Thermal Flammable Gas Production from Bulk Vitrification Feed

The baseline bulk-vitrification (BV) process (also known as in-container vitrification ICV™) includes a mixer/dryer to convert liquid low-activity waste (LAW) into a dried, blended feed for vitrification. Feed preparation includes blending LAW with glass-forming minerals (GFMs) and cellulose and drying the mixture to a suitable dryness, consistency, and particle size for transport to the ICVTM container. The cellulose is to be added to the BV feed at a rate sufficient to destroy 75% of the nitrogen present as nitrate or nitrite. Concern exists that flammable gases may be produced during drying operations at levels that could pose a risk. The drying process is conducted under vacuum in the temperature range of 60 to 80°C. These flammable gases could be produced either through thermal decomposition of cellulose or waste organics or as a by-product of the reaction of cellulose and/or waste organics with nitrate or the postulated small amount of nitrite present in the waste. To help address the concern about flammable gas production during drying, the Pacific Northwest National Laboratory (PNNL) performed studies to identify the gases produced at dryer temperatures and at possible process upset conditions. Studies used a thermogravimetric analyzer (TGA) up to 525°C and isothermal testing up to 120°C to determine flammable gas production resulting from the cellulose and organic constituents in bulk vitrification feed. This report provides the results of those studies to determine the effects of cellulose and waste organics on flammable gas evolutio

Laboratory Testing of Bulk Vitrified Low-Activity Waste Forms to Support the 2005 Integrated Disposal Facility Performance Assessment

The purpose of this report is to document the results from laboratory testing of the bulk vitri-fied (BV) waste form that was conducted in support of the 2005 integrated disposal facility (IDF) performance assessment (PA). Laboratory testing provides a majority of the key input data re-quired to assess the long-term performance of the BV waste package with the STORM code. Test data from three principal methods, as described by McGrail et al. (2000a; 2003a), are dis-cussed in this testing report including the single-pass flow-through test (SPFT) and product con-sistency test (PCT). Each of these test methods focuses on different aspects of the glass corrosion process. See McGrail et al. (2000a; 2003a) for additional details regarding these test methods and their use in evaluating long-term glass performance. In addition to evaluating the long-term glass performance, this report discusses the results and methods used to provided a recommended best estimate of the soluble fraction of 99Tc that can be leached from the engineer-ing-scale BV waste package. These laboratory tests are part of a continuum of testing that is aimed at improving the performance of the BV waste package

Bulk Vitrification Castable Refractory Block Protection Study

Bulk vitrification (BV) was selected for a pilot-scale test and demonstration facility for supplemental treatment to accelerate the cleanup of low-activity waste (LAW) at the Hanford U.S. DOE Site. During engineering-scale (ES) tests, a small fraction of radioactive Tc (and Re, its nonradioactive surrogate) were transferred out of the LAW glass feed and molten LAW glass, and deposited on the surface and within the pores of the castable refractory block (CRB). Laboratory experiments were undertaken to understand the mechanisms of the transport Tc/Re into the CRB during vitrification and to evaluate various means of CRB protection against the deposition of leachable Tc/Re. The tests used Re as a chemical surrogate for Tc. The tests with the baseline CRB showed that the molten LAW penetrates into CRB pores before it converts to glass, leaving deposits of sulfates and chlorides when the nitrate components decompose. Na2O from the LAW reacts with the CRB to create a durable glass phase that may contain Tc/Re. Limited data from a single CRB sample taken from an ES experiment indicate that, while a fraction of Tc/Re is present in the CRB in a readily leachable form, most of the Tc/Re deposited in the refractory is retained in the form of a durable glass phase. In addition, the molten salts from the LAW, mainly sulfates, chlorides, and nitrates, begin to evaporate from BV feeds at temperatures below 800 C and condense on solid surfaces at temperatures below 530 C. Three approaches aimed at reducing or preventing the deposition of soluble Tc/Re within the CRB were proposed: metal lining, sealing the CRB surface with a glaze, and lining the CRB with ceramic tiles. Metal liners were deemed unsuitable because evaluations showed that they can cause unacceptable distortions of the electric field in the BV system. Sodium silicate and a low-alkali borosilicate glaze were selected for testing. The glazes slowed down molten salt condensate penetration, but did little to reduce the penetration of molten salt. Out of several refractory tile candidates, only greystone and fused-cast alumina-zirconia-silica (AZS) refractory remained intact and well bonded to the CRB after firing to 1000 C. The deformation of the refractory-tile composite was avoided by prefiring the greystone tile to 800 C. Condensed vapors did not penetrate the tiles, but Re salts condensed on their surface. Refractory corrosion tests indicated that a 0.25-inch-thick greystone tile would not corrode during a BV melt. Tiles can reduce both vapor penetration and molten salt penetration, but vapor deposition above the melt line will occur even on tiles. The Tc/Re transport scenario was outlined as follows. At temperatures below 700 C, molten ionic salt (MIS) that includes all the Tc/Re penetrates, by capillarity, from the feed into the CRB open porosity. At approximately 750 C, the MIS decomposes through the loss of NOx, leaving mainly sulfate and chloride salts. The Na2O formed in the decomposition of the nitrates reacts with insoluble grains in the feed and with the aluminosilicates in the CRB to form more viscous liquids that reduce further liquid penetration into the CRB. At 800 to 1000 C, a continuous glass phase traps the remains of the MIS in the form of inclusions in the bulk glass melt. At 1000 to 1200 C, the salt inclusions in the glass slowly dissolve but also rise to the surface. The Tc/Re salts also evaporate from the free surface of the glass melt that is rapidly renewed by convective currents. The vapors condense on cooler surfaces in the upper portion of the CRB, the box lid, and the off-gas system

Bulk Vitrification Performance Enhancement: Refractory Lining Protection Against Molten Salt Penetration

Bulk vitrification (BV) is a process that heats a feed material that consists of glass-forming solids and dried low-activity waste (LAW) in a disposable refractory-lined metal box using electrical power supplied through carbon electrodes. The feed is heated to the point that the LAW decomposes and combines with the solids to generate a vitreous waste form. This study supports the BV design and operations by exploring various methods aimed at reducing the quantities of soluble Tc in the castable refractory block portion of the refractory lining, which limits the effectiveness of the final waste form

Investigation of Tc Migration Mechanism During Bulk Vitrification Process Using Re Surrogate

As a part of Bulk vitrification (BV) performance enhancement tasks, Laboratory scoping tests were performed in FY 2004-2005 to explore possible ways to reduce the amount of soluble Tc in the BV waste package. Theses scoping tests helped identify which mechanisms play an important role in the migration of Tc in the BV process (Hrma et al. 2005 and Kim et al. 2005). Based on the results from these scoping tests, additional tests were identified that will improve the understanding of Tc migration and to clearly identify the dominant mechanisms. The additional activities identified from previous studies were evaluated and prioritized for planning for Tasks 29 and 30 conducted in FY2006. Task 29 focused on the improved understanding of Tc migration mechanisms, and Task 30 focused on identifying the potential process changes that might reduce Tc/Re migration into the castable refractory block (CRB). This report summarizes the results from the laboratory- and crucible-scale tests in the lab for improved Tc migration mechanism understanding utilizing Re as a surrogate performed in Task 29

Analysis of Soluble Re Concentrations in Refractory from Bulk Vitrification Full-Scale Test 38B

The capacity of the waste treatment plant (WTP) being built at the Hanford Site is not sufficient to process all of the tank waste accumulated from more than 40 years of nuclear materials production. Bulk vitrification can accelerate tank waste treatment by providing some supplemental low-activity waste (LAW) treatment capacity. Bulk vitrification combines LAW and glass-forming chemicals in a large metal container and melts the contents using electrical resistance heating. A castable refractory block (CRB) is used along with sand to insulate the container from the heat generated while melting the contents into a glass waste form. This report describes engineering-scale (ES) and full-scale (FS) tests that have been conducted. Several ES tests showed that a small fraction of soluble Tc moves in the CRB and results in a groundwater peak different than WTP glass. The total soluble Tc-99 fraction in the FS CRB is expected to be different than that determined in the ES tests, but until FS test results are available, the best-estimate soluble Tc-99 fraction from the ES tests has been used as a conservative estimate. The first FS test results are from cold simulant tests that have been spiked with Re. An estimated scale-up factor extrapolates the Tc-99 data collected at the ES to the FS bulk vitrification waste package. Test FS-38A tested the refractory design and did not have a Re spike. Samples were taken and analyzed to help determine Re CRB background concentrations using a Re-spiked, six-tank composite simulant mixed with soil and glass formers to produce the waste feed. Although this feed is not physically the same as the Demonstration Bulk Vitrification System feed , the chemical make-up is the same. Extensive sampling of the CRB was planned, but difficulties with the test prevented completion of a full box. An abbreviated plan is described that looks at duplicate samples taken from refractory archive sections, a lower wall sample, and two base samples to gain early information about Re and projected Tc-99 levels in the FS box

Evaluation of Exothermic Reactions from Bulk-Vitrification Melter Feeds Containing Cellulose

PNNL has demonstrated that cellulose effectively reduces the amount of molten ionic salt during Bulk Vitrification of simulated Hanford Low Level Waste (LLW). To address concerns about the potential reactivity of cellulose-LLW, PNNL used thermogravimetric analysis, differential thermal analysis, and accelerating rate calorimetry to determine in these preliminary studies that these mixtures will support a self-sustaining reaction if heated to 110°C at adiabatic conditions. Additional testing is recommended

Uranium Oxide Aerosol Transport in Porous Graphite

The objective of this paper is to investigate the transport of uranium oxide particles that may be present in carbon dioxide (CO2) gas coolant, into the graphite blocks of gas-cooled, graphite moderated reactors. The transport of uranium oxide in the coolant system, and subsequent deposition of this material in the graphite, of such reactors is of interest because it has the potential to influence the application of the Graphite Isotope Ratio Method (GIRM). The GIRM is a technology that has been developed to validate the declared operation of graphite moderated reactors. GIRM exploits isotopic ratio changes that occur in the impurity elements present in the graphite to infer cumulative exposure and hence the reactor’s lifetime cumulative plutonium production. Reference Gesh, et. al., for a more complete discussion on the GIRM technology

Uranium Oxide Aerosol Transport in Porous Graphite

The objective of this paper is to investigate the transport of uranium oxide particles that may be present in carbon dioxide (CO2) gas coolant, into the graphite blocks of gas-cooled, graphite moderated reactors. The transport of uranium oxide in the coolant system, and subsequent deposition of this material in the graphite, of such reactors is of interest because it has the potential to influence the application of the Graphite Isotope Ratio Method (GIRM). The GIRM is a technology that has been developed to validate the declared operation of graphite moderated reactors. GIRM exploits isotopic ratio changes that occur in the impurity elements present in the graphite to infer cumulative exposure and hence the reactor’s lifetime cumulative plutonium production. Reference Gesh, et. al., for a more complete discussion on the GIRM technology