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Sludge Batch 4 Baseline Melt Rate Furnace and Slurry-Fed Melt Rate Furnace Tests With Frits 418 and 510 (U)
Several Slurry-Fed Melt Rate Furnace (SMRF) tests with earlier projections of the Sludge Batch 4 (SB4) composition have been performed.1,2 The first SB4 SMRF test used Frits 418 and 320, however it was found after the test that the REDuction/OXidation (REDOX) correlation at that time did not have the proper oxidation state for manganese. Because the manganese level in the SB4 sludge was higher than previous sludge batches tested, the impact of the higher manganese oxidation state was greater. The glasses were highly oxidized and very foamy, and therefore the results were inconclusive. After resolving this REDOX issue, Frits 418, 425, and 503 were tested in the SMRF with the updated baseline SB4 projection. Based on dry-fed Melt Rate Furnace (MRF) tests and the above mentioned SMRF tests, two previous frit recommendations were made by the Savannah River National Laboratory (SRNL) for processing of SB4 in the Defense Waste Processing Facility (DWPF). The first was Frit 503 based on the June 2006 composition projections.3 The recommendation was changed to Frit 418 as a result of the October 2006 composition projections (after the Tank 40 decant was implemented as part of the preparation plan). However, the start of SB4 processing was delayed due to the control room consolidation outage and the repair of the valve box in the Tank 51 to Tank 40 transfer line. These delays resulted in changes to the projected SB4 composition. Due to the slight change in composition and based on preliminary dry-fed MRF testing, SRNL believed that Frit 510 would increase throughput in processing SB4 in DWPF. Frit 418, which was used in processing Sludge Batch 3 (SB3), was a viable candidate and available in DWPF. Therefore, it was used during the initial SB4 processing. Due to the potential for higher melt rates with Frit 510, SMRF tests with the latest SB4 composition (1298 canisters) and Frits 510 and 418 were performed at a targeted waste loading (WL) of 35%. The '1298 canisters' describes the number of equivalent canisters that would be produced from the beginning of the current contract period before SB3 is blended with SB4. The melt rate for the SMRF SB4/Frit 510 test was 14.6 grams/minute. Due to cold cap mounding problems with the SMRF SB4/Frit 418 feed at 50 weight % solids that prevented a melt rate determination, this feed was diluted to 45 weight % solids. The melt rate for this diluted feed was 8.9 grams/minute. A correction factor of 1.2 for estimating the melt rate at 50 weight % solids from 45 weight % solids test results (based on previous SMRF testing5) was then used to estimate a melt rate of 10.7 grams/minute for SB4/Frit 418 at 50 weight % solids. Therefore, the use of Frit 510 versus Frit 418 with SB4 resulted in a higher melt rate (14.6 versus an estimated 10.7 grams/minute). For reference, a previous SMRF test with SB3/Frit 418 feed at 35% waste loading and 50 weight % solids resulted in a melt rate of 14.1 grams/minute. Therefore, depending on the actual feed rheology, the use of Frit 510 with SB4 could result in similar melt rates as experienced with SB3/Frit 418 feed in the DWPF
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OFFGAS GENERATION FROM THE DISPOSITION OF SCRAP PLUTONIUM BY VITRIFICATION SIMULANT TESTS
The Department of Energy Office of Environmental Management is supporting R&D for the conceptual design of the Plutonium Disposition Project at the Savannah River Site in Aiken, SC to reduce the attractiveness of plutonium scrap by fabricating a durable plutonium oxide glass form and immobilizing this form within the high-level waste glass prepared in the Defense Waste Processing Facility. A glass formulation was developed that is capable of incorporating large amounts of actinides as well as accommodating many impurities that may be associated with impure Pu feed streams. The basis for the glass formulation was derived from commercial glasses that had high lanthanide loadings. A development effort led to a Lanthanide BoroSilicate (LaBS) glass that accommodated significant quantities of actinides, tolerated impurities associated with the actinide feed streams and could be processed using established melter technologies. A Cylindrical Induction Melter (CIM) was used for vitrification of the Pu LaBS glass. Induction melting for the immobilization of americium and curium (Am/Cm) in a glass matrix was first demonstrated in 1997. The induction melting system was developed to vitrify a non-radioactive Am/Cm simulant combined with a glass frit. Most of the development of the melter itself was completed as part of that work. This same melter system used for Am/Cm was used for the current work. The CIM system used consisted of a 5 inch (12.7 cm) diameter inductively heated platinum-rhodium (Pt-Rh) containment vessel with a control system and offgas characterization. Scrap plutonium can contain numerous impurities including significant amounts of chlorides, fluorides, sodium, potassium, lead, gallium, chromium, and nickel. Smaller amounts of additional elements can also be present. The amount of chlorides present is unusually high for a melter feed. In commercial applications there is no reason to have chloride at such high concentrations. Because the melter operates at 1400-1475 C, many of the impurities present are extremely volatile. An alternative being considered is to pre-treat the impure PuO{sub 2} by water washing to remove the soluble salts, which would significantly reduce the melter emissions. The disadvantage of the washing alternative is the criticality concerns of using water with plutonium. In this paper, the testing that has been conducted at the Savannah River National Laboratory (SRNL) to demonstrate induction melting of impure plutonium simulants will be described. The work described concentrates on quantification of the gaseous and particulate emissions from the induction melter. The Pt-Rh melter vessel is a cylinder with a conical bottom and a tubular drain as shown in Figure 1. A 5-inch (12.7 cm) diameter CIM was used for all of the emissions tests. A 6-inch (15.24 cm) diameter CIM, which is the size of the full-scale melter, has since been constructed for further testing. The 5-inch CIM is heated by three induction coils: one for the 5 inch cylinder, one for the conical section, and one for the 1/4-inch (6.35 mm) drain tube. The 6-inch CIM is similar except the cylinder heater extends lower and also heats the cone. The induction heating system is manufactured by Ameritherm{trademark}. The heating system is controlled by a PC to maintain a specific heat up profile and then maintain a constant energy input that maintains a constant temperature. The CIM is operated in batch mode where the plutonium simulant and the glass-forming frit are first thoroughly mixed in an attrittor mill, then added to the melter. Hafnium oxide (HfO{sub 2}) is used as a simulant for the radioactive PuO{sub 2}. The melter is heated until the mixture begins to melt at about 1100 C, then completely melts at about 1400-1450 C. This temperature is maintained for about three hours. While the temperature is maintained at {approx} 1400 C, an air bubbler is normally used to promote mixing of the glass-forming frit and the waste simulant