Engineering topics

Steimke, J. L.

Publications and source records attributed to Steimke, J. L..

4 records

DOE OSTI2014

SRNL Review And Assessment Of WTP UFP-02 Sparger Design And Testing

During aerosol testing conducted by Parsons Constructors and Fabricators, Inc. (PCFI), air sparger plugging was observed in small-scale and medium-scale testing. Because of this observation, personnel identified a concern that the steam spargers in Pretreatment Facility vessel UFP-02 could plug during Waste Treatment and Immobilization Plant (WTP) operation. The U. S. Department of Energy (DOE) requested that Savannah River National Laboratory (SRNL) provide consultation on the evaluation of known WTP bubbler, and air and steam sparger issues. The authors used the following approach for this task: reviewed previous test reports (including smallscale testing, medium-scale testing, and Pretreatment Engineering Platform [PEP] testing), met with Bechtel National, Inc. (BNI) personnel to discuss sparger design, reviewed BNI documents supporting the sparger design, discussed sparger experience with Savannah River Site Defense Waste Processing Facility (DWPF) and Sellafield personnel, talked to sparger manufacturers about relevant operating experience and design issues, and reviewed UFP-02 vessel and sparger drawings.

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DOE OSTI2014

CRADA Final Report For CRADA NO. CR-12-006 [Operation and Testing of an SO 2 -depolarized Electrolyzer (SDE) for the Purpose of Hydrogen and Sulfuric Acid Production]

Over the past several years, Savannah River National Laboratory (SRNL) has led a team of collaborators under the Department of Energy’s (DOE) nuclear hydrogen production program to develop the Hybrid Sulfur (HyS) Process. HyS is a 2-step water-splitting process consisting of high temperature decomposition of sulfuric acid to generate SO 2 , followed by the electrolysis of aqueous SO 2 to generate hydrogen and sulfuric acid. The latter is fed back into the high temperature reactor. SRNL designed and built an SO 2 -depolarized electrolyzer (SDE) and a test facility. Over 40 SDE’s were tested using different catalysts, membranes and other components. SRNL demonstrated that an SDE could be operated continuously for approximately 200 hours under certain conditions without buildup of sulfur at the SDE’s cathode, thus solving a key technical problem with SDE technology. Air Products and Chemicals, Inc. (APCI) is a major supplier of hydrogen production systems, and they have proprietary technology that could benefit from the SDE developed by SRNS, or some improved version thereof. However, to demonstrate that SRNL’s SDE is a truly viable approach to the electrolyzer design, continuous operation for far greater periods of time than 200 hours must be demonstrated, and the electrolyzer must be scaled up to greater hydrogen production capacities. SRNL and Air Products entered into a Cooperative Research and Development Agreement with the objective of demonstrating the effectiveness of the SDE for hydrogen and sulfuric acid production and to demonstrate long-term continuous operation so as to dramatically increase the confidence in the SDE design for commercial operation. SRNL prepared a detailed technical report documenting previous SDE development, including the current SDE design and operating conditions that led to the 200-hour sulfurfree testing. SRNL refurbished its single cell SDE test facility and qualified the equipment for continuous operation. A new membrane electrode assembly (MEA) was fabricated and installed in the single cell electrolyzer (60 cm 2 active cell area). Shakedown testing was conducted, and several modifications were made to the test facility equipment. Seven different MEAs were used during testing. Beginning on May 20, 2013, SRNL was able to test the SDE continuously for 1200 hours, including 1000 hours under power to generate hydrogen at an average rate of 10.8 liters per hour. The SDE was not removed or repaired during the 50-day test and was successfully restarted after each shutdown. The test was intentionally stopped after 1200 hours (1000 hours of hydrogen production) due to funding constraints. Post-test examination of the MEA using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Microanalysis (EDAX) showed no elemental sulfur deposits or sulfur layer inside the cell, thus successfully achieving the test goals. The results demonstrated that the SDE could be operated for extended periods without major performance degradation or the buildup of sulfur inside the MEA. Air Products conducted an assessment of the economic viability of the SDE based on the “as tested” design. The results indicated that the SDE faces significant economic obstacles in its current state. Further development and scale-up are necessary before the SDE is ready for commercialization.

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DOE OSTI2013

Glass Frit Clumping and Dusting

DWPF mixes a slurry of glass frit (Frit 418) and dilute (1.5 wt%) formic acid solution with high level waste in the Slurry Mix Evaporator (SME). There would be advantages to introducing the frit in a non-slurry form to minimize water addition to the SME, however, adding completely dry frit has the potential to generate dust which could clog filters or condensers. Prior testing with another type of frit, Frit 320, and using a minimal amount of water reduced dust generation, however, the formation of hard clumps was observed. To examine options and behavior, a TTQAP [McCabe and Stone, 2013] was written to initiate tests that would address these concerns. Tests were conducted with four types of glass frit; Frit 320, DWPF Frit 418, Bekeson Frit 418 and Multi-Aspirator Frit 418. The last two frits are chemically identical to DWPF Frit 418 but smaller particles were removed by the respective vendors. Test results on Frit Clumping and Dusting are provided in this report. This report addresses the following seven questions. Short answers are provided below with more detailed answers to follow. 1. Will the addition of a small amount of water, 1.5 wt%, to dry DWPF Frit 418 greatly reduce the dust generation during handling at DWPF? a. Yes, a small scale test showed that adding a little water to the frit greatly reduced dust generation during handling. 2. Will the addition of small amounts of water to the frit cause clumping that will impair frit handling at DWPF? a. No, not with Frit 418. Although clumps were observed to form when 1.5 wt% water was mixed with DWPF Frit 418, then compressed and air-dried overnight, the clumps were easily crushed and did not form the hardened material noted when Frit 320 was tested. 3. What is the measured size distribution of dust generated when dry frit is handled? (This affects the feasibility and choice of processing equipment for removing the dust generating fraction of the frit before it is added to the SME.) a. The size distribution for the dust removed from fresh DWPF Frit 418 while it was being shaken in a small scale LabRAM test was measured. The median size on a volume basis was 7.6 μm and 90% of the frit particles were between 1.6 and 28 μm. The mass of dust collected using this test protocol was much less than 1% of the original frit. 4. Can the dust be removed in a small number of processing steps and without the larger frit particles continuing to spall additional dust sized particles? a. Test results using a LabRAM were inconclusive. The LaRAM performs less efficient particle size separation than the equipment used by Bekeson and Multi-Aspirator. 5. What particle size of frit is expected to create a dust problem? a. The original criterion for creating a dusting problem was those particle sizes that were readily suspended when being shaken. For that criterion calculations and Microtrac size analyses indicated that particles smaller than 37 μm are likely dust generators. Subsequently a more sophisticated criterion for dust problem was considered, particle sizes that would become suspended in the air flow patterns inside the SME and possibly plug the condenser. That size may be larger than 37 μm but has not yet been determined. 6. If particles smaller than 37 μm are removed will bulk dust generation be eliminated? a. Video-taped tests were performed using three gallons each of three types of frit 418, DWPF frit, Bekeson frit and Multi-Aspirator frit. Frit was poured through air from a height of approximately eight feet into a container half filled with water. Pouring Bekeson frit or Multi-Aspirator frit generated markedly less visible dust, but there was still a significant amount, which still has the potential of causing a dust problem. 7. Can completely dry frit be poured into the SME without having dust plug the condenser at the top of the vessel? a. Because of the complexity of air currents inside the SME and the difficulty of defensible size scaling a more prototypical test will be required to answer this question. We recommend construction of a full scale mockup of the top half of the SME with a shallow basin of water at the bottom and a simulated condenser at the top. It could be made from simple materials such as PVC pipe, cardboard and clear plastic and tested with dry frit. Depending on results, this may need to be coupled with the proposed pneumatic transfer system.

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DOE OSTI2012

Solids Accumulation Scouting Studies

The objective of Solids Accumulation activities was to perform scaled testing to understand the behavior of remaining solids in a Double Shell Tank (DST), specifically AW-105, at Hanford during multiple fill, mix, and transfer operations. It is important to know if fissionable materials can concentrate when waste is transferred from staging tanks prior to feeding waste treatment plants. Specifically, there is a concern that large, dense particles containing plutonium could accumulate in poorly mixed regions of a blend tank heel for tanks that employ mixing jet pumps. At the request of the DOE Hanford Tank Operations Contractor, Washington River Protection Solutions, the Engineering Development Laboratory of the Savannah River National Laboratory performed a scouting study in a 1/22-scale model of a waste staging tank to investigate this concern and to develop measurement techniques that could be applied in a more extensive study at a larger scale. Simulated waste tank solids: Gibbsite, Zirconia, Sand, and Stainless Steel, with stainless steel particles representing the heavier particles, e.g., plutonium, and supernatant were charged to the test tank and rotating liquid jets were used to mix most of the solids while the simulant was pumped out. Subsequently, the volume and shape of the mounds of residual solids and the spatial concentration profiles for the surrogate for heavier particles were measured. Several techniques were developed and equipment designed to accomplish the measurements needed and they included: 1. Magnetic particle separator to remove simulant stainless steel solids. A device was designed and built to capture these solids, which represent the heavier solids during a waste transfer from a staging tank. 2. Photographic equipment to determine the volume of the solids mounds. The mounds were photographed as they were exposed at different tank waste levels to develop a composite of topographical areas. 3. Laser rangefinders to determine the volume of the solids mounds. The mounds were scanned after tank supernatant was removed. 4. Core sampler to determine the stainless steel solids distribution within the solids mounds. This sampler was designed and built to remove small sections of the mounds to evaluate concentrations of the stainless steel solids at different special locations. 5. Computer driven positioner that placed the laser rangefinders and the core sampler in appropriate locations over solids mounds that accumulated on the bottom of a scaled staging tank where mixing is poor. These devices and techniques were effective to estimate the movement, location, and concentrations of the solids representing heavier particles and could perform well at a larger scale The experiment contained two campaigns with each comprised of ten cycles to fill and empty the scaled staging tank. The tank was filled without mixing, but emptied, while mixing, in seven batches; the first six were of equal volumes of 13.1 gallons each to represent the planned fullscale batches of 145,000 gallons, and the last, partial, batch of 6.9 gallons represented a full-scale partial batch of 76,000 gallons that will leave a 72-inch heel in the staging tank for the next cycle. The sole difference between the two campaigns was the energy to mix the scaled staging tank, i.e., the nozzle velocity and jet rotational speed of the two jet pumps. Campaign 1 used 22.9 ft/s, at 1.54 rpm based on past testing and Campaign 2 used 23.9 ft/s at 1.75 rpm, based on visual observation of minimum velocity that allowed fast settling solids, i.e., sand and stainless steel, to accumulate on the scaled tank bottom.

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