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Matlack, Keith S.

Publications and source records attributed to Matlack, Keith S..

Integrated DM1200 Melter Testing of HLW AZ-102 Composition Using Bubblers (Final Report)

This report documents melter and off-gas performance results obtained on the DM1200 HLW Pilot Melter during processing of simulated HLW AZ-102 feed. The principal objectives of the DM1200 melter testing were to determine the achievable glass production rates for simulated HLW AZ-102 feed; determine the effect of bubbling rate on production rate; characterize melter off-gas emissions; characterize the performance of the prototypical off-gas system components as well as their integrated performance; characterize the feed, glass product, and off-gas effluents; and to perform pre- and post test inspections of system components.

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DM1200 Tests with C-104/AY-101 HLW Simulants (Final Report)

This report documents melter and off-gas performance results obtained on the DM1200 HLW Pilot Melter during processing of simulated HLW C-104/AY-101 feed. The principal objectives of the DM1200 melter testing were to determine the achievable glass production rates for simulated HLW C-104/AY-101 feed; determine the effect of bubbling rate on production rate; characterize melter off-gas emissions; characterize the performance of the prototypical off-gas system components as well as their integrated performance; characterize the feed, glass product, and off-gas effluents; and to perform pre- and post test inspections of system components.

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Compositional Variation Tests on DuraMelter 100 with LAW Sub-Envelope C2 Feed in Support of the LAW Pilot Melter (Final Report)

One of the principal objectives of the DM100 melter tests was to demonstrate that the LAW Sub-Envelope C2 feeds with ± 15% variations in the amounts of waste simulant are suitable for large-scale tests on the LAW Pilot melter. The other principle objective for the DM100 tests was to determine the relative effects of sugar versus waste organics on glass redox state, NOx emissions, sulfur emissions, sulfur retention in the glass, secondary sulfate layer formation, and glass-melt foaming. Additional objectives included measurement of the feed rheological properties and collection of melter emissions data. Screening tests are conducted at the DM100 scale in order to identify and correct potential problems before testing at the larger scale LAW Pilot melter. Testing goals were met in that the results of the DM100 melter test resulted in selection of LAW Sub-Envelope C2 feed suitable for Pilot Melter testing.

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Integrated Off-Gas System Tests on the DM1200 Melter with RPP-WTP LAW Sub-Envelope C1 Simulants (Final Report)

The report documents melter and off-gas performance results obtained on the DM1200 during processing of LAW Sub-Envelope Cl feed. The principal objectives of the DM1200 melter testing were to demonstrate suitable processing and production rates for LAW Cl feed; characterize the glass product for elemental composition, the presence of organic compounds, and TCLP response for metals; and measure destruction and removal efficiencies (DREs) for organic compounds across the melter and off-gas treatment components. The feed was spiked with organic compounds for part of the testing duration. Data were collected for both process engineering needs and to support regulatory activities. The data needed for regulatory support were collected using EPA methods and independent data analyses and data checking were performed.

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Compositional Variation Tests on DuraMelter 100 with LAW Sub-Envelope C1 Feed (LAWC22) Glass in Support of the LAW Pilot Melter (Final Report)

The Vitreous State Laboratory at The Catholic University of America (VSL) is developing and testing glass formulations for RPP-WTP waste envelopes to provide data to meet the RPP-WTP contract requirements and to support system design activities. That work is based upon small-scale batch melts (“crucible melts”) using waste envelope simulants. Selected formulations have also been tested in small-scale continuously-fed joule-heated melters (DM10 and DM100 systems) and, ultimately, in the LAW Pilot Melter. Such melter tests provide information on key process factors such as feed processing behavior, dynamic effects during processing, sulfate incorporation, processing rates, off-gas amounts and compositions, foaming control, etc., that cannot be reliably obtained from crucible melts. This sequential scale-up approach in the vitrification testing program ensures that maximum benefit is obtained from the more costly pilot-scale tests and that the most effective use is made of that resource. The principal objective of the work described in this report was to collect the necessary small-scale melter test data with a LAW Sub-Envelope C1 waste simulant in order to support the next series of tests with the same melter feed on the LAW Pilot Melter. This work was conducted under a corresponding Test Specification and Test Plan.

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Glass Formulation and Testing with RPP-WTP HLW Simulants (Final Report)

This report presents the results from HLW glass formulation work that was conducted at the Vitreous State Laboratory of The Catholic University of America during Part B1 of the RPP-WTP Project (formally known as TWRS-P) in support of the Privatization contractor, BNFL, Inc. Glass formulation development is required to provide data that are essential for design of the vitrification facility in the near term and for safe and reliable operation of that facility in the longer-term. These data also form the bases from which contractually and technically acceptable immobilized high-level waste (IHLW) products will be devised. Glass formulation therefore impacts many aspects of the vitrification facility design, overall process economics, and contractual compliance. As an integral part of the overall system design, development of glass formulations requires input from many sources including tank waste characterization, pretreatment process definition, flow sheet development, and processing schedules. Accordingly, the glass formulation effort must be responsive to new information as the facility design basis evolves.

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Compositional Variation Tests on DuraMelter 100 with LAW Sub-Envelope C1 Feed (LAWC22 Glass) in Support of the LAW Pilot Melter (Final Report)

This report provides the results from tests that were performed on a DM100 system with LAW Sub-Envelope Cl and Al feeds in support of the subsequent Pilot Melter tests. The principal objectives of the DM100 tests were to determine the processing characteristics as the simulated melter feed transitioned from the LAW Sub-Envelope Cl to the Sub-Envelope Al composition and to determine the effect of bubbling rate on production rate.

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Integrated Off-Gas System Tests on the DM1200 Melter with RPP-WTP LAW Sub-Envelope Bl Simulants, VSL-03R3851-1, Rev. 0 (Oct 2003)

The report documents melter and off-gas performance results obtained on the DM1200 melter during processing of LAW Sub-Envelope B1 feed. The principal objectives of the DM1200 melter testing were to demonstrate suitable processing and production rates for LAW B1 feed; characterize the glass product for elemental composition; measure elemental emission rates and decontamination factors (DFs) across the melter and off-gas treatment components; and provide additional data on the performance of the thermal catalytic oxidation and selective catalytic reduction (TCO/SCR) unit efficiency in treating organic emissions. The feed was spiked with organic compounds for part of the testing duration. All data were collected for use in engineering and system design purposes. No sampling and analysis to collect environmental data was performed during these tests.

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Compositional Variation Tests on DuraMelter 100 with LAW Sub-Envelope A1 Feed (LAWA44 Glass) in Support of the LAW Pilot Melter, VSL-02R62N0-4, Rev. 0 (Nov 2002)

The two tests described in this report utilized blended feed (glass formers plus waste simulant) prepared by Optima Chemicals according to VSL specifications generating about 1. 7 metric tons of glass. Sugar was added (at VSL) to the nominal feed at a "sugar ratio" of 0.5 for each of the two variation tests1; however, since the sugar addition is assumed to be "blind" to the variations, the actual sugar ratios were 0.57 and 0.44. The DMl00-WV melter was used in order to provide a direct comparison with the LAW tests previously conducted on the same melter. Two 100-hour melter tests were conducted: one with a 15% deficiency in simulant and one with 15% excess in simulant. Key operating parameters including cold cap coverage, feed rate, and glass pool temperature were held constant to investigate the effects of the glass compositional changes on processing characteristics (including salt formation) and the product glass. The bubbling rate was adjusted to provide the desired glass production rate with a near complete cold cap (90-100% of melt surface covered with feed). Quantitative measurements of glass production rates, melter operating conditions (temperatures, pressures, power, flows, etc.), and off-gas characteristics (NOx, SO 2, CO, particulate load and composition, and acid gases) were made for each test.

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Compositional Variation Tests on DuraMelter 100 with LAW Sub-Envelope B1 Feed in Support of the LAW Pilot Melter, VSL-02R62N0-5, Rev. 0 (May 2003)

The principal objective of the DM100 tests was to demonstrate the robustness of the vitrification process with respect to feed and glass compositional changes resulting from variations in the simulant-to-additive ratio. The DM100-WV unit was selected for these tests; this melter was used for all of the Part B 1 tests on LAW Envelopes A, B, and C sulfate incorporation that were used to support the subsequent tests on the Pilot Melter as well as for the more recent LAW Sub-Envelope Al, A2, A3 and Cl tests. The same melter was selected for the present tests in order to maintain comparisons between the data sets. In addition, the somewhat smaller glass volume for the same melt surface area as compared to the DM100-BL melter means that more glass turnovers are achieved for a given test duration. The DM100 tests used nominal feed and feed with a 15% surplus in waste simulant. Previous Pilot Melter tests on Envelope A with 10% variations (but with sulfate removal) showed significant impacts on glass production rates that were ultimately corrected by adjustments in the sugar additions. Consequently, robustness with respect to throughput as well as sulfate tolerance are important motivations for these tests.

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Low Activity Waste Tuning Feed Material Testing VSL-18R4350-1 (Final Report)

High level waste (HLW) from the Hanford tank farms will be retrieved and transferred to the Hanford Tank Waste Treatment and Immobilization Plant (WTP). The waste will be pretreated to separate the soluble chemical salts (mostly sodium nitrate/nitrite and sodium hydroxide) from the bulk of the radioactive materials. This decontaminated salt solution is the low activity waste (LAW) stream which constitutes most of the total waste volume. The remaining HLW contains most of the radioactive materials but a fraction of the volume. Each of these waste streams is directed to an independent processing facility where the waste is mixed with glass forming chemicals (mostly silica and borax or boric acid) and fed into the melters for stabilization by conversion into glass. The molten glass is poured into stainless steel containers to produce packages for disposal: local shallow burial for the LAW containers and a future geologic repository for the HLW containers. The LAW facility melters produce significant quantities of NOx-laden off-gas that require abatement in accordance with 10 CFR 830 and air emission requirements. The NOx emissions also pose a safety risk. The LAW facility commissioning sequence requires that the melters be operated and process control loops tuned prior to introducing waste or waste feed materials that produce NOx. Therefore, a temporary or permanent system architecture is needed that provides a feed supply to the melters for the purpose of melter testing and off-gas tuning that does not result in the production of significantly hazardous off-gas products.

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Iodine Removal in the DFLAW Flow-Sheet

In support of the WTP project, off-gas system and regulatory testing has been conducted previously on the DM1200 pilot melter equipped with a prototypical off-gas system installed at The Catholic University of America’s Vitreous State Laboratory (VSL). During the regulatory tests, an AC-S test bed filled with Kombisorb BAT 37 was included in the prototypical off-gas system and evaluated for response to HLW and LAW exhaust streams. Offline testing and small-scale testing of that media were also conducted. Testing demonstrated that a temperature rise occurred in the activated carbon media when water vapor was first introduced to virgin Kombisorb BAT 37, in response to high nitrogen oxide concentrations, and in response to the presence of organic compounds. Conditioning of the test bed by gradually increasing the NOx concentration prior to the introduction of organics was found to be an important operational strategy for preventing larger temperature excursions. However, no mercury was present in the exhaust stream during DM1200 testing and therefore comparable test data for mercury removal efficiency or temperature response of the carbon media in the presence of mercury were not collected in the DM1200 tests. In view of the need for data on mercury removal performance, BNI contracted with Atkins and the VSL to install and operate a suitable test system at VSL to collect the required data. That testing was designed to assess the performance of Kombisorb BAT-37 and the guard bed material, Sofnolime RG, for simulated melter exhaust streams that contain the highest concentrations of mercury, nitrogen oxides, acid gases, and organic compounds expected in WTP LAW melter exhaust. During shakedown testing with the new system, however, it became evident that a number of issues with Sofnolime RG as the guard bed material would render it unsuitable for this application. BNI subsequently determined that the guard bed was redundant for removal of acid gases since they could be adequately removed by the SBS and WESP. However, since the guard bed material was also credited with significant iodine removal , there was a need for a replacement material that would adequately perform that role. BNI identified several candidate media but performance data in gas compositions that are representative of the WTP LAW off-gas were not available. Accordingly, there was a need to test and evaluate the performance of these candidate media prior to performing the originally-planned tests. To that end, small scale tests were conducted to assess the performance of various adsorbents in simulated melter exhaust streams that contain mercury, iodine, nitrogen oxides, acid gases, and acetonitrile, which are expected to be present in WTP LAW melter exhaust.

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Cesium-Technetium Volatility in the DFLAW Flow-Sheet (VSL-21R4780-1 Rev. 0)

The tests were conducted on the DM10 vitrification system with prototypical off-gas treatment system, which includes an SBS and WESP. This allowed determination of the partitioning and speciation of cesium between the melter and the off-gas system components, including liquid effluents from the SBS and WESP. The tests were conducted using simulated Hanford LAW AP-107, which is the planned first feed to DFLAW, at a nominal feed concentration of 5.6 molar Na over about 200 hours of testing.

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Iodine Speciation Effects in LAW Feeds

Tests were conducted on a DM10 vitrification system with prototypical off-gas treatment system, which includes an SBS, WESP, and evaporator based on the design of the evaporator to be installed at the WTP for concentration of the liquid effluents. This allowed determination of the partitioning and speciation of iodine between the melter and the off gas system components, including liquid effluents from the SBS and WESP as well as in the evaporator condensate and concentrate. Evaporator testing was decoupled from melter testing to permit filtration and pH adjustments of process solutions prior to evaporation. In addition, a slip stream was pulled from the exhaust downstream of the WESP and High-Efficiency Particulate Air (HEPA) filters and passed through a caustic scrubber simulating the WTP caustic scrubber to assess iodine partitioning to the caustic scrubber liquid effluent. The tests were conducted using simulated Hanford LAW from tank AP-107, which is the planned first feed for Direct Feed LAW (DFLAW) operations, at a nominal feed concentration of 5.6 molar Na over about 120 hours of testing.

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Mercury Speciation During Vitrification of LAW

n this work, laboratory and engineering-scale tests were conducted that mimic the reactive environment of the Hanford Tank Waste Treatment and Immobilization Plant (WTP) low activity waste (LAW) melter and off-gas system in order to assess the speciation of mercury at select points in the processing system. The experimental protocols, test equipment, feed materials used, and rationale for testing are detailed in the Test Plan for this work. Particular attention was paid to the amount and speciation of mercury in submerged bed scrubber (SBS) solutions, which are intended to be recycled back to the melter feed at the WTP. Results are presented from detailed mercury analysis of these solutions using Environmental Protection Agency (EPA) Method 1630 and modifications to this method for dimethyl mercury and methyl mercury as well as EPA Method 1631 and modifications to this method for total, dissolved, elemental, suspended, and ionic mercury. Testing was conducted in two separate sets of experiments: (1) One set of tests (crucible-scale furnace tests) that involved heating small batches of mercury-spiked melter feed in crucibles to determine the amount of mercury retained in the glass and the species of mercury in the exhaust gases; (2) A second set of tests (DM10 melter tests) was planned that involved creating LAW melter plenum gas compositions using the DM10 melter system, injecting mercury into the off-gas stream, and passing that stream though a reactor that simulates various plenum gas conditions. Operational issues led to the need to use one of the VSL DM100 melters in place of the planned DM10 melter for these tests. The speciation of mercury after exposure to those conditions was monitored. In both sets of tests, the exhaust gases were run through a scrubber that was intended to mimic the LAW SBS in order to determine how much of the mercury exiting the melter would be retained in the primary off-gas system fluids and in what form. After passing through the SBS, the exhaust stream was analyzed to determine particulate, ionic, elemental, and total mercury passing downstream of the SBS. In tests employing gases derived from the DM100 melter that were spiked with elemental mercury, the processing system provided gas temperatures and residence times that are representative of the WTP LAW vitrification system in order to assess the effect of those conditions on mercury speciation. The Decontamination Factor (DF) across the system in the tests with mercury-spiked DM100 melter exhaust was determined using the analytical data from EPA Method 30B (Fluegas Adsorption Mercury Speciation (FAMS TM )) exhaust samples and the amount of mercury detected in the SBS solutions. Mercury species used in melter feed crucible scale tests were divalent (chloride and iodide), monovalent (chloride and fluoride), and elemental mercury. Individual tests included only a single form of mercury in the feed. The results for total mercury mass balances in the crucible tests are also presented.

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