Dynamic (G2) Model Design Document, 24590-WTP-MDD-PR-01-002, Rev. 12

The Hanford Tank Waste Treatment and Immobilization Plant (WTP) Statement of Work (Department of Energy Contract DE-AC27-01RV14136, Section C) requires the contractor to develop and use process models for flowsheet analyses and pre-operational planning assessments. The Dynamic (G2) Flowsheet is a discrete-time process model that enables the project to evaluate impacts to throughput from eventdriven activities such as pumping, sampling, storage, recycle, separation, and chemical reactions. The model is developed by the Process Engineering (PE) department, and is based on the Flowsheet Bases, Assumptions, and Requirements Document (24590-WTP-RPT-PT-02-005), commonly called the BARD. The terminologies of Dynamic (G2) Flowsheet and Dynamic (G2) Model are interchangeable in this document. The foundation of this model is a dynamic material balance governed by prescribed initial conditions, boundary conditions, and operating logic. The dynamic material balance is achieved by tracking the storage and material flows within the plant as time increments. The initial conditions include a feed vector that represents the waste compositions and delivery sequence of the Tank Farm batches, and volumes and concentrations of solutions in process equipment before startup. The boundary conditions are the physical limits of the flowsheet design, such as piping, volumes, flowrates, operation efficiencies, and physical and chemical environments that impact separations, phase equilibriums, and reaction extents. The operating logic represents the rules and strategies of running the plant

Memo, "Incorporation of HLW Glass Shell V2.0 into the Flowsheets," to ED Lee, CCN: 184905, October 20, 2009

Efforts are being made to increase the efficiency and decrease the cost of vitrifying radioactive waste stored in tanks at the U.S. Department of Energy Hanford Site. The compositions of acceptable and processable high-level waste (HL W) glasses need to be optimized to minimize the waste-form volume and, hence, to reduce cost. A database of glass properties of waste glass and associated simulated waste glasses was collected and documented in PNNL 18501, Glass Property Data and Models for Estimating High-Level Waste Glass Volume and glass property models were curve-fitted to the glass compositions. A routine was developed that estimates HL W glass volumes using the following glass property models: II Nepheline, II One-Percent Crystal Temperature (T1%), II Viscosity (11) II Product Consistency Tests (PCT) for boron, sodium, and lithium, and II Liquidus Temperature (TL). The routine, commonly called the HL W Glass Shell, is presented in this document. In addition to the use of the glass property models, glass composition constraints and rules, as recommend in PNNL 18501 and in other documents (as referenced in this report) were incorporated. This new version of the HL W Glass Shell should generally estimate higher waste loading in the HL W glass than previous versions

WTP Calculation Sheet: Determining the LAW Glass Former Constituents and Amounts for G2 and Acm Models. 24590-LAW-M4C-LFP-00002, Rev. B

The purpose of this calculation is to determine the LAW glass former recipe and additives with their respective amounts. The methodology and equations contained herein are to be used in the G2 and ACM models until better information is supplied by R&T efforts. This revision includes calculations that determines the mass and volume of the bulk chemicals/minerals needed per batch. Plus, it contains calculations (for the G2 model) to help prevent overflow in LAW Feed Preparation Vessel

Final Report - DuraMelter 100 Tests to Support LAW Glass Formulation Correlation Development, VSL-06R6480-1, Rev. 0

This report describes the results of work and testing specified by Test Specifications 24590-LAW-TSP-RT-04-004, Rev. 0, Test Plans VSL-05T5480-1, Rev. 0 and Text Exceptions 24590-LAW-TEF-RT-05-00002. The work and any associated testing followed established quality assurance requirements and was conducted as authorized. The descriptions provided in this test report are an accurate account of both the conduct of the work and the data collected. Results required by the Test Plan are reported. Also reported are any unusual or anomalous occurences that are different from the starting hypotheses. The test results and this report have been reviewed and verified

Hanford Low-Activity Waste Vitrification: A Review

This Paper Summarizes the Vast Body of Literature (Over 200 Documents) Related to Vitrification of the Low-Activity Waste (LAW) Fraction of the Hanford Tank Wastes. Details Are Provided on the Origins of the Hanford Tank Wastes that Resulted from Nuclear Operations Conducted between 1944 and 1989 to Support Nuclear Weapons Production. Waste Treatment Processes Are Described, Including the Baseline Process to Separate the Tank Waste into LAW and High-Level Waste Fractions, and the LAW Vitrification Facility Being Started at Hanford. Significant Focus is Placed on the Glass Composition Development and the Property-Composition Relationships for Hanford LAW Glasses. Glass Disposal Plans and Criteria for Minimizing Long-Term Environmental Impacts Are Discussed Along with Research Perspectives

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

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-hydroxide methods. The above tests were proposed based on previous tests for WTP in which there were few differences in the melter processing characteristics, such as processing rate and melter emissions, between precipitated and direct hydroxide simulants, even though there were differences in rheological properties. To the extent this similarity is found also for simulants for SRS HLW, the direct hydroxide methods may offer the potential for faster, simpler, and cheaper simulant production. There was no plan to match the yield stress and particle size of the direct hydroxide simulant to that of the precipitated simulant because that would have increased the preparation cost and complexity and defeated the purpose of the tests. These objectives were addressed by first developing a series of glass frits and then conducting a crucible scale study to determine the waste loading achievable for the waste composition and to select the preferred frit. Waste loadings were increased until the limits of a glass property were exceeded experimentally. Glass properties for evaluation included: viscosity, electrical conductivity, crystallinity (including liquidus temperature and nepheline formation after canister centerline cooling (CCC) heat-treatment), gross glass phase separation, and the 7- day Product Consistency Test (PCT, ASTM-1285) response. Glass property limits were based upon the constraints used for DWPF process control

Preliminary ILAW Formulation Algorithm Description, 24590 LAW RPT-RT-04-0003, Rev. 1

The U.S. Department of Energy (DOE), Office of River Protection (ORP), has contracted with Bechtel National, Inc. (BNI) to design, construct, and commission the Hanford Tank Waste Treatment and Immobilization Plant (WTP) at the Hanford Site (DOE 2000). This plant is designed to operate for 40 years and treat roughly 50 million gallons of mixed hazardous high-level waste (HLW) stored in 177 underground tanks at the Hanford Site. The process involves separating the hight-level and low-activity waste (LAW) fractions through filtration, leaching, Cs ion exchange, and precipitation. Each fraction will be separately vitrified into borosilicate waste glass. This report documents the initial algorithm for use by Hanford WTP in batching LAW and glass-forming chemicals (GFCs) in the LAW melter feed preparation vessel (MFPV). Algorithm inputs include the chemical analyses of the pretreated LAW in the concentrate receipt vessel (CRV), the volume of the MFPV heel, and the compositions of individual GFCs. In addition to these inputs, uncertainties in the LAW composition and processing parameters are included in the algorithm

Final Report - ILAW PCT, VHT, Viscosity, and Electrical Conductivity Model Development, VSL-07R1230-1

This report describes the results of work and testing specified by the Test Specifications (24590-LAW-TSP-RT-01-013 Rev.1 and 24590-WTP-TSP-RT-02-001 Rev.0), Test Plans (VSL-02T4800-1 Rev.1 & TP-RPP-WTP-179 Rev.1), and Text Exception (24590-WTP-TEF-RT-03-040). The work and any associated testing followed established quality assurance requirements and conducted as authorized. The descriptions provided in this test report are an accurate account of both the conduct of the work and the data collected. Results required by the Test Plans are reported. Also reported are any unusual or anomalous occurrences that are different from the starting hypotheses. The test results and this report have been reviewed and verified

Hanford Low-activity Waste Glass Composition-temperature-melt Viscosity Relationships

This study developed a model for predicting viscosity of alkali-alumino-borosilicate glass melts as functions of composition and temperature. The model is based on a total of 3935 viscosity-temperature data from 574 glasses with viscosity values ranging from 2.53 to 7260 Poise (P) in the temperature range of 900–1260°C. Several different model forms were surveyed, including those based on Arrhenius, Vogel-Fulcher-Tammann, Avramov-Milchev, and Mauro-Yue-Ellison-Gupta-Allen. For each of these models, combinations of the temperature-independent parameters were fitted to composition. It was found that generally fitting more than one temperature-independent parameter as functions of composition resulted in overfitting. The Avramov-Milchev-based model was found to best represent the Hanford low-activity waste glass melt viscosity data based on model fit and validation statistics. A 21-term partial quadratic mixture model was recommended for use. This model predicts melt viscosity with a root-mean square error of.1736 ln(P), which is similar to the error in viscosity measurements from replicate glass analyses of.1383 ln(P). Viscosity was found to be most increased by SiO2 \u3e Al2O3 \u3e ZrO2 \u3e SnO2 and most decreased by Li2O \u3e Na2O \u3e B2O3 \u3e CaO \u3e K2O \u3e MgO, at temperatures from 900 to 1260°C