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DOE OSTI2024

Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels

Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.

09 BIOMASS FUELS↗
DOE OSTI2024

Supporting data for Site-specific Design Case Study for Wet Waste Hydrothermal Liquefaction and Biocrude Upgrading to Hydrocarbon Fuels

Hydrothermal liquefaction (HTL) is a thermal process that converts wet biomass to renewable hydrocarbon fuel blendstocks (i.e., renewable naphtha, renewable diesel, and sustainable aviation fuel (SAF)). It can utilize a wide range of pure and blended wet feedstocks, including sewage sludge from water resource recovery facilities (WRRF), food and agriculture wastes, algae, fats, oils and greases (FOG) and blends of dry and wet wastes/feedstocks. Historically, techno-economic analysis (TEA) and annual state of technology (SOT) assessments with standard economic assumptions used by the Bioenergy Technologies Office (BETO) were conducted for the wet waste HTL pathway leveraging experimental data collected from Pacific Northwest National Laboratory’s (PNNL) continuous flow reactor systems. The objective of the SOT assessment has been to guide and track progress of BETO’s HTL research and development (R&D) toward reduced cost and greenhouse gas (GHG) emissions for the pathway. However, gaps exist between BETO’s traditional SOT updates and the needs of key external stakeholders that – if addressed – will accelerate technology adoption. This Business Case Study aims to bridge this gap by providing an updated design, TEA, and LCA based on PNNL’s FY23 R&D with added analyses and information that provide enhanced relevance for stakeholders of the HTL technology. This includes specific siting, regional wet waste resource inventory and transportation cost analyses, fuel market information, sustainable fuel policy impacts, economic metrics of net present value (NPV) and internal rate of return (IRR), greenhouse gas (GHG) emissions analysis, and statistical analysis of cost and technical uncertainties of the HTL plant design. The study focuses on the “Detroit combined statistical area (CSA)” region for siting of a wet waste HTL plant adjacent to the Great Lakes Water Authority (GLWA) facility with guidance from industry participants. Regional resource and siting analyses were conducted to identify feedstock availability, scale, and cost, as well as a beneficial site location. TEA with detailed rigorous capital cost estimation for the specific site application was conducted to evaluate the key economic metrics of most value to industrial partners. These include total capital investment, operating costs, minimum fuel selling price (MFSP) of the biocrude and fuel blendstock, and NPV and internal rate of return IRR with sustainable fuel credits. Life cycle analysis was conducted to evaluate the supply chain greenhouse gas (GHG) emissions for the wet waste HTL process as compared with petroleum derived diesel. This study is also informed by years of R&D and process de-risking learnings and was conducted with a basic engineering HTL plant design and costing that akin to a “first-of-a-kind” plant economics. This differs from our conventional “nth plant ” SOT assessments. Specifically, the HTL process model has been updated with more operationally reliable methods for feed heating and phase separations. Further, we have implemented additional spare equipment for redundancy, a more rigorous installed equipment cost estimation approach, and additional costs associated with feed formatting and delivery, building, piping and site development. An Excel-based cost sheet based on the basic engineering design is also released alongside the report that allows users to conduct customized TEA with their own feed composition and financial assumptions.

Li, Shuyun↗
DOE OSTI2021

Polyacrylonitrile Composites of Ag–Al–Si–O Aerogels and Xerogels as Iodine and Iodide Sorbents

Mechanically robust engineered sorbents were constructed by embedding Ag-loaded aerogels or xerogels in a polyacrylonitrile (PAN) matrix at 30 or 50 mass% loadings of gel in PAN. Here, the process for making the base gels as well as the composite materials is described herein, a technology that is very flexible for making hybrid sorbents using various inorganic or organic active sorbents. The PAN-gel composite materials were evaluated for iodine uptake in the form of gaseous iodine [I 2(g) ] at room temperature and at 150°C as well as iodide (I – ) at room temperature from simulated liquid nuclear wastes. The composites show high I 2(g) uptake and high I – uptake (= 93 mass%) in simulated liquid secondary waste spiked with 5 mg L -1 I – . These results demonstrate the utility of such a composite form for iodine removal from contaminated gas and liquid streams.

36 MATERIALS SCIENCE↗
DOE OSTI2021

National Alliance for Water Innovation (NAWI) Power Sector Technology Roadmap 2021

The National Alliance for Water Innovation (NAWI) is a research consortium formed to accelerate transformative research in desalination and treatment to lower the cost and energy required to produce clean water from nontraditional water sources and realize a circular water economy. NAWI’s goal is to enable the manufacturing of energy-efficient desalination technologies in the United States at a lower cost with the same (or higher) quality and reduced environmental impact for 90 percent of nontraditional water sources within the next 10 years. The nontraditional source waters of interest include brackish water; seawater; produced and extracted water; power, mining, industrial, municipal, and agricultural waste waters. When these desalination and treatment technologies are fully developed and utilized, they will be able to contribute to the water needs for many existing end-use sectors. NAWI has identified five end-use sectors that are critical to the U.S. economy for further exploration: Power, Resource Extraction, Industry, Municipal, and Agriculture (PRIMA). This Power Sector roadmap aims to advance desalination and treatment of nontraditional source waters for beneficial use in public water supplies by identifying research and development (R&D) opportunities that help overcome existing treatment challenges. Under NAWI’s vision, the transition from a linear to a circular water economy with nontraditional source waters will be achieved by advancing desalination and reuse technologies in six key areas: Autonomous operations, Precision separations, Resilient treatment and transport, Intensified brine management, Modular membrane systems, and Electrified treatment systems, collectively known as the A-PRIME areas. Technological advances in these different areas will enable nontraditional source waters to achieve pipe parity with traditional supplies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

National Alliance for Water Innovation (NAWI) Resource Extraction Sector Technology Roadmap 2021

The National Alliance for Water Innovation (NAWI) is a research consortium formed to accelerate transformative research in desalination and treatment to lower the cost and energy required to produce clean water from nontraditional water sources and realize a circular water economy. NAWI’s goal is to enable the manufacturing of energy-efficient desalination technologies in the United States at a lower cost with the same (or higher) quality and reduced environmental impact for 90 percent of nontraditional water sources within the next 10 years. The nontraditional source waters of interest include brackish water; seawater; produced and extracted water; power, mining, industrial, municipal, and agricultural waste waters. When these desalination and treatment technologies are fully developed and utilized, they will be able to contribute to the water needs for many existing end-use sectors. NAWI has identified five end-use sectors that are critical to the U.S. economy for further exploration: Power, Resource Extraction, Industry, Municipal, and Agriculture (PRIMA). This Resource Extraction Sector roadmap aims to advance desalination and treatment of nontraditional source waters for beneficial use in public water supplies by identifying research and development (R&D) opportunities that help overcome existing treatment challenges. Under NAWI’s vision, the transition from a linear to a circular water economy with nontraditional source waters will be achieved by advancing desalination and reuse technologies in six key areas: Autonomous operations, Precision separations, Resilient treatment and transport, Intensified brine management, Modular membrane systems, and Electrified treatment systems, collectively known as the A-PRIME areas. Technological advances in these different areas will enable nontraditional source waters to achieve pipe parity with traditional supplies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

National Alliance for Water Innovation (NAWI) Agriculture Sector Technology Roadmap 2021

The National Alliance for Water Innovation (NAWI) is a research consortium formed to accelerate transformative research in desalination and treatment to lower the cost and energy required to produce clean water from nontraditional water sources and realize a circular water economy. NAWI's goal is to enable the manufacturing of energy-efficient desalination technologies in the United States at a lower cost with the same (or higher) quality and reduced environmental impact for 90 percent of nontraditional water sources within the next 10 years. The nontraditional source waters of interest include brackish water; seawater; produced and extracted water; power, mining, industrial, municipal, and agricultural waste waters. When these desalination and treatment technologies are fully developed and utilized, they will be able to contribute to the water needs for many existing end-use sectors. NAWI has identified five end-use sectors that are critical to the U.S. economy for further exploration: Power, Resource Extraction, Industry, Municipal, and Agriculture (PRIMA). This Agriculture Sector roadmap aims to advance desalination and treatment of nontraditional source waters for beneficial use in public water supplies by identifying research and development (R&D) opportunities that help overcome existing treatment challenges. Under NAWI's vision, the transition from a linear to a circular water economy with nontraditional source waters will be achieved by advancing desalination and reuse technologies in six key areas: Autonomous operations, Precision separations, Resilient treatment and transport, Intensified brine management, Modular membrane systems, and Electrified treatment systems, collectively known as the A-PRIME areas. Technological advances in these different areas will enable nontraditional source waters to achieve pipe parity with traditional supplies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

National Alliance for Water Innovation (NAWI) Municipal Sector Technology Roadmap 2021

The National Alliance for Water Innovation (NAWI) is a research consortium formed to accelerate transformative research in desalination and treatment to lower the cost and energy required to produce clean water from nontraditional water sources and realize a circular water economy. NAWI's goal is to enable the manufacturing of energy-efficient desalination technologies in the United States at a lower cost with the same (or higher) quality and reduced environmental impact for 90 percent of nontraditional water sources within the next 10 years. The nontraditional source waters of interest include brackish water; seawater; produced and extracted water; power, mining, industrial, municipal, and agricultural waste waters. When these desalination and treatment technologies are fully developed and utilized, they will be able to contribute to the water needs for many existing end-use sectors. NAWI has identified five end-use sectors that are critical to the U.S. economy for further exploration: Power, Resource Extraction, Industry, Municipal, and Agriculture (PRIMA). This Municipal Sector roadmap aims to advance desalination and treatment of nontraditional source waters for beneficial use in public water supplies by identifying research and development (R&D) opportunities that help overcome existing treatment challenges. Under NAWI's vision, the transition from a linear to a circular water economy with nontraditional source waters will be achieved by advancing desalination and reuse technologies in six key areas: Autonomous operations, Precision separations, Resilient treatment and transport, Intensified brine management, Modular membrane systems, and Electrified treatment systems, collectively known as the A-PRIME areas. Technological advances in these different areas will enable nontraditional source waters to achieve pipe parity with traditional supplies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

National Alliance for Water Innovation (NAWI) Industrial Sector Technology Roadmap 2021

The National Alliance for Water Innovation (NAWI) is a research consortium formed to accelerate transformative research in desalination and treatment to lower the cost and energy required to produce clean water from nontraditional water sources and realize a circular water economy. NAWI's goal is to enable the manufacturing of energy-efficient desalination technologies in the United States at a lower cost with the same (or higher) quality and reduced environmental impact for 90 percent of nontraditional water sources within the next 10 years. The nontraditional source waters of interest include brackish water; seawater; produced and extracted water; power, mining, industrial, municipal, and agricultural waste waters. When these desalination and treatment technologies are fully developed and utilized, they will be able to contribute to the water needs for many existing end-use sectors. NAWI has identified five end-use sectors that are critical to the U.S. economy for further exploration: Power, Resource Extraction, Industry, Municipal, and Agriculture (PRIMA). This Industrial Sector roadmap aims to advance desalination and treatment of nontraditional source waters for beneficial use in public water supplies by identifying research and development (R&D) opportunities that help overcome existing treatment challenges. Under NAWI's vision, the transition from a linear to a circular water economy with nontraditional source waters will be achieved by advancing desalination and reuse technologies in six key areas: Autonomous operations, Precision separations, Resilient treatment and transport, Intensified brine management, Modular membrane systems, and Electrified treatment systems, collectively known as the A-PRIME areas. Technological advances in these different areas will enable nontraditional source waters to achieve pipe parity with traditional supplies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Recycling polyolefin plastic waste at short contact times via rapid joule heating

Abstract The chemical deconstruction of polyolefins to fuels, lubricants, and waxes offers a promising strategy for mitigating their accumulation in landfills and the environment. Yet, achieving true recyclability of polyolefins into C 2 -C 4 monomers with high yields, low energy demand, and low carbon dioxide emissions under realistic polymer-to-catalyst ratios remains elusive. Here, we demonstrate a single-step electrified approach utilizing Rapid Joule Heating over an H-ZSM-5 catalyst to efficiently deconstruct polyolefin plastic waste into light olefins (C 2 -C 4 ) in milliseconds, with high productivity at much higher polymer-to-catalyst ratio than prior work. The catalyst is essential in producing a narrow distribution of light olefins. Pulsed operation and steam co-feeding enable highly selective deconstruction (product fraction of >90% towards C 2 -C 4 hydrocarbons) with minimal catalyst deactivation compared to Continuous Joule Heating. This laboratory-scale approach demonstrates effective deconstruction of real-life waste materials, resilience to additives and impurities, and versatility for circular polyolefin plastic waste management.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Implementation of a High-Fidelity Interface Resolving Method in Nek5000

The development and utilization of computational fluid dynamics (CFD) models for large, high-temperature electric melters in the Waste Treatment and Immobilization Plant (WTP) in eastern Washington State have proven to be valuable for various purposes. These models allow for a better understanding of the physio-chemical processes occurring within the melter vessels and can contribute to improving operational efficiency, throughput, and addressing operational issues related to vitrification. The CFD models employed for these melter vessels incorporate multiphase fluid flow and heat transfer simulations in different regions, including the plenum, cold cap, and molten glass regions. As the tank waste and glass formers are introduced into the melter, a reacting batch layer known as the cold cap forms on top of the molten glass. To enhance the melt rate, forced convection bubblers located at the bottom of the melters generate convection currents that help homogenize the molten glass and provide heat to the cold cap. As the bubbles rise through the highly viscous glass, they adopt a spherical-cap shape [1]. Meanwhile, the conversion of the batch to glass generates significant amounts of gases (such as water vapor, carbon dioxide, sulfur dioxide, and NOx) due to thermal decomposition [2]. These gases become trapped between the cold cap and molten glass, forming a foam layer [3]. For modeling multiphase flow in CFD and heat transfer simulations of waste glass melters at different scales, efforts are underway to augment the capabilities of the Nek5000 [4] and NekRS [5] open-source codes [6]. Nek5000/NekRS is a scalable and efficient spectral element code that has been successfully applied to a wide range of fluid dynamics problems. By leveraging the Nek5000/NekRS software, it becomes possible to model the melter systems more affordably and with lower computational requirements compared to currently utilized commercial CFD software. The specific objectives of this ongoing effort include: 1. Implementation of a level set method in Nek5000/NekRS: The level set method is a numerical technique commonly employed in CFD simulations to track and represent the interface between different phases or materials accurately. By incorporating this method into Nek5000/NekRS, the ability to simulate multiphase flows in waste glass melters at a high level of fidelity can be achieved. 2. Demonstration of capability for air bubbling through molten glass: As part of the development process, a specific case of air bubbling through molten glass will be simulated using the augmented Nek5000/NekRS code. This demonstration aims to showcase the ability of the software to accurately capture and analyze the complex phenomena involved in the multiphase flow within waste glass melters. By achieving these objectives, the improved Nek5000/NekRS code will offer a powerful computational tool for simulating and analyzing waste glass melter systems, enabling better understanding, optimization, and troubleshooting of these vitrification processes. The ability to accurately model and simulate multiphase flows has broad relevance across many industries and scientific domains, and the improved functionality can contribute to advancements in various fields beyond waste glass melter simulations.

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

Harnessing photoautotroph-methanotroph interactions for biogas conversion to fuels and chemicals using binary consortia (Project Final Technical Report)

Industrial, municipal, and agricultural waste streams containing stranded organic carbon represent a significant and underutilized feedstock to produce fuels and chemicals. With anaerobic digestion deployed at large scales to capture organic waste streams, over 6 million tons of biogas are available today. However, the utilization of biogas represents a significant challenge due to its low pressure and presence of contaminants such as H 2 S, ammonia, and volatile organic carbon compounds. To tap into this immense potential, effective biotechnologies that co-utilize both CO 2 and CH 4 are needed. Recent studies demonstrated that, in nature, microbial communities have developed a highly efficient way to recover energy and capture carbon from both CH 4 and CO 2 through metabolic coupling of methane oxidation to oxygenic photosynthesis. Using two synthetic methanotroph – photoautotroph (M-P) co-cultures that exhibit stable growth under a broad range of cultivation conditions, in this project we proposed to harness the interspecies interactions within these cocultures for biogas conversion to fuels and chemicals. To facilitate this overarching objective, we aim to develop experimental and computational tools to gain qualitative and quantitative understandings on the interactions and dynamics of the coculture at both systems and molecular levels, and to validate our findings through experiments and mutant development. The fundamental understanding on the interactions and dynamics of the photoautotroph-methanotroph will lay the foundation for the design and optimization of synthetic binary consortia for production of fuels and chemicals from biogas. We expect the knowledge gained from this project may be generally applicable to other cross-feeding binary consortium, and the tools developed can be adapted to study the interactions and dynamics of other multi-organism platforms.

09 BIOMASS FUELS↗
DOE OSTI2026

Biogas Utilization in Refuse Power Plants (BURP 2 )

The BURP 2 project investigated the technical and financial viability of co firing biogas with waste coal for power generation while using carbon capture and sequestration to achieve net negative emissions. A comparative assessment integrating geospatial mapping, technoeconomic analysis, and life cycle analysis was carried out to evaluate retrofitting an existing coal fired facility in West Virginia, versus developing a new greenfield power plant in Kentucky located near a low quality coal resource. The study found that CO 2 capture rates of 90% or higher, in combination with biogas feedstocks such as animal manure, could significantly reduce global warming potential compared to plants using neither biogas nor CO 2 capture systems. Economic feasibility depended heavily on federal tax credits and proximity to fuel sources. In both greenfield and retrofit scenarios, access to biogas played a key role. Because the retrofit site was located close to existing biogas resources, it represented a feasible option, whereas the greenfield site, being far from pipelines or biogas sources, would require prohibitively expensive biogas transport infrastructure. Overall, the research showed that repurposing waste or low-quality coal with renewable biogas and CO 2 capture systems could provide a viable approach for reducing carbon emissions in power production, if biogas resources are easily accessible and available in sufficient quantities.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Treatment of Problematic Reactive Metal Wastes Using GeoMelt ICV - WM2020 Conference Paper

Decommissioning of sodium-cooled reactors and fast reactor technologies has generated a number of reactive metal waste configurations that are problematic to treat and typically lack cost effective treatment methods and disposition options. As a result, Veolia Nuclear Solutions, under contract with Idaho National Laboratory (owned by the U.S. Department of Energy and managed and operated by Battelle Energy Alliance, LLC) demonstrated its GeoMelt® In-Container Vitrification (ICV)™ technology to safely convert sodium metal to a non-reactive vitrified oxide form. The demonstration project, supported by glass formulation and crucible testing, consisted of a series of ICV™ melts that processed elemental sodium into stable non-reactive glass. INL is currently implementing GeoMelt® technology as a means to safely and reliably convert radioactive reactive metal residues that contaminate sodium cooled reactor components into waste forms that comply with existing disposition pathways. Reactive metal wastes require treatment in order to remove the Resource Conservation and Recovery Act (RCRA) reactivity and ignitability characteristics to comply with land disposal restrictions. GeoMelt®, which is an alternative to other potential treatment approaches, provides a robust approach that chemically converts the reactive metals to an inert oxide while also immobilizing radionuclides in a vitrified waste form with durability equal to or better than vitrified nuclear fuel reprocessing wastes (very robust and inert waste forms). Most other treatment approaches generate hydrogen gas which is problematic. In 2016, Veolia Nuclear Solutions first demonstrated the effectiveness of the GeoMelt® ICV™ process in deactivating reactive sodium metal. Crucible, bench-scale, and engineering-scale demonstrations were conducted on several surrogate waste configurations with various ratios of sodium metal and glass-formers. Each ratio and configuration demonstrated complete deactivation of the surrogate sodium metal. Follow-on work in 2017 demonstrated the deactivation of reactive sodium by GeoMelt® ICV™ at a higher waste loading relative to previously demonstrated work performed in 2016; the higher waste loading optimized glass chemistry while enhancing the economical full-scale treatment of reactive metals. Additionally, follow-on demonstration testing in 2018 and 2019 focused on more complex shapes and other reactive-metals (mocked up Experimental Breeder Reactor II [EBR-II] subassembly, sodium filled heat exchanger, and a can containing sodium potassium alloy) which were all performed at engineering-scale. Since 2018, a 10-metric ton full-scale GeoMelt unit (GeoMelt® Richland) was designed, installed, and commissioned at Perma-Fix Northwest in Richland, Washington for the treatment of reactive metal wastes. As of September 2019, over 900 55-gallon drums containing a total of around 3,500 lb of sodium with low levels of radioactivity have been treated at GeoMelt ® Richland, with resulting glass monoliths disposed at the Nevada National Security Site (NNSS). A full-scale radiological demonstration melt on an actual EBR-II subassembly has also been performed using the full-scale melter in 2019. The GeoMelt® technology is a proven radioactive waste treatment technology capable of immobilizing radioactive wastes, including bulk rubble such as drums and other steel vessels usually without pretreatment. Utilizing the GeoMelt® technology to treat reactive metals eliminates pretreatment steps resulting from having to separate the reactive metal from steel containers or jackets as GeoMelt® can easily operate at temperatures sufficient to melt the steel and expose the reactive metal for treatment. Eliminating handling steps of reactive metals is a significant safety advantage since reactive metals are pyrophoric. The results generated as a part of the 2018-2019 demonstration program are presented in the paper.

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

Physical Sciences Vistas Issue 3 2021

In this issue, highlights of our contributions to mission operations include descriptions of the following. • How exact and scrupulous planning in concert with sophisticated science enabled a first-ever direct measurement of a radionuclide with a half-life as short as six days. The work, which included operations at the Los Alamos Neutron Science Centers (LANSCE) Weapons Neutron Research Facility and the Isotope Production Facility’s hot cell facility, is a boon for both astrophysics and weapons science. • An introduction to Christie Davis and her role in ensuring the Lab’s execution of simultaneous excellence. • A look at progress by AOT’s Target and Experimental Support Team in reclaiming long-dormant space in a radiological controlled area for new work improving target systems for the Lujan Center. • A story showcasing a cross-organizational effort to minimize the directorate’s legacy and environmental footprint. Staff from across the Lab joined together to ensure the safe and efficient disposal of Rocky Flats legacy waste stored in a transportainer at the Target Fabrication Facility. • How the Lab’s Utilities and Infrastructure experts collaborated with stakeholders in our directorate to safety execute preventive maintenance on the LANSCE mesa’s large electrical substation. The Safe Conduct of Research principles provided a common framework for the planning and process. • A description of the resources called upon and the procedures undertaken by MPA to inventory the division’s time-sensitive chemicals, including the careful and conscientious response of an alert team member when something seemed amiss.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Modelling the Liquid Waste Operation at the Savannah River Site

Modeling Successes Dounreay – Site Closure Optimization and Risk Reduction Re-structuring and streamlining a complex project plan to achieve site decommissioning in reduced time and at reduced cost, through automated task prioritization. Idaho AMWTP – Multi-stream Optimization Speeding up a complex facility with many process lines, by utilizing all of the process lines more efficiently and reducing overall plant downtime, by coordinating repairs and shutdowns. AWE –Waste Repackaging and Relocation Relocating schedule for waste material from an old storage facility to a new purpose-built one, safely, and in a timely fashion that removed the need to reassure the safety of the old facility. Sellafield – Effluent, Sludge and HAW Treatment Improving a wide range of chemical engineered processes including aqueous effluent treatment, chemically-reactive sludge management and waste vitrification processing. Strategic Petroleum Reserve – Cavern Management Linking chemistry models of petroleum prediction, through engineering cavern management to financial modeling of gasoline sales to benefit US government

Jung, Andrew W.↗
DOE OSTI2020

Treatment of Problematic Reactive Metal Wastes Using the GeoMelt{sup R} In-Container Vitrification (ICV{sup TM}) Process - 20326

Decommissioning of sodium-cooled reactors and fast reactor technologies has generated a number of reactive metal waste configurations that are problematic to treat and typically lack cost effective treatment methods and disposition options. As a result, Veolia Nuclear Solutions, under contract with Idaho National Laboratory (owned by the U.S. Department of Energy and managed and operated by Battelle Energy Alliance, LLC) demonstrated its GeoMelt{sup R} In-Container Vitrification (ICV){sup TM} technology to safely convert sodium metal to a non-reactive vitrified oxide form. The demonstration project, supported by glass formulation and crucible testing, consisted of a series of ICV{sup TM} melts that processed elemental sodium into stable non-reactive glass. INL is currently implementing GeoMelt{sup R} technology as a means to safely and reliably convert radioactive reactive metal residues that contaminate sodium cooled reactor components into waste forms that comply with existing disposition pathways. Reactive metal wastes require treatment in order to remove the Resource Conservation and Recovery Act (RCRA) reactivity and ignitability characteristics to comply with land disposal restrictions. GeoMelt{sup R}, which is an alternative to other potential treatment approaches, provides a robust approach that chemically converts the reactive metals to an inert oxide while also immobilizing radionuclides in a vitrified waste form with durability equal to or better than vitrified nuclear fuel reprocessing wastes (very robust and inert waste forms). Most other treatment approaches generate hydrogen gas which is problematic. In 2016, Veolia Nuclear Solutions first demonstrated the effectiveness of the GeoMelt{sup R} ICV{sup TM} process in deactivating reactive sodium metal. Crucible, bench-scale, and engineering-scale demonstrations were conducted on several surrogate waste configurations with various ratios of sodium metal and glass formers. Each ratio and configuration demonstrated complete deactivation of the surrogate sodium metal. Follow-on work in 2017 demonstrated the deactivation of reactive sodium by GeoMelt{sup R} ICV{sup TM} at a higher waste loading relative to previously demonstrated work performed in 2016; the higher waste loading optimized glass chemistry while enhancing the economical full-scale treatment of reactive metals. Additionally, follow-on demonstration testing in 2018 and 2019 focused on more complex shapes and other reactive-metals (mocked up Experimental Breeder Reactor II [EBR-II] subassembly, sodium filled heat exchanger, and a can containing sodium potassium alloy) which were all performed at engineering scale. Veolia Nuclear Solutions designed, installed, and commissioned in September 2018, at Perma-Fix Northwest in Richland Washington, a 10-metric ton full-scale GeoMelt unit (GeoMelt{sup R} Richland) for the treatment of reactive metal wastes. As of September 2019, over 900 55-gallon drums containing a total of around 3,500 lb of sodium with low levels of radioactivity have been treated at GeoMelt{sup R} Richland, with resulting glass monoliths disposed at the Nevada National Security Site (NNSS). A full-scale radiological demonstration melt on an actual EBR-II subassembly has also been performed using the full-scale melter in 2019. The GeoMelt{sup R} technology is a proven radioactive waste treatment technology capable of immobilizing radioactive wastes, including bulk rubble such as drums and other steel vessels usually without pretreatment. Utilizing the GeoMelt{sup R} technology to treat reactive metals eliminates pretreatment steps resulting from having to separate the reactive metal from steel containers or jackets as GeoMelt{sup R} can easily operate at temperatures sufficient to melt the steel and expose the reactive metal for treatment. Eliminating handling steps of reactive metals is a significant safety advantage since reactive metals are pyrophoric. The results generated as a part of the 2018-2019 demonstration program are presented in the paper. (authors)

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

Plastic waste gasification for low-carbon hydrogen production: a comprehensive review

Hydrogen is one of the most important feedstocks for the chemical industry, power production, and the decarbonization of other sectors that rely on natural gas. The production of hydrogen from plastics enables sustainable use of plastic waste and offers significant environmental benefits. Gasification emerges as a promising route for chemical recycling, converting plastic into hydrogen and other valuable chemicals. Although the gasification of plastic waste has recently gained attention, the number of studies regarding low-carbon hydrogen production is still limited. The effective integration of carbon capture, utilization, and storage (CCUS) is essential for achieving low-carbon hydrogen production via gasification, which enables the efficient capture and storage of CO 2 emissions. Incorporating coal waste and biomass into plastic gasification can synergistically enhance reforming reactions for hydrogen production, reduce tar content, and resolve feeding issues caused by plastic stickiness. Based on the previous studies, this paper briefly reviews the mechanisms of plastic gasification including plastic depolymerization, reforming, tar and char formation, and gasification; the discussions on feedstocks and effects of operating conditions on H 2 production including plastic-type, temperature, steam/carbon ratio, equivalence ratio, and catalysts; and the integration of CCUS and alternative recovery processes in plastic gasification for low-carbon hydrogen.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗