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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Process-based cost estimation framework for assessing economic viability of environmentally and socially sustainable rare earth element feedstocks

Rare Earth Elements (REEs) are critical raw material inputs that are required to enable the energy transition. Constraints on the U.S. supply of conventional REE feedstocks and the desire to diversify U.S. reliance on foreign supply chains have motivated the pursuit of REE recovery from unconventional feedstocks including waste products. Recovery of REEs from unconventional sources is also motivated by environmental and social considerations, including the potential to offset new mining activity and subsidize the remediation of REE-containing wastes from coal, natural gas, and other mineral extraction activities. Sourcing REEs from unconventional feedstocks would reduce supply chain constraints and minimize the environmental impacts of REE extraction, but current processes to exploit these feedstocks have uncertain technical and economic performance and the processes have not been demonstrated at scale. This work aims to reduce uncertainty in evaluating the performance of new REE production pathways. A database of operating and capital expenses for REE recovery and establish consistent process unit costs for common stages in the conventional supply chain are developed. Market prices are used to develop well-defined methods for determining product values for a diverse set of products that can be generated (e.g. oxalates, alloys, end-use products such as magnets) but are not typically considered in technoeconomic analyses. Finally, to provide insight on the effects of economies of scale and feedstock purity on capital and operating costs, process unit level cost functions relating total costs per kilogram of REE produced are reported. These tools can be applied to assess and facilitate scale-up of REE production from diverse sources of REEs.

Fritz, Alison↗
DOE OSTI2025

Slow Strain Rate Testing of A537 Tank Wall Material

At Savannah River Site (SRS), High-Level Waste is stored in below-grade carbon steel tanks. This waste in part consists of sludge, salt cake, and/or supernate. Preparation of this waste for future processing involves dissolution of the salt cake layer. The salt dissolution process can create conditions that leave the carbon steel tanks susceptible to localized corrosion. The salt to be dissolved contains high concentrations of nitrate, that once released, create an environment that may be conducive to pitting corrosion and/or stress corrosion cracking (SCC) of carbon steel. The salt dissolution process also liberates interstitial liquid trapped between the salt crystals. This liquid is initially high in nitrite and hydroxide concentration. High pH and greater ratios of nitrite to nitrate act as inhibitors to minimize corrosion of carbon steel in high nitrate environments. However, as dissolution proceeds, the concentration of nitrate will increase, while the hydroxide and nitrite concentration of the interstitial liquid will deplete and become insufficient to prevent the onset of corrosion attack. Tank blending and the addition of inhibitors are used to ensure adequate concentrations of hydroxide and nitrite. However, this is not desirable during salt dissolution as it can reduce process efficiency and increase the amount of waste that needs processing. This testing program was designed to examine the risk of SCC associated with utilizing the pitting factor (PF) and nitrite/nitrate (NO 2 - /NO 3 - ) ratio limits for handling dissolved salt solutions at an elevated temperature in the carbon steel waste tanks. The previously identified limits are a PF of 1.2 and an NO 2 - /NO 3 - ratio of 0.15. The results indicate that as long as the NO 2 - /NO 3 - ratio exceeds 0.1 and the PF is above approximately 0.8, there is a discernible safety margin between the open circuit potential (OCP) and the critical cracking potential (CCP) observed during applied potential testing. However, this margin, defined by the difference between the OCP and CCP, is relatively narrow, ranging from 0.1 to 0.25 volts. This small margin raises concerns about potential shifts in OCP during waste retrieval operations, which could inadvertently increase the risk of SCC if the OCP approaches or exceeds the CCP. These results confirm that dissolved salt solutions provide a potent chemistry that, under certain conditions, makes carbon steel susceptible to SCC. The next question to consider is the influence these results have on decisions for storage and retrieval of waste from the tanks. For Type III/IIIA waste tanks, the risk of SCC remains very low. First, and most importantly, the post-weld stress relief of the tanks has reduced the residual stress near the welds. Thus, without the stress component, SCC risk is minimized. The material of construction (A537 Carbon steel) for the Type III/IIIA tanks is superior to the steel in its resistance to SCC than the steel that was utilized for the Type I, II, and IV tanks (A285 carbon steel). From a chemistry control standpoint for a Type III/IIIA tank directly involved with handling dissolved salt solutions, the PF and NO 2 - /NO 3 - ratio limits may be utilized wherein chemistry control provides an extra layer of defense against SCC. Chemistry control for a Type III/IIIA tank minimizes the risk for a tank that may receive the dissolved salt solution, particularly if that tank is a Type I, II, or IV waste tank. On the other hand, if the dissolved salt solution is handled by a Type I, II, or IV waste tank the risk of SCC is real. The potent chemistry, absence of stress relief, and inferior material result in a condition that is conducive to cracking. Efforts should be made to either avoid transferring waste that may not meet the PF and NO 2 - /NO 3 - ratio criteria to one of these tanks or if it is unavoidable, take measures to minimize the consequences of a leak. As shown by these tests, even if the PF and NO 2 - /NO 3 - ratio criteria are met, there is a risk that the tank potential may be disturbed in the positive direction and the risk of SCC increase.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Comparing Parallel Plastic‐to‐X Pathways and Their Role in a Circular Economy for PET Bottles

Abstract The United States generates the most plastic waste of any country and is a top contributor to global plastic pollution. Multiple end‐of‐life strategies must be implemented to minimize environmental impacts and retain valuable plastic material, but it is challenging to compare options that generate products with different lifetimes and utilities. Herein, they present a material flow model equipped with consequential life cycle assessment, cost analysis, and a plastic circularity indicator that considers product quality and lifetime. The model is used to estimate the greenhouse gas (GHG) emissions, circularity, and cost of polyethylene terephthalate (PET) bottle mechanical downcycling to lower‐quality resin, closed‐loop glycolysis to food‐grade PET, upcycling to glass fiber‐reinforced plastic, and conversion to non‐plastic products (electricity, oil) on a United States economy‐wide basis for the year 2020. A brute force algorithm suggests that a combination of 68% glycolysis, 11% mechanical recycling, 6% upcycling, 9% landfilling, and 5% incineration can minimize the cost and GHG emissions and maximize the circularity of the current PET economy. However, uncertainty around transportation distances, materials recovery facility efficiencies, and recycling yields can result in different “optimal” pathway mixes. This flexible framework enables informed decision‐making to move toward a cost‐ and environment‐conscious circular economy for plastic.

09 BIOMASS FUELS↗
DOE OSTI2021

District EnErgy Planner (DEEP) v2

The District EnErgy Planner - DEEP is an Mixed Integer Linear Programming (MILP) optimization software tool to solve district energy system, technology configuration, operation strategies, and energy retail business schemes. DEEP takes user input energy demand on heating, cooling and electricity demand. Energy loss through pipeline is calculated for heating and cooling from central plants. The optimal system configuration to minimize the district energy system life cycle cost or minimize CO2 emission is calculated based on energy balance equations and various constraints. The recent update on DEEP include a feature of waste heat utilization energy balance based optimization to take into accounts of different temperature bands of heat into account to maximize system efficiency. Another feature is to optimize district energy retail by provide optimal pricing scheme for heating, cooling and electricity to end users to incorporate district to grid demand response.

Feng, Wei↗
DOE OSTI2020

The German Site Selection Process - Implementation and Challenges - 20528

Federal Company for Radioactive Waste Disposal (Bundesgesellschaft fuer Endlagerung mbH; hereinafter referred to as BGE) is a state-owned company established in September 2016 following the 'Act on the Organisational Restructuring in the Field of Radioactive Waste Storage'. 'Repository Site Selection Act' (hereinafter referred to as StandAG) defines the site selection procedure, aiming to ensure the best possible safety for storing high-level radioactive waste in Germany for the duration of one million years. The selection procedure is a participatory, transparent, learning and self-questioning process based on scientific expertise. Possible repository sites are sought all over Germany, without excluding or predetermining any potential site at the beginning. The procedure consists of three phases. After each phase, the legislative decides on the regions for further consideration in the next phase of the site selection procedure. The current first phase (Phase I) is divided into two steps. Objective of Step 1 is to determine subareas of favorable geological conditions based on available data. Step 2 of Phase I will lead to identification of specific regions that are considered for further surface-based geoscientific and geophysical exploration. Potential host rocks are rock salt, clay rock and crystalline rock. As part of the site selection procedure, an overview of the status of the planning and implementation of R and D activities is given. Topics of particular interest are, for example, the adaptation of the maximum temperature of 100 deg. C at the container surface, the impact of long-term climate variations as well as minimally invasive exploration methods. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Surfactants are Ineffective for Reducing Imbibition of Water-Based Fracturing Fluids in Deep Gas Reservoirs

Minimizing loss of injected hydraulic fracturing fluids into shale along fracture-matrix boundaries is desired because imbibed water restricts gas production and wastes valuable water resources. This problem has motivated the addition of surfactants into water-based hydraulic fracturing fluids in order to reduce the capillary driving force for imbibition. Here, we show that reduction in interfacial tension and wettability alteration has negligible ability to reduce imbibition in deep gas reservoirs. The effectiveness of altering capillary forces acting at the wetting front also depends on the injection pressure acting at the fracture-matrix boundary. The pressure at the interface between the fracture and the shale matrix is constrained between the reservoir pore pressure and formation pressure (rock fracture pressure, also known as breakdown pressure of the rock) and increases with depth to magnitudes that greatly exceed that of capillary pressures. Furthermore, the analyses presented here show that even maximum alteration of interfacial properties that result in strongly hydrophobic interactions between the fracturing fluid and reservoir rock is incapable of significantly reducing imbibition in deep reservoirs. Instead of using surfactants, this analysis points to decreases in wellbore shut-in pressures and shut-in times as practical options for reducing imbibition losses of water-based fluids.

03 NATURAL GAS↗
DOE OSTI2021

Extended catalyst lifetime testing for HTL biocrude hydrotreating to produce fuel blendstocks from wet wastes

This paper presents the upgrading of HTL (Hydrothermal Liquefaction) bio oil produced by from various sources such as sewage sludge and food wastes. The HTL oil was hydrotreated over a CoMo/Al2O3 (guardbed) and NiMo/Al2O3 (mainbed) catalysts at WHSV 0.5hr-1, 400°C and 1500 psi. The steady state densities (at 40°C) were 0.79 and 0.81 g/ml for HTL biocrude derived from sewage sludge and food waste, respectively. After 1500 hours of steady state operation, variations in process conditions that affect the hydrotreating performance had been identified in the following order; Pressure>WHSV>Temperature. Pressure had huge impact on the hydrotreating performance. The hydrotreating efficiency was reestablished to base line conditions with minimal deactivation of catalyst at 2000 hours run time.

Hydrothermal Liquefaction, HTL, Hydrotreating, Bio↗
DOE OSTI2020

A Study of a Monitoring Program for Intermediate Depth Disposal of Low- Level Radioactive Waste - 20167

This study investigated a monitoring program for intermediate depth disposal of low-level radioactive waste. At first, it extracted monitoring targets, such as the status of cracks in the low diffusion layer after closure of the facility. Secondly, it focused on distributed optical fiber sensors which can minimize the amount of cable, and measurement positions and methods were specifically determined to propose the monitoring method. Finally, conformity to regulatory requirements was verified to clarify key points and issues to be addressed in performing monitoring. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Technology Impact and Resource Assessment of Existing and Planned U.S. Biofuel Production: Life Cycle Water Consumption, Water Stress, Land Use, and Criteria Air Pollutants

Biofuels have the potential to strengthen the U.S. energy supply, enhance energy security, and promote economic development. As the United States continues to expand biofuel production, quantifying resource requirements and location-specific constraints is crucial for planning, siting, and technology development to support long-term viability. Accordingly, this work assesses the life cycle resource consumption (water consumption, and land use), water stress and criteria air pollutants associated with expanded U.S. biofuel production over the 2020–2035 period, based on producers’ plans. We perform a bottom-up technology impact assessment and resource assessment by integrating facility-level production statistics with Argonne’s Research and Development (R&D) GREET model and county-level water-stress characterization factors from Available Water Remaining for the United States (AWARE-US) model. Results suggest that by 2035, biofuels could meaningfully contribute to U.S. energy demand, driven primarily by first-generation and waste-based feedstocks with plans for substantial capacity expansion, although cellulosic and e-fuel technologies remain limited. However, growth must be managed to minimize impacts on water resources and land use. These impacts vary by fuel type and facility location, specifically, projected expansion increases water consumption and can elevate water-stress impacts in certain regions like Nebraska, Kansas, Colorado, Idaho, California and North Texas. Direct land use also increases overall, particularly for first-generation feedstocks such as corn and soybeans. These findings underscore the need for continued technological improvements and innovative strategies to manage resource demands as the industry scales and to support complementary deployment within the evolving U.S. energy system.

09 BIOMASS FUELS↗
DOE OSTI2020

Electrolyte Engineering for Efficient Electrochemical Nitrate Reduction to Ammonia on a Titanium Electrode

Nitrates from agricultural runoff and industrial waste streams are a notorious waste product and hazardous pollutant. Traditional electrochemical water remediation approaches aim to solve this problem by converting nitrates to environmentally benign N 2 while minimizing the production of environmentally hazardous side products such as ammonia and nitrous oxide in a process known as “denitrification”. We modify this concept and outline an opportunity to optimize the conversion of nitrates into ammonia, which is also a key commodity product used as a fertilizer, potential fuel, and chemical precursor. The electrochemical conversion of nitrates to ammonia recycles the fixed nitrogen and offers an appealing and supplementary alternative to the energy- and resource-intensive Haber-Bosch process. In this study, we investigated the effect of varying electrochemical conditions (pH, nitrate concentration, and applied potential) on the selective reduction of nitrate to ammonia at a titanium cathode. We observed that high concentrations of both protons and nitrate ions are needed to achieve high selectivity, reaching a peak of 82% Faradaic efficiency to ammonia at an applied potential of -1 V versus RHE and a partial current density to NH 3 of -22 mA/cm 2 , using 0.4 M [NO 3 – ] at pH ~0.77. The Ti electrode, as a poor hydrogen evolution catalyst with notable corrosion resistance, provides a large window of operating conditions to achieve high selectivity in the reduction of nitrate anions. Stability of the system was evaluated, and we found a high Faradaic efficiency throughout the course of an 8 h experiment. After electrochemical testing, titanium hydride was observed at the cathode surface. We also show a preliminary technoeconomic study, indicating that it may be feasible to employ an electrochemical strategy for the production of ammonium nitrate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Synergistic Thermo-Microbial-Electrochemical (T-MEC) Approach for Drop-In Fuel Production from Wet Waste

This project successfully developed and demonstrated the synergistic thermo-microbial-electrochemical (T-MEC) process, converting food waste into sustainable biofuels while achieving self-sustaining wastewater treatment and hydrogen production. By integrating hydrothermal liquefaction (HTL) and microbial electrolysis cells (MECs), the project advanced waste-to-fuel technology and expanded the understanding of sustainable waste valorization. It established a scalable framework for achieving high carbon efficiency, effective pollutant removal, and energy recovery, showcasing the potential of combining biological, thermal, and electrochemical systems to optimize resource recovery and reduce environmental impacts. The project demonstrated the technical effectiveness of the T-MEC process, achieving over 50% improvement in carbon efficiency and reducing waste processing costs by more than 25% compared to anaerobic digestion (AD). The HTL pilot reactor processed food waste at 90 kg/h, producing up to 200 L/day of biocrude oil with high conversion efficiency. A critical desalting step in pretreatment prevented catalyst fouling, enabling efficient hydrotreating with 100% deoxygenation and denitrogenation and sulfur reduction to <15 ppm. This positioned the kerosene fraction as a strong candidate for sustainable aviation fuel (SAF). The MECs achieved rapid startup, 86.4% COD removal, and hydrogen production rates of 1.8 L H 2 /L cat /day, among the highest recorded for pilot-scale systems. The integrated process achieved 65% carbon efficiency to biocrude and 58% to finished fuels, outperforming AD's 41% and 33% efficiencies for biogas and natural gas vehicle fuels. System analysis highlighted economic potential, with minimum fuel selling prices (MFSP) decreasing from $\$$25/GGE at 5 tpd to $\$$10/GGE at 500 tpd due to economies of scale. Future work will focus on reducing MEC material and membrane costs, enhancing performance through higher current densities, and creating tailored operational strategies for diverse feedstocks. Optimization of the integrated system will improve scalability and feasibility, positioning the T-MEC process as a competitive solution for converting wet waste into sustainable fuels and clean water. Beyond its technical and economic achievements, the project offers significant public benefits. The T-MEC process provides a sustainable alternative to landfilling and incineration, reducing greenhouse gas emissions and conserving resources. Converting waste into SAF and renewable fuels supports decarbonization in the transportation sector, advancing energy independence and reducing reliance on fossil fuels. Additionally, the process minimizes environmental pollutants, transforming them into valuable products like hydrogen and fuels, contributing to a cleaner and more sustainable future.

09 BIOMASS FUELS↗
DOE OSTI2020

Incorporating the Impacts of Climate Change on Hydrology in a Performance Assessment Model - 20403

The evidence of climate change is increasingly well-documented and impacts should be incorporated in performance assessment studies. The current climate literature provides both observational evidence and climate model projections of climate trends and/or climate change in the late 20. and early 21. centuries for North America and the northeast United States. Probabilistic modeling is a core requirement for quantifying uncertainty and evaluating its impacts. Not evaluating future climate states in a performance assessment because of the existence of uncertainty is contradictory to good modeling practices - the most uncertain issues and parameters require the most attention in effective probabilistic modeling. Excluding climate change limits development of modeling information that could aid in effective decision making. In this work we develop methods to use the output from hydrologic models and analysis of historical aerial imagery to quantify and implement the impacts of climate change on hydrologic processes at a nuclear waste site in West Valley, New York. Specifically, we used the HELP (Hydraulic Performance of Landfill Performance) model to characterize key hydrologic processes under both current and future climate conditions to assess the impacts of changing climate on hydrology. A suite of previous climatic models were reviewed and synthesized to produce a cohesive representation of the current state of knowledge of the impact of climate change on important model inputs such as precipitation. Output from the HELP simulations was coupled to the GoldSim model that was used to develop the Probabilistic Performance Assessment (PPA) approach through the application of a novel 'nearest neighbor' technique. First, several thousand realizations were generated from the HELP model using a Latin Hypercube experimental design to ensure adequate coverage of the parameter space of explanatory variables used to drive HELP. For example, porosity is a physical parameter that is used as an input to both HELP and the GoldSim PA model. We then ran sensitivity analysis (SA) algorithms on the output of HELP for each of the responses of interest. For each predictor, each time we build an SA model we get a different value for the sensitivity index (SI). From the collection of all the SA models, the average was computed among all of the SIs to represent the predictor within the context of the nearest neighbor approach. That is, we conduct SA on each HELP outcome for each scenario. This gives us parameter sensitivity indices for the outcomes. We average the parameter sensitivity indices across the outcomes to get the average SI for a scenario. For each realization that is generated from the Goldsim PA model, Goldsim generates random values for physical/empirical parameters that HELP uses as well. For each vector of physical/empirical parameters that Goldsim generates, the vector from the 5,000 HELP runs that is most 'similar' to the Goldsim vector is computed using the nearest neighbor approach. In this context 'similar' means minimization of the SA-weighted sum of the absolute differences among the 5,000 values computed for this statistic, where each value corresponds to a different HELP realization. In order to account for the impacts of climate change, this process was repeated using the spatially downscaled future climate projections. For each of the key parameters of interest, it was assumed that a linear change depicted the relationship between the values for the present day and those for 2100. In this way, the climatically-driven changes in key parameters used to inform the GoldSim model are quantified and incorporated into the PA model output for the future. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Technoeconomic Analysis of a Microwave-Assisted Novel Process That Converts Polypropylene Plastic Waste to Propylene

Propylene is an important petrochemical that is used in various industries, including the automobile and polymer sectors. Conventionally, propylene has been produced through fluid catalytic cracking, steam cracking, and propane dehydrogenation. In this project, a novel process to produce propylene from polypropylene plastic waste using a microwave reactor is introduced. Propylene production is simulated in Aspen Plus for both the conventional propane dehydrogenation process and the novel design, with heat integration applied to minimize utility demands and the conventional process serving as the base case for comparison. Finally, a tailored technoeconomic analysis is carried out for both simulated cases to estimate important economic indicators. Analysis of the results shows that the novel microwave-assisted process outperforms the conventional route for propylene production, achieving a single-pass conversion of almost 100%, compared with only 33.8% in the conventional plant. The Net Present Value of the novel plant is $\$1720.3$ MM, which is 3.5 times higher than the conventional process, while the Levelized Cost of Propylene is reduced by 40%. Capital and operating expenditure are also improved in the proposed scheme, with reductions of approximately $\$29$ MM and $\$222$ MM/yr, respectively. In addition to cost savings, this novel process also provides a convenient means to recycle waste polypropylene.

42 ENGINEERING↗
DOE OSTI2024

Special Considerations for the Removal and Disposal of Micro-Reactor Experiments

Idaho National Laboratory (INL) is preparing to host several microreactor experiments through 2030 and beyond. Two new test beds currently under development will operate as microreactor or nuclear system experiment user facilities. Test bed experiments will be performed in series, with each nuclear experiment installed, operated, and removed before installation of the subsequent experiment. The necessarily brief transition period between experiments introduces unique equipment removal and radioactive waste disposal challenges. This paper evaluates equipment removal and radioactive waste management topics associated with tight sequencing of nuclear experiments and presents some of the solutions and approaches currently planned to meet these special considerations for one such experiment, the Molten Chloride Reactor Experiment (MCRE), slated for operation at INL’s Laboratory for Operation and Testing in the United States (LOTUS). The MCRE project is a collaboration between Southern Company Services, TerraPower, and INL, among others, to provide integral nuclear data that will advance molten salt fast reactor technology. MCRE will be the first critical fast-spectrum circulating fuel system ever operated and the first experiment operated in the LOTUS test bed. The experiment will nominally operate at zero power with planned low power excursions as part of operational planning for MCRE has been to minimize at-power operations to limit fission product formation while still achieving experimental objectives. After the experiment is complete, MCRE will be allowed to radioactively decay for a short period (nominally 90 days) prior to system defueling, flushing, removal, and disposal of all MCRE equipment, readying the test bed for the next nuclear experiment. Equipment removal and radioactive waste disposal have been integral to MCRE project planning since the Cooperative Research and Development Agreement was formalized in 2021. Due to requirements for future use of the test bed, the MCRE system, of necessity, must be removed in a much shorter time frame than typical for historic reactor decommissioning projects at INL. This results in minimal time for radioactive decay, resulting in not only elevated radiation dose rates but also the presence of short-to-medium-lived isotopes not typically encountered in the reactor decommissioning and radioactive waste management space. Additional unique constraints placed on the project include lack of intrinsic remote-operations capabilities in the test bed, space constraints in the test bed once MCRE has been installed, and contamination minimization requirements to return the test bed to as-found conditions to enable future use. This paper discusses planned solutions to these challenges. Approaches for implementing remote or semi-remote technologies in a non-hot cell environment with limited space availability are discussed. The paper also summarizes the systems engineering approach for concept development and design of equipment removal systems, which are being implemented concurrent with the MCRE design phase, providing feedback to system designers to incorporate features enabling efficient and safe equipment removal approaches. The timing of this paper at a relatively early phase of the project is meant to highlight the importance of early planning for nuclear system decommissioning while reactor design is ongoing to allow design feedback on componentry driven from decommissioning system needs. As new, innovative nuclear reactor technologies enter the nuclear market sector, reactor experiments are crucial for providing new integral nuclear data that establish safe operational margins for technology advancement. Microreactor experiments at INL will require safe, effective, and timely decommissioning approaches, which in turn require nuclear systems designed to expedite decommissioning. In addition to the advancement of nuclear reactor technologies, these nuclear experiments provide an opportunity to demonstrate, deploy, and test new removal and disposal capabilities to support the next generation of nuclear reactor technology.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Uranium Solubility and Supernate Enrichment Testing for Accelerated Basin De-Inventory Discards to Concentration, Storage, and Transfer Facilities

After future Accelerated Basin De-inventory (ABD) enriched uranium discards into sludge batches (SB), portions of supernate decants during SB preparation will be blended into salt batches (StB) and the resulting feeds must meet the nuclear safety requirements for the Salt Waste Processing Facility (SWPF). During previous SB10 sampling and testing, which involved H-Canyon material containing enriched uranium being mixed with Tank 51 sludge shortly after the H-Canyon stream was neutralized, it was identified that the uranium isotopic enrichment in the supernate deviated from the uranium isotopic enrichment in the slurry. The higher uranium isotopic enrichment in the supernate introduced the risk of challenging the feed requirements of SWPF. The ABD material added to SB11 was isotopically diluted with depleted uranium, mitigating any downstream impacts. However, H-Canyon desires to eliminate or minimize future depleted uranium additions in order to meet the mission schedule.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Lessons Learned from Demolition of Hanford's Plutonium Finishing Plant - 20507

U.S. Department of Energy (DOE) contractor CH2M Hill Plateau Remediation Company (CHPRC), a Jacobs owned company, is making significant progress demolishing the Plutonium Finishing Plant (PFP), which has long been known as one of the most hazardous buildings in the DOE Environmental Management Complex (DOE Complex). The facility is located on the Hanford Site and produced plutonium metal during the Cold War. Production was stopped in 1989, the facility was formally shut down in 1996, and material processing was completed in 2004. After approximately 25 years of demolition preparations, open-air demolition of the main portions of the Hazard Category II nuclear facility began in November 2016. To prepare the PFP for demolition, CHPRC employees performed some of the most hazardous work across the DOE Complex. In addition to extensive demolition preparations, including a wide-reaching communication strategy across the Hanford Site, CHPRC implemented robust controls and monitoring during demolition, and when necessary, adjusted demolition practices and sequence to maintain employee safety and project efficiency. Demolition of the main PFP building began in November 2016. The technical complexity, high hazards and radiological concerns have all led to a difficult demolition environment. Following a spread of contamination at the project site beyond the radiological boundaries in December 2017, work was halted and a recovery plan was generated to allow the demolition work to continue. After the implementation of additional controls and concurrence from regulatory agencies and DOE, the demolition was ready to resume work and reinitiated in August 2018. There are a number of lessons learned from the demolition activities and recovery plan process. This paper allows CHPRC and DoE's Richland Operations Office (RL) to share lessons learned and progress to date with other challenging and hazardous projects across the DOE Complex. Understanding the risk acceptance level is critical to execution of any open-air demolition project and is unique to each facility. Four key lessons learned from this project include: 1) plan execution issues, 2) stakeholder communication issues, 3) watching for summit fever and 4) minimizing exposed contaminated surfaces during demolition. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

DECOVALEX-2023: Task C Final Report

The Full-scale Emplacement (FE) heater experiment at the Mont Terri Underground Rock Laboratory (URL) was designed and conducted by Nagra to replicate an emplacement tunnel of Nagra’s reference repository design at 1:1 scale. Alongside testing the technical feasibility of constructing disposal tunnels, emplacing waste containers in the tunnels and then backfilling them, the main goals of the FE experiment are (1) to obtain a better understanding of the coupled effects of induced thermo-hydro-mechanical (THM) processes that may occur and (2) to validate existing coupled THM models (Müller et al., 2017). A key aspect of ensuring safety for repositories located in low-permeability rock involves minimizing any damage to the rock itself, thereby preserving its integrity and promoting a stable environment Amongst a number of processes that could damage the rock is the increase in pore pressure due to thermal loading caused by heat emitted from the waste. To reduce the potential damage of the rock, it is important to analyse the evolution of heat over time due to the heat load of the containers and assess possible consequences by coupled THM models. The aim of Task C of DECOVALEX-2023 was to build 3D numerical models of the FE experiment, focussing in particular on the heating induced pore pressure change in the Opalinus Clay. Data from a large number of sensors were available from the FE experiment for model comparison. These sensors measured temperature and relative humidity in the bentonite around the heaters, and temperature, pressure and displacement/strain in the surrounding Opalinus clay. Data were available from the start of excavation (April 2012) up to August 2020 for most sensors (more than 5 years from the start of heating in December 2014). To fulfil the overall aim of the task, the work was broken down into a number of steps, starting with simpler models to build confidence in each team’s approach and then moving to more complex models that better represent the FE experiment. Step 0 consisted of 2D benchmark models, gradually increasing the number of processes that are represented from thermal (T) only models in Step 0a, to coupled thermal hydraulic (TH) models in Step 0b with a representation of changing porosity, to coupled thermo-hydro-mechanical (THM) models in Step 0c, where porosity changes are calculated by the mechanical model. A detailed specification of processes, parameters, initial and boundary conditions was provided for this step, with the ambition that all teams would work towards close agreement in their model results, thus building confidence in the model implementations. vi It was not straightforward to achieve agreement between the teams, so additional steps (Step 0b2, 0b3, 0c2, 0c3) were added along with derivation of some analytical solutions against which the models could be compared. The reasons for the differences between teams were investigated and found to be caused primarily by different conceptual model assumptions (including temperature dependence of the thermal expansion of water), different model formulations (including porosity evolution) and differences in modelled domain sizes, boundary conditions and grid discretisation. This demonstrates that comparisons between multiple modelling teams and/or comparison with analytical results and experimental data are highly beneficial in providing an indication of uncertainty in model predictions. At the conclusion of Step 0, almost all teams had achieved a close agreement in model results and those that had not achieved an agreement knew the reason for this. Step 1 moved from 2D models to 3D models of the FE experiment without adding technical features like shotcrete or EDZ, and only considering the heating phase. Initially the 3D model was tightly specified to continue to build confidence in the model implementations (Step 1a). The results of Step 1a were compared to the data from the FE-experiment without the teams seeing the data. The teams were then provided with a sub-set of the data from the FE-experiment and invited to consider how best to use the large dataset for model comparison (Step 1b). Teams were then asked to use the data provided to calibrate their models, only changing material property values rather than adding features or processes to their models (Step 1c). In Step 1, teams were asked to only model the heating phase of the experiment, so pressure in the Opalinus Clay was reported as change in pressure since the initial conditions were specified rather than modelled. The change from 2D to 3D models was accompanied by an increase in the dispersion of results between the teams. Some of this was resolved during the task, but some remained and is potentially due to model discretisation. Calibration of parameters was useful in improving the fit of the models to the data but the remaining differences indicated that the models were missing features or processes. In Step 2, the teams were asked to update their models with additional features and processes as well as calibrating parameters to try and improve the fit of the models to the data. Teams were encouraged to represent ventilation of the open FE tunnel prior to backfilling with heaters and bentonite and in Step 2, the absolute pressure in the Opalinus Clay was compared between the teams. Teams took different approaches, but there was consideration of adding shotcrete and an EDZ into the model, representing stress change during excavation and different approaches to modelling ventilation of the FE tunnel. Overall, the documented results showed a very good agreement for temperature. The results for porewater pressure evolution showed a significant improvement for most teams compared to Step 1c with a good agreement to the measurements for several teams whereas some teams overpredicted the pressure increase and others overpredicted the drainage effect especially for the sensors close to the heater. Step 3 was an opportunity for teams to use the models developed in Step 1 and Step 2 to make predictions about the temperature and pressure changes that will be expected at the FE experiment over the next few years in light of the planned changes in thermal output of the heaters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Review of recent developments in iodine wasteform production

Radioiodine capture and immobilization is not only important to consider during the operation of reactors (i.e., I-131), during nuclear accidents (i.e., I-131 and I-129) or nuclear fuel reprocessing (i.e., I-131 and I-129), but also during disposal of nuclear wastes (i.e., I-129). Most disposal plans for I-129-containing waste forms (including spent nuclear fuel) propose to store them in underground repositories. Here, iodine can be highly mobile and, given its radiotoxicity, needs to be carefully managed to minimize long-term environmental impacts arising from disposal. Typically, any process that has been used to capture iodine from reprocessing or in a reactor is not suitable for direct disposal, rather conversion into a wasteform for disposal is required. The objectives of these materials are to use either chemical immobilization or physical encapsulation to reduce the leaching of iodine by groundwaters. Some of the more recent ideas have been to design capture materials that better align with disposal concepts, making the industrial processing requirements easier. Research on iodine capture materials and wasteforms has been extensive. This review will act as both an update on the state of the research since the last time it was comprehensively summarized, and an evaluation of the industrial techniques required to create the proposed iodine wasteforms in terms of resulting material chemistry and applicability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗