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Koopman, D

Publications and source records attributed to Koopman, D.

7 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2011

IMPACT OF THE SMALL COLUMN ION EXCHANGE PROCESS ON THE DEFENSE WASTE PROCESSING FACILITY - 12112

The Savannah River Site (SRS) is investigating the deployment of a parallel technology to the Salt Waste Processing Facility (SWPF, presently under construction) to accelerate high activity salt waste processing. The proposed technology combines large waste tank strikes of monosodium titanate (MST) to sorb strontium and actinides with two ion exchange columns packed with crystalline silicotitanate (CST) resin to sorb cesium. The new process was designated Small Column Ion Exchange (SCIX), since the ion exchange columns were sized to fit within a waste storage tank riser. Loaded resins are to be combined with high activity sludge waste and fed to the Defense Waste Processing Facility (DWPF) for incorporation into the current glass waste form. Decontaminated salt solution produced by SCIX will be fed to the SRS Saltstone Facility for on-site immobilization as a grout waste form. Determining the potential impact of SCIX resins on DWPF processing was the basis for this study. Accelerated salt waste treatment is projected to produce a significant savings in the overall life cycle cost of waste treatment at SRS.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2011

DWPF SIMULANT CPC STUDIES FOR SB7B

Lab-scale DWPF simulations of Sludge Batch 7b (SB7b) processing were performed. Testing was performed at the Savannah River National Laboratory - Aiken County Technology Laboratory (SRNL-ACTL). The primary goal of the simulations was to define a likely operating window for acid stoichiometry for the DWPF Sludge Receipt and Adjustment Tank (SRAT). In addition, the testing established conditions for the SRNL Shielded Cells qualification simulation of SB7b-Tank 40 blend, supported validation of the current glass redox model, and validated the coupled process flowsheet at the nominal acid stoichiometry. An acid window of 105-140% by the Koopman minimum acid (KMA) equation (107-142% DWPF Hsu equation) worked for the sludge-only flowsheet. Nitrite was present in the SRAT product for the 105% KMA run at 366 mg/kg, while SME cycle hydrogen reached 94% of the DWPF Slurry Mix Evaporator (SME) cycle limit in the 140% KMA run. The window was determined for sludge with added caustic (0.28M additional base, or roughly 12,000 gallons 50% NaOH to 820,000 gallons waste slurry). A suitable processing window appears to be 107-130% DWPF acid equation for sludge-only processing allowing some conservatism for the mapping of lab-scale simulant data to full-scale real waste processing including potentially non-conservative noble metal and mercury concentrations. This window should be usable with or without the addition of up to 7,000 gallons of caustic to the batch. The window could potentially be wider if caustic is not added to SB7b. It is recommended that DWPF begin processing SB7b at 115% stoichiometry using the current DWPF equation. The factor could be increased if necessary, but changes should be made with caution and in small increments. DWPF should not concentrate past 48 wt.% total solids in the SME cycle if moderate hydrogen generation is occurring simultaneously. The coupled flowsheet simulation made more hydrogen in the SRAT and SME cycles than the sludge-only run with the same acid stoichiometric factor. The slow acid addition in MCU seemed to alter the reactions that consumed the small excess acid present such that hydrogen generation was promoted relative to sludge-only processing. The coupled test reached higher wt.% total solids, and this likely contributed to the SME cycle hydrogen limit being exceeded at 110% KMA. It is clear from the trends in the SME processing GC data, however, that the frit slurry formic acid contributed to driving the hydrogen generation rate above the SME cycle limit. Hydrogen generation rates after the second frit addition generally exceeded those after the first frit addition. SRAT formate loss increased with increasing acid stoichiometry (15% to 35%). A substantial nitrate gain which was observed to have occurred after acid addition (and nitrite destruction) was reversed to a net nitrate loss in runs with higher acid stoichiometry (nitrate in SRAT product less than sum of sludge nitrate and added nitric acid). Increased ammonium ion formation was also indicated in the runs with nitrate loss. Oxalate loss on the order 20% was indicated in three of the four acid stoichiometry runs and in the coupled flowsheet run. The minimum acid stoichiometry run had no indicated loss. The losses were of the same order as the official analytical uncertainty of the oxalate concentration measurement, but were not randomly distributed about zero loss, so some actual loss was likely occurring. Based on the entire set of SB7b test data, it is recommended that DWPF avoid concentrating additional sludge solids in single SRAT batches to limit the concentrations of noble metals to SB7a processing levels (on a grams noble metal per SRAT batch basis). It is also recommended that DWPF drop the formic acid addition that accompanies the process frit 418 additions, since SME cycle data showed considerable catalytic activity for hydrogen generation from this additional acid (about 5% increase in stoichiometry occurred from the frit formic acid). Frit 418 also does not appear to need formic acid addition to prevent gel formation in the frit slurry. Simulant processing was successful using 100 ppm of 747 antifoam added prior to nitric acid instead of 200 ppm. This is a potential area for DWPF to cut antifoam usage in any future test program. An additional 100 ppm was added before formic acid addition. Foaming during formic acid addition was not observed. No build-up of oily or waxy material was observed in the off-gas equipment. Lab-scale mercury stripping behavior was similar to SB6 and SB7a. More mercury was unaccounted for as the acid stoichiometry increased.

08 HYDROGEN↗
DOE OSTI2011

SCIX IMPACT ON DWPF CPC

A program was conducted to systematically evaluate potential impacts of the proposed Small Column Ion Exchange (SCIX) process on the Defense Waste Processing Facility (DWPF) Chemical Processing Cell (CPC). The program involved a series of interrelated tasks. Past studies of the impact of crystalline silicotitanate (CST) and monosodium titanate (MST) on DWPF were reviewed. Paper studies and material balance calculations were used to establish reasonable bounding levels of CST and MST in sludge. Following the paper studies, Sludge Batch 10 (SB10) simulant was modified to have both bounding and intermediate levels of MST and ground CST. The SCIX flow sheet includes grinding of the CST which is larger than DWPF frit when not ground. Nominal ground CST was not yet available, therefore a similar CST ground previously in Savannah River National Laboratory (SRNL) was used. It was believed that this CST was over ground and that it would bound the impact of nominal CST on sludge slurry properties. Lab-scale simulations of the DWPF CPC were conducted using SB10 simulants with no, intermediate, and bounding levels of CST and MST. Tests included both the Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME) cycles. Simulations were performed at high and low acid stoichiometry. A demonstration of the extended CPC flowsheet was made that included streams from the site interim salt processing operations. A simulation using irradiated CST and MST was also completed. An extensive set of rheological measurements was made to search for potential adverse consequences of CST and MST and slurry rheology in the CPC. The SCIX CPC impact program was conducted in parallel with a program to evaluate the impact of SCIX on the final DWPF glass waste form and on the DWPF melter throughput. The studies must be considered together when evaluating the full impact of SCIX on DWPF. Due to the fact that the alternant flowsheet for DWPF has not been selected, this study did not consider the impact of proposed future alternative DWPF CPC flowsheets. The impact of the SCIX streams on DWPF processing using the selected flowsheet need to be considered as part of the technical baseline studies for coupled processing with the selected flowsheet. In addition, the downstream impact of aluminum dissolution on waste containing CST and MST has not yet been evaluated. The current baseline would not subject CST to the aluminum dissolution process and technical concerns with performing the dissolution with CST have been expressed. Should this option become feasible, the downstream impact should be considered. The main area of concern for DWPF from aluminum dissolution is an impact on rheology. The SCIX project is planning for SRNL to complete MST, CST, and sludge rheology testing to evaluate any expected changes. The impact of ground CST transport and flush water on the DWPF CPC feed tank (and potential need for decanting) has not been defined or studied.

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DOE OSTI2011

GLYCOLIC-FORMIC ACID FLOWSHEET SLUDGE MATRIX STUDY

Testing was completed to demonstrate the viability of the newly developed glycolic acid/formic acid flowsheet on processing in the Defense Waste Processing Facility's (DWPF) Chemical Process Cell (CPC). The Savannah River National Laboratory (SRNL) initiated a sludge matrix study to evaluate the impact of changing insoluble solid composition on the processing characteristics of slurries in DWPF. Four sludge simulants were prepared to cover two compositional ranges in the waste. The first was high iron/low aluminum versus low iron/high aluminum (referred to as HiFe or LoFe in this report). The second was high calcium-manganese/low nickel, chromium, and magnesium versus low calcium-manganese/high nickel, chromium, and magnesium (referred to as HiMn or LoMn in this report). These two options can be combined to form four distinct sludge compositions. The sludge matrix study called for testing each of these four simulants near the minimum acid required for nitrite destruction (100% acid stoichiometry) and at a second acid level that produced significant hydrogen by noble metal catalyzed decomposition of formic acid (150% acid stoichiometry). Four simulants were prepared based on the four possible combinations of the Al/Fe and Mn-Ca/Mg-Ni-Cr options. Preliminary simulant preparation work has already been documented. The four simulants were used for high and low acid testing. Eight planned experiments (GF26 to GF33) were completed to demonstrate the viability of the glycolic-formic flowsheet. Composition and physical property measurements were made on the SRAT product. Composition measurements were made on the condensate from the Mercury Water Wash Tank (MWWT), Formic Acid Vent Condenser (FAVC), ammonia scrubber and on SRAT samples pulled throughout the SRAT cycle. Updated values for formate loss and nitrite-tonitrate conversion were found that can be used in the acid calculations for future sludge matrix process simulations with the glycolic acid/formic acid flowsheet. Preliminary results of the initial testing indicate: (1) Hydrogen generation rate was very low throughout all SRAT cycles. (2) The mercury concentration of the SRAT product was below the 0.8 wt% limit in all runs. (3) Nitrite in the SRAT product was <100 mg/kg for all runs. (4) Foaminess was not an issue using the nominal antifoam addition strategy in these tests. (5) The high aluminum sludges (LoFe, HM type sludges) were much more viscous than the Hi Fe sludges. At 100% acid stoichiometry, the SRAT products from the high aluminum sludges were very viscous but at 150% acid stoichiometry, the SRAT products from the high aluminum sludges were very thin. This makes the glycolic acid/formic acid flowsheet an improvement for processing more viscous sludges. (6) The pH of the SRAT products was from 2.7-3.1 for the 150% acid stoichiometry runs and 5.1-6.1 for the 100% acid stoichiometry runs, significantly lower than is typical of the baseline nitric acid/formic acid flowsheet.

08 HYDROGEN↗
DOE OSTI2011

RHEOLOGY OF SETTLED SOLIDS IN THE SMALL COLUMN ION EXCHANGE PROCESS

The Small Column Ion Exchange (SCIX) process is being developed to remove cesium, strontium, and actinides from Savannah River Site (SRS) Liquid Waste using an existing waste tank as process housing. This method includes the addition of monosodium titanate (MST) to a waste tank containing salt solution and entrained sludge solids, followed by tank mixing and filtration. The filtrate is then processed through in-tank ion exchange columns containing crystalline silicotitanate (CST) media. While the process is operating, it is known that solid particles begin to settle in the tank and temperatures may reach beyond 45 C. Previous testing has shown that sludge-MST slurries that sit for extended periods at elevated temperatures can develop large shear strengths, making them difficult to resuspend and remove from the tank. The authors conducted rheological testing of mixtures containing various concentrations of sludge simulant, MST, and CST (three preparations) that were aged at different times (i.e., 0 to 13 weeks) and isothermally maintained to 30, 45, or 60 C. Two types of grinding methodologies were employed to prepare CST for this testing, herein called Savannah River National Laboratory (SRNL) and Vitreous State Laboratory (VSL) ground materials. Unground CST particles were also tested. A small number of samples were irradiated prior to 4 week settling and 60 C temperature treatment, with exposures ranging from 0 to 100 MRad. Additional tests are also being conducted that will allow the solid particles to settle at 45 C for 6, 12, and 24 months. The objectives of this task are to determine the impact of feed composition, settling time, and temperature on the shear strength, yield stress, and consistency of the slurries and to determine the impact of radiation on slurry rheology. The testing will determine the relative impact of these parameters rather than predict the shear strength, yield stress, and consistency as a function of feed and operating conditions. This document describes the rheology of slurries containing MST, CST, and simulated sludge that sat at indicated temperatures for up to 13 weeks. A previous SRNL report described preliminary rheology data of slurries containing MST and sludge. Preliminary results of the irradiation tests are also presented in this report, though additional data are still being collected. Rheology of the long term settling samples (6, 12, and 24 months) and additional irradiation test results will be reported at a later date. Conclusions from this analysis are as follows: (1) Slurries containing MST and unground CST have the largest shear strength. Due to the high shear strengths measured in slurries containing unground CST, evaluations of specific tank contents and mixing capability should be performed prior to any addition of this material into a waste tank. Experimentally determined shear strengths indicate mixing could be problematic in mixtures containing unground CST. (2) Increasing the ground CST fraction in the slurry increases the slurry shear strength, yield stress, and consistency. (3) Increasing the sludge fraction in the slurry decreases the slurry shear strength, yield stress, and consistency. (4) Slurries containing VSL ground CST have larger shear strength, yield stress, and consistency than slurries containing SRNL ground CST. (5) The effects of settling time and temperature on slurry shear strength are slurry dependent. (6) No effects of settling time and temperature on slurry yield stress or consistency were observed. (7) Radiation up to 100 MRad does not appear to affect properties of shear strength, yield stress, or consistency of process feeds.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2011

IMPACT OF SMALL COLUMN ION EXCHANGE STREAMS ON DWPF GLASS FORMULATION MELT RATE STUDIES

This study was undertaken to evaluate the potential impacts of the Small Column Ion Exchange (SCIX) streams - particularly the addition of Monosodium Titanate (MST) and Crystalline Silicotitanate (CST) - on the melt rate of simulated feed for the Defense Waste Processing Facility (DWPF). Additional MST was added to account for contributions from the Salt Waste Processing Facility (SWPF). The Savannah River National Laboratory (SRNL) Melt Rate Furnace (MRF) was used to evaluate four melter feed compositions: two with simulated SCIX and SWPF material and two without. The Slurry-fed Melt Rate Furnace (SMRF) was then used to compare two different feeds: one with and one without bounding concentrations of simulated SCIX and SWPF material. Analyses of the melter feed materials confirmed that they met their targeted compositions. Four feeds were tested in triplicate in the MRF. The linear melt rates were determined by using X-ray computed tomography to measure the height of the glass formed along the bottom of the beakers. The addition of the SCIX and SWPF material reduced the average measured melt rate by about 10% in MRF testing, although there was significant scatter in the data. Two feeds were tested in the SMRF. It was noted that the ground CST alone (ground CST with liquid in a bucket) was extremely difficult to resuspend during preparation of the feed with material from SCIX and SWPF. This feed was also more difficult to pump than the material without MST and CST due to settling occurring in the melter feed line, although the yield stress of both feeds was high relative to the DWPF design basis. Steady state feeding conditions were maintained for about five hours for each feed. There was a reduction in the feed and pour rates of approximately 15% when CST and MST were added to the feed, although there was significant scatter in the data. Analysis of samples collected from the SMRF pour stream showed that the composition of the glass changed as expected when MST and CST were added to the feed. These reductions in melt rate are consistent with previous studies that showed a negative impact of increased TiO{sub 2} concentrations on the rate of melting. The impact of agitating the melt pool via bubbling was not studied as part of this work, but may be of interest for further testing. It is recommended that additional melt rate testing be performed should a potential reduction in melt rate of 10-15% be considered an issue of concern, or should the anticipated composition of the glass with the addition of material from salt waste processing be modified significantly from the current projections, either due to changes in sludge batch preparation or changes in the composition or volume of SCIX and SWPF material.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗