Engineering topics

Reigel, M

Publications and source records attributed to Reigel, M.

14 records

DOE OSTI2011

ELAWD GROUT HOPPER MOCK-UP TESTING

A 10-inch READCO mixer is used for mixing the premix (45 (wt%) fly ash, 45 wt% slag, and 10 wt% portland cement) with salt solution in the Saltstone Production Facility (SPF). The Saltstone grout free falls into the grout hopper which feeds the suction line leading to the Watson SPX 100 duplex hose pump. The Watson SPX 100 pumps the grout through approximately 1500 feet of piping prior to being discharged into the Saltstone Disposal Facility (SDF) vaults. The existing grout hopper has been identified by the Saltstone Enhanced Low Activity Waste Disposal (ELAWD) project for re-design. The current nominal working volume of this hopper is 12 gallons and does not permit handling an inadvertent addition of excess dry feeds. Saltstone Engineering has proposed a new hopper tank that will have a nominal working volume of 300 gallons and is agitated with a mechanical agitator. The larger volume hopper is designed to handle variability in the output of the READCO mixer and process upsets without entering set back during processing. The objectives of this task involve scaling the proposed hopper design and testing the scaled hopper for the following processing issues: (1) The effect of agitation on radar measurement. Formation of a vortex may affect the ability to accurately measure the tank level. The agitator was run at varying speeds and with varying grout viscosities to determine what parameters cause vortex formation and whether measurement accuracy is affected. (2) A dry feeds over addition. Engineering Calculating X-ESR-Z-00017 1 showed that an additional 300 pounds of dry premix added to a 300 gallon working volume would lower the water to premix ratio (W/P) from the nominal 0.60 to 0.53 based on a Salt Waste Processing Facility (SWPF) salt simulant. A grout with a W/P of 0.53 represents the upper bound of grout rheology that could be processed at the facility. A scaled amount of dry feeds will be added into the hopper to verify that this is a recoverable situation. (3) The necessity of baffles in the hopper. The preference of the facility is not to have baffles in the hopper; however, if the initial testing indicates inadequate agitation or difficulties with the radar measurement, baffles will be tested.

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DOE OSTI2011

RESULTS FOR THE THIRD QUARTER 2011 TANK 50 WAC SLURRY SAMPLE: CHEMICAL AND RADIONUCLIDE CONTAMINANT RESULTS

The Saltstone Facility is designed and permitted to immobilize and dispose of low-level radioactive and hazardous liquid waste (salt solution) remaining from the processing of radioactive material at the Savannah River Site. Low-level waste (LLW) streams from the Effluent Treatment Project (ETP), H-Canyon, and the decontaminated salt solution product from the Actinide Removal Process/Modular Caustic Side Solvent Extraction (CSSX) Unit (ARP/MCU) process are stored in Tank 50 until the LLW can be transferred to the Saltstone Facility for treatment and disposal. The LLW must meet the specified waste acceptance criteria (WAC) before it is processed into saltstone. The specific chemical and radionuclide contaminants and their respective WAC limits are in the current Saltstone WAC. Waste Solidification Engineering (WSE) requested that Savannah River National Laboratory (SRNL) perform quarterly analysis on saltstone samples. The concentrations of chemical and radionuclide contaminants are measured to ensure the saltstone produced during each quarter is in compliance with the current WAC. This report documents the concentrations of chemical and radionuclide contaminants for the 2011 Third Quarter samples collected from Tank 50 on July 7, 2011 and discusses those results in further detail than the previously issued results report.

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DOE OSTI2011

RESULTS FOR THE FIRST QUARTER 2011 TANK 50 WAC SLURRY SAMPLE: CHEMICAL AND RADIONUCLIDE CONTAMINANT RESULTS

This report details the chemical and radionuclide contaminant results for the characterization of the 2011 First Quarter sampling of Tank 50 for the Saltstone Waste Acceptance Criteria (WAC). Information from this characterization will be used by Waste Solidification Engineering (WSE) to support the transfer of low-level aqueous waste from Tank 50 to the Salt Feed Tank in the Saltstone Facility in Z-Area, where the waste will be immobilized. This information is also used to update the Tank 50 Waste Characterization System. The following conclusions are drawn from the analytical results provided in this report: (1) The concentrations of the reported chemical and radioactive contaminants were less than their respective WAC targets or limits unless noted in this section; (2) The reported detection limit for {sup 59}Ni is above both the requested limits from Reference 2 and the established limits in Reference 3; (3) The reported detection limit for {sup 94}Nb is above the requested limit from Reference 2; however, it is below the established limits in Reference 3. This is a change from previously reported results; (4) The reported concentration of {sup 242m}Am is above the target in Listed in Attachment 8.4 of the Saltstone WAC. This is a change from the previously reported results; (5) {sup 247}Cm and {sup 249}Cf are above the requested limits from Reference 2. However, they are below the limits established in Reference 3; (6) The reported detection limit for Norpar 13 is greater than the limit from Table 4 and Attachment 8.2 of the WAC; (7) The reported detection limit for Isopar L is greater than the limit from Table 3 of the WAC; and (8) Isopar L and Norpar 13 have limited solubility in aqueous solutions making it difficult to obtain consistent and reliable sub-samples. The values reported in this memo are the concentrations in the sub-sample as detected by the instrument; however, the results may not accurately represent the concentrations of the analytes in Tank 50.

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DOE OSTI2011

SALTSTONE 1QCY11 TCLP RESULTS

A Saltstone waste form was prepared in the Savannah River National Laboratory (SRNL) from a Tank 50H sample and Z-Area premix material for the first quarter of calendar year 2011 (1QCY11). After the prescribed 28 day cure, samples of the saltstone were collected, and the waste form was shown to meet the South Carolina Hazardous Waste Management Regulations (SCHWMR) R.61-79.261.24 and R.61-79.268.48(a) requirements for a nonhazardous waste form with respect to RCRA metals and underlying hazardous constituents. These analyses met all quality assurance specifications of USEPA SW-846. The Saltstone Production Facility (SPF) receives waste from Tank 50H for treatment. In the first quarter of the 2011 calendar year (1QCY11), Tank 50H accepted transfers of approximately 15 kgal from the Effluent Treatment Project (ETP), approximately 15 kgal from Tank 710 - the H-Canyon General Purpose Evaporator, approximately 73 kgal from the H-Canyon Super Kukla campaign, approximately 285 kgal from the Actinide Removal Process/Modular Caustic Side Solvent Extraction Unit (ARP/MCU) Decontaminated Salt Solution Hold Tank (DSS-HT), and approximately 21 kgal from other sources. The Saltstone Grout Sampling plan provides the South Carolina Department of Health and Environmental Control (SCDHEC) with the chemical and physical characterization strategy for the salt solution which is to be disposed of in the Z-Area Solid Waste Landfill (SWLF). During operation, samples were collected from Tank 50H and grout samples prepared to determine the non-hazardous nature of the grout to meet the requirements of the South Carolina Hazardous Waste Management Regulations (SCHWMR) R.61-79.261.24(b) and R.61-79.268.48(a). Savannah River National Laboratory (SRNL) was asked to prepare saltstone from samples of Tank 50H obtained January 5, 2011 during 1QCY11 to determine the non-hazardous nature of the grout. The samples were cured and shipped to Babcock & Wilcox Technical Services Group-Radioisotope and Analytical Chemistry Laboratory (B&W TSG-RACL) to perform the Toxic Characteristic Leaching Procedure (TCLP) and subsequent extract analysis on saltstone samples for the analytes required for the quarterly analysis saltstone sample. In addition to the eight toxic metals-arsenic, barium, cadmium, chromium, mercury, lead, selenium and silver-analytes included the underlying hazardous constituents (UHC) antimony, beryllium, nickel, and thallium which could not be eliminated from analysis by process knowledge. B&W TSG-RACL provided subsamples to GEL Laboratories, LLC for analysis for the UHCs benzene, phenols and total and amenable cyanide.

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DOE OSTI2011

SALTSTONE 4QCY10 TCLP RESULTS

Saltstone waste form was prepared in the Savannah River National Laboratory (SRNL) from a Tank 50H sample and Z-Area premix material for the fourth quarter of calendar year 2010 (4QCY10). After the prescribed 28 day cure, samples of the saltstone were collected, and the waste form was shown to meet the South Carolina Hazardous Waste Management Regulations (SCHWMR) R.61-79.261.24 and R.61-79.268.48(a) requirements for a nonhazardous waste form with respect to RCRA metals and underlying hazardous constituents. These analyses met all quality assurance specifications of USEPA SW-846.

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DOE OSTI2011

EVALUATION OF THE DURABILITY OF THE STRUCTURAL CONCRETE OF REACTOR BUILDINGS AT SRS

The Department of Energy (DOE) intends to close 100-150 facilities in the DOE complex using an in situ decommissioning (ISD) strategy that calls for grouting the below-grade interior volume of the structure and leaving the above-grade interior open or demolishing it and disposing of it in the slit trenches in E Area. These closures are expected to persist and remain stable for centuries, but there are neither facility-specific monitoring approaches nor studies on the rate of deterioration of the materials used in the original construction or on the ISD components added during closure (caps, sloped roofs, etc). This report will focus on the evaluation of the actual aging/degradation of the materials of construction used in the ISD structures at Savannah River Site (SRS) above grade, specifically P & R reactor buildings. Concrete blocks (six 2 to 5 ton blocks) removed from the outer wall of the P Reactor Building were turned over to SRNL as the first source for concrete cores. Larger cores were received as a result of grouting activities in P and R reactor facilities. The cores were sectioned and evaluated using microscopy, x-ray diffraction (XRD), ion chromatography (IC) and thermal analysis. Scanning electron microscopy shows that the aggregate and cement phases present in the concrete are consistent with the mix design and no degradation mechanisms are evident at the aggregate-cement interfaces. Samples of the cores were digested and analyzed for chloride ingress as well as sulfate attack. The concentrations of chloride and sulfate ions did not exceed the limits of the mix design and there is no indication of any degradation due to these mechanisms. Thermal analysis on samples taken along the longitudinal axis of the cores show that there is a 1 inch carbonation layer (i.e., no portlandite) present in the interior wall of the reactor building and a negligible carbonation layer in the exterior wall. A mixed layer of carbonate and portlandite extends deeper into the interior (2-3 inches) and exterior (1-2 inches) walls. This is more extensive than measured in previous SRS structures. Once the completely carbonated layer reaches the rebar that is approximately 2-3 inches into the concrete wall, the steel is susceptible to corrosion. The growth rate of the carbonated layer was estimated from current observations and previous studies. Based on the estimated carbonation rate, the steel rebar should be protected from carbonation induced corrosion for at least another 100 years. If degradation of these structures is dominated by the carbonation mechanism, the length of time before water intrusion is expected into the process room of P-reactor is estimated to be between 425-675 years.

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DOE OSTI2011

RESULTS FOR THE FOURTH QUARTER 2010 TANK 50 WAC SLURRY SAMPLE: CHEMICAL AND RADIONUCLIDE CONTAMINANT RESULTS

This report details the chemical and radionuclide contaminant results for the characterization of the 2010 Fourth Quarter sampling of Tank 50 for the Saltstone Waste Acceptance Criteria (WAC). Information from this characterization will be used by Liquid Waste Operations (LWO) to support the transfer of low-level aqueous waste from Tank 50 to the Salt Feed Tank in the Saltstone Facility in Z-Area, where the waste will be immobilized. This information is also used to update the Tank 50 Waste Characterization System. The following conclusions are drawn from the analytical results provided in this report: (1) The concentrations of the reported chemical and radioactive contaminants were less than their respective WAC targets or limits unless noted in this section. (2) The reported detection limits for {sup 94}Nb, {sup 247}Cm and {sup 249}Cf are above the requested limits from Reference 2. However, they are below the limits established in Reference 3. (3) There is an estimated concentration of trimethylbenzene (2.25 mg/L). This is not a WAC analyte, but it is the first time this organic compound has been detected in a quarterly WAC sample from Tank 50. (4) The reported detection limit for Norpar 13 is greater than the limit from Table 4 and Attachment 8.2 of the WAC. (5) The reported detection limit for Isopar L is greater than the limit from Table 3 of the WAC. (6) Isopar L and Norpar 13 have limited solubility in aqueous solutions making it difficult to obtain consistent and reliable sub-samples. The values reported in this memo are the concentrations in the sub-sample as detected by the GC/MS; however, the results may not accurately represent the concentrations of the analytes in Tank 50.

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DOE OSTI2010

SALTSTONE 3QCY10 TCLP RESULTS

The Saltstone Production Facility (SPF) receives waste from Tank 50H for treatment. In the third quarter of the 2010 calendar year (3QCY10), Tank 50H accepted transfers of approximately 76 kgal from the Effluent Treatment Project (ETP), approximately 7 kgal from Tank 710 - the HCanyon General Purpose Evaporator, approximately 57 kgal from the H-Canyon Super Kukla campaign, approximately 58 kgal from the Modular Caustic Side Solvent Extraction Unit (MCU) Decontaminated Salt Solution Hold Tank (DSS-HT), and approximately 6 kgal from other sources. The Saltstone Grout Sampling plan provides the South Carolina Department of Health and Environmental Control (SCDHEC) with the chemical and physical characterization strategy for the salt solution which is to be disposed of in the Z-Area Solid Waste Landfill (ISWLF). During operation, samples were collected from Tank 50H and grout samples prepared to determine the non-hazardous nature of the grout to meet the requirements of the South Carolina Hazardous Waste Management Regulations (SCHWMR) R.61-79.261.24(b) and R.61-79.268.48(a). Savannah River National Laboratory (SRNL) was asked to prepare saltstone from samples of Tank 50H obtained July 1, 2010 during 3QCY10 to determine the non-hazardous nature of the grout. The samples were cured and shipped to Babcock & Wilcox Technical Services Group-Radioisotope and Analytical Chemistry Laboratory (B&W TSG-RACL) to perform the Toxic Characteristic Leaching Procedure (TCLP) and subsequent extract analysis on saltstone samples for the analytes required for the quarterly analysis saltstone sample. In addition to the eight toxic metals - arsenic, barium, cadmium, chromium, mercury, lead, selenium and silver - analytes included the underlying hazardous constituents (UHC) antimony, beryllium, nickel, and thallium which could not be eliminated from analysis by process knowledge. B&W TSG-RACL provided subsamples to GEL Laboratories, LLC for analysis for the UHCs benzene, phenols and total and amenable cyanide.

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DOE OSTI2010

RESULTS FOR THE THIRD QUARTER 2010 TANK 50 WAC SLURRY SAMPLE: CHEMICAL AND RADIONUCLIDE CONTAMINANT RESULTS

This report details the chemical and radionuclide contaminant results for the characterization of the 2010 Third Quarter sampling of Tank 50 for the Saltstone Waste Acceptance Criteria (WAC). Information from this characterization will be used by Liquid Waste Operations (LWO) to support the transfer of low-level aqueous waste from Tank 50 to the Salt Feed Tank in the Saltstone Facility in Z-Area, where the waste will be immobilized. This information is also used to update the Tank 50 Waste Characterization System. The following conclusions are drawn from the analytical results provided in this report: (i) The concentrations of the reported chemical and radioactive contaminants were less than their respective WAC targets or limits unless noted in this section. (ii) The reported detection limits for {sup 94}Nb, {sup 247}Cm and {sup 249}Cf are above the requested limits from Reference 4. However, they are below the limits established in Reference 3. (iii) The reported detection limit for {sup 242m}Am is greater than the requested limit from Attachment 8.4 of the WAC. (iv) The reported detection limit for Isopar L is greater than the limit from Table 3 of the WAC. (v) The reported concentration of Isopropanol is greater than the limit from Table 4 of the WAC. (vi) Isopar L and Norpar 13 have limited solubility in aqueous solutions making it difficult to obtain consistent and reliable sub-samples. The values reported in this memo are the concentrations in the sub-sample as detected by the GC/MS; however, the results may not accurately represent the concentrations of the analytes in Tank 50.

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DOE OSTI2010

SALTSTONE 2QCY10 TCLP RESULTS

The Saltstone Production Facility (SPF) receives waste from Tank 50H for treatment. In the second quarter of the 2010 calendar year (2QCY10), Tank 50H accepted transfers of approximately 19 kgal from the Effluent Treatment Project (ETP), approximately 5 kgal from Tank 710 - the H-Canyon General Purpose Evaporator, approximately 42 kgal from the HCanyon Super Kukla campaign, and approximately 73 kgal from the Modular Caustic Side Solvent Extraction Unit (MCU) Decontaminated Salt Solution Hold Tank (DSS-HT). The Saltstone Grout Sampling plan provides the South Carolina Department of Health and Environmental Control (SCDHEC) with the chemical and physical characterization strategy for the salt solution which is to be disposed of in the Z-Area Solid Waste Landfill (ISWLF). During operation, samples were collected from Tank 50H and grout samples prepared to determine the non-hazardous nature of the grout to meet the requirements of the South Carolina Hazardous Waste Management Regulations (SCHWMR) R.61-79.261.24(b) and R.61-79.268.48(a). Savannah River National Laboratory (SRNL) was asked to prepare saltstone from samples of Tank 50H obtained April 4, 2010 during 2QCY10 to determine the non-hazardous nature of the grout. The samples were cured and shipped to Babcock & Wilcox Technical Services Group-Radioisotope and Analytical Chemistry Laboratory (B&W TSG-RACL) to perform the Toxic Characteristic Leaching Procedure (TCLP) and subsequent extract analysis on saltstone samples for the analytes required for the quarterly analysis saltstone sample. In addition to the eight toxic metals - arsenic, barium, cadmium, chromium, mercury, lead, selenium and silver - analytes included the underlying hazardous constituents (UHC) antimony, beryllium, nickel, and thallium which could not be eliminated from analysis by process knowledge. B&W TSG-RACL provided subsamples to GEL Laboratories, LLC for analysis for the UHCs benzene, phenols and total and amenable cyanide.

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DOE OSTI2010

ANALYSIS OF SLUDGE BATCH 4 (MACROBATCH 5) FOR CANISTER S02902 AND SLUDGE BATCH 5 (MACROBATCH 6) FOR CANISTER S03317 DWPF POUR STREAM GLASS SAMPLES

The Defense Waste Processing Facility (DWPF) began processing Sludge Batch 4 (SB4), Macrobatch 5 (MB5) on May 29, 2007. Sludge Batch 4 was a blend of the heel of Tank 40 from Sludge Batch 3 (SB3) and SB4 material qualified in Tank 51. On November 28, 2008, DWPF began processing Sludge Batch 5 (SB5) from Tank 40 which is a blend of the heel of Tank 40 from SB4, SB5 material qualified in Tank 51 and H-Canyon Pu and Np transfers. SB4 was processed using Frit 510 and SB5 used Frit 418. During processing of each sludge batch, the DWPF is required to take at least one glass sample to meet the objectives of the Glass Product Control Program and to complete the necessary Production Records so that the final glass product may be disposed of at a Federal Repository. During the processing of SB4 and SB5, glass samples were obtained during the pouring of canisters S02902 and S03317, respectively. The samples were transferred to the Savannah River National Laboratory (SRNL) where they were analyzed (durability, chemical and radionuclide composition). The following observations and conclusions are drawn from the analytical results provided in this report: (1) The sum of the oxides for the chemical composition of both the SB4 and SB5 pour stream glasses is within the Product Composition Control System (PCCS) acceptance limits (95 {le} sum of oxides {le} 105). (2) The calculated Sludge Dilution Factor (SDF) for SB4 is 2.52. The measured radionuclide content is in good agreement with the calculated values from the dried sludge results from the SB4 Waste Acceptance Production Specification (WAPS) sample (References 1 and 19). (3) The calculated SDF for SB5 is 2.60. The measured radionuclide content is in good agreement with the calculated values from the dried sludge results from the SB5 WAPS sample (References 2 and 20). (4) Scanning Electron Microscopy (SEM) analysis shows there are noble metal inclusions, primarily ruthenium, present in both pour stream samples. (5) The Product Consistency Test (PCT) results show that the SB4 pour stream glass meets the waste acceptance criteria for durability with a normalized boron release of 0.67 g/L which is an order of magnitude lower than the Environmental Assessment (EA) glass. (6) The PCT results show that the SB5 pour stream glass meets the waste acceptance criteria for durability with a normalized boron release of 0.72 g/ which is an order of magnitude lower than the EA glass. (7) The density of the SB4 glass is 2.5 g/cm{sup 3}. (8) The density of the SB5 glass is 2.6 g/cm{sup 3}.

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DOE OSTI2010

RESULTS FOR THE MAY 19, 2010 INADVERTENT TRANSFER TO THE SALTSTONE DISPOSAL FACILITY SLURRY: SAMPLE ANALYTICAL RESULTS

This report details the chemical analysis results for the characterization of the May 19, 2010 inadvertent transfer from the Saltstone Production Facility (SPF) to the Saltstone Disposal Facility (SDF). On May 19, 2010, the Saltstone Processing Facility (SPF) inadvertently transferred approximately 1800 gallons of untreated low-level salt solution from the salt feed tank (SFT) to Cell F of Vault 4. The transfer was identified and during safe configuration shutdown, approximately 70 gallons of SFT material was left in the Saltstone hopper. After the shutdown, the material in the hopper was undisturbed, while the SFT has received approximately 1400 gallons of drain water from the Vault 4 bleed system. The drain water path from Vault 4 to the SFT does not include the hopper (Figure 1); therefore it was determined that the material remaining in the hopper was the most representative sample of the salt solution transferred to the vault. To complete item No.5 of Reference 1, Savannah River National Laboratory (SRNL) was asked to analyze the liquid sample retrieved from the hopper for pH, and metals identified by the Resource Conservation and Recovery Act (RCRA). SRNL prepared a report to complete item No.5 and determine the hazardous nature of the transfer. Waste Solidification Engineering then instructed SRNL to provide a more detailed analysis of the slurried sample to assist in the determination of the portion of Tank 50 waste in the hopper sample.

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DOE OSTI2010

RESULTS FOR THE SECOND QUARTER 2010 TANK 50 WAC SLURRY SAMPLE: CHEMICAL AND RADIONUCLIDE CONTAMINANT RESULTS

This report details the chemical and radionuclide contaminant results for the characterization of the 2010 Second Quarter sampling of Tank 50 for the Saltstone Waste Acceptance Criteria (WAC).1 Information from this characterization will be used by Liquid Waste Operations (LWO) to support the transfer of low-level aqueous waste from Tank 50 to the Salt Feed Tank in the Saltstone Facility in Z-Area, where the waste will be immobilized. This information is also used to update the Tank 50 Waste Characterization System. The following conclusions are drawn from the analytical results provided in this report: (1) The concentrations of the reported chemical and radioactive contaminants were less than their respective WAC targets or limits unless noted in this section. (2) The reported detection limits for {sup 94}Nb and {sup 144}Ce are above both the established and requested limits from References 4 and 6. (3) The reported detection limits for {sup 247}Cm and {sup 249}Cf are above the requested limits from Reference 4. However, they are below the limits established in Reference 6. (4) The reported detection limit for Isopar L is greater than the limit from Table 3 of the WAC. (5) A measurable concentration of Norpar 13 is present in the sample. The reported concentration is greater than the requested limit from Table 4 and Attachment 8.2 of the WAC. (6) Isopar L and Norpar 13 have limited solubility in aqueous solutions making it difficult to obtain consistent and reliable sub-samples. The values reported in this memo are the concentrations in the sub-sample as detected by the GC/MS; however, the results may not accurately represent the concentrations of the analytes in Tank 50. (7) The detection limit for isopropanol has been lowered from 0.5 mg/L to 0.25 mg/L{sup 7}. This revised limit now satisfies the limit in Table 4 of the WAC.

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DOE OSTI2010

SALTSTONE PROCESSING FACILITY TRANSFER SAMPLE

On May 19, 2010, the Saltstone Production Facility inadvertently transferred 1800 gallons of untreated waste from the salt feed tank to Vault 4. During shut down, approximately 70 gallons of the material was left in the Saltstone hopper. A sample of the slurry in the hopper was sent to Savannah River National Laboratory (SRNL) to analyze the density, pH and the eight Resource Conservation and Recovery Act (RCRA) metals. The sample was hazardous for chromium, mercury and pH. The sample received from the Saltstone hopper was analyzed visually while obtaining sample aliquots and while the sample was allowed to settle. It was observed that the sample contains solids that settle in approximately 20 minutes (Figure 3-1). There is a floating layer on top of the supernate during settling and disperses when the sample is agitated (Figure 3-2). The untreated waste inadvertently transferred from the SFT to Vault 4 was toxic for chromium and mercury. In addition, the pH of the sample is at the regulatory limit. Visually inspecting the sample indicates solids present in the sample.

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