Testing Report: Littleford-Day Dryer Operation: Dryer Operation Impacts of Proposed MIS Mitigation Changes

Pacific Northwest National Laboratory performed a series of tests using the Littleford Day 22-liter dryer during investigations that evaluated changes in the melter-feed composition for the Demonstration Bulk Vitrification System. During testing, a new melter-feed formulation was developed that improved dryer performance while improving the retention of waste salts in the melter feed during vitrification

A Brief Review of Filtration Studies for Waste Treatment at the Hanford Site

This document completes the requirements of Milestone 1-2, PNNL Draft Literature Review, discussed in the scope of work outlined in the EM-31 Support Project task plan WP-2.3.6-2010-1. The focus of task WP 2.3.6 is to improve the U.S. Department of Energy’s (DOE’s) understanding of filtration operations for high-level waste (HLW) to enhance filtration and cleaning efficiencies, thereby increasing process throughput and reducing the sodium demand (through acid neutralization). Developing the processes for fulfilling the cleaning/backpulsing requirements will result in more efficient operations for both the Hanford Tank Waste Treatment and Immobilization Plant (WTP) and the Savannah River Site (SRS), thereby increasing throughput by limiting cleaning cycles. The purpose of this document is to summarize Pacific Northwest National Laboratory’s (PNNL’s) literature review of historical filtration testing at the laboratory and of testing found in peer-reviewed journals. Eventually, the contents of this document will be merged with a literature review by SRS to produce a summary report for DOE of the results of previous filtration testing at the laboratories and the types of testing that still need to be completed to address the questions about improved filtration performance at WTP and SRS. To this end, this report presents 1) a review of the current state of crossflow filtration knowledge available in the peer-reviewed literature, 2) a detailed review of PNNL-related filtration studies specific to the Hanford site, and 3) an overview of current waste filtration models developed by PNNL and suggested avenues for future model development

Large-Scale Spray Releases: Additional Aerosol Test Results

One of the events postulated in the hazard analysis for the Waste Treatment and Immobilization Plant (WTP) and other U.S. Department of Energy (DOE) nuclear facilities is a breach in process piping that produces aerosols with droplet sizes in the respirable range. The current approach for predicting the size and concentration of aerosols produced in a spray leak event involves extrapolating from correlations reported in the literature. These correlations are based on results obtained from small engineered spray nozzles using pure liquids that behave as a Newtonian fluid. The narrow ranges of physical properties on which the correlations are based do not cover the wide range of slurries and viscous materials that will be processed in the WTP and in processing facilities across the DOE complex. To expand the data set upon which the WTP accident and safety analyses were based, an aerosol spray leak testing program was conducted by Pacific Northwest National Laboratory (PNNL). PNNL’s test program addressed two key technical areas to improve the WTP methodology (Larson and Allen 2010). The first technical area was to quantify the role of slurry particles in small breaches where slurry particles may plug the hole and prevent high-pressure sprays. The results from an effort to address this first technical area can be found in Mahoney et al. (2012a). The second technical area was to determine aerosol droplet size distribution and total droplet volume from prototypic breaches and fluids, including sprays from larger breaches and sprays of slurries for which literature data are mostly absent. To address the second technical area, the testing program collected aerosol generation data at two scales, commonly referred to as small-scale and large-scale testing. The small-scale testing and resultant data are described in Mahoney et al. (2012b), and the large-scale testing and resultant data are presented in Schonewill et al. (2012). In tests at both scales, simulants were used to mimic the relevant physical properties projected for actual WTP process streams

Characterization of Filtration Scale-Up Performance

The scale-up performance of sintered stainless steel crossflow filter elements planned for use at the Pretreatment Engineering Platform (PEP) and at the Waste Treatment and Immobilization Plant (WTP) were characterized in partial fulfillment (see Table S.1) of the requirements of Test Plan TP RPP WTP 509. This test report details the results of experimental activities related only to filter scale-up characterization. These tests were performed under the Simulant Testing Program supporting Phase 1 of the demonstration of the pretreatment leaching processes at PEP. Pacific Northwest National Laboratory (PNNL) conducted the tests discussed herein for Bechtel National, Inc. (BNI) to address the data needs of Test Specification 24590-WTP-TSP-RT-07-004. Scale-up characterization tests employ high-level waste (HLW) simulants developed under the Test Plan TP-RPP-WTP-469. The experimental activities outlined in TP-RPP-WTP-509 examined specific processes from two broad areas of simulant behavior: 1) leaching performance of the boehmite simulant as a function of suspending phase chemistry and 2) filtration performance of the blended simulant with respect to filter scale-up and fouling. With regard to leaching behavior, the effect of anions on the kinetics of boehmite leaching was examined. Two experiments were conducted: 1) one examined the effect of the aluminate anion on the rate of boehmite dissolution and 2) another determined the effect of secondary anions typical of Hanford tank wastes on the rate of boehmite dissolution. Both experiments provide insight into how compositional variations in the suspending phase impact the effectiveness of the leaching processes. In addition, the aluminate anion studies provide information on the consequences of gibbsite in waste. The latter derives from the expected fast dissolution of gibbsite relative to boehmite. This test report concerns only results of the filtration performance with respect to scale-up. Test results for boehmite dissolution kinetics and filter fouling are reported elsewhere (see Table S.1). The primary goal of scale-up testing was to examine how filter length influenced permeate flux rates. To accomplish this, the existing cells unit filter system, which employs a 2-ft-long, 0.5-in. (inner) diameter sintered stainless steel filter element, was redesigned to accommodate an 8-ft. sintered stainless steel filter element of the same diameter. Testing was then performed to evaluate the filtration performance of waste simulant slurries. Scale-up testing consisted of two separate series of filtration tests: 1) scale-up axial velocity (AV)/transmembrane pressure (TMP) matrix tests and 2) scale-up temperature tests. The AV/TMP matrix tests examined filtration performance of two different waste simulant slurries in the 8-ft. cells unit filter system. Waste simulant slurry formulations for the 8-ft. scale-up test was selected to match simulant slurries for which filtration performance had been characterized on the 2-ft CUF. For the scale-up temperature tests, the filtration performance at three test temperatures (i.e., 25°C, 40°C, and 60°C) was determined to evaluate if filter flux versus temperature correlations developed using the 2-ft filters were also valid for the 8-ft filters

Characterization, Leaching, and Filtration Testing for Tributyl Phosphate (TBP, Group 7) Actual Waste Sample Composites

.A testing program evaluating actual tank waste was developed in response to Task 4 from the M-12 External Flowsheet Review Team (EFRT) issue response plan. The bulk water-insoluble solid wastes that are anticipated to be delivered to the Waste Treatment and Immobilization Plant (WTP) were identified according to type such that the actual waste testing could be targeted to the relevant categories. Eight broad waste groupings were defined. Samples available from the 222S archive were identified and obtained for testing. The actual waste-testing program included homogenizing the samples by group, characterizing the solids and aqueous phases, and performing parametric leaching tests. The tributyl phosphate sludge (TBP, Group 7) is the subject of this report. The Group 7 waste was anticipated to be high in phosphorus as well as aluminum in the form of gibbsite. Both are believed to exist in sufficient quantities in the Group 7 waste to address leaching behavior. Thus, the focus of the Group 7 testing was on the removal of both P and Al. The waste-type definition, archived sample conditions, homogenization activities, characterization (physical, chemical, radioisotope, and crystal habit), and caustic leaching behavior as functions of time, temperature, and hydroxide concentration are discussed in this report. Testing was conducted according to TP-RPP-WTP-467

Optimization of Hydride Rim Formation in Unirradiated Zr 4 Cladding

The purpose of this work is to build on the results reported in the M2 milestone M2FT 13PN0805051, document number FCRD-USED-2013-000151 (Hanson, 2013). In that work, it was demonstrated that unirradiated samples of zircaloy-4 cladding could be pre-hydrided at temperatures below 400°C in pure hydrogen gas and that the growth of hydrides on the surface could be controlled by changing the surface condition of the samples and form a desired hydride rim on the outside diameter of the cladding. The work performed at Pacific Northwest National Laboratory since the issuing of the M2 milestone has focused its efforts to optimize the formation of a hydride rim on available zircaloy-4 cladding samples by controlling temperature variation and gas flow control during pre-hydriding treatments. Surface conditioning of the outside surface was also examined as a variable. The results of test indicate that much of the variability in the hydride thickness is due to temperature variation occurring in the furnaces as well as how hydrogen gas flows across the sample surface. Efforts to examine other alloys, gas concentrations, and different surface conditioning plan to be pursed in the next FY as more cladding samples become availabl

A Brief Review of Filtration Studies for Waste Treatment at the Hanford Site

This document completes the requirements of Milestone 1-2, PNNL Draft Literature Review, discussed in the scope of work outlined in the EM-31 Support Project task plan WP-2.3.6-2010-1. The focus of task WP 2.3.6 is to improve the U.S. Department of Energy’s (DOE’s) understanding of filtration operations for high-level waste (HLW) to enhance filtration and cleaning efficiencies, thereby increasing process throughput and reducing the sodium demand (through acid neutralization). Developing the processes for fulfilling the cleaning/backpulsing requirements will result in more efficient operations for both the Hanford Tank Waste Treatment and Immobilization Plant (WTP) and the Savannah River Site (SRS), thereby increasing throughput by limiting cleaning cycles. The purpose of this document is to summarize Pacific Northwest National Laboratory’s (PNNL’s) literature review of historical filtration testing at the laboratory and of testing found in peer-reviewed journals. Eventually, the contents of this document will be merged with a literature review by SRS to produce a summary report for DOE of the results of previous filtration testing at the laboratories and the types of testing that still need to be completed to address the questions about improved filtration performance at WTP and SRS. To this end, this report presents 1) a review of the current state of crossflow filtration knowledge available in the peer-reviewed literature, 2) a detailed review of PNNL-related filtration studies specific to the Hanford site, and 3) an overview of current waste filtration models developed by PNNL and suggested avenues for future model development

Filtration Understanding: FY10 Testing Results and Filtration Model Update

This document completes the requirements of Milestone 2-4, Final Report of FY10 Testing, discussed in the scope of work outlined in the EM31 task plan WP-2.3.6-2010-1. The focus of task WP 2.3.6 is to improve the U.S. Department of Energy’s (DOE’s) understanding of filtration operations for high-level waste (HLW) to improve filtration and cleaning efficiencies, thereby increasing process throughput and reducing the Na demand (through acid neutralization). Developing the cleaning/backpulsing requirements will produce much more efficient operations for both the Hanford Tank Waste Treatment and Immobilization Plant (WTP) and the Savannah River Site (SRS), thereby significantly increasing throughput by limiting cleaning cycles. The scope of this work is to develop the understanding of filter fouling to allow developing this cleaning/backpulsing strategy

Large-Scale Spray Releases: Additional Aerosol Test Results

One of the events postulated in the hazard analysis for the Waste Treatment and Immobilization Plant (WTP) and other U.S. Department of Energy (DOE) nuclear facilities is a breach in process piping that produces aerosols with droplet sizes in the respirable range. The current approach for predicting the size and concentration of aerosols produced in a spray leak event involves extrapolating from correlations reported in the literature. These correlations are based on results obtained from small engineered spray nozzles using pure liquids that behave as a Newtonian fluid. The narrow ranges of physical properties on which the correlations are based do not cover the wide range of slurries and viscous materials that will be processed in the WTP and in processing facilities across the DOE complex. To expand the data set upon which the WTP accident and safety analyses were based, an aerosol spray leak testing program was conducted by Pacific Northwest National Laboratory (PNNL). PNNL’s test program addressed two key technical areas to improve the WTP methodology (Larson and Allen 2010). The first technical area was to quantify the role of slurry particles in small breaches where slurry particles may plug the hole and prevent high-pressure sprays. The results from an effort to address this first technical area can be found in Mahoney et al. (2012a). The second technical area was to determine aerosol droplet size distribution and total droplet volume from prototypic breaches and fluids, including sprays from larger breaches and sprays of slurries for which literature data are mostly absent. To address the second technical area, the testing program collected aerosol generation data at two scales, commonly referred to as small-scale and large-scale testing. The small-scale testing and resultant data are described in Mahoney et al. (2012b), and the large-scale testing and resultant data are presented in Schonewill et al. (2012). In tests at both scales, simulants were used to mimic the relevant physical properties projected for actual WTP process streams

Characterization, Leaching, and Filtrations Testing of Ferrocyanide Tank sludge (Group 8) Actual Waste Composite

This is the final report in a series of eight reports defining characterization, leach, and filtration testing of a wide variety of Hanford tank waste sludges. The information generated from this series is intended to supplement the Waste Treatment and Immobilization Plant (WTP) project understanding of actual waste behaviors associated with tank waste sludge processing through the pretreatment portion of the WTP. The work described in this report presents information on a high-iron waste form, specifically the ferrocyanide tank waste sludge. Iron hydroxide has been shown to pose technical challenges during filtration processing; the ferrocyanide tank waste sludge represented a good source of the high-iron matrix to test the filtration processing