program has been established to immobilize selected Hanford nuclear wastes before shipment to a geologic repository. The HWVP program is directed by the U.S. Department of Energy (DOE). The Pacific Northwest Laboratory (PNL) provides waste processing and vitrification technology to assist the design effort. The focus of this letter report is melter feed rheology, Process/Product Development, which is part of the Task in the PNL HWVP Technology Development (PHTD) Project. Specifically, the melter feed must be transported to the liquid fed ceramic melter (LFCM) to ensure HWVP operability and the manufacture of an immobilized waste form. The objective of the PHTD Project slurry flow technology development is to understand and correlate dilute and concentrated waste, formatted waste, waste with recycle addition, and melter feed transport properties. The objectives of the work described in this document were to examine frit effects and several processing conditions on melter feed rheology. The investigated conditions included boiling time, pH, noble metal containing melter feed, solids loading, and aging time. The results of these experiments contribute to the understanding of melter feed rheology. This document is organized in eight sections. This section provides the introductory remarks, followed by Section 2.0 that contains conclusions and recommendations. Section 3.0 reviews the scientific principles, and Section 4.0 details the experimental methods. The results and discussion and the review of related rheology data are in Sections 5.0 and 6.0, respectively. Section 7.0, an analysis of NCAW melter feed rheology data, provides an overall review of melter feed with FY 91 frit. References are included in Section 8.0. This letter report satisfies contractor milestone PHTD C93-03.02E, as described in the FY 1993 Pacific Northwest Hanford Laboratory Waste Plant Technology Development (PHTD) Project Work Plan.

  1. Chronic toxicity evaluation of simulated DWPF effluent to Ceriodaphnia dubia. Revision 1

    SciTech Connect

    Not Available

    1990-04-01

    A 7-Day Full Series Chronic Toxicity test was conducted April 13--20, 1990, for the Savannah River Site to assess the chronic toxicity of Simulated defense waste processing facility (DWPF) effluent to Ceriodaphnia dubia. The simulated effluented consisted of Sodium Nitrate, Sodium Oxalate, Sodium Formate, and Corros. Inib.

  2. Melt Rate Improvement for DWPF MB3: Foaming Theory and Mitigation Techniques

    SciTech Connect

    Peeler, D.K.

    2001-07-24

    The objective of this research is to enhance the basic understanding of the role of glass chemistry, including the chemical kinetics of pre-melting, solid state reactions, batch melting, and the reaction pathways in glass and/or acid addition strategy changes on the overall melting process for the Defense Waste Processing Facility (DWPF) Macrobatch 3 (MB3).

  3. Tests of Cs-137 removal from DWPF samples prior to analysis

    SciTech Connect

    Dewberry, R.A.; Coleman, C.J.

    1994-11-10

    The Defense Waste Processing Facility (DWPF) will be used to encapsulate high-level radioactive waste into borosilicate glass at the Savannah River Site. To ensure that the process streams will be blended in the right proportions to produce durable glass, process control analyses will be performed in a laboratory in the DWPF. The high radioactivity of DWPF samples will require that sample preparation, including dissolution and dilution of samples, be performed in shielded cells. However the final analyses will be made with instruments and spectrometers contained in unshielded fume hoods. The primary radiation concern is the exposure to y-rays from the decay of Cs-137 after samples are removed from the shielded cells. Since there are several methods available for removing Cs-137 from samples, investigations were made into removing Cs-137 from DWPF samples prior to analysis in order to reduce worker exposure. Results are presented of the efficiency of various Cs-137 removal techniques and the effects of these techniques on analytical precision and accuracy.

  4. Vectra GSI, Inc. low-level waste melter testing Phase 1 test report

    SciTech Connect

    Stegen, G.E.; Wilson, C.N.

    1996-02-21

    A multiphase program was initiated in 1994 to test commercially available melter technologies for the vitrification of the low-level waste (LLW) stream from defense wastes stored in underground tanks at the Hanford Site in southeastern Washington State. Vectra GSI, Inc. was one of seven vendors selected for Phase 1 of the melter demonstration tests using simulated LLW that were completed during fiscal year 1995. The attached report prepared by Vectra GSI, Inc. describes results of melter testing using slurry feed and dried feeds. Results of feed drying and prereaction tests using a fluid bed calciner and rotary dryer also are described.

  5. An evaluation of foaming potential in the IDMS melter

    SciTech Connect

    Hutson, N.D.

    1992-10-22

    The present DWPF flowsheet calls for the chemical treatment of waste sludge with 90 wt% formic acid prior to the addition of the Precipitate Hydrolysis Aqueous (PHA) product. An alternative processing methodology, denoted the ``Nitric Acid Flowsheet``, has been proposed. In the application of this flowsheet, nitric acid would be used to neutralize sludge base components (hydroxides and carbonates) prior to the addition of late wash PHA. The late wash PHA will contain sufficient quantities of formic acid to adequately complete necessary reduction-oxidation (REDOX) reactions. The use of this flowsheet may result in a change in the nominal concentrations of two of the major REDOX reaction participants: formate (HCOO{sup minus}) and nitrate (NO{sub 3}{sup minus}).

  6. Incorporating Cold Cap Behavior in a Joule-heated Waste Glass Melter Model

    SciTech Connect

    Varija Agarwal; Donna Post Guillen

    2013-08-01

    In this paper, an overview of Joule-heated waste glass melters used in the vitrification of high level waste (HLW) is presented, with a focus on the cold cap region. This region, in which feed-to-glass conversion reactions occur, is critical in determining the melting properties of any given glass melter. An existing 1D computer model of the cold cap, implemented in MATLAB, is described in detail. This model is a standalone model that calculates cold cap properties based on boundary conditions at the top and bottom of the cold cap. Efforts to couple this cold cap model with a 3D STAR-CCM+ model of a Joule-heated melter are then described. The coupling is being implemented in ModelCenter, a software integration tool. The ultimate goal of this model is to guide the specification of melter parameters that optimize glass quality and production rate.

  7. Preliminary evaluation of PSCM and BIPP melter design and operating conditions using physical modeling

    SciTech Connect

    Skarda, R.J.; Hauser, S.G.; Fort, J.A.

    1985-05-01

    The Glass Melter Physical Modeling investigation was initiated to support Pacific Northwest Laboratory (PNL) Hanford Waste Vitrification Program. Specifically, results discussed herein are those of the modeled B-Plant Immobilization Pilot Plant (BIPP) and Pilot Scale Ceramic Melter (PSCM) designs. The purpose of this study was to evaluate various melter design features using laboratory scale models. Hydrodynamic, thermal, and electrical similarity between the modeling fluid and the molten glass were primary objectives. Stroboscopic velocity measurements (flow visualization), temperature measurements, and electrical potential measurements were used to investigate the molten glass behavior. Results from this effort are to provide input to melter design and proposed operation in addition to providing a data base for verifying numerical models. 13 refs., 48 figs., 24 tabs.

  8. Evaluation of Sludge Batch 5 Qualification with ISDP Salt Batch 1 Compliance to DWPF Waste Acceptance Criteria

    SciTech Connect

    Shafer, A.

    2010-05-05

    The purpose of this report is to document the acceptability of Sludge Batch 5 with the initial macrobatch operation of the Interim Salt Disposition Project (ISDP) waste to the Defense Waste Processing Facility (DWPF). This report was prepared to comply with the requirements listed in the Waste Acceptance Criteria for Sludge, Actinide Removal Process (ARP), and Modular Caustic Side Solvent Extraction Unit (MCU) Process Transfers to 512-S and DWPF. The requirements for transfers to 512-S were evaluated during ISDP Salt Batch 1 qualification. The calculations of sludge concentrations are based entirely on the Tank 51 sample processed at SRNL. This is conservative because Tank 51 is blended with the dilute feed in the DWPF Feed Tank (Tank 40). This report documents the acceptability of sludge only as well as Sludge Batch 5 sludge slurry combined with ARP/MCU products for feed to DWPF. All criteria were met for unblended Tank 51 material.

  9. Effect of Melter-Feed-Makeup on Vitrification Process

    SciTech Connect

    Hrma, Pavel R.; Kruger, Albert A.; Schweiger, M. J.; Humrickhouse, Carissa J.; Moody, Adam; Tate, Rachel M.; Tegrotenhuis, Nathan E.; Arrigoni, Benjamin M.; Rodriguez, Carmen

    2009-09-02

    Increasing the rate of glass processing in the Hanford Tank Waste Treatment and Immobilization Plant (WTP) will allow shortening the life cycle of waste cleanup at the Hanford Site. While the WTP melters have approached the limit of increasing the rate of melting by enhancing the heat transfer rate from molten glass to the cold cap, a substantial improvement can still be achieved by accelerating the feed-to-glass conversion kinetics. This study investigates how the feed-to-glass conversion process responds to the feed makeup. By identifying the means of control of primary foam formation and silica grain dissolution, it provides data needed for a meaningful and economical design of large-scale experiments aimed at achieving faster melting.

  10. EFFECT OF MELTER-FEED-MAKEUP ON VITRIFICATION PROCESS

    SciTech Connect

    KRUGER AA; HRMA PR; SCHWEIGER MJ; HUMRICKHOUSE CJ; MOODY JA; TATE RM; TEGROTENHUIS NE; ARRIGONI BM; RODRIGUEZ CP

    2009-09-10

    Increasing the rate of glass processing in the Hanford Tank Waste Treatment and Immobilization Plant (WTP) will allow shortening the life cycle of waste cleanup at the Hanford Site. While the WTP melters have approached the limit of increasing the rate of melting by enhancing the heat transfer rate from molten glass to the cold cap, a substantial improvement can still be achieved by accelerating the feed-to-glass conversion kinetics. This study investigates how the feed-to-glass conversion process responds to the feed makeup. By identifying the means of control of primary foam formation and silica grain dissolution, it provides data needed for a meaningful and economical design of large-scale experiments aimed at achieving faster melting.

  11. Settling of Spinel in a High-Level Waste Glass Melter

    SciTech Connect

    Hrma, Pavel R.; Schill, Pert; Nemec, Lubomir

    2002-01-18

    High-level nuclear waste is being vitrified, i.e., converted to a durable glass that can be stored in a safe repository for hundreds of thousands of years. Waste vitrification is accomplished in reactors called melters to which the waste is charged together with glass-forming additives. The mixture is electrically heated to a temperature as high as 1150?C (or even higher in advanced melters) to create a melt that becomes glass on cooling. This process is slow and expensive. Moreover, the melters that are currently in use or are going to be used in the U.S. are sensitive to clogging and thus cannot process melt in which solid particles are suspended. These particles settle and gradually accumulate on the melter bottom. Such particles, most often small crystals of spinel (a mineral containing iron, nickel, chromium, and other minor oxides), inevitably occur in the melt when the content of the waste in the glass (called waste loading) increases above a certain limit. To avoid the presence of solid particles in the melter, the waste loading is kept rather low, in average 15% lower than in glass formulated for more robust melters.

  12. Settling of Spinel in A High-Level Waste Glass Melter

    SciTech Connect

    Pavel Hrma; Pert Schill; Lubomir Nemec

    2002-01-07

    High-level nuclear waste is being vitrified, i.e., converted to a durable glass that can be stored in a safe repository for hundreds of thousands of years. Waste vitrification is accomplished in reactors call melters to which the waste is charged together with glass-forming additives. The mixture is electrically heated to a temperature as high as 1150 degree C (or even higher in advanced melters) to create a melt that becomes glass on cooling. This process is slow and expensive. Moreover, the melters that are currently in use or are going to be used in the U.S. are sensitive to clogging and thus cannot process melt in which solid particles are suspended. These particles settle and gradually accumulate on the melter bottom. Such particles, most often small crystals of spinel ( a mineral containing iron, nickel, chromium, and other minor oxides), inevitably occurred in the melt when the content of the waste in the glass (called waste loading) increases above a certain limit. To avoid the presence of solid particles in the melter, the waste loading is kept rather low, in average 15% lower than in glass formulated for more robust melters.

  13. VERIFICATION OF THE DEFENSE WASTE PROCESSING FACILITY'S (DWPF) PROCESS DIGESTION METHOD FOR THE SLUDGE BATCH 7A QUALIFICATION SAMPLE

    SciTech Connect

    Click, D.; Edwards, T.; Jones, M.; Wiedenman, B.

    2011-03-14

    For each sludge batch that is processed in the Defense Waste Processing Facility (DWPF), the Savannah River National Laboratory (SRNL) performs confirmation of the applicability of the digestion method to be used by the DWPF lab for elemental analysis of Sludge Receipt and Adjustment Tank (SRAT) receipt samples and SRAT product process control samples. DWPF SRAT samples are typically dissolved using a room temperature HF-HNO{sub 3} acid dissolution (i.e., DWPF Cold Chem Method, see DWPF Procedure SW4-15.201) and then analyzed by inductively coupled plasma - atomic emission spectroscopy (ICP-AES). This report contains the results and comparison of data generated from performing the Aqua Regia (AR), Sodium peroxide/Hydroxide Fusion (PF) and DWPF Cold Chem (CC) method digestions of Sludge Batch 7a (SB7a) SRAT Receipt and SB7a SRAT Product samples. The SB7a SRAT Receipt and SB7a SRAT Product samples were prepared in the SRNL Shielded Cells, and the SRAT Receipt material is representative of the sludge that constituates the SB7a Batch or qualification composition. This is the sludge in Tank 51 that is to be transferred into Tank 40, which will contain the heel of Sludge Batch 6 (SB6), to form the Sb7a Blend composition.

  14. Hanford Waste Vitrification Program process development: Melt testing subtask, pilot-scale ceramic melter experiment, run summary

    SciTech Connect

    Nakaoka, R.K.; Bates, S.O.; Elmore, M.R.; Goles, R.W.; Perez, J.M.; Scott, P.A.; Westsik, J.H.

    1996-03-01

    Hanford Waste Vitrification Program (HWVP) activities for FY 1985 have included engineering and pilot-scale melter experiments HWVP-11/HBCM-85-1 and HWVP-12/PSCM-22. Major objectives designated by HWVP fo these tests were to evaluate the processing characteristics of the current HWVP melter feed during actual melter operation and establish the product quality of HW-39 borosilicate glass. The current melter feed, defined during FY 85, consists of reference feed (HWVP-RF) and glass-forming chemicals added as frit.

  15. U.S. Bureau of Mines, Phase 1 Hanford low-level waste melter tests. Final report

    SciTech Connect

    Eaton, W.C.; Oden, L.L.; O`Connor, W.K.

    1995-11-01

    A multiphase program was initiated in 1994 to test commercially available melter technologies for the vitrification of the low-level waste (LLW) stream from defense wastes stored in underground tanks at the Hanford Site in southeastern Washington State. Phase 1 of the melter demonstration tests using simulated LLW was completed during fiscal year 1995. This document is the melter offgas report on testing performed by the U.S. Department of the Interior, Bureau of Mines, Albany Research Center in Albany, Oregon. The Bureau of Mines (one of the seven vendors selected) was chosen to demonstrate carbon electrode melter technology (also called carbon arc or electric arc) under WHC Subcontract number MMI-SVV-384216. The report contains description of the tests, observation, test data and some analysis of the data as it pertains to application of this technology for LLW vitrification. Testing consisted of melter feed preparation and three melter tests, the first of which was to fulfill the requirements of the statement of work (WHC-SD-EM-RD-044), and the second and third were to address issues identified during the first test. The document also contains summaries of the melter offgas report issued as a separate document U.S. Bureau of Mines, Phase 1 Hanford Low-Level Waste Melter Tests: Melter Offgas Report (WHC-SD-WM-VI-032).

  16. Vitrification of high-level radioactive waste in a pilot-scale liquid-fed ceramic melter

    SciTech Connect

    Bjorklund, W.J.; Holton, L.K.; Knowlton, D.E.

    1985-03-01

    Under the sponsorship of the Nuclear Waste Treatment Program (NWTP), a high-level radioactive waste vitrification system has been installed in a Radiochemical Engineering Facility at Hanford, Washington. The facility is designed for remote operation of equipment using master-slave manipulators and overhead cranes. The pilot-scale radioactive system consists of a melter, canister handling turntable, glass-level detection system and supporting waste preparation, offgas treatment and condensate treatment systems. The vitrification system will be operated with radioactive wastes to test remote equipment features and process performance. Destructive and nondestructive methods will be used in the characterization of the waste glass product after canisters are filled with specific waste compositions. 4 refs., 9 figs.

  17. TECHNETIUM RETENTION IN WTP LAW GLASS WITH RECYCLE FLOW-SHEET DM10 MELTER TESTING VSL-12R2640-1 REV 0

    SciTech Connect

    Abramowitz, Howard; Brandys, Marek; Cecil, Richard; D'Angelo, Nicholas; Matlack, Keith S.; Muller, Isabelle S.; Pegg, Ian L.; Callow, Richard A.; Joseph, Innocent

    2012-12-11

    Melter tests were conducted to determine the retention of technetium and other volatiles in glass while processing simulated Low Activity Waste (LAW) streams through a DM10 melter equipped with a prototypical off-gas system that concentrates and recycles fluid effiuents back to the melter feed. To support these tests, an existing DM10 system installed at Vitreous State Laboratory (VSL) was modified to add the required recycle loop. Based on the Hanford Tank Waste Treatment and Immobilization Plant (WTP) LAW off-gas system design, suitably scaled versions of the Submerged Bed Scrubber (SBS), Wet Electrostatic Precipitator (WESP), and TLP vacuum evaporator were designed, built, and installed into the DM10 system. Process modeling was used to support this design effort and to ensure that issues associated with the short half life of the {sup 99m}Tc radioisotope that was used in this work were properly addressed and that the system would be capable of meeting the test objectives. In particular, this required that the overall time constant for the system was sufficiently short that a reasonable approach to steady state could be achieved before the {sup 99m}Tc activity dropped below the analytical limits of detection. The conceptual design, detailed design, flow sheet development, process model development, Piping and Instrumentation Diagram (P&ID) development, control system design, software design and development, system fabrication, installation, procedure development, operator training, and Test Plan development for the new system were all conducted during this project. The new system was commissioned and subjected to a series of shake-down tests before embarking on the planned test program. Various system performance issues that arose during testing were addressed through a series of modifications in order to improve the performance and reliability of the system. The resulting system provided a robust and reliable platform to address the test objectives.

  18. Small-Scale High Temperature Melter-1 (SSHTM-1) Data Package. Appendix B

    SciTech Connect

    1996-03-01

    This appendix provides the data for Alternate HTM Flowsheet 2 (Glycolic Acid) melter feed preparation activities in both the laboratory- and small-scale testing. The first section provides an outline of this appendix. The melter feed preparation data are presented in the next two main sections, laboratory melter feed preparation data and small-scale melter feed preparation data. Section 3.0 provides the laboratory data which is discussed in the main body of the Small-Scale High Temperature-1 (SSHTM-1) Data Package, milestone C95-02.02Y. Section 3.1 gives the flowsheet in outline form as used in the laboratory-scale tests. This section also includes the ``Laboratory Melter Feed Preparation Activity Log`` which gives A chronological account of the test in terms of time, temperature, slurry pH, and specific observations about slurry appearance, acid addition rates, and samples taken. The ``Laboratory Melter Feed Preparation Activity Log`` provides a road map to the reader by which all the activity and data from the laboratory can be easily accessed. A summary of analytical data is presented next, section 3.2, which covers starting materials and progresses to the analysis of the melter feed. The next section, 3.3, characterizes the off-gas generation that occurs during the slurry processing. The following section, 3.4, provides the rheology data gathered including gram waste oxide loading information for the various slurries tested. The final section, 3.5, includes data from standard crucible redox testing. Section 4.0 provides the small-scale data in parallel form to section 3.0. Section 5.0 concludes with the references for this appendix.

  19. PROCESS CHANGES TO DWPF TO INCREASE THROUGHPUT AND INCORPORATE SALT STREAMS

    SciTech Connect

    Herman, C; David Peeler, D; Tommy Edwards, T; Michael Stone, M; Michael02 Smith, M

    2007-06-13

    The Defense Waste Processing Facility (DWPF) has been vitrifying High Level Waste sludge since 1996. Sludge batch 1a, 1b, 2, and 3 have been successfully stabilized. In the last several years, the Savannah River National Laboratory (SRNL) has worked with DWPF to implement process and compositional changes to improve throughput. These changes allowed significant increases in waste throughput for processing of sludge batch 3 and will be necessary to maintain reasonable throughput for Sludge Batch 4 (SB4). SB4 processing was initiated in June 2007 and will be the first significantly HM-type sludge batch processed. This sludge is high in aluminum and other components troublesome to DWPF processing. In addition, coupled processing is scheduled to start in the next fiscal year, which will also impact throughput. Coupled processing will begin with the incorporation of waste streams from the Actinide Removal Process and the Modular Caustic Side Solvent Extraction Unit and will eventually transition to the feed from the larger scale Salt Waste Processing Facility. A discussion of the programs to improve throughput and implement salt processing will be provided.

  20. Review of Catalytic Hydrogen Generation in the DWPF Chemical Processing Cell, Part II

    SciTech Connect

    Koopman, David C.; Lambert, Daniel P.; Baich, Mark A.

    2005-08-01

    The Savannah River National Laboratory is in the process of investigating factors suspected of impacting catalytic hydrogen generation in the Defense Waste Processing Facility, DWPF, Chemical Process Cell, CPC. Noble metal catalyzed hydrogen generation in simulation work constrains the allowable acid addition operating window in DWPF. This constraint potentially impacts washing strategies during sludge batch preparation. It can also influence decisions related to the addition of secondary waste streams to a sludge batch. Catalytic hydrogen generation data from 2002-2005 were reviewed. The data came from process simulations of the DWPF Sludge Receipt and Adjustment Tank, SRAT, and Slurry Mix Evaporator, SME. Most of the data was from the development work for the Sludge Batch 3 process flowsheet. This included simulant and radioactive waste testing. Preliminary Sludge Batch 4 data were also reviewed. A statistical analysis of SB3 simulant hydrogen generation data was performed. One factor considered in the statistical analysis was excess acid. Excess acid was determined experimentally as the acid added beyond that required to achieve satisfactory nitrite destruction.

  1. Statistical Review of Data from DWPF's Process Samples for Batches 19 Through 30

    SciTech Connect

    Edwards, T.B.

    1999-04-06

    The measurements derived from samples taken during the processing of batches 19 through 30 at the Defense Waste Processing Facility (DWPF) affords an opportunity for review and comparisons. This report has looked at some of the statistics from these data. Only the data reported by the DWPF lab (that is, the data provided by the lab as representative of the samples taken) are available for this analysis. In some cases, the sample results reported may be a subset of the sample results generated by the analytical procedures. A thorough assessment of the DWPF lab's analytical procedures would require the complete set of data. Thus, the statistics reported here, specifically, as they relate to analytical uncertainties, are limited to the reported data for these samples, A fell for the consistency of the incoming slurry is the estimation of the components of variation for the Sludge Receipt and Adjustment Tank (SRAT) receipts. In general, for all of the vessels, the data from batches after 21 show smaller batch-to-batch variation than the data from all the batches. The relative contributions of batch-to-batch versus residual, which includes analytical, are presented in these analyses.

  2. Assessment of water/glass interactions in waste glass melter operation

    SciTech Connect

    Postma, A.K.; Chapman, C.C.; Buelt, J.L.

    1980-04-01

    A study was made to assess the possibility of a vapor explosion in a liquid-fed glass melter and during off-standard conditions for other vitrification processes. The glass melter considered is one designed for the vitrification of high-level nuclear wastes and is comprised of a ceramic-lined cavity with electrodes for joule heating and processing equipment required to add feed and withdraw glass. Vapor explosions needed to be considered because experience in other industrial processes has shown that violent interactions can occur if a hot liquid is mixed with a cooler, vaporizable liquid. Available experimental evidence and theoretical analyses indicate that destructive glass/water interactions are low probability events, if they are possible at all. Under standard conditions, aspects of liquid-fed melter operation which work against explosive interactions include: (1) the aqueous feed is near its boiling point; (2) the feed contains high concentrations of suspended particles; (3) molten glass has high viscosity (greater than 20 poise); and (4) the glass solidifies before film boiling can collapse. While it was concluded that vapor explosions are not expected in a liquid-fed melter, available information does not allow them to be ruled out altogether. Several precautionary measures which are easily incorporated into melter operation procedures were identified and additional experiments were recommended.

  3. Effect of bubbles and silica dissolution on melter feed rheology during conversion to glass.

    PubMed

    Marcial, José; Chun, Jaehun; Hrma, Pavel; Schweiger, Michael

    2014-10-21

    Nuclear-waste melter feeds are slurry mixtures of wastes with glass-forming and glass-modifying additives (unless prefabricated frits are used), which are converted to molten glass in a continuous electrical glass-melting furnace. The feeds gradually become continuous glass-forming melts. Initially, the melts contain dissolving refractory feed constituents that are suspended together with numerous gas bubbles. Eventually, the bubbles escape, and the melts homogenize and equilibrate. Knowledge of various physicochemical properties of the reacting melter feed is crucial for understanding the feed-to-glass conversion that occurs during melting. We studied the melter feed viscosity during heating and correlated it with the volume fractions of dissolving quartz (SiO2) particles and the gas phase. The measurements were performed with a rotating spindle rheometer on the melter feed heated at 5 K/min, starting at several different temperatures. The effects of undissolved quartz particles, gas bubbles, and compositional inhomogeneity on the melter feed viscosity were determined by fitting a linear relationship between the logarithm of viscosity and the volume fractions of suspended phases. PMID:25229521

  4. Combustion space modelling of oxy-fuel fired glass melter

    SciTech Connect

    Richter, W. , Irvine, CA ); Kobayashi, Hisashi )

    1990-01-01

    A three-dimensional heat transfer code based on the zonal method was applied to evaluate the oxygen-fuel firing of a cross-fired regenerative glass melter. A furnace end section which includes the bridge wall and a pair of the regenerator ports was modelled in detail for a base air case and several oxy-fuel firing cases. The firing rates of two oxy-fuel burners that matched the heat flux distribution of the base air case were determined. The effects of the height and angle of the oxy-fuel burners on the temperature and heat flux distributions were predicted to evaluate the optimum burner placement of the oxy-fuel burners. The main conclusions of the simulation are that; (1) in spite of the small flame diameters, the high momentum low flame temperature oxy-fuel burners can create temperature and heat flux distributions equivalent to those of the base air case with a wide flame and (2) both lower burner elevation and angling of the oxy-fuel burners toward the glass surface tend to increase heat transfer to glass surface and reduce the peak refractory temperatures. 12 refs., 21 figs., 4 tabs.

  5. Safety assessment of the liquid-fed ceramic melter process

    SciTech Connect

    Buelt, J.L.; Partain, W.L.

    1980-08-01

    As part of its development program for the solidification of high-level nuclear waste, Pacific Northwest Laboratory assessed the safety issues for a complete liquid-fed ceramic melter (LFCM) process. The LFCM process, an adaption of commercial glass-making technology, is being developed to convert high-level liquid waste from the nuclear fuel cycle into glass. This safety assessment uncovered no unresolved or significant safety problems with the LFCM process. Although in this assessment the LFCM process was not directly compared with other solidification processes, the safety hazards of the LFCM process are comparable to those of other processes. The high processing temperatures of the glass in the LFCM pose no additional significant safety concerns, and the dispersible inventory of dried waste (calcine) is small. This safety assessment was based on the nuclear power waste flowsheet, since power waste is more radioactive than defense waste at the time of solidification, and all accident conditions for the power waste would have greater radiological consequences than those for defense waste. An exhaustive list of possible off-standard conditions and equipment failures was compiled. These accidents were then classified according to severity of consequence and type of accident. Radionuclide releases to the stack were calculated for each group of accidents using conservative assumptions regarding the retention and decontamination features of the process and facility. Two recommendations that should be considered by process designers are given in the safety assessment.

  6. Test plan for BWID Phase 2 electric arc melter vitrification tests

    SciTech Connect

    Soelberg, N.R.; Turner, P.C.; Oden, L.L.; Anderson, G.L.

    1994-10-01

    This test plan describes the Buried Waste Integrated Demonstration (BWID), Phase 2, electric arc melter, waste treatment evaluation tests to be performed at the US Bureau of Mines (USBM) Albany Research Center. The BWID Arc Melter Vitrification Project is being conducted to evaluate and demonstrate existing industrial arc melter technology for thermally treating mixed transuranic-contaminated wastes and soils. Phase 1 baseline tests, performed during fiscal year 1993 at the USBM, were conducted on waste feeds representing incinerated buried mixed wastes and soils. In Phase 2, surrogate feeds will be processed that represent actual as-retrieved buried wastes from the Idaho National Engineering Laboratory`s Subsurface Disposal Area at the Radioactive Waste Management Complex.

  7. Modeling principles applied to the simulation of a joule-heated glass melter

    SciTech Connect

    Routt, K.R.

    1980-05-01

    Three-dimensional conservation equations applicable to the operation of a joule-heated glass melter were rigorously examined and used to develop scaling relationships for modeling purposes. By rigorous application of the conservation equations governing transfer of mass, momentum, energy, and electrical charge in three-dimensional cylindrical coordinates, scaling relationships were derived between a glass melter and a physical model for the following independent and dependent variables: geometrical size (scale), velocity, temperature, pressure, mass input rate, energy input rate, voltage, electrode current, electrode current flux, total power, and electrical resistance. The scaling relationships were then applied to the design and construction of a physical model of the semiworks glass melter for the Defense Waste Processing Facility. The design and construction of such a model using glycerine plus LiCl as a model fluid in a one-half-scale Plexiglas tank is described.

  8. Volatilization and redox testing in a DC arc melter: FY-93 and FY-94

    SciTech Connect

    Grandy, J.D.; Sears, J.W.; Soelberg, N.R.; Reimann, G.A.; McIlwain, M.E.

    1996-07-01

    The purpose of these experiments was to study the dissolution, retention, volatilization, and trapping of transuranic radionuclide elements (TRUs), mixed fission and activation products, and high vapor pressure metals (HVPMS) during processing in a high temperature arc furnace. In all cases, surrogate elements (lanthanides) were used in place of radioactive ones. The experiments were conducted utilizing a small DC arc melter developed at the Idaho National Engineering Laboratory (INEL) Research Center (IRC). The small arc melter was originally developed in 1992 and has been used previously for waste form studies of iron enriched basalt (IEB) and IEB with zirconium and titanium additions (IEB4). Section 3 contains a description of the small arc melter and its operational capabilities are discussed in Chapter 4. The remainder of the document describes each testing program and then discusses results and findings.

  9. The Effect of Foaming and Silica Dissolution on Melter Feed Rheology during Conversion to Glass

    SciTech Connect

    Marcial, Jose; Chun, Jaehun; Hrma, Pavel R.; Schweiger, Michael J.

    2014-11-23

    As the nuclear waste glass melter feed is converted to molten glass, the feed eventually becomes a continuous glass-forming melt in which dissolving refractory constituents are suspended together with numerous gas bubbles. Knowledge of mechanical properties of the melter feed is crucial for understanding the feed-to-glass conversion as it occurs in the cold cap. We measured the viscosity during heating of the feed and correlated it with the independently determined volume fractions of dissolving quartz particles and the gas phase. The measurement was performed with a rotating spindle rheometer on the melter feed heated at 5 K/min starting at several different temperatures. The effect of quartz particles, gas bubbles, and compositional inhomogeneity on the glass-forming melt viscosity was determined by fitting a linear relationship between log viscosity and volume fractions of suspended phases to data.

  10. Small-Scale High Temperature Melter-1 (SSHTM-1) Data Package. Appendix A

    SciTech Connect

    Smith, G.L.

    1996-03-01

    This appendix provides the data for Alternate HTM Flowsheet 1 (No Reductant Addition, Nitric Acid) melter feed preparation activities in both the laboratory and small-scale testing. The first section provides an outline of this appendix. The melter feed preparation data are presented in the next two main sections, laboratory welter feed preparation data and small-scale melter feed preparation data. Section 3.0 provides the laboratory data which is discussed in the main body of the Small-Scale High Temperature-1 (SSHTM-1) Data Package, milestone C95-02.02Y. Section 3.1 gives the flowsheet in outline form as used in the laboratory-scale tests. This section also includes the ``Laboratory Melter Feed Preparation Activity Log`` which gives a chronological account of the test in terms of time, temperature, slurry pH, and specific observations about slurry appearance, acid addition rates, and samples taken. The ``Laboratory Melter Feed Preparation Activity Log`` provides a road map to the reader by which all the activity and data from the laboratory can be easily accessed. A summary of analytical data is presented next, section 3.2, which covers starting materials and progresses to the analysis of the melter feed. The next section, 3.3, characterizes the off-gas generation that occurs during the slurry processing. The following section, 3.4, provides the rheology data gathered including gram waste oxide loading information for the various slurries tested. The final section, 3.5. includes data from standard crucible redox testing. Section 4.0 provides the small-scale data tn parallel form to section 3.0. Section 5.0 concludes with the references for this appendix.

  11. THE RESULTS OF TESTING TO EVALUATE CRYSTAL FORMATION AND SETTLING IN THE COLD CRUCIBLE INDUCTION MELTER

    SciTech Connect

    Marra, J.

    2009-06-30

    The Cold Crucible Induction Melter (CCIM) technology offers the potential to increase waste loading for High Level Waste (HLW) glasses leading to significant improvements in waste throughput rates compared to the reference Joule Heated Melter (JHM). Prior to implementation of a CCIM in a production facility it is necessary to better understand processing constraints associated with the CCIM. The glass liquidus temperature requirement for processing in the CCIM is an open issue. Testing was conducted to evaluate crystal formation and crystal settling during processing in the CCIM to gain insight into the effects on processing. A high aluminum/high iron content glass composition with known crystal formation tendencies was selected for testing. A continuous melter test was conducted for approximately 51 hours. To evaluate crystal formation, glass samples were obtained from pours and from glass receipt canisters where the glass melt had varying residence time in the melter. Additionally, upon conclusion of the testing, glass samples from the bottom of the melter were obtained to assess the degree of crystal settling. Glass samples were characterized in an attempt to determine quantitative fractions of crystals in the glass matrix. Crystal identity and relative composition were determined using a combination of x-ray diffraction (XRD) and scanning electron microscopy coupled with energy dispersive spectroscopy (SEM/EDS). Select samples were also analyzed by digesting the glass and determining the composition using inductively coupled atomic emission spectroscopy (ICP-AES). There was evidence of crystal formation (primarily spinels) in the melt and during cooling of the collected glass. There was evidence of crystal settling in the melt over the duration of the melter campaign.

  12. Volatilization of heavy metals and radionuclides from soil heated in an induction ``cold`` crucible melter

    SciTech Connect

    Aloy, A.S.; Belov, V.Z.; Trofimenko, A.S.; Dmitriev, S.A.; Stefanovsky, S.V.; Gombert, D.; Knecht, D.A.

    1997-12-31

    The behavior of heavy metals and radionuclides during high-temperature treatment is very important for the design and operational capabilities of the off-gas treatment system, as well as for a better understanding of the nature and forms of the secondary waste. In Russia, a process for high-temperature melting in an induction heated cold crucible system is being studied for vitrification of Low Level Waste (LLW) flyash and SYNROC production with simulated high level waste (HLW). This work was done as part of a Department of Energy (DOE) funded research project for thermal treatment of mixed low level waste (LLW). Soil spiked with heavy metals (Cd, Pb) and radionuclides (Cs-137, U-239, Pu-239) was used as a waste surrogate. The soil was melted in an experimental lab-scale system that consisted of a high-frequency generator (1.76 MHz, 60 kW), a cold crucible melter (300 mm high and 90 mm in diameter), a shield box, and an off-gas system. The process temperature was 1,350--1,400 C. Graphite and silicon carbide were used as sacrificial conductive materials to start heating and initial melting of the soil batch. The off-gas system was designed in such a manner that after each experiment, it can be disconnected to collect and analyze all deposits to determine the mass balance. The off-gases were also sampled during an experiment to analyze for hydrogen, NO{sub x}, carbon dioxide, carbon monoxide and chlorine formation. This paper describes distribution and mass balance of metals and radionuclides in various parts of the off-gas system. The leach rate of the solidified blocks identified by the PCT method is also reported.

  13. Waste-Incidental-to-Reprocessing Evaluation for the West Valley Demonstration Project Vitrification Melter - 12167

    SciTech Connect

    McNeil, Jim; Kurasch, David; Sullivan, Dan; Crandall, Thomas

    2012-07-01

    The Department of Energy (DOE) has determined that the vitrification melter used in the West Valley Demonstration Project can be disposed of as low-level waste (LLW) after completion of a waste-incidental-to-reprocessing evaluation performed in accordance with the evaluation process of DOE Manual 435.1-1, Radioactive Waste Management Manual. The vitrification melter - which consists of a ceramic lined, electrically heated box structure - was operated for more than 5 years melting and fusing high-level waste (HLW) slurry and glass formers and pouring the molten glass into 275 stainless steel canisters. Prior to shutdown, the melter was decontaminated by processing low-activity decontamination flush solutions and by extracting molten glass from the melter cavity. Because it could not be completely emptied, residual radioactivity conservatively estimated at approximately 170 TBq (4,600 Ci) remained in the vitrification melter. To establish whether the melter was incidental to reprocessing, DOE prepared an evaluation to demonstrate that the vitrification melter: (1) had been processed to remove key radionuclides to the maximum extent technically and economically practical; (2) would be managed to meet safety requirements comparable to the performance objectives for LLW established by the Nuclear Regulatory Commission (NRC); and (3) would be managed by DOE in accordance with DOE's requirements for LLW after it had been incorporated in a solid physical form with radionuclide concentrations that do not exceed the NRC concentration limits for Class C LLW. DOE consulted with the NRC on the draft evaluation and gave other stakeholders an opportunity to submit comments before the determination was made. The NRC submitted a request for additional information in connection with staff review of the draft evaluation; DOE provided the additional information and made improvements to the evaluation, which was issued in January 2012. DOE considered the NRC Technical Evaluation Report

  14. Advanced waste form and Melter development for treatment of troublesome high-level wastes

    SciTech Connect

    Marra, James; Kim, Dong -Sang; Maio, Vincent

    2015-10-01

    A number of waste components in US defense high level radioactive wastes (HLW) have proven challenging for current Joule heated ceramic melter (JHCM) operations and have limited the ability to increase waste loadings beyond already realized levels. Many of these “troublesome" waste species cause crystallization in the glass melt that can negatively impact product quality or have a deleterious effect on melter processing. Recent efforts at US Department of Energy laboratories have focused on understanding crystallization behavior within HLW glass melts and investigating approaches to mitigate the impacts of crystallization so that increases in waste loading can be realized. Advanced glass formulations have been developed to highlight the unique benefits of next-generation melter technologies such as the Cold Crucible Induction Melter (CCIM). Crystal-tolerant HLW glasses have been investigated to allow sparingly soluble components such as chromium to crystallize in the melter but pass out of the melter before accumulating.The Hanford site AZ-101 tank waste composition represents a waste group that is waste loading limited primarily due to high concentrations of Fe2O3 (also with high Al2O3 concentrations). Systematic glass formulation development utilizing slightly higher process temperatures and higher tolerance to spinel crystals demonstrated that an increase in waste loading of more than 20% could be achieved for this waste composition, and by extension higher loadings for wastes in the same group. An extended duration CCIM melter test was conducted on an AZ-101 waste simulant using the CCIM platform at the Idaho National Laboratory (INL). The melter was continually operated for approximately 80 hours demonstrating that the AZ-101 high waste loading glass composition could be readily processed using the CCIM technology. The resulting glass was close to the targeted composition and exhibited excellent durability in both

  15. Evaluation of a Novel Temperature Sensing Probe for Monitoring and Controlling Glass Temperature in a Joule-Heated Glass Melter

    SciTech Connect

    A. D. Watkins; C. A. Musick; C. Cannon; N. M. Carlson; P. D. Mullenix; R. D. Tillotson

    1999-04-29

    A self-verifying temperature sensor that employs advanced contact thermocouple probe technology was tested in a laboratory-scale, joule-heated, refractory-lined glass melter used for radioactive waste vitrification. The novel temperature probe monitors melt temperature at any given level of the melt chamber. The data acquisition system provides the real-time temperature for molten glass. Test results indicate that the self-verifying sensor is more accurate and reliable than classic platinum/rhodium thermocouple and sheath assemblies. The results of this test are reported as well as enhancements being made to the temperature probe. To obtain more reliable temperature measurements of the molten glass for improving production efficiency and ensuring consistent glass properties, optical sensing was reviewed for application in a high temperature environment.

  16. Impact of Zeolite Transferred from Tank 19F to Tank 18F on DWPF Vitrification of Sludge Batch 3

    SciTech Connect

    Jantzen, C.M.

    2004-01-07

    The Defense Waste Processing Facility (DWPF) is planning to initiate vitrification of Sludge Batch 3 (SB3) in combination with Sludge Batch 2 (SB2) in the spring of 2004. The contents of Sludge Batch 3 will be a mixture of the heel remaining from Sludge Batch 1B, sludge from Tank 7F (containing coal, sand, and sodium oxalate), and sludge materials from Tank 18F. The sludge materials in Tank 18F contain part of a mound of zeolitic material transferred there from Tank 19F. This mound was physically broken up and transfers were made from Tank 19F to Tank 18F for vitrification into SB3. In addition, excess Pu and Am/Cm materials were transferred to Tank 51H to be processed through the DWPF as part of SB3. Additional Pu material and a Np stream from the Canyons are also planned to be added to SB3 before processing of this batch commences at DWPF. The primary objective of this task was to assess the impacts of the excess zeolite mound material in Tank 19F on the predicted glass and processing properties of interest when the zeolite becomes part of SB3. The two potential impacts of the Tank 19F zeolite mound on DWPF processing relates to (1) the samples taken for determination of the acceptability of a macrobatch of DWPF feed and (2) the achievable waste loading. The potential effects of the large size of the zeolite particles found in the Tank 19F solids, as reported in this study, are considered minimal for processing of SB3 in DWPF. Other findings about the zeolite conversion mechanism via a process of Ostwald ripening are discussed in the text and in the conclusions.

  17. Formation rate of ammonium nitrate in the off-gas line of SRAT and SME in DWPF

    SciTech Connect

    Lee, L.

    1992-02-25

    A mathematical model for the formation rate of ammonium nitrate in the off-gas line of the Sludge Receipt and Adjustment Tank (SRAT) and the Slurry Mixed Evaporator (SME) in DWPF has been developed. The formation rate of ammonium nitrate in the off-gas line depends on pH, temperature, volume and total concentration of ammonia and ammonium ion. Based on a typical SRAT and SME cycle in DWPF, this model predicts the SRAT contributes about 50 lbs of ammonium nitrate while SME contributes about 60 lbs of ammonium nitrate to the off-gas line.

  18. Tank 42 sludge-only process development for the Defense Waste Processing Facility (DWPF)

    SciTech Connect

    Lambert, D.P.

    2000-03-22

    Defense Waste Processing Facility (DWPF) requested the development of a sludge-only process for Tank 42 sludge since at the current processing rate, the Tank 51 sludge has been projected to be depleted as early as August 1998. Testing was completed using a non-radioactive Tank 42 sludge simulant. The testing was completed under a range of operating conditions, including worst case conditions, to develop the processing conditions for radioactive Tank 42 sludge. The existing Tank 51 sludge-only process is adequate with the exception that 10 percent additional acid is recommended during sludge receipt and adjustment tank (SRAT) processing to ensure adequate destruction of nitrite during the SRAT cycle.

  19. DWPF Algorithm for Calculation of Source Terms and Consequences for EXCEL

    Energy Science and Technology Software Center (ESTSC)

    1997-02-11

    The DWPFAST software application algorithm is an Excel spreadsheet, with optional macros, designed to calculate the radiological source terms and consequences due to postulated accident progressions in non-reactor nuclear facilities (currently it is being used for DWPF). Upon input of a multi-character accident progression identification code, and basic facility data, the algorithm calculates individual accident segment releases, overall facility releases, and radiological consequences for various receptors, for up to 13 individual radionuclides. The algorithm wasmore » designed to support probabilistic safety assements (PSAs).« less

  20. Laboratory Optimization Tests of Technetium Decontamination of Hanford Waste Treatment Plant Direct Feed Low Activity Waste Melter Off-Gas Condensate Simulant

    SciTech Connect

    Taylor-Pashow, K.; McCabe, D.

    2015-12-23

    The Hanford Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) vitrification facility will generate an aqueous condensate recycle stream (LAW Off-Gas Condensate) from the off-gas system. The baseline plan for disposition of this stream is to send it to the WTP Pretreatment Facility, where it will be blended with LAW, concentrated by evaporation and recycled to the LAW vitrification facility. Alternate disposition of this stream would eliminate recycling of problematic components, and would enable less integrated operation of the LAW melter and the Pretreatment Facilities. Eliminating this stream from recycling within WTP would also decrease the LAW vitrification mission duration and quantity of glass waste.

  1. FY-97 operations of the pilot-scale glass melter to vitrify simulated ICPP high activity sodium-bearing waste

    SciTech Connect

    Musick, C.A.

    1997-11-01

    A 3.5 liter refractory-lined joule-heated glass melter was built to test the applicability of electric melting to vitrify simulated high activity waste (HAW). The HAW streams result from dissolution and separation of Idaho Chemical Processing Plant (ICPP) calcines and/or radioactive liquid waste. Pilot scale melter operations will establish selection criteria needed to evaluate the application of joule heating to immobilize ICPP high activity waste streams. The melter was fabricated with K-3 refractory walls and Inconel 690 electrodes. It is designed to be continuously operated at 1,150 C with a maximum glass output rate of 10 lbs/hr. The first set of tests were completed using surrogate HAW-sodium bearing waste (SBW). The melter operated for 57 hours and was shut down due to excessive melt temperatures resulting in low glass viscosity (< 30 Poise). Due to the high melt temperature and low viscosity the molten glass breached the melt chamber. The melter has been dismantled and examined to identify required process improvement areas and successes of the first melter run. The melter has been redesigned and is currently being fabricated for the second run, which is scheduled to begin in December 1997.

  2. Laboratory-Scale Melter for Determination of Melting Rate of Waste Glass Feeds

    SciTech Connect

    Kim, Dong-Sang; Schweiger, Michael J.; Buchmiller, William C.; Matyas, Josef

    2012-01-09

    The purpose of this study was to develop the laboratory-scale melter (LSM) as a quick and inexpensive method to determine the processing rate of various waste glass slurry feeds. The LSM uses a 3 or 4 in. diameter-fused quartz crucible with feed and off-gas ports on top. This LSM setup allows cold-cap formation above the molten glass to be directly monitored to obtain a steady-state melting rate of the waste glass feeds. The melting rate data from extensive scaled-melter tests with Hanford Site high-level wastes performed for the Hanford Tank Waste Treatment and Immobilization Plant have been compiled. Preliminary empirical model that expresses the melting rate as a function of bubbling rate and glass yield were developed from the compiled database. The two waste glass feeds with most melter run data were selected for detailed evaluation and model development and for the LSM tests so the melting rates obtained from LSM tests can be compared with those from scaled-melter tests. The present LSM results suggest the LSM setup can be used to determine the glass production rates for the development of new glass compositions or feed makeups that are designed to increase the processing rate of the slurry feeds.

  3. A JOULE-HEATED MELTER TECHNOLOGY FOR THE TREATMENT AND IMMOBILIZATION OF LOW-ACTIVITY WASTE

    SciTech Connect

    KELLY SE

    2011-04-07

    This report is one of four reports written to provide background information regarding immobilization technologies remaining under consideration for supplemental immobilization of Hanford's low-activity waste. This paper provides the reader a general understanding of joule-heated ceramic lined melters and their application to Hanford's low-activity waste.

  4. Electromagnetic and Thermal-flow Modeling of a Cold-Wall Crucible Induction Melter

    SciTech Connect

    Fort, James A.; Garnich, Mark R.; Klymyshyn, Nicholas A.

    2005-02-01

    An approach for modeling cold-wall crucible induction melters is described. Materials in the melt and melter are non-ferromagnetic. In contrast to other modeling works reported in the literature, the numerical models utilize commercial codes. The ANSYS finite element code is employed for electromagnetic field simulations and the STAR-CD finite volume code for thermal-flow calculations. Results from the electromagnetic calculations in the form of local Joule heat and Lorentz force distributions are included as loads in the thermal-flow analysis. This loosely-coupled approach is made possible by the small variation in temperature and, consequently, small variation in electrical properties across the melt as well as the quasi-steady state nature of the thermal flow calculations. A three dimensional finite element grid for electromagnetic calculations is adapted to a similar axisymmetric finite volume grid for data transfer to the thermal-flow model. Results from the electromagnetic model compare well with operational data from a 175 mm diameter melter. Results from the thermal-flow simulation provide insight toward molten metal circulation patterns, temperature variations, and velocity magnitudes. Initial results are included for a model that simulates the formation of a solid (skull) layer on the crucible base and wall. Overall, the modeling approach is shown to produce useful results relating operational parameters to the physics of steady state melter operation.

  5. Crystal-Tolerant Glass Approach For Mitigation Of Crystal Accumulation In Continuous Melters Processing Radioactive Waste

    SciTech Connect

    Kruger, Albert A.; Rodriguez, Carmen P.; Lang, Jesse B.; Huckleberry, Adam R.; Matyas, Josef; Owen, Antoinette T.

    2012-08-28

    High-level radioactive waste melters are projected to operate in an inefficient manner as they are subjected to artificial constraints, such as minimum liquidus temperature (T{sub L}) or maximum equilibrium fraction of crystallinity at a given temperature. These constraints substantially limit waste loading, but were imposed to prevent clogging of the melter with spinel crystals [(Fe, Ni, Mn, Zn)(Fe, Cr){sub 2}O{sub 4}]. In the melter, the glass discharge riser is the most likely location for crystal accumulation during idling because of low glass temperatures, stagnant melts, and small diameter. To address this problem, a series of lab-scale crucible tests were performed with specially formulated glasses to simulate accumulation of spinel in the riser. Thicknesses of accumulated layers were incorporated into empirical model of spinel settling. In addition, T{sub L} of glasses was measured and impact of particle agglomeration on accumulation rate was evaluated. Empirical model predicted well the accumulation of single crystals and/or smallscale agglomerates, but, excessive agglomeration observed in high-Ni-Fe glass resulted in an under-prediction of accumulated layers, which gradually worsen over time as an increased number of agglomerates formed. Accumulation rate of ~14.9 +- 1 nm/s determined for this glass will result in ~26 mm thick layer in 20 days of melter idling.

  6. The Production of Advanced Glass Ceramic HLW Forms using Cold Crucible Induction Melter

    SciTech Connect

    Veronica J Rutledge; Vince Maio

    2013-10-01

    Cold Crucible Induction Melters (CCIMs) will favorably change how High-Level radioactive Waste (from nuclear fuel recovery) is treated in the 21st century. Unlike the existing Joule-Heated Melters (JHMs) currently in operation for the glass-based immobilization of High-Level Waste (HLW), CCIMs offer unique material features that will increase melt temperatures, increase throughput, increase mixing, increase loading in the waste form, lower melter foot prints, eliminate melter corrosion and lower costs. These features not only enhance the technology for producing HLW forms, but also provide advantageous attributes to the waste form by allowing more durable alternatives to glass. This paper discusses advantageous features of the CCIM, with emphasis on features that overcome the historical issues with the JHMs presently utilized, as well as the benefits of glass ceramic waste forms over borosilicate glass waste forms. These advantages are then validated based on recent INL testing to demonstrate a first-of-a-kind formulation of a non-radioactive ceramic-based waste form utilizing a CCIM.

  7. The Burden Structure and Its Consumption in the Melter Gasifier of the Corex Process

    NASA Astrophysics Data System (ADS)

    Guo, Yanling; Xu, Wanren; Zhu, Jinming; Zhang, Jieyu

    2013-10-01

    A major advancement in the Corex ironmaking process is the usage of lump coal considering the shortage of coking coal resources worldwide. However, the burden similar to that of the blast furnace is still essential for the enlarged melter gasifier. The notable difference is that the burden of the melter gasifier is composed of char formed from lump coal with a small amount of coke. The burden structure of the melter gasifier was investigated by the tuyere probing while the plant was shut down at different operating conditions. The specimens representing the different positions of lump zone, cohesive zone, and dripping zone were analyzed by means of coke/char size distribution and X-ray diffraction (XRD) for the degree of graphitization of coke. A chemical analysis of metal composition has also been performed to get a better understanding of the final reduction in the melter gasifier. The burden structure is supposed to be divided into three zones: active zone, outer of deadman, and deadman core, where coke/char was consumed differently. Based on these analyses, some technical advice to improve the Corex operation is given.

  8. The production of advanced glass ceramic HLW forms using cold crucible induction melter

    SciTech Connect

    Rutledge, V.J.; Maio, V.

    2013-07-01

    Cold Crucible Induction Melters (CCIM) will favorably change how High-Level radioactive Waste (from nuclear fuel recovery) is treated in a near future. Unlike the existing Joule-Heated Melters (JHM) currently in operation for the glass-based immobilization of High-Level Waste (HLW), CCIM offers unique material features that will increase melt temperatures, increase throughput, increase mixing, increase loading in the waste form, lower melter foot prints, eliminate melter corrosion and lower costs. These features not only enhance the technology for producing HLW forms, but also provide advantageous attributes to the waste form by allowing more durable alternatives to glass. It is concluded that glass ceramic waste forms that are tailored to immobilize fission products of HLW can be can be made from the HLW processed with the CCIM. The advantageous higher temperatures reached with the CCIM and unachievable with JHM allows the lanthanides, alkali, alkaline earths, and molybdenum to dissolve into a molten glass. Upon controlled cooling they go into targeted crystalline phases to form a glass ceramic waste form with higher waste loadings than achievable with borosilicate glass waste forms. Natural cooling proves to be too fast for the formation of all targeted crystalline phases.

  9. Initial Laboratory-Scale Melter Test Results for Combined Fission Product Waste

    SciTech Connect

    Riley, Brian J.; Crum, Jarrod V.; Buchmiller, William C.; Rieck, Bennett T.; Schweiger, Michael J.; Vienna, John D.

    2009-10-01

    This report describes the methods and results used to vitrify a baseline glass, CSLNTM-C-2.5 in support of the AFCI (Advanced Fuel Cycle Initiative) using a Quartz Crucible Scale Melter at the Pacific Northwest National Laboratory. Document number AFCI-WAST-PMO-MI-DV-2009-000184.

  10. Processing of Oak Ridge B&C pond sludge surrogate in the transportable vitrification system

    SciTech Connect

    Zamecnik, J.R.; Young, S.R.; Peeler, D.K.; Smith, M.E.

    1997-04-16

    The Transportable Vitrification System (TVS) developed at the Savannah River Site is designed to process low-level and mixed radioactive wastes into a stable glass product. The TVS consists of a feed preparation and delivery system, a joule-heated melter, and an offgas treatment system. Surrogate Oak Ridge Reservation (ORR) B&C pond sludge was treated in a demonstration of the TVS system at Clemson University and at ORR. After initial tests with soda-lime-silica (SLS) feed, three melter volumes of glass were produced from the surrogate feed. A forthcoming report will describe glass characterization; and melter feeding, operation, and glass pouring. Melter operations described will include slurry characterization and feeding, factors affecting feed melt rates, glass pouring and pour rate constraints, and melter operating temperatures. Residence time modeling of the melter will also be discussed. Characterization of glass; including composition, predicted liquidity and viscosity, Toxic Characteristic Leaching Procedure (TCLP), and devitrification will be covered. Devitrification was a concern in glass container tests and was found to be mostly dependent on the cooling rate. Crucible tests indicated that melter shutdown with glass containing Fe and Li was also a devitrification concern, so the melter was flushed with SLS glass before cooldown.

  11. Calibration and Measurement of the Viscosity of DWPF Start-Up Glass

    SciTech Connect

    Schumacher, R.F.

    2001-04-17

    The Harrop, High-Temperature Viscometer has been in operation at the Savannah River Technology Center (SRTC) for several years and has proven itself to be reasonably accurate and repeatable. This is particularly notable when taking into consideration the small amount of glass required to make the viscosity determination. The volume of glass required is only 2.60 cc or about 6 to 7 grams of glass depending on the glass density. This may be compared to the more traditional viscosity determinations, which generally require between 100 to 1000 grams of glass. Before starting the present investigation, the unit was re-aligned and the furnace thermal gradients measured. The viscometer was again calibrated with available NIST Standard Reference Material glasses (717a and 710a) and a spindle constant equation was determined. Standard DWPF Waste Compliance Glasses (Purex, HM, and Batch 1) were used to provide additional verification for the determinations at low temperature. The Harrop, High-Temperature Viscometer was then used to determine the viscosity of three random samples of ground and blended DWPF, Black, Start -Up Frit, which were obtained from Pacific Northwest National Laboratory (PNNL). The glasses were in powder form and required melting prior to the viscosity determination. The results from this evaluation will be compared to ''Round Robin'' measurements from other DOE laboratories and a number of commercial laboratories.

  12. Determination Of Reportable Radionuclides For DWPF Sludge Batch 7B (Macrobatch 9)

    SciTech Connect

    Crawford, C. L.; Diprete, D. P.

    2012-12-17

    The DWPF is receiving radioactive sludge slurry from HLW Tank 40. The radioactive sludge slurry in Tank 40 is a blend of the heel from Sludge Batch 7a (SB7a) and Sludge Batch 7b (SB7b) that was transferred to Tank 40 from Tank 51. The blend of sludge in Tank 40 is also referred to as Macrobatch 9 (MB9). This report develops the list of reportable radionuclides and associated activities as a function of time. Twenty-seven radionuclides have been identified as reportable for DWPF SB7b. Each of these radionuclides has a half-life greater than ten years and contributes more than 0.01% of the radioactivity on a Curie basis at some point from production through the 1100 year period between 2015 and 3115. For SB7b, all of the radionuclides in the Design Basis glass are reportable except for three radionuclides: Pd-107, Cs-135, and Th-230. At no time during the 1100- year period between 2015 and 3115 did any of these three radionuclides contribute to more than 0.01% of the radioactivity on a Curie basis. The radionuclide measurements made for SB7b are the most extensive conducted to date. Some method development/refinement occurred during the conduct of these measurements, leading to lower detection limits and more accurate measurement of some isotopes than was previously possible.

  13. Determination of halogen content in glass for assessment of melter decontamination factors

    SciTech Connect

    Goles, R.W.

    1996-03-01

    Melter decontamination factor (DF) values for the halogens (fluorine, chlorine, and iodine) are important to the Hanford Waste Vitrification Plant (HWVP) process because of the potential influence of DF on secondary-waste recycle strategies (fluorine and chlorine) as well as its impact on off-gas emissions (iodine). This study directly establishes the concentrations of halides-in HWVP simulated reference glasses rather than relying on indirect off-gas data. For fluorine and chlorine, pyrohydrolysis coupled with halide (ion chromatographic) detection has proven to be a useful analytical approach suitable for glass matrices, sensitive enough for the range of halogens encountered, and compatible with remote process support applications. Results obtained from pyrohydrolytic analysis of pilot-scale ceramic melter (PSCM) -22 and -23 glasses indicate that the processing behavior of fluorine and chlorine is quite variable even under similar processing conditions. Specifically, PSCM-23 glass exhibited a {approximately}90% halogen (F and Cl) retention efficiency, while only 20% was incorporated in PSCM-22 glass. These two sets of very dissimilar test results clearly do not form a sufficient basis for establishing design DF values for fluorine and chlorine. Because the present data do not provide any new halogen volatility information, but instead reconfirm the validity of previously obtained offgas derived values, melter DF values of 4, 2, and 1 for fluorine, chlorine, and iodine, respectively, are recommended for adoption; these values were conservatively established by a team of responsible engineers at Westinghouse Hanford Company (WHC) and Pacific Northwest Laboratory (PNL) on the basis of average behavior for many comparable melter tests. In the absence of further HWVP process data, these average melter DFs are the best values currently available.

  14. Sludge Washing And Demonstration Of The DWPF Flowsheet In The SRNL Shielded Cells For Sludge Batch 8 Qualification

    SciTech Connect

    Pareizs, J. M.; Crawford, C. L.

    2013-04-26

    The current Waste Solidification Engineering (WSE) practice is to prepare sludge batches in Tank 51 by transferring sludge from other tanks to Tank 51. Tank 51 sludge is washed and transferred to Tank 40, the current Defense Waste Processing Facility (DWPF) feed tank. Prior to transfer of Tank 51 to Tank 40, the Savannah River National Laboratory (SRNL) typically simulates the Tank Farm and DWPF processes using a Tank 51 sample (referred to as the qualification sample). WSE requested the SRNL to perform characterization on a Sludge Batch 8 (SB8) sample and demonstrate the DWPF flowsheet in the SRNL shielded cells for SB8 as the final qualification process required prior to SB8 transfer from Tank 51 to Tank 40. A 3-L sample from Tank 51 (the SB8 qualification sample; Tank Farm sample HTF-51-12-80) was received by SRNL on September 20, 2012. The as-received sample was characterized prior to being washed. The washed material was further characterized and used as the material for the DWPF process simulation including a Sludge Receipt and Adjustment Tank (SRAT) cycle, a Slurry Mix Evaporator (SME) cycle, and glass fabrication and chemical durability measurements.

  15. Summary Report For The Analysis Of The Sludge Batch 7b (Macrobatch 9) DWPF Pour Stream Glass Sample For Canister S04023

    SciTech Connect

    Johnson, F. C.

    2013-11-18

    In order to comply with the Defense Waste Processing Facility (DWPF) Waste Form Compliance Plan for Sluldge Batch 7b, Savannah River National Laboratory (SRNL) personnel characterized the Defense Waste Processing Facility (DWPF) pour stream (PS) glass sample collected while filling canister S04023. This report summarizes the results of the compositional analysis for reportable oxides and radionuclides and the normalized Product Consistency Test (PCT) results. The PCT responses indicate that the DWPF produced glass that is significantly more durable than the Environmental Assessment glass.

  16. SUMMARY REPORT FOR THE ANALYSIS OF THE SLUDGE BATCH 6 (MACROBATCH 7) DWPF POUR STREAM GLASS SAMPLE FOR CANISTER S03472

    SciTech Connect

    Johnson, F.

    2012-01-23

    In order to comply with the Waste Acceptance Specifications in Sludge Batch 6 (Macrobatch 7), Savannah River National Laboratory personnel performed characterization analyses on the Defense Waste Processing Facility (DWPF) pour stream glass sample collected while filling canister S03472. This report summarizes results of the characterization, which indicate that the DWPF produced glass that is significantly more durable than the Environmental Assessment glass. Results and further details are documented in 'Analysis of DWPF Sludge Batch 6 (Macrobatch 7) Pour Stream Glass Samples,' SRNL-STI-2011-00555.

  17. SUMMARY REPORT FOR THE ANALYSIS OF THE SLUDGE BATCH 7A (MACROBATCH 8) DWPF POUR STREAM GLASS SAMPLE FOR CANISTER S03619

    SciTech Connect

    Johnson, F.

    2012-05-01

    In order to comply with the Waste Acceptance Specifications in Sludge Batch 7a (Macrobatch 8), Savannah River National Laboratory personnel characterized the Defense Waste Processing Facility (DWPF) pour stream glass sample collected while filling canister S03619. This report summarizes the results of the compositional analysis for reportable oxides and radionuclides, and the normalized Product Consistency Test (PCT) results. The PCT responses indicate that the DWPF produced glass that is significantly more durable than the Environmental Assessment glass. Results and further details are documented in 'Analysis of DWPF Sludge Batch 7a (Macrobatch 8) Pour Stream Samples,' SRNL-STI-2012-00017.

  18. Flammability Control In A Nuclear Waste Vitrification System

    SciTech Connect

    Zamecnik, John R.; Choi, Alexander S.; Johnson, Fabienne C.; Miller, Donald H.; Lambert, Daniel P.; Stone, Michael E.; Daniel, William E. Jr.

    2013-07-25

    The Defense Waste Processing Facility at the Savannah River Site processes high-level radioactive waste from the processing of nuclear materials that contains dissolved and precipitated metals and radionuclides. Vitrification of this waste into borosilicate glass for ultimate disposal at a geologic repository involves chemically modifying the waste to make it compatible with the glass melter system. Pretreatment steps include removal of excess aluminum by dissolution and washing, and processing with formic and nitric acids to: 1) adjust the reduction-oxidation (redox) potential in the glass melter to reduce radionuclide volatility and improve melt rate; 2) adjust feed rheology; and 3) reduce by steam stripping the amount of mercury that must be processed in the melter. Elimination of formic acid in pretreatment has been studied to eliminate the production of hydrogen in the pretreatment systems, which requires nuclear grade monitoring equipment. An alternative reductant, glycolic acid, has been studied as a substitute for formic acid. However, in the melter, the potential for greater formation of flammable gases exists with glycolic acid. Melter flammability is difficult to control because flammable mixtures can be formed during surges in offgases that both increase the amount of flammable species and decrease the temperature in the vapor space of the melter. A flammable surge can exceed the 60% of the LFL with no way to mitigate it. Therefore, careful control of the melter feed composition based on scaled melter surge testing is required. The results of engineering scale melter tests with the formic-nitric flowsheet and the use of these data in the melter flammability model are presented.

  19. Noble metals-compatible melter features development Phase 1: Establishing functional and design criteria and design concepts

    SciTech Connect

    Elmore, M.R.; Siemens, D.H.; Chapman, C.C.

    1996-03-01

    Premature failures have occurred in melters at Japan`s Tokai Mockup Facility and at the Federal Republic of Germany (FRG) PAMELA plant during processing of feeds with high levels of noble metals. Melter failure was due to the accumulation of an electrically conductive, noble metals-containing precipitates in the glass, that then resulted in short circuiting of the electrodes. A comparison was made of the anticipated Hanford Waste Vitrification Plant (HWVP) feed with the feeds processed in the FRG and Japanese melters. The evaluation showed that comparable levels of noble metals and other potential precipitate-forming components (e.g. Cr/Fe/Ni-spinels) exist in the HWVP feed. As a result, the HWVP project made a decision to modify the present reference melter design to include features to prevent the precipitation and accumulation or otherwise accommodate precipitated phases on a routine basis without loss of production capacity.

  20. CHARACTERIZATION OF A PRECIPITATE REACTOR FEED TANK (PRFT) SAMPLE FROM THE DEFENSE WASTE PROCESSING FACILITY (DWPF)

    SciTech Connect

    Crawford, C.; Bannochie, C.

    2014-05-12

    A sample of from the Defense Waste Processing Facility (DWPF) Precipitate Reactor Feed Tank (PRFT) was pulled and sent to the Savannah River National Laboratory (SRNL) in June of 2013. The PRFT in DWPF receives Actinide Removal Process (ARP)/ Monosodium Titanate (MST) material from the 512-S Facility via the 511-S Facility. This 2.2 L sample was to be used in small-scale DWPF chemical process cell testing in the Shielded Cells Facility of SRNL. A 1L sub-sample portion was characterized to determine the physical properties such as weight percent solids, density, particle size distribution and crystalline phase identification. Further chemical analysis of the PRFT filtrate and dissolved slurry included metals and anions as well as carbon and base analysis. This technical report describes the characterization and analysis of the PRFT sample from DWPF. At SRNL, the 2.2 L PRFT sample was composited from eleven separate samples received from DWPF. The visible solids were observed to be relatively quick settling which allowed for the rinsing of the original shipping vials with PRFT supernate on the same day as compositing. Most analyses were performed in triplicate except for particle size distribution (PSD), X-ray diffraction (XRD), Scanning Electron Microscopy (SEM) and thermogravimetric analysis (TGA). PRFT slurry samples were dissolved using a mixed HNO3/HF acid for subsequent Inductively Coupled Plasma Atomic Emission Spectroscopy (ICPAES) and Inductively Coupled Plasma Mass Spectroscopy (ICP-MS) analyses performed by SRNL Analytical Development (AD). Per the task request for this work, analysis of the PRFT slurry and filtrate for metals, anions, carbon and base were primarily performed to support the planned chemical process cell testing and to provide additional component concentrations in addition to the limited data available from DWPF. Analysis of the insoluble solids portion of the PRFT slurry was aimed at detailed characterization of these solids (TGA, PSD

  1. Release of ammonia from HAN-type PHA

    SciTech Connect

    Zamecnik, J.R.

    1992-06-10

    A preliminary design basis for ammonia scrubbers in the DWPF has been issued. This design basis is based on a theoretical model of ammonia evolution from the SRAT, SME and RCT. It is desirable to acquire actual process data on ammonia evolution prior to performing detailed design of scrubbers for DWPF. The evolution of ammonia from the SRAT and SME in the Integrated DWPF Melter System (IDMS) was investigated during the HM4 run. In this run, Precipitate Hydrolysis Aqueous (PHA), which was made in the Precipitate Hydrolysis Experimental Facility (PHEF) using the HAN (hydroxylamine nitrate) process was used, thus resulting in PHA with a high concentration of ammonium ion.

  2. Vitrification of HLW Produced by Uranium/Molybdenum Fuel Reprocessing in COGEMA's Cold Crucible Melter

    SciTech Connect

    Do Quang, R.; Petitjean, V.; Hollebecque, F.; Pinet, O.; Flament, T.; Prod'homme, A.

    2003-02-25

    The performance of the vitrification process currently used in the La Hague commercial reprocessing plants has been continuously improved during more than ten years of operation. In parallel COGEMA (industrial Operator), the French Atomic Energy Commission (CEA) and SGN (respectively COGEMA's R&D provider and Engineering) have developed the cold crucible melter vitrification technology to obtain greater operating flexibility, increased plant availability and further reduction of secondary waste generated during operations. The cold crucible is a compact water-cooled melter in which the radioactive waste and the glass additives are melted by direct high frequency induction. The cooling of the melter produces a solidified glass layer that protects the melter's inner wall from corrosion. Because the heat is transferred directly to the melt, high operating temperatures can be achieved with no impact on the melter itself. COGEMA plans to implement the cold crucible technology to vitrify high level liquid waste from reprocessed spent U-Mo-Sn-Al fuel (used in gas cooled reactor). The cold crucible was selected for the vitrification of this particularly hard-to-process waste stream because it could not be reasonably processed in the standard hot induction melters currently used at the La Hague vitrification facilities : the waste has a high molybdenum content which makes it very corrosive and also requires a special high temperature glass formulation to obtain sufficiently high waste loading factors (12 % in molybdenum). A special glass formulation has been developed by the CEA and has been qualified through lab and pilot testing to meet standard waste acceptance criteria for final disposal of the U-Mo waste. The process and the associated technologies have been also being qualified on a full-scale prototype at the CEA pilot facility in Marcoule. Engineering study has been integrated in parallel in order to take into account that the Cold Crucible should be installed

  3. THE USE OF DI WATER TO MITIGATE DUSTING FOR ADDITION OF DWPF FRIT TO THE SLURRY MIX EVAPORATOR

    SciTech Connect

    Hansen, E.

    2010-07-21

    The Defense Waste Processing Facility (DPWF) presently is in the process to determine means to reduce water utilization in the Slurry Mix Evaporator (SME) process, thus reducing effluent and processing times. The frit slurry addition system mixes the dry frit with water, yielding approximately a 50 weight percent slurry containing frit and the other fraction water. This slurry is discharged into the SME and excess water is removed via boiling. To reduce this water load to the SME, DWPF has proposed using a pneumatic system in conveying the frit to the SME, in essence a dry delivery system. The problem associated with utilizing a dry delivery system with the existing frit is the generation of dust when discharged into the SME. The use of water has been shown to be effective in the mining industry as well in the DOE complex to mitigate dusting. The method employed by SRNL to determine the quantity of water to mitigate dusting in dry powders was effective, between a lab and bench scale tests. In those tests, it was shown that as high as five weight percent (wt%) of water addition was required to mitigate dust from batches of glass forming minerals used by the Waste Treatment Plant at Hanford, Washington. The same method used to determine the quantity of water to mitigate dusting was used in this task to determine the quantity of water to mitigate this dusting using as-received frit. The ability for water to mitigate dusting is due to its adhesive properties as shown in Figure 1-1. Wetting the frit particles allows for the smaller frit particles (including dust) to adhere to the larger frit particles or to agglomerate into large particles. Fluids other than water can also be used, but their adhesive properties are different than water and the quantity required to mitigate dusting is different, as was observed in reference 1. Excessive water, a few weight percentages greater than that required to mitigate dusting can cause the resulting material not to flow. The primary

  4. Use of Optical and Imaging Techniques for Inspection of Off-Line Joule-Heated Melter at the West Valley Demonstration Project

    SciTech Connect

    Plodinec, M. J.; Jang, P-R; Long, Z.; Monts, D. L.; Philip, T.; Su, Y.

    2003-02-25

    The West Valley melter has been taken out of service. Its design is the direct ancestor of the current melter design for the Hanford Waste Treatment Plant. Over its eight years of service, the West Valley melter has endured many of the same challenges that the Hanford melter will encounter with feeds that are similar to many of the Hanford double shell tank wastes. Thus, inspection of the West Valley melter prior to its disposal could provide valuable--even crucial--information to the designers of the melters to be used at the Hanford Site, particularly if quantitative information can be obtained. The objective of Mississippi State University's Diagnostic Instrumentation and Analysis Laboratory's (DIAL) efforts is to develop, fabricate, and deploy inspection tools for the West Valley melter that will (i) be remotely operable in the West Valley process cell; (ii) provide quantitative information on melter refractory wear and deposits on the refractory; and (iii) indicate areas of heterogeneity (e.g., deposits) requiring more detailed characterization. A collaborative arrangement has been established with the West Valley Demonstration Project (WVDP) to inspect their melter.

  5. DWPF coupled feed flowsheet material balance with batch one sludge and copper nitrate catalyst

    SciTech Connect

    Choi, A.S.

    1993-09-28

    The SRTC has formally transmitted a recommendation to DWPF to replace copper formate with copper nitrate as the catalyst form during precipitate hydrolysis [1]. The SRTC was subsequently requested to formally document the technical bases for the recommendation. A memorandum was issued on August 23, 1993 detailing the activities (and responsible individuals) necessary to address the impact of this change in catalyst form on process compatibility, safety, processibility environmental impact and product glass quality [2]. One of the activities identified was the preparation of a material balance in which copper nitrate is substituted for copper formate and the identification of key comparisons between this material balance and the current Batch 1 sludge -- Late Wash material balance [3].

  6. Determination of Reportable Radionuclides for DWPF Sludge Batch 3 (Macrobatch 4)

    SciTech Connect

    Bannochie, C

    2005-05-01

    The Waste Acceptance Product Specifications (WAPS) 1.2 require that ''The Producer shall report the inventory of radionuclides (in Curies) that have half-lives longer than 10 years and that are, or will be, present in concentrations greater than 0.05 percent of the total inventory for each waste type indexed to the years 2015 and 3115''. As part of the strategy to meet WAPS 1.2, the Defense Waste Processing Facility (DWPF) will report for each waste type, all radionuclides (with half-lives greater than 10 years) that have concentrations greater than 0.01 percent of the total inventory from time of production through the 1100 year period from 2015 through 3115. The initial listing of radionuclides to be included is based on the design-basis glass as identified in the Waste Form Compliance Plan (WCP) and Waste Form Qualification Report (WQR). However, it is required that this list be expanded if other radionuclides with half-lives greater than 10 years are identified that meet the greater than 0.01% criterion for Curie content. Specification 1.6 of the WAPS, IAEA Safeguards Reporting for HLW, requires that the ratio by weights of the following uranium and plutonium isotopes be reported: U-233, U-234, U-235, U-236, U-238, Pu-238, Pu-239, Pu-240, Pu-241, and Pu-242. Therefore, the complete set of reportable radionuclides must also include this set of U and Pu isotopes. The Defense Waste Processing Facility (DWPF) is receiving radioactive sludge slurry from High Level Waste Tank 40. The radioactive sludge slurry in Tank 40 is a blend of the previous contents of Tank 40 (Sludge Batch 2) and the sludge that was transferred to Tank 40 from Tank 51. The blend of sludge from Tank 51 and Tank 40 defines Macrobatch 4 (also referred to as Sludge Batch 3). This report develops the list of reportable radionuclides and associated activities and determines the radionuclide activities as a function of time. The DWPF will use this list and the activities as one of the inputs for the

  7. SETTLING OF SPINEL IN A HIGH-LEVEL WASTE GLASS MELTER

    SciTech Connect

    Pavel Hrma; Pert Schill; Lubomir Nemec

    2002-01-07

    High-level nuclear waste is being vitrified, i.e., converted to a durable glass that can be stored in a safe repository for hundreds of thousands of years. Waste vitrification is accomplished in reactors called melters to which the waste is charged together with glass-forming additives. The mixture is electrically heated to a temperature as high as 1150 decrees C to create a melt that becomes glass on cooling.

  8. Model for the conversion of nuclear waste melter feed to glass

    SciTech Connect

    Pokorny, Richard; Hrma, Pavel R.

    2014-02-01

    The rate of batch-to-glass conversion is a primary concern for the vitrification of nuclear waste, as it directly influences the life cycle of the cleanup process. This study describes the development of an advanced model of the cold cap, which augments the previous model by further developments on the structure and the dynamics of the foam layer. The foam layer on the bottom of the cold cap consists of the primary foam, cavities, and the secondary foam, and forms an interface through which the heat is transferred to the cold cap. Other model enhancements include the behavior of intermediate crystalline phases and the dissolution of quartz particles. The model relates the melting rate to feed properties and melter conditions, such as the molten glass temperature, foaminess of the feed, or the heat fraction supplied to the cold cap from the plenum space. The model correctly predicts a 25% increase in melting rate when changing the alumina source in the melter feed from Al(OH)3 to AlO(OH). It is expected that this model will be incorporated in the full glass melter model as its integral component.

  9. Model for the conversion of nuclear waste melter feed to glass

    NASA Astrophysics Data System (ADS)

    Pokorny, Richard; Hrma, Pavel

    2014-02-01

    The rate of batch-to-glass conversion is a primary concern for the vitrification of nuclear waste, as it directly influences the life cycle of the cleanup process. This study describes the development of an advanced model of the cold cap, which augments the previous model by further developments on the structure and the dynamics of the foam layer. The foam layer on the bottom of the cold cap consists of the primary foam, cavities, and the secondary foam, and forms an interface through which the heat is transferred to the cold cap. Other model enhancements include the behavior of intermediate crystalline phases and the dissolution of quartz particles. The model relates the melting rate to feed properties and melter conditions, such as the molten glass temperature, foaminess of the melt, or the heat fraction supplied to the cold cap from the plenum space. The model correctly predicts a 25% increase in melting rate when changing the alumina source in the melter feed from Al(OH)3 to AlO(OH). It is expected that this model will be incorporated in the full glass melter model as its integral component.

  10. Experimental Investigation and Mathematical Modeling of Cold Cap Behavior in High-Level-Waste Glass Melter

    SciTech Connect

    Hrma, Pavel R.

    2014-03-03

    The cold cap is a layer of reacting melter feed floating on the surface of molten glass in a glass-melting furnace. The cold cap consists of two distinct portions, of which the upper allows the reaction gases to escape through open pores, whereas the lower portion traps the gases within the continuous glass-forming melt, creating foam. The temperature span over the cold cap is ~1000 K. Data needed to simulate the cold cap mathematically include the kinetics of multiple reactions, reaction enthalpies, heat capacity, density, porosity, and heat conductivity as functions of both the temperature and the rate of heating. These data were produced via crucible experiments. The mathematical model has been completed. It relates the cold cap thickness, the rate of melting, the temperature field, and cold cap structure (foaming, dissolution of quartz particles, and formation and subsequent dissolution of crystalline phases, such as spinel) to the cold cap bottom temperature, the fraction of heat flow to the upper cold cap surface, the melt foaminess, and the chemical and physical nature of melter feed materials. To verify the model, cold caps were produced in a laboratory-scale melter and their structure is currently investigated.

  11. Determination of heat conductivity and thermal diffusivity of waste glass melter feed: Extension to high temperatures

    SciTech Connect

    Rice, Jarrett A.; Pokorny, Richard; Schweiger, Michael J.; Hrma, Pavel R.

    2014-06-01

    The heat conductivity ({lambda}) and the thermal diffusivity (a) of reacting glass batch, or melter feed, control the heat flux into and within the cold cap, a layer of reacting material floating on the pool of molten glass in an all-electric continuous waste glass melter. After previously estimating {lambda} of melter feed at temperatures up to 680 deg C, we focus in this work on the {lambda}(T) function at T > 680 deg C, at which the feed material becomes foamy. We used a customized experimental setup consisting of a large cylindrical crucible with an assembly of thermocouples, which monitored the evolution of the temperature field while the crucible with feed was heated at a constant rate from room temperature up to 1100°C. Approximating measured temperature profiles by polynomial functions, we used the heat transfer equation to estimate the {lambda}(T) approximation function, which we subsequently optimized using the finite-volume method combined with least-squares analysis. The heat conductivity increased as the temperature increased until the feed began to expand into foam, at which point the conductivity dropped. It began to increase again as the foam turned into a bubble-free glass melt. We discuss the implications of this behavior for the mathematical modeling of the cold cap.

  12. Pilot-scale ceramic melter 1985-1986 rebuild: Nuclear Waste Treatment Program

    SciTech Connect

    Koegler, S.S.

    1987-07-01

    The pilot-scale ceramic melter (PSCM) was subsequently dismantled, and the damaged and corroded components were repaired or replaced. The PSCM rebuild ensures that the melter will be available for an additional three to five years of planned testing. An analysis of the corrosion products and the failed electrodes indicated that the electrode bus connection welds may have failed due to a combination of chemical and mechanical effects. The electrodes were replaced with a design similar to the original electrodes, but with improved electrical bus connections. The implications of the PSCM electrode corrosion evaluation are that, although Inconel 690 has excellent corrosion resistance to molten glass, corrosion at the melt line in stagnant regions is a significant concern. Functional changes made during the rebuild included increases in wall and floor insulation to better simulate well-insulated melters, a decrease in the lid height for more prototypical plenum and off-gas conditions, and installation of an Inconel 690 trough and dam to improve glass pouring and prevent glass seepage. 9 refs., 33 figs., 5 tabs.

  13. FINAL REPORT INTEGRATED DM1200 MELTER TESTING OF REDOX EFFECTS USING HLW AZ-101 AND C-106/AY-102 SIMULANTS VSL-04R4800-1 REV 0 5/6/

    SciTech Connect

    KRUGER AA; MATLACK KS; GONG W; BARDAKCI T; D'ANGELO NA; LUTZE W; BIZOT PM; CALLOW RA; BRANDYS M; KOT WK; PEGG IL

    2011-12-29

    This report documents melter and off-gas performance results obtained on the DM1200 HLW Pilot Melter during processing of AZ-101 and C-106/AY-102 HLW simulants. The tests reported herein are a subset of three tests from a larger series of tests described in the Test Plan for the work; results from the remaining tests will be reported separately. Three nine day tests, one with AZ-101 and two with C-106/AY-102 feeds were conducted with variable amounts of added sugar to address the effects of redox. The test with AZ-101 included ruthenium spikes to also address the effects of redox on ruthenium volatility. One of tests addressed the effects of increased flow-sheet nitrate levels using C-106/AY-102 feeds. With high nitrate/nitrite feeds (such as WTP LAW feeds), reductants are required to prevent melt foaming and deleterious effects on glass production rates. Sugar is the baseline WTP reductant for this purpose. WTP HLW feeds typically have relatively low nitrate/nitrite content in comparison to the organic carbon content and, therefore, have typically not required sugar additions. However, HLW feed variability, particularly with respect to nitrate levels, may necessitate the use of sugar in some instances. The tests reported here investigate the effects of variable sugar additions to the melter feed as well as elevated nitrate levels in the waste. Variables held constant to the extent possible included melt temperature, bubbling rate, plenum temperature, cold cap coverage, the waste simulant composition, and the target glass composition. The principal objectives of the DM1200 melter testing were to determine the achievable glass production rates for simulated HLW feeds with variable amounts of added sugar and increased nitrate levels; characterize melter off-gas emissions; characterize the performance of the prototypical off-gas system components as well as their integrated performance; characterize the feed, glass product, and off-gas effluents; and perform pre- and

  14. Phase II of a Six sigma Initiative to Study DWPF SME Analytical Turnaround Times: SRNL's Evaluation of Carbonate-Based Dissolution Methods

    SciTech Connect

    Edwards, Thomas

    2005-09-01

    The Analytical Development Section (ADS) and the Statistical Consulting Section (SCS) of the Savannah River National Laboratory (SRNL) are participating in a Six Sigma initiative to improve the Defense Waste Processing Facility (DWPF) Laboratory. The Six Sigma initiative has focused on reducing the analytical turnaround time of samples from the Slurry Mix Evaporator (SME) by developing streamlined sampling and analytical methods [1]. The objective of Phase I was to evaluate the sub-sampling of a larger sample bottle and the performance of a cesium carbonate (Cs{sub 2}CO{sub 3}) digestion method. Successful implementation of the Cs{sub 2}CO{sub 3} fusion method in the DWPF would have important time savings and convenience benefits because this single digestion would replace the dual digestion scheme now used. A single digestion scheme would result in more efficient operations in both the DWPF shielded cells and the inductively coupled plasma--atomic emission spectroscopy (ICP-AES) laboratory. By taking a small aliquot of SME slurry from a large sample bottle and dissolving the vitrified SME sample with carbonate fusion methods, an analytical turnaround time reduction from 27 hours to 9 hours could be realized in the DWPF. This analytical scheme has the potential for not only dramatically reducing turnaround times, but also streamlining operations to minimize wear and tear on critical shielded cell components that are prone to fail, including the Hydragard{trademark} sampling valves and manipulators. Favorable results from the Phase I tests [2] led to the recommendation for a Phase II effort as outlined in the DWPF Technical Task Request (TTR) [3]. There were three major tasks outlined in the TTR, and SRNL issued a Task Technical and QA Plan [4] with a corresponding set of three major task activities: (1) Compare weight percent (wt%) total solids measurements of large volume samples versus peanut vial samples. (2) Evaluate Cs{sub 2}CO{sub 3} and K{sub 2}CO{sub 3

  15. SLUDGE WASHING AND DEMONSTRATION OF THE DWPF FLOWSHEET IN THE SRNL SHIELDED CELLS FOR SLUDGE BATCH 5 QUALIFICATION

    SciTech Connect

    Pareizs, J; Cj Bannochie, C; Damon Click, D; Dan Lambert, D; Michael Stone, M; Bradley Pickenheim, B; Amanda Billings, A; Ned Bibler, N

    2008-11-10

    Sludge Batch 5 (SB5) is predominantly a combination of H-modified (HM) sludge from Tank 11 that underwent aluminum dissolution in late 2007 to reduce the total mass of sludge solids and aluminum being fed to the Defense Waste Processing Facility (DWPF) and Purex sludge transferred from Tank 7. Following aluminum dissolution, the addition of Tank 7 sludge and excess Pu to Tank 51, Liquid Waste Operations (LWO) provided the Savannah River National Laboratory (SRNL) a 3-L sample of Tank 51 sludge for SB5 qualification. SB5 qualification included washing the sample per LWO plans/projections (including the addition of a Pu/Be stream from H Canyon), DWPF Chemical Process Cell (CPC) simulations, waste glass fabrication (vitrification), and waste glass chemical durability evaluation. This report documents: (1) The washing (addition of water to dilute the sludge supernatant) and concentration (decanting of supernatant) of the Tank 51 qualification sample to adjust sodium content and weight percent insoluble solids to Tank Farm projections. (2) The performance of a DWPF CPC simulation using the washed Tank 51 sample. This includes a Sludge Receipt and Adjustment Tank (SRAT) cycle, where acid is added to the sludge to destroy nitrite and remove mercury, and a Slurry Mix Evaporator (SME) cycle, where glass frit is added to the sludge in preparation for vitrification. The SME cycle also included replication of five canister decontamination additions and concentrations. Processing parameters for the CPC processing were based on work with a non radioactive simulant. (3) Vitrification of a portion of the SME product and Product Consistency Test (PCT) evaluation of the resulting glass. (4) Rheology measurements of the initial slurry samples and samples after each phase of CPC processing. This work is controlled by a Task Technical and Quality Assurance Plan (TTQAP) , and analyses are guided by an Analytical Study Plan. This work is Technical Baseline Research and Development (R

  16. Evaluation of ISDP Batch 2 Qualification Compliance to 512-S, DWPF, Tank Farm, and Saltstone Waste Acceptance Criteria

    SciTech Connect

    Shafer, A.

    2010-05-05

    The purpose of this report is to document the acceptability of the second macrobatch (Salt Batch 2) of Tank 49H waste to H Tank Farm, DWPF, and Saltstone for operation of the Interim Salt Disposition Project (ISDP). Tank 49 feed meets the Waste Acceptance Criteria (WAC) requirements specified by References 11, 12, and 13. Salt Batch 2 material is qualified and ready to be processed through ARP/MCU to the final disposal facilities.

  17. DOWNSTREAM IMPACTS OF SLUDGE MASS REDUCTION VIA ALUMINUM DISSOLUTION ON DWPF PROCESSING OF SAVANNAH RIVER SITE HIGH LEVEL WASTE - 9382

    SciTech Connect

    Pareizs, J; Cj Bannochie, C; Michael Hay, M; Daniel McCabe, D

    2009-01-14

    The SRS sludge that was to become a major fraction of Sludge Batch 5 (SB5) for the Defense Waste Processing Facility (DWPF) contained a large fraction of H-Modified PUREX (HM) sludge, containing a large fraction of aluminum compounds that could adversely impact the processing and increase the vitrified waste volume. It is beneficial to reduce the non-radioactive fraction of the sludge to minimize the number of glass waste canisters that must be sent to a Federal Repository. Removal of aluminum compounds, such as boehmite and gibbsite, from sludge can be performed with the addition of NaOH solution and heating the sludge for several days. Preparation of SB5 involved adding sodium hydroxide directly to the waste tank and heating the contents to a moderate temperature through slurry pump operation to remove a fraction of this aluminum. The Savannah River National Laboratory (SRNL) was tasked with demonstrating this process on actual tank waste sludge in our Shielded Cells Facility. This paper evaluates some of the impacts of aluminum dissolution on sludge washing and DWPF processing by comparing sludge processing with and without aluminum dissolution. It was necessary to demonstrate these steps to ensure that the aluminum removal process would not adversely impact the chemical and physical properties of the sludge which could result in slower processing or process upsets in the DWPF.

  18. Ruthenium volatility from the vitrification of melter feeds prepared using the Nitric Acid Flowsheet

    SciTech Connect

    Hutson, N.D.

    1992-10-22

    The present DWPF flowsheet calls for the chemical treatment of waste sludge with 90 wt% formic acid prior to the addition of the Precipitate Hydrolysis Aqueous (PHA) product. An alternative processing methodology, denoted the ``Nitric Acid Flowsheet``, has been proposed. In the application of this flowsheet, nitric acid would be used to neutralize sludge base components (hydroxides and carbonates) prior to the addition of late wash PHA. The late wash PHA will contain sufficient quantities of formic acid to adequately complete necessary reduction-oxidation (REDOX) reactions.

  19. Ruthenium volatility from the vitrification of melter feeds prepared using the Nitric Acid Flowsheet

    SciTech Connect

    Hutson, N.D.

    1992-10-22

    The present DWPF flowsheet calls for the chemical treatment of waste sludge with 90 wt% formic acid prior to the addition of the Precipitate Hydrolysis Aqueous (PHA) product. An alternative processing methodology, denoted the Nitric Acid Flowsheet'', has been proposed. In the application of this flowsheet, nitric acid would be used to neutralize sludge base components (hydroxides and carbonates) prior to the addition of late wash PHA. The late wash PHA will contain sufficient quantities of formic acid to adequately complete necessary reduction-oxidation (REDOX) reactions.

  20. DETERMINATION OF REPORTABLE RADIONUCLIDES FOR DWPF SLUDGE BATCH 7B (MACROBATCH 9)

    SciTech Connect

    Crawford, C. L.; Diprete, D. P.

    2014-05-01

    The Waste Acceptance Product Specifications (WAPS) 1.2 require that “The Producer shall report the inventory of radionuclides (in Curies) that have half-lives longer than 10 years and that are, or will be, present in concentrations greater than 0.05 percent of the total inventory for each waste type indexed to the years 2015 and 3115”. As part of the strategy to comply with WAPS 1.2, the Defense Waste Processing Facility (DWPF) will report for each waste type, all radionuclides (with half-lives greater than 10 years) that have concentrations greater than 0.01 percent of the total inventory from time of production through the 1100 year period from 2015 through 3115. The initial listing of radionuclides to be included is based on the design-basis glass as identified in the Waste Form Compliance Plan (WCP) and Waste Form Qualification Report (WQR). However, it is required that this list be expanded if other radionuclides with half-lives greater than 10 years are identified that may meet the greater than 0.01% criterion for Curie content. Specification 1.6 of the WAPS, International Atomic Energy Agency (IAEA) Safeguards Reporting for High Level Waste (HLW), requires that the ratio by weights of the following uranium and plutonium isotopes be reported: U-233, U-234, U-235, U-236, U-238, Pu-238, Pu-239, Pu-240, Pu-241, and Pu- 242. Therefore, the complete set of reportable radionuclides must also include this set of U and Pu isotopes. The DWPF is receiving radioactive sludge slurry from HLW Tank 40. The radioactive sludge slurry in Tank 40 is a blend of the heel from Sludge Batch 7a (SB7a) and Sludge Batch 7b (SB7b) that was transferred to Tank 40 from Tank 51. The blend of sludge in Tank 40 is also referred to as Macrobatch 9 (MB9). This report develops the list of reportable radionuclides and associated activities as a function of time. The DWPF will use this list and the activities as one of the inputs for the development of the Production Records that relate to

  1. Determination Of Reportable Radionuclides For DWPF Sludge Batch 7B (Macrobatch 9)

    SciTech Connect

    Crawford, C. L.; DiPrete, D. P.

    2013-08-22

    The Waste Acceptance Product Specifications (WAPS) 1.2 require that “The Producer shall report the inventory of radionuclides (in Curies) that have half-lives longer than 10 years and that are, or will be, present in concentrations greater than 0.05 percent of the total inventory for each waste type indexed to the years 2015 and 3115”. As part of the strategy to comply with WAPS 1.2, the Defense Waste Processing Facility (DWPF) will report for each waste type, all radionuclides (with half-lives greater than 10 years) that have concentrations greater than 0.01 percent of the total inventory from time of production through the 1100 year period from 2015 through 3115. The initial listing of radionuclides to be included is based on the design-basis glass as identified in the Waste Form Compliance Plan (WCP) and Waste Form Qualification Report (WQR). However, it is required that this list be expanded if other radionuclides with half-lives greater than 10 years are identified that may meet the greater than 0.01% criterion for Curie content. Specification 1.6 of the WAPS, International Atomic Energy Agency (IAEA) Safeguards Reporting for High Level Waste (HLW), requires that the ratio by weights of the following uranium and plutonium isotopes be reported: U-233, U-234, U-235, U-236, U-238, Pu-238, Pu-239, Pu-240, Pu-241, and Pu-242. Therefore, the complete set of reportable radionuclides must also include this set of U and Pu isotopes. The DWPF is receiving radioactive sludge slurry from HLW Tank 40. The radioactive sludge slurry in Tank 40 is a blend of the heel from Sludge Batch 7a (SB7a) and Sludge Batch 7b (SB7b) that was transferred to Tank 40 from Tank 51. The blend of sludge in Tank 40 is also referred to as Macrobatch 9 (MB9). This report develops the list of reportable radionuclides and associated activities as a function of time. The DWPF will use this list and the activities as one of the inputs for the development of the Production Records that relate to

  2. DETERMINATION OF REPORTABLE RADIONUCLIDES FOR DWPF SLUDGE BATCH 4 MACROBATCH 5

    SciTech Connect

    Bannochie, C; Ned Bibler, N; David Diprete, D

    2008-05-30

    The Waste Acceptance Product Specifications (WAPS)1 1.2 require that 'The Producer shall report the inventory of radionuclides (in Curies) that have half-lives longer than 10 years and that are, or will be, present in concentrations greater than 0.05 percent of the total inventory for each waste type indexed to the years 2015 and 3115'. As part of the strategy to meet WAPS 1.2, the Defense Waste Processing Facility (DWPF) will report for each waste type, all radionuclides (with half-lives greater than 10 years) that have concentrations greater than 0.01 percent of the total inventory from time of production through the 1100 year period from 2015 through 3115. The initial listing of radionuclides to be included is based on the design-basis glass as identified in the Waste Form Compliance Plan (WCP)2 and Waste Form Qualification Report (WQR)3. However, it is required that this list be expanded if other radionuclides with half-lives greater than 10 years are identified that may meet the greater than 0.01% criterion for Curie content. Specification 1.6 of the WAPS, International Atomic Energy Agency (IAEA) Safeguards Reporting for High Level Waste (HLW), requires that the ratio by weights of the following uranium and plutonium isotopes be reported: U-233, U-234, U-235, U-236, U-238, Pu-238, Pu-239, Pu-240, Pu-241, and Pu-242. Therefore, the complete set of reportable radionuclides must also include this set of U and Pu isotopes. The DWPF is receiving radioactive sludge slurry from HLW Tank 40. The radioactive sludge slurry in Tank 40 is a blend of the previous contents of Tank 40 (Sludge Batch 3) and the sludge that was transferred to Tank 40 from Tank 51. The blend of sludge from Tank 51 and Tank 40 defines Sludge Batch 4 (also referred to as Macrobatch 5 (MB5)). This report develops the list of reportable radionuclides and associated activities and determines the radionuclide activities as a function of time. The DWPF will use this list and the activities as one of

  3. DETERMINATION OF REPORTABLE RADIONUCLIDES FOR DWPF SLUDGE BATCH 5 (MACROBATCH 6)

    SciTech Connect

    Bannochie, C.; Bibler, N.; Diprete, D.

    2010-02-04

    The Waste Acceptance Product Specifications (WAPS) 1.2 require that ''The Producer shall report the inventory of radionuclides (in Curies) that have half-lives longer than 10 years and that are, or will be, present in concentrations greater than 0.05 percent of the total inventory for each waste type indexed to the years 2015 and 3115''. As part of the strategy to comply with WAPS 1.2, the Defense Waste Processing Facility (DWPF) will report for each waste type, all radionuclides (with half-lives greater than 10 years) that have concentrations greater than 0.01 percent of the total inventory from time of production through the 1100 year period from 2015 through 3115. The initial listing of radionuclides to be included is based on the design-basis glass as identified in the Waste Form Compliance Plan (WCP) and Waste Form Qualification Report (WQR). However, it is required that this list be expanded if other radionuclides with half-lives greater than 10 years are identified that may meet the greater than 0.01% criterion for Curie content. Specification 1.6 of the WAPS, International Atomic Energy Agency (IAEA) Safeguards Reporting for High Level Waste (HLW), requires that the ratio by weights of the following uranium and plutonium isotopes be reported: U-233, U-234, U-235, U-236, U-238, Pu-238, Pu-239, Pu-240, Pu-241, and Pu-242. Therefore, the complete set of reportable radionuclides must also include this set of U and Pu isotopes. The DWPF is receiving radioactive sludge slurry from HLW Tank 40. The radioactive sludge slurry in Tank 40 is a blend of the heel from Tank 40 (Sludge Batch 4 (SB4)), Sludge Batch 5 (SB5) that was transferred to Tank 40 from Tank 51, and H-Canyon Np transfers completed after the start of processing. The blend of sludge in Tank 40 is also referred to as Macrobatch 6 (MB6). This report develops the list of reportable radionuclides and associated activities and determines the radionuclide activities as a function of time. The DWPF will use

  4. DETERMINATION OF REPORTABLE RADIONUCLIDES FOR DWPF SLUDGE BATCH 6 (MACROBATCH 7)

    SciTech Connect

    Bannochie, C.; Diprete, D.

    2011-06-01

    The Waste Acceptance Product Specifications (WAPS) 1.2 require that 'The Producer shall report the inventory of radionuclides (in Curies) that have half-lives longer than 10 years and that are, or will be, present in concentrations greater than 0.05 percent of the total inventory for each waste type indexed to the years 2015 and 3115'. As part of the strategy to comply with WAPS 1.2, the Defense Waste Processing Facility (DWPF) will report for each waste type, all radionuclides (with half-lives greater than 10 years) that have concentrations greater than 0.01 percent of the total inventory from time of production through the 1100 year period from 2015 through 3115. The initial listing of radionuclides to be included is based on the design-basis glass as identified in the Waste Form Compliance Plan (WCP) and Waste Form Qualification Report (WQR). However, it is required that this list be expanded if other radionuclides with half-lives greater than 10 years are identified that may meet the greater than 0.01% criterion for Curie content. Specification 1.6 of the WAPS, International Atomic Energy Agency (IAEA) Safeguards Reporting for High Level Waste (HLW), requires that the ratio by weights of the following uranium and plutonium isotopes be reported: U-233, U-234, U-235, U-236, U-238, Pu-238, Pu-239, Pu-240, Pu-241, and Pu-242. Therefore, the complete set of reportable radionuclides must also include this set of U and Pu isotopes. The DWPF is receiving radioactive sludge slurry from HLW Tank 40. The radioactive sludge slurry in Tank 40 is a blend of the heel from Sludge Batch 5 (SB5) with H-Canyon Np transfers completed after the start of processing SB5, and Sludge Batch 6 (SB6) that was transferred to Tank 40 from Tank 51. The blend of sludge in Tank 40 is also referred to as Macrobatch 7 (MB7). This report develops the list of reportable radionuclides and associated activities as a function of time. The DWPF will use this list and the activities as one of the

  5. DWPF Hydrogen Generation Study-Form of Noble Metal SRAT Testing

    SciTech Connect

    Bannochie, C

    2005-09-01

    The Defense Waste Processing Facility, DWPF, has requested that the Savannah River National Laboratory, SRNL, investigate the factors that contribute to hydrogen generation to determine if current conservatism in setting the DWPF processing window can be reduced. A phased program has been undertaken to increase understanding of the factors that influence hydrogen generation in the DWPF Chemical Process Cell, CPC. The hydrogen generation in the CPC is primarily due to noble metal catalyzed decomposition of formic acid with a minor contribution from radiolytic processes. Noble metals have historically been added as trim chemicals to process simulations. The present study investigated the potential conservatism that might be present from adding the catalytic species as trim chemicals to the final sludge simulant versus co-precipitating the noble metals into the insoluble sludge solids matrix. Two sludge simulants were obtained, one with co-precipitated noble metals and one without noble metals. Co-precipitated noble metals were expected to better match real waste behavior than using trimmed noble metals during CPC simulations. Portions of both sludge simulants were held at 97 C for about eight hours to qualitatively simulate the effects of long term storage on particle morphology and speciation. The two original and two heat-treated sludge simulants were then used as feeds to Sludge Receipt and Adjustment Tank, SRAT, process simulations. Testing was done at relatively high acid stoichiometries, {approx}175%, and without mercury in order to ensure significant hydrogen generation. Hydrogen generation rates were monitored during processing to assess the impact of the form of noble metals. The following observations were made on the data: (1) Co-precipitated noble metal simulant processed similarly to trimmed noble metal simulant in most respects, such as nitrite to nitrate conversion, formate destruction, and pH, but differently with respect to hydrogen generation: (A

  6. Extended Development Work to Validate a HLW Calcine Waste Form via INL's Cold Crucible Induction Melter

    SciTech Connect

    James A. King; Vince Maio

    2011-09-01

    To accomplish calcine treatment objectives, the Idaho Clean-up Project contractor, CWI, has chosen to immobilize the calcine in a glass-ceramic via the use of a Hot-Isostatic-Press (HIP); a treatment selection formally documented in a 2010 Record of Decision (ROD). Even though the HIP process may prove suitable for the calcine as specified in the ROD and validated in a number of past value engineering sessions, DOE is evaluating back-up treatment methods for the calcine as a result of the technical, schedule, and cost risk associated with the HIPing process. Consequently DOE HQ has requested DOE ID to make INL's bench-scale cold-crucible induction melter (CCIM) available for investigating its viability as a process alternate to calcine treatment. The waste form is the key component of immobilization of radioactive waste. Providing a solid, stable, and durable material that can be easily be stored is the rationale for immobilization of radioactive waste material in glass, ceramic, or glass-ceramics. Ceramic waste forms offer an alternative to traditional borosilicate glass waste forms. Ceramics can usually accommodate higher waste loadings than borosilicate glass, leading to smaller intermediate and long-term storage facilities. Many ceramic phases are known to possess superior chemical durability as compared to borosilicate glass. However, ceramics are generally multiphase systems containing many minor phase that make characterization and prediction of performance within a repository challenging. Additionally, the technologies employed in ceramic manufacture are typically more complex and expensive. Thus, many have proposed using glass-ceramics as compromise between in the more inexpensive, easier to characterize glass waste forms and the more durable ceramic waste forms. Glass-ceramics have several advantages over traditional borosilicate glasses as a waste form. Borosilicate glasses can inadvertently devitrify, leading to a less durable product that could crack

  7. IMPACT OF IRRADIATION AND THERMAL AGING ON DWPF SIMULATED SLUDGE PROPERTIES

    SciTech Connect

    Eibling, R; Michael Stone, M

    2006-10-16

    The research and development programs in support of the Defense Waste Processing Facility (DWPF) and other high-level waste vitrification processes require the use of both nonradioactive waste simulants and actual waste samples. While actual waste samples are the ideal materials to study, acquiring large quantities of actual waste is difficult and expensive. Tests utilizing actual high-level waste require the use of expensive shielded cells facilities to provide sufficient shielding for the researchers. Nonradioactive waste simulants have been used for laboratory testing, pilot-scale testing and full-scale integrated facility testing. These waste simulants were designed to reproduce the chemical and, if possible, the physical properties of the actual high-level waste. This technical report documents a study on the impact of irradiating a Sludge Batch 3 (SB3) simulant and of additional tests on aging a SB3 simulant by additional thermal processing. Prior simulant development studies examined methods of producing sludge and supernate simulants and processes that could be used to alter the physical properties of the simulant to more accurately mimic the properties of actual waste. Development of a precipitated sludge simulant for the River Protection Project (RPP) demonstrated that the application of heat for a period of time could significantly alter the rheology of the sludge simulant. The RPP precipitated simulant used distillation to concentrate the sludge solids and produced a reduction in sludge yield stress of up to 80% compared to the initial sludge properties. Observations at that time suggested that a substantial fraction of the iron hydroxide had converted to the oxide during the distillation. DWPF sludge simulant studies showed a much smaller reduction in yield stress ({approx}10%), demonstrated the impact of shear on particle size, and showed that smaller particle sizes yielded higher yield stress products. The current study documented in this report

  8. ANALYSIS OF SLUDGE BATCH 4 (MACROBATCH 5) FOR CANISTER S02902 AND SLUDGE BATCH 5 (MACROBATCH 6) FOR CANISTER S03317 DWPF POUR STREAM GLASS SAMPLES

    SciTech Connect

    Reigel, M.; Bibler, N.

    2010-10-04

    The Defense Waste Processing Facility (DWPF) began processing Sludge Batch 4 (SB4), Macrobatch 5 (MB5) on May 29, 2007. Sludge Batch 4 was a blend of the heel of Tank 40 from Sludge Batch 3 (SB3) and SB4 material qualified in Tank 51. On November 28, 2008, DWPF began processing Sludge Batch 5 (SB5) from Tank 40 which is a blend of the heel of Tank 40 from SB4, SB5 material qualified in Tank 51 and H-Canyon Pu and Np transfers. SB4 was processed using Frit 510 and SB5 used Frit 418. During processing of each sludge batch, the DWPF is required to take at least one glass sample to meet the objectives of the Glass Product Control Program and to complete the necessary Production Records so that the final glass product may be disposed of at a Federal Repository. During the processing of SB4 and SB5, glass samples were obtained during the pouring of canisters S02902 and S03317, respectively. The samples were transferred to the Savannah River National Laboratory (SRNL) where they were analyzed (durability, chemical and radionuclide composition). The following observations and conclusions are drawn from the analytical results provided in this report: (1) The sum of the oxides for the chemical composition of both the SB4 and SB5 pour stream glasses is within the Product Composition Control System (PCCS) acceptance limits (95 {le} sum of oxides {le} 105). (2) The calculated Sludge Dilution Factor (SDF) for SB4 is 2.52. The measured radionuclide content is in good agreement with the calculated values from the dried sludge results from the SB4 Waste Acceptance Production Specification (WAPS) sample (References 1 and 19). (3) The calculated SDF for SB5 is 2.60. The measured radionuclide content is in good agreement with the calculated values from the dried sludge results from the SB5 WAPS sample (References 2 and 20). (4) Scanning Electron Microscopy (SEM) analysis shows there are noble metal inclusions, primarily ruthenium, present in both pour stream samples. (5) The Product

  9. Demonstration of an approach to waste form qualification through simulation of liquid-fed ceramic melter process operations

    SciTech Connect

    Reimus, P.W.; Kuhn, W.L.; Peters, R.D.; Pulsipher, B.A.

    1986-07-01

    During fiscal year 1982, the US Department of Energy (DOE) assigned responsibility for managing civilian nuclear waste treatment programs in the United States to the Nuclear Waste Treatment Program (NWTP) at the Pacific Northwest Laboratory (PNL). One of the principal objectives of this program is to establish relationships between vitrification process control and glass quality. Users of the liquid-fed ceramic melter (LFCM) process will need such relationships in order to establish acceptance of vitrified high-level nuclear waste at a licensed federal repository without resorting to destructive examination of the canisters. The objective is to be able to supply a regulatory agency with an estimate of the composition, durability, and integrity of the glass in each waste glass canister produced from an LFCM process simply by examining the process data collected during the operation of the LFCM. The work described here will continue through FY-1987 and culminate in a final report on the ability to control and monitor an LFCM process through sampling and process control charting of the LFCM feed system.

  10. Effect of Feeding Rate on the Cold Cap Configuration in a Laboratory-Scale Melter

    SciTech Connect

    Dixon, Derek R.; Schweiger, Michael J.; Hrma, Pavel R.

    2013-02-25

    High level waste melter feed is converted into glass in a joule heated melter, where it forms a floating layer of reacting feed, called the cold cap. After the glass-forming phase becomes connected, evolving gases produce bubbles that form a foam layer under the cold cap. The bubbles coalesce into cavities that escape around the edges of the cold cap. The foam layer insulates the cold cap from the heat transferred from the molten glass below. More information is needed about the formation and behavior of the foam layer to control, limit and possibly avoid foaming, thus allowing for a higher rate of melting. The cold cap behavior was investigated in a laboratory scale assembly with a sealed silica-glass crucible. A high alumina waste simulant was fed into the crucible and the feed charging rate was varied from 3 to 7 mL min-1. After a fixed amount of time (35 min), feed charging was stopped and the crucible was removed from the furnace and quenched on a copper block to preserve the structure of the cold cap and foam during cooling. During the rapid quenching, thermal cracking of the glass and cold cap allowed it to be broken up into sections for analysis. The effect of the charging rate on the height, area and volume of the cold cap was determined. The size of the bubbles collected in the foam layer under the cold cap increased as the cold cap expanded. Under the cold cap, the bubbles coalesced into oblong cavities. These cavities allowed the evolved gases to escape around the edges of the cold cap through the molten glass into the melter plenum.

  11. Evaluation of DWPF canister closure welds containing ceramic rings of lava A, alumina, or steatite

    SciTech Connect

    Herman, D.T.; Harbour, J.R.; Marra, J.C.; Eberhard, B.J.

    1994-06-01

    A ceramic ring is used to ensure proper positioning of the weld plug for the Defense Waste Processing Facility (DWPF) final weld. The weld plug is assembled by sandwiching a ceramic ring between two stainless steel pieces. The function of the ceramic ring is to center the weld plug in the nozzle opening. This ring must be electrically insulating to ensure that current flow and consequently welding occur only between the nozzle and the top piece of the weld plug. In the past, Lava A, a naturally occurring material, has been used to fabricate these rings. Testing was performed to identify compositionally controllable ceramic rings to replace the current lava A weld plug ring material. A series of tests were performed to assure that a change in ring material would not detrimentally affect the final canister closure weld integrity. Alumina and steatite rings proved functionally equivalent to the lava A ceramic rings. These materials also had a lower moisture content which reduces the Potential for internal localized corrosion. The need for careful cleaning of the stainless steel weld Plug components was also identified, resulting in more stringent control of the cleaning process.

  12. ANALYSES AND COMPARISON OF BULK AND COIL SURFACE SAMPLES FROM THE DWPF SLURRY MIX EVAPORATOR

    SciTech Connect

    Hay, M.; Nash, C.; Stone, M.

    2012-02-17

    Sludge samples from the DWPF Slurry Mix Evaporator (SME) heating coil frame and coil surface were characterized to identify differences that might help identify heat transfer fouling materials. The SME steam coils have seen increased fouling leading to lower boil-up rates. Samples of the sludge were taken from the coil frame somewhat distant from the coil (bulk tank material) and from the coil surface (coil surface sample). The results of the analysis indicate the composition of the two SME samples are very similar with the exception that the coil surface sample shows {approx}5-10X higher mercury concentration than the bulk tank sample. Elemental analyses and x-ray diffraction results did not indicate notable differences between the two samples. The ICP-MS and Cs-137 data indicate no significant differences in the radionuclide composition of the two SME samples. Semi-volatile organic analysis revealed numerous organic molecules, these likely result from antifoaming additives. The compositions of the two SME samples also match well with the analyzed composition of the SME batch with the exception of significantly higher silicon, lithium, and boron content in the batch sample indicating the coil samples are deficient in frit relative to the SME batch composition.

  13. Test plan for evaluation of plasma melter technology for vitrification of high-sodium content low-level radioactive liquid wastes

    SciTech Connect

    McLaughlin, D.F.; Lahoda, E.J.; Gass, W.R.; D`Amico, N.

    1994-10-20

    This document provides a test plan for the conduct of plasma arc vitrification testing by a vendor in support of the Hanford Tank Waste Remediation System (TWRS) Low-Level Waste (LLW) Vitrification Program. The vendor providing this test plan and conducting the work detailed within it [one of seven selected for glass melter testing under Purchase Order MMI-SVV-384212] is the Westinghouse Science and Technology Center (WSTC) in Pittsburgh, PA. WSTC authors of the test plan are D. F. McLaughlin, E. J. Lahoda, W. R. Gass, and N. D`Amico. The WSTC Program Manager for this test is D. F. McLaughlin. This test plan is for Phase I activities described in the above Purchase Order. Test conduct includes melting of glass frit with Hanford LLW Double-Shell Slurry Feed waste simulant in a plasma arc fired furnace.

  14. Vitrification of SRP waste by a slurry-fed ceramic melter

    SciTech Connect

    Wicks, G.G.

    1980-01-01

    Savannah River Plant (SRP) high-level waste (HLW) can be vitrified by feeding a slurry, instead of a calcine, to a joule-heated ceramic melter. Potential advantages of slurry feeding include (1) use of simpler equipment, (2) elimination of handling easily dispersed radioactive powder, (3) simpler process control, (4) effective mixing, (5) reduced off-gas volume, and (6) cost savings. Assessment of advantages and disadvantages of slurry feeding along with experimental studies indicate that slurry feeding is a promising way of vitrifying waste.

  15. DEMONSTRATION AND EVALUATION OF POTENTIAL HIGH LEVEL WASTE MELTER DECONTAMINATION TECHNOLOGIES FOR SAVANNAH RIVER SITE

    SciTech Connect

    Weger, Hans, Ph.D.; Kodanda, Raja Tilek Meruva; Mazumdar, Anindra; Srivastava, Rajiv Ph.D.; Ebadian, M.A. Ph.D.

    2003-02-27

    Four hand-held tools were tested for failed high-level waste melter decontamination and decommissioning (D&D). The forces felt by the tools during operation were measured using a tri-axial accelerometer since they will be operated by a remote manipulator. The efficiency of the tools was also recorded. Melter D&D consists of three parts: (1) glass fracturing: removing from the furnace the melted glass that can not be poured out through normal means, (2) glass cleaning: removing the thin layer of glass that has formed over the surface of the refractory material, and (3) K-3 refractory breakup: removing the K-3 refractory material. Surrogate glass, from a formula provided by the Savannah River Site, was melted in a furnace and poured into steel containers. K-3 refractory material, the same material used in the Defense Waste Processing Facility, was utilized for the demonstrations. Four K-3 blocks were heated at 1150 C for two weeks with a glass layer on top to simulate the hardened glass layer on the refractory surface in the melter. Tools chosen for the demonstrations were commonly used D&D tools, which have not been tested specifically for the different aspects of melter D&D. A jackhammer and a needle gun were tested for glass fracturing; a needle gun and a rotary grinder with a diamond face wheel (diamond grinder) were tested for glass cleaning; and a jackhammer, diamond grinder, and a circular saw with a diamond blade were tested for refractory breakup. The needle gun was not capable of removing or fracturing the surrogate glass. The diamond grinder only had a removal rate of 3.0 x 10-4 kg/s for K-3 refractory breakup and needed to be held firmly against the material. However, the diamond grinder was effective for glass cleaning, with a removal rate of 3.9 cm2/s. The jackhammer was successful in fracturing glass and breaking up the K-3 refractory block. The jackhammer had a glass-fracturing rate of 0.40 kg/s. The jackhammer split the K-3 refractory block into two

  16. Effect of Feeding Rate on the Cold Cap Configuration in a Laboratory-Scale Melter - 13362

    SciTech Connect

    Dixon, Derek R.; Schweiger, Michael J.; Hrma, Pavel

    2013-07-01

    High-level-waste melter feed is converted into glass in a joule-heated melter, where it forms a floating layer of reacting feed, called the cold cap. After the glass-forming phase becomes connected, evolving gases produce bubbles that form a foam layer under the feed. The bubbles coalesce into cavities, from which most of the gases are released around the edges of the cold cap while gases also escape through small shafts in the reacting feed. The foam layer insulates the cold cap from the heat transferred from the molten glass below. The cold cap behavior was investigated in a laboratory-scale assembly with a fused silica crucible. A high-alumina waste simulant was fed into the crucible and the feed charging rate was varied from 3 to 7 mL min{sup -1}. After a fixed amount of time (35 min), feed charging was stopped and the crucible was removed from the furnace and quenched on a copper block to preserve the structure of the cold cap during cooling. During the rapid quenching, thermal cracking of the glass and cold cap allowed it to be broken up into sections for analysis. The effect of the charging rate on the height, area and volume of the cold cap was determined. The size of the bubbles collected in the foam layer under the feed increased as the cold cap expanded and the relationship between these bubbles and temperature will be determined for input into a mathematical model. (authors)

  17. DEMONSTRATION OF THE DWPF FLOWSHEET IN THE SRNL SHIELDED CELLS WITH TANK 40 AND H CANYON NEPTUNIUM

    SciTech Connect

    Pareizs, J; Bradley Pickenheim, B; Cj Bannochie, C; Michael Stone, M

    2009-04-28

    The Defense Waste Processing Facility (DWPF) is currently processing Sludge Batch 5 (SB5) from Tank 40. SB5 contains the contents of Tank 51 from November 2008, qualified by the Savannah River National Laboratory (SRNL) and the heel in Tank 40 remaining from Sludge Batch 4. Current Liquid Waste Operations (LWO) plans are to (1) decant supernatant from Tank 40 to remove excess liquid caused by a leaking slurry pump and (2) receive a Np stream from H Canyon It should be noted that the Np stream contains significant nitrate requiring addition of nitrite to Tank 40 to maintain a high nitrite to nitrate ratio for corrosion control. SRNL has been requested to qualify the proposed changes; determine the impact on DWPF processability in terms of hydrogen generation, rheology, etc.; evaluate antifoam addition strategy; and evaluate mercury stripping. Therefore, SRNL received a 3 L sample of Tank 40 following the transfer of Tank 51 to Tank 40 (Tank Farm Sample HTF-40-08-157 to be used in testing and to perform the required Waste Acceptance Product Specifications radionuclide analyses). Based on Tank Farm projections, SRNL decanted a portion* of the sample, added sodium nitrite, and added a Np solution from H Canyon representative of the Np to be dispositioned to Tank 40 (neutralized to 0.6 M excess hydroxide). The resulting material was used in a DWPF Chemical Process Cell (CPC) demonstration -- a Sludge Receipt and Adjustment Tank (SRAT) cycle and a Slurry Mix Evaporator (SME) cycle. Preliminary data from the demonstration has been reported previously. This report includes discussion of these results and additional results, including comparisons to Tank Farm projections and the SB5 demonstration.

  18. The Development of an Innovative Vertical Floatation Melter and Scrap Dryer for Use in the Aluminum Processing Industry

    SciTech Connect

    Robert De Saro

    2004-08-24

    The project aimed at the development of a Vertical Floatation melter, for application to the aluminum industry. This is intended to improve both the energy efficiency and environmental performance of aluminum melting furnaces. Phase I of this project dealt primarily with the initial research effort. Phase II, dealt with pilot-scale testing.

  19. Rheological Properties of Defense Waste processing Facility Melter Feeds

    SciTech Connect

    Mao, F.; Ebadian, M.A.

    1998-10-20

    In the present investigation, viscosity measurements have been carried out for two types of simulated Defense waste slurries, a Savannah River slurry and a Hanford slurry. The measurements were conducted in two experimental options. A rotational viscometer was used to measure viscosity under well-defined temperature and pH value operating conditions. The solids concentration used for this option was lower than 15 wt.%. Both the slurries have been investigated using this experimental option. The Savannah River slurry has also been investigated in a pipeline flow system, which measured the pressure drop as the slurry flowed through the pipe. The slurry's viscosity can be extracted from the pressure drop information. These investigations have been performed in relatively wide parameter ranges. The solids concentration of the slurry tested in the pipeline system was as high as 25 wt.%.The slurry pH in both experimental options covered a range of 4 to 13.5. The highest operating temperature was 66 C for the rotational viscometer and 55 C for the pipeline system. In FY97, the experiments for the Hanford slurry in the pipeline system will be performed.

  20. Preparation and Heat-Treatment of DWPF Simulants With and Without Co-Precipitated Noble Metals

    SciTech Connect

    Koopman, David C.:Eibling, Russel E

    2005-08-01

    The Savannah River National Laboratory is in the process of investigating factors suspected of impacting catalytic hydrogen generation in the Chemical Process Cell of the Defense Waste Processing Facility, DWPF. Noble metal catalyzed hydrogen generation in simulation work constrains the allowable acid addition operating window in DWPF. This constraint potentially impacts washing strategies during sludge batch preparation. It can also influence decisions related to the addition of secondary waste streams to a sludge batch. Noble metals have historically been added as trim chemicals to process simulations. The present study investigated the potential conservatism that might be present from adding the catalytic species as trim chemicals to the final sludge simulant versus co-precipitating the noble metals into the insoluble sludge solids matrix. Parallel preparations of two sludge simulants targeting the composition of Sludge Batch 3 were performed in order to evaluate the impact of the form of noble metals. Identical steps were used except that one simulant had dissolved palladium, rhodium, and ruthenium present during the precipitation of the insoluble solids. Noble metals were trimmed into the other stimulant prior to process tests. Portions of both sludge simulants were held at 97 C for about eight hours to qualitatively simulate the effects of long term storage on particle morphology and speciation. The simulants were used as feeds for Sludge Receipt and Adjustment Tank, SRAT, process simulations. The following conclusions were drawn from the simulant preparation work: (1) The first preparation of a waste slurry simulant with co-precipitated noble metals was successful, based on the data obtained. It appears that 99+% of the noble metals were retained in the simulant. (2) Better control of carbonate, hydroxide, and post-wash trim chemical additions is needed before the new method of simulant preparation will be as reproducible as the old method. (3) The two new

  1. Miscibility Evaluation Of The Next Generation Solvent With Polymers Currently Used At DWPF, MCU, And Saltstone

    SciTech Connect

    Fondeur, F. F.

    2013-04-17

    The Office of Waste Processing, within the Office of Technology Innovation and Development, funded the development of an enhanced Caustic-Side Solvent Extraction (CSSX) solvent for deployment at the Savannah River Site for removal of cesium from High Level Waste. This effort lead to the development of the Next Generation Solvent (NGS) with Tris (3,7-dimethyl octyl) guanidine (TiDG). The first deployment target for the NGS solvent is within the Modular CSSX Unit (MCU). Deployment of a new chemical within an existing facility requires verification that the new chemical components are compatible with the installed equipment. In the instance of a new organic solvent, the primary focus is on compatibility of the solvent with organic polymers used in the affected facility. This report provides the calculated data from exposing these polymers to the Next Generation Solvent. An assessment of the dimensional stability of polymers known to be used or present in the MCU, Defense Waste Processing Facility (DWPF), and Saltstone facilities that will be exposed to the NGS showed that TiDG could selectively affect the elastomers and some thermoplastics to varying extents, but the typical use of these polymers in a confined geometry will likely prevent the NGS from impacting component performance. The polymers identified as of primary concern include Grafoil® (flexible graphite), Tefzel®, Isolast®, ethylene-propylene-diene monomer (EPDM) rubber, nitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), ultra high molecular weight polyethylene (UHMWPE), and fluorocarbon rubber (FKM). Certain polymers like NBR and EPDM were found to interact mildly with NGS but their calculated swelling and the confined geometry will impede interaction with NGS. In addition, it was found that Vellumoid (cellulose fibers-reinforced glycerin and protein) may leach protein and Polyvinyl Chloride (PVC) may leach plasticizer (such as Bis-Ethylhexyl-Phthalates) into the NGS solvent. Either case

  2. CATALYTIC INTERACTIONS OF RHODIUM, RUTHENIUM, AND MERCURY DURING SIMULATED DWPF CPC PROCESSING WITH HYDROGEN GENERATION

    SciTech Connect

    Koopman, D

    2008-10-09

    Simulations of the Defense Waste Processing Facility (DWPF) Chemical Processing Cell (CPC) vessels were performed as part of the ongoing investigation into catalytic hydrogen generation. Rhodium, ruthenium, and mercury have been identified as the principal elemental factors affecting the peak hydrogen generation rate in the DWPF Sludge Receipt and Adjustment Tank (SRAT) for a given acid addition. The primary goal of this study is to identify any significant interactions between the three factors. Noble metal concentrations were similar to recent sludge batches. Rh ranged from 0.0026-0.013% and Ru ranged from 0.010-0.050% in the dried sludge solids, while initial Hg ranged from 0.5-2.5 wt%. An experimental matrix was developed to ensure that the existence of statistically significant two-way interactions could be determined without confounding of the main effects with the two-way interaction effects. The nominal matrix design consisted of twelve SRAT cycles. Testing included: a three factor (Rh, Ru, and Hg) study at two levels per factor (eight runs), two duplicate midpoint runs, and two additional replicate runs to assess reproducibility away from the midpoint. Midpoint testing can identify potential quadratic effects from the three factors. A single sludge simulant was used for all tests. Acid addition was kept effectively constant except to compensate for variations in the starting mercury concentration. Six Slurry Mix Evaporator (SME) cycles were performed to supplement the SME hydrogen generation database. Some of the preliminary findings from this study include: (1) Rh was linked to the maximum SRAT hydrogen generation rate in the first two hours after acid addition in preliminary statistical modeling. (2) Ru was linked conclusively to the maximum SRAT hydrogen generation rate in the last four hours of reflux in preliminary statistical modeling. (3) Increasing the ratio of Hg/Rh shifted the noble metal controlling the maximum SRAT hydrogen generation rate from

  3. DWPF saltstone study: Effects of thermal history on leach index and physical integrity

    SciTech Connect

    Orebaugh, E.G.

    1992-11-18

    This report summarizes the observations made during the curing and testing of DWPF simulated saltstones which have been cured under isothermal conditions in sealed glass envelopes at temperatures from room temperature to 95[degrees]C. This study was performed to evaluate the effect of curing at and around temperatures representing conditions created within large pours of grout. There appears to be no difference in the leaching resistance of samples cured at the same temperature for varying times to 1 year. Curing at higher temperatures decreases the effective diffusivity of this waste formulation. These results are encouraging in that leaching resistance for samples near the expected maximum vault temperature (55[degrees]C) show effective diffusion coefficients (D[sub effective] [approximately]10[sup [minus]8] cm[sup 2]/sec) that agree with previous work and values that are believed to adequately protect the groundwater. The isothermal conditions of these tests simulate the nearly adiabatic conditions existing near the centerline of the monolith. The elevated temperatures due to hydration heat decrease over long times. This has been simulated by a series (1X) of staged isothermal cures. Since modeling indicated it would take nearly two years for emplaced grout to cool to near ambient temperatures, accelerated (2X) cooling curves were also tested. Specimens cured under these staged-isothermal conditions appear to be no different from specimens cured under isothermal conditions for the same time at the maximum temperature. The unexpected generation of nitrous oxide within saltstone creates internal stresses which cause fracturing when exposed to leaching conditions. Such fracturing is not considered significant for saltstone emplaced in engineered vaults for disposal.

  4. Characterization of the Defense Waste Processing Facility (DWPF) Environmental Assessment (EA) glass Standard Reference Material. Revision 1

    SciTech Connect

    Jantzen, C.M.; Bibler, N.E.; Beam, D.C.; Crawford, C.L.; Pickett, M.A.

    1993-06-01

    Liquid high-level nuclear waste at the Savannah River Site (SRS) will be immobilized by vitrification in borosilicate glass. The glass will be produced and poured into stainless steel canisters in the Defense Waste Processing Facility (DWPF). Other waste form producers, such as West Valley Nuclear Services (WVNS) and the Hanford Waste Vitrification Project (HWVP), will also immobilize high-level radioactive waste in borosilicate glass. The canistered waste will be stored temporarily at each facility for eventual permanent disposal in a geologic repository. The Department of Energy has defined a set of requirements for the canistered waste forms, the Waste Acceptance Product Specifications (WAPS). The current Waste Acceptance Primary Specification (WAPS) 1.3, the product consistency specification, requires the waste form producers to demonstrate control of the consistency of the final waste form using a crushed glass durability test, the Product Consistency Test (PCI). In order to be acceptable, a waste glass must be more durable during PCT analysis than the waste glass identified in the DWPF Environmental Assessment (EA). In order to supply all the waste form producers with the same standard benchmark glass, 1000 pounds of the EA glass was fabricated. The chemical analyses and characterization of the benchmark EA glass are reported. This material is now available to act as a durability and/or redox Standard Reference Material (SRM) for all waste form producers.

  5. Initial results from the canistered waste forms produced during the first campaign of the DWPF Startup Test Program

    SciTech Connect

    Harbour, J.R.

    1995-01-01

    As part of the Defense Waste Processing Facility (DWPF) Startup Test Program, approximately 90 canisters will be filled with glass containing simulated radioactive waste during five separate campaigns. The first campaign is a facility acceptance test to demonstrate the operability of the facility and to collect initial data on the glass and the canistered waste forms. During the next four campaigns (the waste qualification campaigns) data will be obtained which will be used to demonstrate that the DWPF product meets DOE`s Waste Acceptance Product Specifications (WAPS). Currently 12 of the 16 canisters have been filled with glass during the first campaign (FA-13). This paper describes the tests that have been carried out on these 12 glass-filled canisters and presents the data with reference to the acceptance criteria of the WAPS. These tests include measurement of canister dimensions prior to and after glass filling. dew point, composition, and pressure of the gas within the free volume of the canister, fill height, free volume, weight, leak rates of welds and temporary seals, and weld parameters.

  6. FY13 GLYCOLIC-NITRIC ACID FLOWSHEET DEMONSTRATIONS OF THE DWPF CHEMICAL PROCESS CELL WITH SIMULANTS

    SciTech Connect

    Lambert, D.; Zamecnik, J.; Best, D.

    2014-03-13

    Savannah River Remediation is evaluating changes to its current Defense Waste Processing Facility flowsheet to replace formic acid with glycolic acid in order to improve processing cycle times and decrease by approximately 100x the production of hydrogen, a potentially flammable gas. Higher throughput is needed in the Chemical Processing Cell since the installation of the bubblers into the melter has increased melt rate. Due to the significant maintenance required for the safety significant gas chromatographs and the potential for production of flammable quantities of hydrogen, eliminating the use of formic acid is highly desirable. Previous testing at the Savannah River National Laboratory has shown that replacing formic acid with glycolic acid allows the reduction and removal of mercury without significant catalytic hydrogen generation. Five back-to-back Sludge Receipt and Adjustment Tank (SRAT) cycles and four back-to-back Slurry Mix Evaporator (SME) cycles were successful in demonstrating the viability of the nitric/glycolic acid flowsheet. The testing was completed in FY13 to determine the impact of process heels (approximately 25% of the material is left behind after transfers). In addition, back-to-back experiments might identify longer-term processing problems. The testing was designed to be prototypic by including sludge simulant, Actinide Removal Product simulant, nitric acid, glycolic acid, and Strip Effluent simulant containing Next Generation Solvent in the SRAT processing and SRAT product simulant, decontamination frit slurry, and process frit slurry in the SME processing. A heel was produced in the first cycle and each subsequent cycle utilized the remaining heel from the previous cycle. Lower SRAT purges were utilized due to the low hydrogen generation. Design basis addition rates and boilup rates were used so the processing time was shorter than current processing rates.

  7. EM-21 HIGHER WASTE LOADING GLASSES FOR ENHANCED DOE HIGH-LEVEL WASTE MELTER THROUGHPUT STUDIES - 10194

    SciTech Connect

    Raszewski, F.; Peeler, D.; Edwards, T.

    2009-11-18

    Supplemental validation data has been generated that will be used to determine the applicability of the current Defense Waste Processing Facility (DWPF) liquidus temperature (T{sub L}) model to expanded DWPF glass regions of interest based on higher waste loadings. For those study glasses which had very close compositional overlap with the model development and/or model validation ranges (except TiO{sub 2} and MgO concentrations), there was very little difference in the predicted and measured TL values, even though the TiO{sub 2} contents were above the 2 wt% upper limit. The results indicate that the current T{sub L} model is applicable in these compositional regions. As the compositional overlap between the model validation ranges diverged from the target glass compositions, the T{sub L} data suggest that the model under-predicted the measured values. These discrepancies imply that there are individual oxides or their combinations that were outside of the model development and/or validation range over which the model was previously assessed. These oxides include B{sub 2}O{sub 3}, SiO{sub 2}, MnO, TiO{sub 2} and/or their combinations. More data is required to fill in these anticipated DWPF compositional regions so that the model coefficients could be refit to account for these differences.

  8. SLUDGE WASHING AND DEMONSTRATION OF THE DWPF FLOWSHEET IN THE SRNL SHIELDED CELLS FOR SLUDGE BATCH 7A QUALIFICATION

    SciTech Connect

    Pareizs, J.; Billings, A.; Click, D.

    2011-07-08

    Waste Solidification Engineering (WSE) has requested that characterization and a radioactive demonstration of the next batch of sludge slurry (Sludge Batch 7a*) be completed in the Shielded Cells Facility of the Savannah River National Laboratory (SRNL) via a Technical Task Request (TTR). This characterization and demonstration, or sludge batch qualification process, is required prior to transfer of the sludge from Tank 51 to the Defense Waste Processing Facility (DWPF) feed tank (Tank 40). The current WSE practice is to prepare sludge batches in Tank 51 by transferring sludge from other tanks. Discharges of nuclear materials from H Canyon are often added to Tank 51 during sludge batch preparation. The sludge is washed and transferred to Tank 40, the current DWPF feed tank. Prior to transfer of Tank 51 to Tank 40, SRNL simulates the Tank Farm and DWPF processes with a Tank 51 sample (referred to as the qualification sample). Sludge Batch 7a (SB7a) is composed of portions of Tanks 4, 7, and 12; the Sludge Batch 6 heel in Tank 51; and a plutonium stream from H Canyon. SRNL received the Tank 51 qualification sample (sample ID HTF-51-10-125) following sludge additions to Tank 51. This report documents: (1) The washing (addition of water to dilute the sludge supernate) and concentration (decanting of supernate) of the SB7a - Tank 51 qualification sample to adjust sodium content and weight percent insoluble solids to Tank Farm projections. (2) The performance of a DWPF Chemical Process Cell (CPC) simulation using the washed Tank 51 sample. The simulation included a Sludge Receipt and Adjustment Tank (SRAT) cycle, where acid was added to the sludge to destroy nitrite and reduce mercury, and a Slurry Mix Evaporator (SME) cycle, where glass frit was added to the sludge in preparation for vitrification. The SME cycle also included replication of five canister decontamination additions and concentrations. Processing parameters were based on work with a non

  9. DWPF Flowsheet Studies with Simulants to Determine Modular Caustic Side Solvent Extraction Unit Solvent Partitioning and Verify Actinide Removal Process Incorporation Strategy

    SciTech Connect

    Herman, C

    2006-04-21

    The Actinide Removal Process (ARP) facility and the Modular Caustic Side Solvent Extraction Unit (MCU) are scheduled to begin processing salt waste in fiscal year 2007. A portion of the streams generated in the salt processing facilities will be transferred to the Defense Waste Processing Facility (DWPF) to be incorporated in the glass matrix. Before the streams are introduced, a combination of impact analyses and research and development studies must be performed to quantify the impacts on DWPF processing. The Process Science & Engineering (PS&E) section of the Savannah River National Laboratory (SRNL) was requested via Technical Task Request (TTR) HLW/DWPF/TTR-2004-0031 to evaluate the impacts on DWPF processing. Simulant Chemical Process Cell (CPC) flowsheet studies have been performed using previous composition and projected volume estimates for the ARP sludge/monosodium titanate (MST) stream. Due to changes in the flammability control strategy for DWPF for salt processing, the incorporation strategy for ARP has changed and additional ARP flowsheet tests were necessary to validate the new processing strategy. The last round of ARP testing included the incorporation of the MCU stream and identified potential processing issues with the MCU solvent. The identified issues included the potential carry-over and accumulation of the MCU solvent components in the CPC condensers and in the recycle stream to the Tank Farm. Therefore, DWPF requested SRNL to perform additional MCU flowsheet studies to better quantify the organic distribution in the CPC vessels. The previous MCU testing used a Sludge Batch 4 (SB4) simulant since it was anticipated that both of these facilities would begin salt processing during SB4 processing. The same sludge simulant recipe was used in this round of ARP and MCU testing to minimize the number of changes between the two phases of testing so a better comparison could be made. ARP and MCU stream simulants were made for this phase of testing

  10. Immobilization of simulated high-level radioactive waste in borosilicate glass: Pilot scale demonstrations

    SciTech Connect

    Ritter, J.A.; Hutson, N.D.; Zamecnik, J.R.; Carter, J.T.

    1991-12-31

    The Integrated DWPF Melter System (IDMS), operated by the Savannah River Laboratory, is a pilot scale facility used in support of the start-up and operation of the Department of Energy`s Defense Waste Processing Facility. The IDMS has successfully demonstrated, on an engineering scale (one-fifth), that simulated high level radioactive waste (HLW) sludge can be chemically treated with formic acid to adjust both its chemical and physical properties, and then blended with simulated precipitate hydrolysis aqueous (PHA) product and borosilicate glass frit to produce a melter feed which can be processed into a durable glass product. The simulated sludge, PHA and frit were blended, based on a product composition program, to optimize the loading of the waste glass as well as to minimize those components which can cause melter processing and/or glass durability problems. During all the IDMS demonstrations completed thus far, the melter feed and the resulting glass that has been produced met all the required specifications, which is very encouraging to future DWPF operations. The IDMS operations also demonstrated that the volatile components of the melter feed (e.g., mercury, nitrogen and carbon, and, to a lesser extent, chlorine, fluorine and sulfur) did not adversely affect the melter performance or the glass product.

  11. Earth melter

    DOEpatents

    Chapman, Christopher C.

    1995-01-01

    An apparatus, and method of operating the apparatus, wherein a feed material is converted into a glassified condition for subsequent use or disposal. The apparatus is particularly useful for disposal of hazardous or noxious waste materials which are otherwise either difficult or expensive to dispose of. The apparatus is preferably constructed either by excavating a melt zone in a quantity of soil or rock, or by constructing a melt zone in an apparatus above grade and lining the melt zone with a back fill material if refractory properties are needed. The feed material is fed into the melt zone and, preferably, combusted to an ash, whereupon the heat of combustion is used to melt the ash to a molten condition. Electrodes may be used to maintain the molten feed material in a molten condition, and to maintain homogeneity of the molten materials.

  12. Letter report: Evaluation of LFCM off-gas system technologies for the HWVP

    SciTech Connect

    Goles, R.W.; Mishima, J.; Schmidt, A.J.

    1996-03-01

    Radioactive high-level liquid waste (HLLW), a byproduct of defense nuclear fuel reprocessing activities, is currently being stored in underground tanks at several US sites. Because its mobility poses significant environmental risks, HLLW is not a suitable waste form for long-term storage. Thus, high-temperature processes for solidifying and isolating the radioactive components of HLLW have been developed and demonstrated by the US Department of Energy (DOE) and its contractors. Vitrification using liquidfed ceramic melters (LFCMs) is the reference process for converting US HLLW into a borosilicate glass. Two vitrification plants are currently under construction in the United States: the West Valley Demonstration Plant (WVDP) being built at the former West Valley Nuclear Fuels Services site in West Valley, New York; and the Defense Waste Processing Facility (DWPF), which is currently 85% complete at DOE`s Savannah River Plant (SRP). A third facility, the Hanford Waste Vitrification Plant (HWVP), is being designed at DOE`s Hanford Site.

  13. Corrosion study for a radioactive waste vitrification facility

    SciTech Connect

    Imrich, K.J.; Jenkins, C.F.

    1993-10-01

    A corrosion monitoring program was setup in a scale demonstration melter system to evaluate the performance of materials selected for use in the Defense Waste Processing Facility (DWPF) at the DOE`s Savannah River Site. The system is a 1/10 scale prototypic version of the DWPF. In DWPF, high activity radioactive waste will be vitrified and encapsulated for long term storage. During this study twenty-six different alloys, including DWPF reference materials of construction and alternate higher alloy materials, were subjected to process conditions and environments characteristic of the DWPF except for radioactivity. The materials were exposed to low pH, elevated temperature (to 1200{degree}C) environments containing abrasive slurries, molten glass, mercury, halides and sulfides. General corrosion rates, pitting susceptibility and stress corrosion cracking of the materials were investigated. Extensive data were obtained for many of the reference materials. Performance in the Feed Preparation System was very good, whereas coupons from the Quencher Inlet region of the Melter Off-Gas System experienced localized attack.

  14. COMPUTER MODELING OF HIGH-LEVEL WASTE GLASS TEMPERATURES WITHIN DWPF CANISTERS DURING POURING AND COOL DOWN

    SciTech Connect

    Amoroso, J.

    2011-10-09

    This report describes the results of a computer simulation study to predict the temperature of the glass at any location inside a DWPF canister during pouring and subsequent cooling. These simulations are an integral part of a larger research focus aimed at developing methods to predict, evaluate, and ultimately suppress nepheline formation in HLW glasses. That larger research focus is centered on holistically understanding nepheline formation in HLW glass by exploring the fundamental thermal and chemical driving forces for nepheline crystallization with respect to realistic processing conditions. Through experimental work, the goal is to integrate nepheline crystallization potential in HLW glass with processing capability to ultimately optimize waste loading and throughput while maintaining an acceptable product with respect to durability. The results of this study indicated severe temperature gradients and prolonged temperature dwell times exist throughout different locations in the canister and that the time and temperatures that HLW glass is subjected to during processing is a function of pour rate. The simulations indicate that crystallization driving forces are not uniform throughout the glass volume in a DWPF (or DWPF-like) canister and illustrate the importance of considering overall kinetics (chemical and thermal driving forces) of nepheline formation when developing methods to predict and suppress its formation in HLW glasses. The intended path forward is to use the simulation data both as a driver for future experimental work and, as an investigative tool for evaluating the impact of experimental results. Simulation data will be used to develop laboratory experiments to more acutely evaluate nepheline formation in HLW glass by incorporating the simulated temperatures throughout the canister into the laboratory experiments. Concurrently, laboratory experiments will be performed to identify nepheline crystallization potential in HLW glass as a function of

  15. Submerged combustion melting processes for producing glass and similar materials, and systems for carrying out such processes

    DOEpatents

    Charbonneau, Mark William

    2015-08-04

    Processes of controlling submerged combustion melters, and systems for carrying out the methods. One process includes feeding vitrifiable material into a melter vessel, the melter vessel including a fluid-cooled refractory panel in its floor, ceiling, and/or sidewall, and heating the vitrifiable material with a burner directing combustion products into the melting zone under a level of the molten material in the zone. Burners impart turbulence to the molten material in the melting zone. The fluid-cooled refractory panel is cooled, forming a modified panel having a frozen or highly viscous material layer on a surface of the panel facing the molten material, and a sensor senses temperature of the modified panel using a protected thermocouple positioned in the modified panel shielded from direct contact with turbulent molten material. Processes include controlling the melter using the temperature of the modified panel. Other processes and systems are presented.

  16. Silicate Based Glass Formulations for Immobilization of U.S. Defense Wastes Using Cold Crucible Induction Melters

    SciTech Connect

    Smith, Gary L.; Kim, Dong-Sang; Schweiger, Michael J.; Marra, James C.; Lang, Jesse B.; Crum, Jarrod V.; Crawford, Charles L.; Vienna, John D.

    2014-05-22

    The cold crucible induction melter (CCIM) is an alternative technology to the currently deployed liquid-fed, ceramic-lined, Joule-heated melter for immobilizing of U.S. tank waste generated from defense related reprocessing. In order to accurately evaluate the potential benefits of deploying a CCIM, glasses must be developed specifically for that melting technology. Related glass formulation efforts have been conducted since the 1990s including a recent study that is first documented in this report. The purpose of this report is to summarize the silicate base glass formulation efforts for CCIM testing of U.S. tank wastes. Summaries of phosphate based glass formulation and phosphate and silicate based CCIM demonstration tests are reported separately (Day and Ray 2013 and Marra 2013, respectively). Combined these three reports summarize the current state of knowledge related to waste form development and process testing of CCIM technology for U.S. tank wastes.

  17. Development of the high-level waste high-temperature melter feed preparation flowsheet for vitrification process testing

    SciTech Connect

    Seymour, R.G.

    1995-02-17

    High-level waste (HLW) feed preparation flowsheet development was initiated in fiscal year (FY) 1994 to evaluate alternative flowsheets for preparing melter feed for high-temperature melter (HTM) vitrification testing. Three flowsheets were proposed that might lead to increased processing capacity relative to the Hanford Waste Vitrification Plant (HWVP) and that were flexible enough to use with other HLW melter technologies. This document describes the decision path that led to the selection of flowsheets to be tested in the FY 1994 small-scale HTM tests. Feed preparation flowsheet development for the HLW HTM was based on the feed preparation flowsheet that was developed for the HWVP. This approach allowed the HLW program to build upon the extensive feed preparation flowsheet database developed under the HWVP Project. Primary adjustments to the HWVP flowsheet were to the acid adjustment and glass component additions. Developmental background regarding the individual features of the HLW feed preparation flowsheets is provided. Applicability of the HWVP flowsheet features to the new HLW vitrification mission is discussed. The proposed flowsheets were tested at the laboratory-scale at Pacific Northwest Laboratory. Based on the results of this testing and previously established criteria, a reductant-based flowsheet using glycolic acid and a nitric acid-based flowsheet were selected for the FY 1994 small-scale HTM testing.

  18. WASHING AND DEMONSTRATION OF THE DWPF FLOWSHEET IN THE SRNL SHIELDED CELLS USING POST ALUMINUM DISSOLUTION TANK 51 SLUDGE SLURRY

    SciTech Connect

    Pareizs, J; Cj Bannochie, C; Damon Click, D; Erich Hansen, E; Dan Lambert, D; Michael Stone, M

    2008-04-28

    The remaining contents of Tank 51 from Sludge Batch 4 will be blended with Purex sludge from Tank 7 to constitute Sludge Batch 5 (SB5). The Savannah River Site (SRS) Liquid Waste Organization (LWO) has completed caustic addition to Tank 51 to perform low temperature Al dissolution on the H-Modified (HM) sludge material to reduce the total mass of sludge solids and Al being fed to the Defense Waste Processing Facility (DWPF). The Savannah River National Lab (SRNL) has also completed aluminum dissolution tests using a 3-L sample of Tank 51 sludge slurry through funding by DOE EM-21. This report documents assessment of downstream impacts of the aluminum dissolved sludge, which were investigated so technical issues could be identified before the start of SB5 processing. This assessment included washing the aluminum dissolved sludge to a Tank Farm projected sodium concentration and weight percent insoluble solids content and DWPF Chemical Process Cell (CPC) processing using the washed sludge. Based on the limited testing, the impact of aluminum dissolution on sludge settling is not clear. Settling was not predictable for the 3-L sample. Compared to the post aluminum dissolution sample, settling after the first wash was slower, but settling after the second wash was faster. For example, post aluminum dissolution sludge took six days to settle to 60% of the original sludge slurry height, while Wash 1 took nearly eight days, and Wash 2 only took two days. Aluminum dissolution did impact sludge rheology. A comparison between the as-received, post aluminum dissolution and washed samples indicate that the downstream materials were more viscous and the concentration of insoluble solids less than that of the starting material. This increase in viscosity may impact Tank 51 transfers to Tank 40. The impact of aluminum dissolution on DWPF CPC processing cannot be determined because acid addition for the Sludge Receipt and Adjustment Tank (SRAT) cycle was under-calculated and thus

  19. Verification Of The Defense Waste Processing Facility's (DWPF) Process Digestion Methods For The Sludge Batch 8 Qualification Sample

    SciTech Connect

    Click, D. R.; Edwards, T. B.; Wiedenman, B. J.; Brown, L. W.

    2013-03-18

    This report contains the results and comparison of data generated from inductively coupled plasma – atomic emission spectroscopy (ICP-AES) analysis of Aqua Regia (AR), Sodium Peroxide/Sodium Hydroxide Fusion Dissolution (PF) and Cold Chem (CC) method digestions and Cold Vapor Atomic Absorption analysis of Hg digestions from the DWPF Hg digestion method of Sludge Batch 8 (SB8) Sludge Receipt and Adjustment Tank (SRAT) Receipt and SB8 SRAT Product samples. The SB8 SRAT Receipt and SB8 SRAT Product samples were prepared in the SRNL Shielded Cells, and the SRAT Receipt material is representative of the sludge that constitutes the SB8 Batch or qualification composition. This is the sludge in Tank 51 that is to be transferred into Tank 40, which will contain the heel of Sludge Batch 7b (SB7b), to form the SB8 Blend composition.

  20. A technical basis to relax the dew point specification for the environment in the vapor space in DWPF canisters

    SciTech Connect

    Louthan, M.R. Jr.

    1995-05-01

    This memorandum establishes the technical basis to conclude that relaxing, from 0 C to 20 C, the dew point specification for the atmosphere in the vapor space (free volume) of a DWPF canister will not provide an environment that will cause significant amounts of corrosion induced degradation of the canister wall. The conclusion is based on engineering analysis, experience and review of the corrosion literature. The basic assumptions underlying the conclusion are: (1) the canister was fabricated from Type 304L stainless steel; (2) the corrosion behavior of the canister material, including base metal, fusion zones and heat effected zones, is typified by literature data for, and industrial experience with, 300 series austenitic stainless steels; and (3) the glass-metal crevices created during the pouring operation will not alter the basic corrosion resistance of the steel although such crevices might serve as sites for the initiation of minor amounts of corrosion on the canister wall.

  1. High level radioactive waste management facility design criteria

    SciTech Connect

    Sheikh, N.A.; Salaymeh, S.R.

    1993-10-01

    This paper discusses the engineering systems for the structural design of the Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS). At the DWPF, high level radioactive liquids will be mixed with glass particles and heated in a melter. This molten glass will then be poured into stainless steel canisters where it will harden. This process will transform the high level waste into a more stable, manageable substance. This paper discuss the structural design requirements for this unique one of a kind facility. A special emphasis will be concentrated on the design criteria pertaining to earthquake, wind and tornado, and flooding.

  2. Performance Characteristics of an Isothermal Freeze Valve

    SciTech Connect

    Hailey, A.E.

    2001-08-22

    This document discusses performance characteristics of an isothermal freeze valve. A freeze valve has been specified for draining the DWPF melter at the end of its lifetime. Two freeze valve designs have been evaluated on the Small Cylindrical Melter-2 (SCM-2). In order to size the DWPF freeze valve, the basic principles governing freeze valve behavior need to be identified and understood.

  3. Rheology of Savannah River Site Tank 51 HLW radioactive sludge

    SciTech Connect

    Ha, B.C.

    1993-01-01

    Savannah River Site (SRS) Tank 51 HLW radioactive sludge represents a major portion of the first batch of sludge to be vitrified in the Defense Waste Processing Facility (DWPF) at SRS. The rheological properties of Tank 51 sludge will determine if the waste sludge can be pumped by the current DWPF process cell pump design and the homogeneity of melter feed slurries. The rheological properties of Tank 51 sludge and sludge/frit slurries at various solids concentrations were measured remotely in the Shielded Cells Operations (SCO) at the Savannah River Technology Center (SRTC) using a modified Haake Rotovisco viscometer system. Rheological properties of Tank 51 radioactive sludge/Frit 202 slurries increased drastically when the solids content was above 41 wt %. The yield stresses of Tank 51 sludge and sludge/frit slurries fall within the limits of the DWPF equipment design basis. The apparent viscosities also fall within the DWPF design basis for sludge consistency. All the results indicate that Tank 51 waste sludge and sludge/frit slurries are pumpable throughout the DWPF processes based on the current process cell pump design, and should produce homogeneous melter feed slurries.

  4. Rheology of Savannah River Site Tank 51 HLW radioactive sludge. Revision 1

    SciTech Connect

    Ha, B.C.

    1993-03-01

    Savannah River Site (SRS) Tank 51 HLW radioactive sludge represents a major portion of the first batch of sludge to be vitrified in the Defense Waste Processing Facility (DWPF) at SRS. The rheological properties of Tank 51 sludge will determine if the waste sludge can be pumped by the current DWPF process cell pump design and the homogeneity of melter feed slurries. The rheological properties of Tank 51 sludge and sludge/frit slurries at various solids concentrations were measured remotely in the Shielded Cells Operations (SCO) at the Savannah River Technology Center (SRTC) using a modified Haake Rotovisco viscometer system. Rheological properties of Tank 51 radioactive sludge/Frit 202 slurries increased drastically when the solids content was above 41 wt %. The yield stresses of Tank 51 sludge and sludge/frit slurries fall within the limits of the DWPF equipment design basis. The apparent viscosities also fall within the DWPF design basis for sludge consistency. All the results indicate that Tank 51 waste sludge and sludge/frit slurries are pumpable throughout the DWPF processes based on the current process cell pump design, and should produce homogeneous melter feed slurries.

  5. GLASS-CERAMICS IN A COLD-CRUCIBLE MELTER : THE OPTIMUM COMBINATION FOR GREATER WASTE PROCESSING EFFICIENCY

    SciTech Connect

    DAY, R.A.; FERENCZY, J.; DRABAREK, E.; ADVOCAT, T.; FILLET, C.; LACOMBE, J.; LADIRAT, C.; VEYER, C.; QUANG, R. DO; THOMASSON, J.

    2003-02-27

    Improving the efficiency of nuclear waste immobilization is constantly desired by all nuclear waste management programs world-wide. For high-level and other waste to be vitrified in traditional ceramic Joule-heated melters operated at temperatures up to 1150 C, process flexibilities including waste loadings are often restricted by this temperature limit as well as the need to consider wasteform corrosion of refractory linings and electrodes. New melter technologies, such as the cold-crucible melter (CCM), enable processing up to significantly higher temperatures free of many of the limitations of conventional melters. Higher processing temperatures open up the way for wider composition and processing envelopes to be considered for the vitrification process, including the possibility for higher waste loadings. In many instances the presence of crystals in the final cooled wasteform is not considered desirable within presently existing glass specifications. For some feed compositions in creased waste loadings can lead to the formation of large amounts of crystals, and thus to a significant departure from the ''glass'' state. Nevertheless it is recognized that, in general, increasing the acceptable volume fractions of crystals in the glass offers the best opportunity to increase waste loading, all other factors being equal. In addition, the deliberate promotion of specific crystalline phases by design may enhance the quality of the wasteform, for example by partitioning a long-lived radionuclide into a very stable crystalline phase, or by depleting the glass in detrimental elements. In order to explore the potential improvements by harnessing the higher achievable processing temperatures and immunity to refractory corrosion available with the cold-crucible melter, and after promising indications for synroc-based matrices, it was decided to investigate the feasibility of designing and producing via melting new high temperature ''glass-ceramic'' wasteforms for high

  6. IMPACT OF PARTICLE AGGLOMERATION ON ACCUMULATION RATES IN THE GLASS DISCHARGE RISER OF HLW MELTER

    SciTech Connect

    Matyas, Josef; Jansik, Danielle P.; Owen, Antionette T.; Rodriguez, Carmen P.; Lang, Jesse B.; Kruger, Albert A.

    2013-08-05

    The major factor limiting waste loading in continuous high-level radioactive waste (HLW) melters is an accumulation of particles in the glass discharge riser during a frequent and periodic idling of more than 20 days. An excessive accumulation can produce robust layers a few centimeters thick, which may clog the riser, preventing molten glass from being poured into canisters. Since the accumulation rate is driven by the size of particles we investigated with X-ray microtomography, scanning electron microscopy, and image analysis the impact of spinel forming components, noble metals, and alumina on the size, concentration, and spatial distribution of particles, and on the accumulation rate. Increased concentrations of Fe and Ni in the baseline glass resulted in the formation of large agglomerates that grew over the time to an average size of ~185±155 µm, and produced >3 mm thick layer after 120 h at 850 °C. The noble metals decreased the particle size, and therefore significantly slowed down the accumulation rate. Addition of alumina resulted in the formation of a network of spinel dendrites which prevented accumulation of particles into compact layers.

  7. Study of raceway in COREX melter gasifier by using three progressive methods

    NASA Astrophysics Data System (ADS)

    Sun, Jun-jie; Luo, Zhi-guo; Di, Zhan-xia; Liu, Chong-lin; Zou, Zong-shu; Shen, Yan-Song

    2013-06-01

    Definition of raceway shape and size has always been a challenging task. In this study, based on physical simulation of the COREX melter gasifier, the pictures near the raceway zone are recorded by a high speed camera and the particles velocity contours are analyzed. Then three progressive methods are developed to describe the raceway size under different blowing rates. In the first method, the raceway depth and height are determined qualitatively through judging the particles velocity contours; In the second method, the fractal dimensions of different particles velocity contours are obtained by using fractal theory, then the two-dimension raceway depth and height are defined through analyzing the fractal dimensions; In the third method, the surface area of three-dimension ellipsoidal raceway is obtained by using the law of additive codimensions and the fractal dimensions which are from the second method. Due to the same data is used by the three methods, different raceway sizes are obtained, but the general trend is similar and the raceway size from all methods increase with the increasing of blowing rate.

  8. Low-NO{sub x} technologies for natural gas-fired regenerative glass melters

    SciTech Connect

    Panahi, S.K.; Abbasi, H.A.; Khinkis, M.J.; Joshi, M.; Neff, G.C. Sr.

    1992-12-31

    Southern California Gas Company (SoCalGas), the Institute of Gas Technology (IGT), and their industrial partners -- Combustion Tec, Inc. (CTI) and Air Products and Chemicals Company, Inc. (APCI) -- have initiated a program to develop a retrofit second-generation NO{sub x} control technology for natural gas-fired regenerative glass melters. The technology would also be applicable to many other types of high-temperature furnaces as well as to other advanced high-performance burners. This second-generation technology combines two NO{sub x} reduction techniques, both using oxygen enrichment: (1) a unique method of air staging to reduce the oxygen availability and somewhat increase the luminosity in the flame`s high-temperature zone while improving flame temperature uniformity and (2) natural gas cracking in a separate oxygen/natural gas cracker to substantially increase the flame luminosity. Versions of these techniques were tested on IGT`s pilot-scale glass tank simulator during earlier efforts and showed excellent potential for NO{sub x} reduction. Furthermore, the concept of oxygen/natural gas cracking has already been demonstrated on a pilot-scale cracker. This paper reviews the results from the earlier development work by IGT, CTI, and others; describes the proof-of-concept testing of the pilot-scale oxygen/natural gas cracker; and discusses the status of the current program as well as other potential combustion modifications for NO{sub x} reduction.

  9. Low-NO[sub x] technologies for natural gas-fired regenerative glass melters

    SciTech Connect

    Panahi, S.K. ); Abbasi, H.A.; Khinkis, M.J. ); Joshi, M.; Neff, G.C. Sr. )

    1992-01-01

    Southern California Gas Company (SoCalGas), the Institute of Gas Technology (IGT), and their industrial partners -- Combustion Tec, Inc. (CTI) and Air Products and Chemicals Company, Inc. (APCI) -- have initiated a program to develop a retrofit second-generation NO[sub x] control technology for natural gas-fired regenerative glass melters. The technology would also be applicable to many other types of high-temperature furnaces as well as to other advanced high-performance burners. This second-generation technology combines two NO[sub x] reduction techniques, both using oxygen enrichment: (1) a unique method of air staging to reduce the oxygen availability and somewhat increase the luminosity in the flame's high-temperature zone while improving flame temperature uniformity and (2) natural gas cracking in a separate oxygen/natural gas cracker to substantially increase the flame luminosity. Versions of these techniques were tested on IGT's pilot-scale glass tank simulator during earlier efforts and showed excellent potential for NO[sub x] reduction. Furthermore, the concept of oxygen/natural gas cracking has already been demonstrated on a pilot-scale cracker. This paper reviews the results from the earlier development work by IGT, CTI, and others; describes the proof-of-concept testing of the pilot-scale oxygen/natural gas cracker; and discusses the status of the current program as well as other potential combustion modifications for NO[sub x] reduction.

  10. Impact Of Particle Agglomeration On Accumulation Rates In The Glass Discharge Riser Of HLW Melter

    SciTech Connect

    Kruger, A. A.; Rodriguez, C. A.; Matyas, J.; Owen, A. T.; Jansik, D. P.; Lang, J. B.

    2012-11-12

    The major factor limiting waste loading in continuous high-level radioactive waste (HLW) melters is an accumulation of particles in the glass discharge riser during a frequent and periodic idling of more than 20 days. An excessive accumulation can produce robust layers a few centimeters thick, which may clog the riser, preventing molten glass from being poured into canisters. Since the accumulation rate is driven by the size of particles we investigated with x-ray microtomography, scanning electron microscopy, and image analysis the impact of spinel forming components, noble metals, and alumina on the size, concentration, and spatial distribution of particles, and on the accumulation rate. Increased concentrations of Fe and Ni in the baseline glass resulted in the formation of large agglomerates that grew over the time to an average size of ~185+-155 {mu}m, and produced >3 mm thick layer after 120 h at 850 deg C. The noble metals decreased the particle size, and therefore significantly slowed down the accumulation rate. Addition of alumina resulted in the formation of a network of spinel dendrites which prevented accumulation of particles into compact layers.

  11. IMPACTS OF SMALL COLUMN ION EXCHANGE STREAMS ON DWPF GLASS FORMULATION: KT01, KT02, KT03, AND KT04-SERIES GLASS COMPOSITIONS

    SciTech Connect

    Fox, K.; Edwards, T.

    2010-11-01

    Four series of glass compositions were selected, fabricated, and characterized as part of a study to determine the impacts of the addition of Crystalline Silicotitanate (CST) and Monosodium Titanate (MST) from the Small Column Ion Exchange (SCIX) process on the Defense Waste Processing Facility (DWPF) glass waste form and the applicability of the DWPF process control models. The KT01 and KT02-series of glasses were chosen to allow for the identification of the influence of the concentrations of major components of the glass on the retention of TiO{sub 2}. The KT03 series of glasses was chosen to allow for the identification of these influences when higher Nb{sub 2}O{sub 5} and ZrO{sub 2} concentrations are included along with TiO2. The KT04 series of glasses was chosen to investigate the properties and performance of glasses based on the best available projections of actual compositions to be processed at the DWPF (i.e., future sludge batches including the SCIX streams).

  12. ALTERNATE REDUCTANT COLD CAP EVALUATION FURNACE PHASE I TESTING

    SciTech Connect

    Johnson, F.; Miller, D.; Zamecnik, J.; Lambert, D.

    2014-04-22

    Savannah River Remediation (SRR) conducted a Systems Engineering Evaluation (SEE) to determine the optimum alternate reductant flowsheet for the Defense Waste Processing Facility (DWPF). Specifically, two proposed flowsheets (nitric–formic–glycolic and nitric–formic–sugar) were evaluated based upon results from preliminary testing. Comparison of the two flowsheets among evaluation criteria indicated a preference towards the nitric–formic–glycolic flowsheet. Further evaluation of this flowsheet eliminated the formic acid1, and as a result, the nitric–glycolic flowsheet was recommended for further testing. Based on the development of a roadmap for the nitric–glycolic acid flowsheet, Waste Solidification Engineering (WS-E) issued a Technical Task Request (TTR) to address flammability issues that may impact the implementation of this flowsheet. Melter testing was requested in order to define the DWPF flammability envelope for the nitric glycolic acid flowsheet. The Savannah River National Laboratory (SRNL) Cold Cap Evaluation Furnace (CEF), a 1/12th scale DWPF melter, was selected by the SRR Alternate Reductant project team as the melter platform for this testing. The overall scope was divided into the following sub-tasks as discussed in the Task Technical and Quality Assurance Plan (TTQAP):  Phase I - A nitric–formic acid flowsheet melter test (unbubbled) to baseline the Cold Cap Evaluation Furnace (CEF) cold cap and vapor space data to the benchmark melter flammability models  Phase II - A nitric–glycolic acid flowsheet melter test (unbubbled and bubbled) to: o Define new cold cap reactions and global kinetic parameters for the melter flammability models o Quantify off-gas surging potential of the feed o Characterize off-gas condensate for complete organic and inorganic carbon species Prior to startup, a number of improvements and modifications were made to the CEF, including addition of cameras, vessel support temperature measurement, and a

  13. ALTERNATE REDUCTANT COLD CAP EVALUATION FURNACE PHASE II TESTING

    SciTech Connect

    Johnson, F.; Stone, M.; Miller, D.

    2014-09-03

    Savannah River Remediation (SRR) conducted a Systems Engineering Evaluation (SEE) to determine the optimum alternate reductant flowsheet for the Defense Waste Processing Facility (DWPF). Specifically, two proposed flowsheets (nitric–formic–glycolic and nitric–formic–sugar) were evaluated based upon results from preliminary testing. Comparison of the two flowsheets among evaluation criteria indicated a preference towards the nitric–formic–glycolic flowsheet. Further research and development of this flowsheet eliminated the formic acid, and as a result, the nitric–glycolic flowsheet was recommended for further testing. Based on the development of a roadmap for the nitric–glycolic acid flowsheet, Waste Solidification Engineering (WS-E) issued a Technical Task Request (TTR) to address flammability issues that may impact the implementation of this flowsheet. Melter testing was requested in order to define the DWPF flammability envelope for the nitric-glycolic acid flowsheet. The Savannah River National Laboratory (SRNL) Cold Cap Evaluation Furnace (CEF), a 1/12th scale DWPF melter, was selected by the SRR Alternate Reductant project team as the melter platform for this testing. The overall scope was divided into the following sub-tasks as discussed in the Task Technical and Quality Assurance Plan (TTQAP):  Phase I - A nitric–formic acid flowsheet melter test (unbubbled) to baseline the CEF cold cap and vapor space data to the benchmark melter flammability models;  Phase II - A nitric–glycolic acid flowsheet melter test (unbubbled and bubbled) to: o Define new cold cap reactions and global kinetic parameters in support of the melter flammability model development; o Quantify off-gas surging potential of the feed; o Characterize off-gas condensate for complete organic and inorganic carbon species. After charging the CEF with cullet from Phase I CEF testing, the melter was slurry-fed with glycolic flowsheet based SB6-Frit 418 melter feed at 36

  14. Iron Phosphate Glass for Vitrifying Hanford AZ102 LAW in Joule Heated and Cold Crucible Induction Melters

    SciTech Connect

    Day, Delbert E.; Brow, R. K.; Ray, C. S.; Kim, Cheol-Woon; Reis, Signo T.; Vienna, John D.; Peeler, David K.; Johnson, Fabienne; Hansen, E. K.; Sevigny, Gary J.; Soelberg, Nicolas R.; Pegg, Ian L.; Gan, Hao

    2012-01-05

    An iron phosphate composition for vitrifying a high sulfate (~17 wt%) and high alkali (~80 wt%) low activity Hanford waste, known as AZ102 LAW, has been developed for processing in a Joule Heated Melter (JHM) or a Cold Crucible Induction Melter (CCIM). This composition produced a glass waste form, designated as MS26AZ102F-2, with a waste loading of 26 wt% of the AZ102 which corresponded to a total alkali and sulfate (SO3) content of 21 and 4.2 wt%, respectively. A slurry (7M Na) of MS26AZ102F-2 simulant was melted continuously at temperatures between 1030 and 1090°C for 10 days in a small JHM at PNNL and for 7 days in a CCIM at INL. The as-cast glasses produced in both melters and in trial laboratory experiments along with their CCC-treated counterparts met the DOE LAW requirements for the Product Consistency Test (PCT) and the Vapor Hydration Test (VHT). These glass waste forms retained up to 77 % of the SO3 (3.3 wt%), 100% of the Cesium, and 33 to 44% of the rhenium, surrogate for Tc-99, all of which either exceeded or were comparable to the retention limit for these species in borosilicate glass nuclear waste form. Analyses of commercial K-3 refractory lining and the Inconel 693 metal electrodes used in JHM indicated only minimum corrosion of these components by the iron phosphate glass. This is the first time that an iron phosphate composition (slurry feed) was melted continuously in the JHM and CCIM, thereby, demonstrating that iron phosphate glasses can be used as alternative hosts for vitrifying nuclear waste.

  15. Environmental Assessment for the Operation of the Glass Melter Thermal Treatment Unit at the US Department of Energy`s Mound Plant, Miamisburg, Ohio

    SciTech Connect

    1995-06-01

    The glass melter would thermally treat mixed waste (hazardous waste contaminated with radioactive constituents largely tritium, Pu-238, and/or Th-230) that was generated at the Mound Plant and is now in storage, by stabilizing the waste in glass blocks. Depending on the radiation level of the waste, the glass melter may operate for 1 to 6 years. Two onsite alternatives and seven offsite alternatives were considered. This environmental assessment indicates that the proposed action does not constitute a major Federal action significantly affecting the human environment according to NEPA, and therefore the finding of no significant impact is made, obviating the need for an environmental impact statement.

  16. Response to requests by FMF and DWPF concerning disposal of FMF saltstone drums in Z-Area vaults

    SciTech Connect

    Langton, C.A.; Cook, J.R.

    1989-07-25

    Disposal of FMF saltstone in 55 gallon drums in the Z-Area Industrial Waste Landfill requires modification of the landfill permit. Approximately 5000 drums of FMF saltstone are currently stored on SC DHEC-permitted concrete storage pads adjacent to the burial ground. At a meeting with DWPF, FMF, and EPS on July 18, 1989, IWT agreed to supply the following information: (1) Consequence of disposal of CCA (Cu, Cr, As) treated wood pallets in the Z-Area vaults. (Four drums of FMF saltstone are currently banded to each pallet.) (2) Consequence of placing partially filled FMF drums in the Z-Area vaults. (3) Formulation for clean grout back-fill. Grout will be emplaced around and over the drums, thereby isolating them from environment (rainwater) prior to vault capping. (4) Maximum loading of FMF saltstone drums in the Z-Area vaults. (5) Consequence of void volume in drums, in clean grout, or both on groundwater modeling results. This document is a response to the above requests.

  17. Nuclear safety of extended sludge processing on tank 42 and 51 sludge (DWPF sludge feed batch one)

    SciTech Connect

    Clemons, J.S.

    1993-02-26

    The sludge in tanks 42 and 51 is to be washed with inhibited water to remove soluble salts and combined in tank 51 in preparation for feed to DWPF. Since these tanks contain uranium and plutonium, the process of washing must be evaluated to ensure subcriticality is maintained. When the sludge is washed, inhibited water is added, the tank contents are slurried and allowed to settle. The sludge wash water is then decanted to the evaporator feed tank where it is fed to the evaporator to reduce the volume. The resulting evaporator concentrate is sent to a salt tank where it cools and forms crystallized salt cake. This salt cake will later be dissolved, processed in ITP and sent to Z-Area. This report evaluates the supernate and sludge during washing, the impact on the evaporator during concentration of decanted wash water, and the salt tank where the concentrated supernate is deposited. The conclusions generated in this report are specific to the sludge currently contained in tanks 42 and 51.

  18. Americium-Curium Stabilization - 5'' Cylindrical Induction Melter System Design Basis

    SciTech Connect

    Witt, D.C.

    1999-11-08

    Approximately 11,000 liters (3,600) gallons of solution containing isotopes of Am and Cm are currently stored in F-Canyon Tank 17.1. These isotopes were recovered during plutonium-242 production campaigns in the mid- and late-1970s. Experimental work for the project began in 1995 by the Savannah River Technology Center (SRTC). Details of the process are given in the various sections of this document.

  19. IMPACT OF PARTICLE SIZE AND AGGLOMERATION ON SETTLING OF SOLIDS IN CONTINUOUS MELTERS PROCESSING RADIOACTIVE WASTE GLASS

    SciTech Connect

    HRMA PR

    2008-12-18

    The major factor limiting waste loading for many waste compositions in continuous waste glass melters is the settling of crystalline materials. The currently used constraints, i.e., the minimum liquidus temperature or the maximum fraction of equilibrium crystallinity at a given temperature, are based on thennodynamic equilibria. Because of the rapid circular convection in the melter, these constraints are probably irrelevant and cannot prevent large crystals from settling. The main factor that detennines the rate of settling ofindividual crystals, such as those ofspinel, is their size. The tiny crystals of RU02 are too small to settle, but they readily fonn large agglomerates that accelerate their rate ofsettling by severalorders ofmagnitude. The RU02 agglomerates originate early in the melting process and then grow by the shear-flocculation mechanism. It is estimated that these agglomerates must either be ofhundreds micrometers in size or have an elongated shape to match the observed rates ofthe sludge-layer fonnation. PACS: 47.57.ef, 81.05.Kj, 81.10.Fg

  20. Crystalline Ceramic Waste Forms: Report Detailing Data Collection In Support Of Potential FY13 Pilot Scale Melter Test

    SciTech Connect

    Brinkman, K. S.; Amoroso, J.; Marra, J. C.; Fox, K. M.

    2012-09-21

    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 successfully produced from a melting and crystallization process. The objective of this report is to summarize the data collection in support of future melter demonstration testing for crystalline ceramic waste forms. The waste stream used as the basis for the development and testing is 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. The principal difficulties encountered during processing of the ?reference ceramic? waste form by a melt and crystallization process were the incomplete incorporation of Cs into the hollandite phase and the presence of secondary Cs-Mo non-durable phases. In the single phase hollandite system, these issues were addressed in this study by refining the compositions to include Cr as a transition metal element and the use of Ti/TiO{sub 2} buffer to maintain reducing conditions. Initial viscosity studies of ceramic waste