Pretreatment Engineering Platform Phase 1 Final Test Report

Pacific Northwest National Laboratory (PNNL) was tasked by Bechtel National Inc. (BNI) on the River Protection Project, Hanford Tank Waste Treatment and Immobilization Plant (RPP-WTP) project to conduct testing to demonstrate the performance of the WTP Pretreatment Facility (PTF) leaching and ultrafiltration processes at an engineering-scale. In addition to the demonstration, the testing was to address specific technical issues identified in Issue Response Plan for Implementation of External Flowsheet Review Team (EFRT) Recommendations - M12, Undemonstrated Leaching Processes.( ) Testing was conducted in a 1/4.5-scale mock-up of the PTF ultrafiltration system, the Pretreatment Engineering Platform (PEP). Parallel laboratory testing was conducted in various PNNL laboratories to allow direct comparison of process performance at an engineering-scale and a laboratory-scale. This report presents and discusses the results of those tests

Pulse Jet Mixing Tests With Noncohesive Solids

This report summarizes results from pulse jet mixing (PJM) tests with noncohesive solids in Newtonian liquid conducted during FY 2007 and 2008 to support the design of mixing systems for the Hanford Waste Treatment and Immobilization Plant (WTP). Tests were conducted at three geometric scales using noncohesive simulants. The test data were used to independently develop mixing models that can be used to predict full-scale WTP vessel performance and to rate current WTP mixing system designs against two specific performance requirements. One requirement is to ensure that all solids have been disturbed during the mixing action, which is important to release gas from the solids. The second requirement is to maintain a suspended solids concentration below 20 weight percent at the pump inlet. The models predict the height to which solids will be lifted by the PJM action, and the minimum velocity needed to ensure all solids have been lifted from the floor. From the cloud height estimate we can calculate the concentration of solids at the pump inlet. The velocity needed to lift the solids is slightly more demanding than "disturbing" the solids, and is used as a surrogate for this metric. We applied the models to assess WTP mixing vessel performance with respect to the two perform¬ance requirements. Each mixing vessel was evaluated against these two criteria for two defined waste conditions. One of the wastes was defined by design limits and one was derived from Hanford waste characterization reports. The assessment predicts that three vessel types will satisfy the design criteria for all conditions evaluated. Seven vessel types will not satisfy the performance criteria used for any of the conditions evaluated. The remaining three vessel types provide varying assessments when the different particle characteristics are evaluated. The assessment predicts that three vessel types will satisfy the design criteria for all conditions evaluated. Seven vessel types will not satisfy the performance criteria used for any of the conditions evaluated. The remaining three vessel types provide varying assessments when the different particle characteristics are evaluated. The HLP-022 vessel was also evaluated using 12 m/s pulse jet velocity with 6-in. nozzles, and this design also did not satisfy the criteria for all of the conditions evaluated

Assessment of Differences in Phase 1 and Phase 2 Test Observations for Waste Treatment Plant Pulse Jet Mixer Tests with Non-Cohesive Solids

The purpose of this work was to assess the apparent discrepancy in critical suspension velocity (UCS) between M3 Phase 1 (Meyer et al. 2009) and Phase 2 testing conducted by Energy Solutions (ES) at Mid-Columbia Engineering (MCE) and to address the applicability of Phase 1 scale-up laws to Phase 2 test results. Three Phase 2 test sequences were analyzed in detail. Several sources of discrepancy were identified including differences in nominal versus actual velocity, definition of model input parameters, and definition of UCS. A remaining discrepancy was shown to not be solely an artifact of Phase 1 data correlations, but was fundamental to the tests. The non-prototypic aspects of Phase 1 testing were reviewed and assessed. The effects of non-prototypic refill associated with the closed loop operation of the jets, previously known to affect cloud height, can be described in terms of a modified settling velocity. When the modified settling velocity is incorporated into the Phase 1 “new” physical model the adjusted new physical model does a better job of predicting the Phase 2 test results. The adjusted new physical model was bench marked with data taken during three prototypic drive tests. Scale-up behavior of the Phase 1 tests was reviewed. The applicability of the Phase 1 scale-up behavior to Phase 2 prototypic testing was analyzed. The effects of non-prototypic refill caused measured values of UCS to be somewhat reduced at larger scales. Hence the scale-up exponents are believed to be smaller than they would have been had there been prototypic refill. Estimated scale-up exponents for the Phase 2 testing are 0.40 for 8-tube tests and 0.36 for 12-tube tests

Development of K-Basin High-Strength Homogeneous Sludge Simulants and Correlations Between Unconfined Compressive Strength and Shear Strength

K-Basin sludge will be stored in the Sludge Transport and Storage Containers (STSCs) at an interim storage location on Central Plateau before being treated and packaged for disposal. During the storage period, sludge in the STSCs may consolidate/agglomerate, potentially resulting in high-shear-strength material. The Sludge Treatment Project (STP) plans to use water jets to retrieve K-Basin sludge after the interim storage. STP has identified shear strength to be a key parameter that should be bounded to verify the operability and performance of sludge retrieval systems. Determining the range of sludge shear strength is important to gain high confidence that a water-jet retrieval system can mobilize stored K-Basin sludge from the STSCs. The shear strength measurements will provide a basis for bounding sludge properties for mobilization and erosion. Thus, it is also important to develop potential simulants to investigate these phenomena. Long-term sludge storage tests conducted by Pacific Northwest National Laboratory (PNNL) show that high-uranium-content K-Basin sludge can self-cement and form a strong sludge with a bulk shear strength of up to 65 kPa. Some of this sludge has 'paste' and 'chunks' with shear strengths of approximately 3-5 kPa and 380-770 kPa, respectively. High-uranium-content sludge samples subjected to hydrothermal testing (e.g., 185 C, 10 hours) have been observed to form agglomerates with a shear strength up to 170 kPa. These high values were estimated by measured unconfined compressive strength (UCS) obtained with a pocket penetrometer. Due to its ease of use, it is anticipated that a pocket penetrometer will be used to acquire additional shear strength data from archived K-Basin sludge samples stored at the PNNL Radiochemical Processing Laboratory (RPL) hot cells. It is uncertain whether the pocket penetrometer provides accurate shear strength measurements of the material. To assess the bounding material strength and potential for erosion, it is important to compare the measured shear strength to penetrometer measurements and to develop a correlation (or correlations) between UCS measured by a pocket penetrometer and direct shear strength measurements for various homogeneous and heterogeneous simulants. This study developed 11 homogeneous simulants, whose shear strengths vary from 4 to 170 kPa. With these simulants, we developed correlations between UCS measured by a Geotest E-280 pocket penetrometer and shear strength values measured by a Geonor H-60 hand-held vane tester and a more sophisticated bench-top unit, the Haake M5 rheometer. This was achieved with side-by-side measurements of the shear strength and UCS of the homogeneous simulants. The homogeneous simulants developed under this study consist of kaolin clay, plaster of Paris, and amorphous alumina CP-5 with water. The simulants also include modeling clay. The shear strength of most of these simulants is sensitive to various factors, including the simulant size, the intensity of mixing, and the curing time, even with given concentrations of simulant components. Table S.1 summarizes these 11 simulants and their shear strengths

Test Loop Demonstration and Evaluation of Slurry Transfer Line Critical Velocity Measurement Instruments

This report presents the results of the evaluation of three ultrasonic sensors for detecting critical velocity during slurry transfer between the Hanford tank farms and the WTP

Test Loop Demonstration and Evaluation of Slurry Transfer Line Critical Velocity Measurement Instruments

This report presents the results of the evaluation of three ultrasonic sensors for detecting critical velocity during slurry transfer between the Hanford tank farms and the WTP

Pulse Jet Mixing Tests With Noncohesive Solids

This report summarizes results from pulse jet mixing (PJM) tests with noncohesive solids in Newtonian liquid. The tests were conducted during FY 2007 and 2008 to support the design of mixing systems for the Hanford Waste Treatment and Immobilization Plant (WTP). Tests were conducted at three geometric scales using noncohesive simulants, and the test data were used to develop models predicting two measures of mixing performance for full-scale WTP vessels. The models predict the cloud height (the height to which solids will be lifted by the PJM action) and the critical suspension velocity (the minimum velocity needed to ensure all solids are suspended off the floor, though not fully mixed). From the cloud height, the concentration of solids at the pump inlet can be estimated. The predicted critical suspension velocity for lifting all solids is not precisely the same as the mixing requirement for 'disturbing' a sufficient volume of solids, but the values will be similar and closely related. These predictive models were successfully benchmarked against larger scale tests and compared well with results from computational fluid dynamics simulations. The application of the models to assess mixing in WTP vessels is illustrated in examples for 13 distinct designs and selected operational conditions. The values selected for these examples are not final; thus, the estimates of performance should not be interpreted as final conclusions of design adequacy or inadequacy. However, this work does reveal that several vessels may require adjustments to design, operating features, or waste feed properties to ensure confidence in operation. The models described in this report will prove to be valuable engineering tools to evaluate options as designs are finalized for the WTP. Revision 1 refines data sets used for model development and summarizes models developed since the completion of Revision 0

Pulse Jet Mixing Tests With Noncohesive Solids

This report summarizes results from pulse jet mixing (PJM) tests with noncohesive solids in Newtonian liquid. The tests were conducted during FY 2007 and 2008 to support the design of mixing systems for the Hanford Waste Treatment and Immobilization Plant (WTP). Tests were conducted at three geometric scales using noncohesive simulants, and the test data were used to develop models predicting two measures of mixing performance for full-scale WTP vessels. The models predict the cloud height (the height to which solids will be lifted by the PJM action) and the critical suspension velocity (the minimum velocity needed to ensure all solids are suspended off the floor, though not fully mixed). From the cloud height, the concentration of solids at the pump inlet can be estimated. The predicted critical suspension velocity for lifting all solids is not precisely the same as the mixing requirement for 'disturbing' a sufficient volume of solids, but the values will be similar and closely related. These predictive models were successfully benchmarked against larger scale tests and compared well with results from computational fluid dynamics simulations. The application of the models to assess mixing in WTP vessels is illustrated in examples for 13 distinct designs and selected operational conditions. The values selected for these examples are not final; thus, the estimates of performance should not be interpreted as final conclusions of design adequacy or inadequacy. However, this work does reveal that several vessels may require adjustments to design, operating features, or waste feed properties to ensure confidence in operation. The models described in this report will prove to be valuable engineering tools to evaluate options as designs are finalized for the WTP. Revision 1 refines data sets used for model development and summarizes models developed since the completion of Revision 0