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Hanford Tank Waste Treatment and Immobilization Plant (WTP) Waste Feed Qualification Program Development Approach - 13114

The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is a nuclear waste treatment facility being designed and constructed for the U.S. Department of Energy by Bechtel National, Inc. and subcontractor URS Corporation (under contract DE-AC27-01RV14136 [1]) to process and vitrify radioactive waste that is currently stored in underground tanks at the Hanford Site. A wide range of planning is in progress to prepare for safe start-up, commissioning, and operation. The waste feed qualification program is being developed to protect the WTP design, safety basis, and technical basis by assuring acceptance requirements can be met before the transfer of waste. The WTP Project has partnered with Savannah River National Laboratory to develop the waste feed qualification program. The results of waste feed qualification activities will be implemented using a batch processing methodology, and will establish an acceptable range of operator controllable parameters needed to treat the staged waste. Waste feed qualification program development is being implemented in three separate phases. Phase 1 required identification of analytical methods and gaps. This activity has been completed, and provides the foundation for a technically defensible approach for waste feed qualification. Phase 2 of the program development is in progress. The activities in this phase include the closure of analytical methodology gaps identified during Phase 1, design and fabrication of laboratory-scale test apparatus, and determination of the waste feed qualification sample volume. Phase 3 will demonstrate waste feed qualification testing in support of Cold Commissioning. (authors)

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Hanford WTP LAW Melter Startup and Tuning Feed Material Development - 17065

The U.S. Department of Energy's (DOE) Hanford Site in southeast Washington state is home to 56 million gallons of chemical and radioactive waste stored in underground tanks, the result of more than four decades of plutonium production. To address this challenge, the U.S. Department of Energy contracted Bechtel National, Inc., to design and build the world's largest radioactive waste treatment plant. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) will use vitrification to immobilize most of Hanford's waste. Vitrification involves blending the waste with glass-forming materials, and heating it to high temperature to form molten glass, then pouring it into stainless steel containers. In this glass form, its radioactivity will decay over hundreds to thousands of years. In advance of full operation of WTP, a sequential process of commissioning will be undertaken to ensure the plant operates safely and within design requirements. The first phase of WTP operations will focus on the Low-Activity Waste (LAW) Vitrification Facility and its supporting facilities and systems. Commissioning of the LAW Facility will employ a progressive approach to address the complexity of system operation and introduction of hazards. This approach starts with introduction of low hazard and simple testing configurations, and incrementally increasing the complexity and hazardous makeup of testing feed materials, culminating in fully integrated treatment of radioactive tank waste during hot commissioning. Testing with simulants that are chemically similar to radioactive tank waste introduces significant chemical hazards into treatment systems in the form of nitrogen oxides (NOx) and anhydrous ammonia. A method of testing to allow tuning and demonstration of equipment and to develop operator proficiency prior to introducing these chemical hazards was deemed necessary. To that end, the development and testing of a new 'tuning feed' material is in progress. The tuning feed is important because its use will enable the first-time integration of all LAW Facility process systems. The tuning feed must include key physical and chemical characteristics that correspond to the commissioning simulant and low activity tank waste, without the inherently hazardous materials or toxic off-gas constituents that result from tank waste treatment. Tuning feed is being developed to provide representative melter feed rheology, glass chemistry, cold cap formation, and off-gas generation rate in order to predict system response to actual tank waste to the extent practical. The tuning feed must also be compatible with process equipment and other process streams that will be encountered during the cold commissioning testing program. (authors)

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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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WTP Waste Feed Qualification: Glass Fabrication Unit Operation Testing Report

The waste feed qualification program is being developed to protect the Hanford Tank Waste Treatment and Immobilization Plant (WTP) design, safety basis, and technical basis by assuring waste acceptance requirements are met for each staged waste feed campaign prior to transfer from the Tank Operations Contractor to the feed receipt vessels inside the Pretreatment Facility. The Waste Feed Qualification Program Plan describes the three components of waste feed qualification: 1. Demonstrate compliance with the waste acceptance criteria 2. Determine waste processability 3. Test unit operations at laboratory scale. The glass fabrication unit operation is the final step in the process demonstration portion of the waste feed qualification process. This unit operation generally consists of combining each of the waste feed streams (high-level waste (HLW) and low-activity waste (LAW)) with Glass Forming Chemicals (GFCs), fabricating glass coupons, performing chemical composition analysis before and after glass fabrication, measuring hydrogen generation rate either before or after glass former addition, measuring rheological properties before and after glass former addition, and visual observation of the resulting glass coupons. Critical aspects of this unit operation are mixing and sampling of the waste and melter feeds to ensure representative samples are obtained as well as ensuring the fabrication process for the glass coupon is adequate. Testing was performed using a range of simulants (LAW and HLW simulants), and these simulants were mixed with high and low bounding amounts of GFCs to evaluate the mixing, sampling, and glass preparation steps in shielded cells using laboratory techniques. The tests were performed with off-the-shelf equipment at the Savannah River National Laboratory (SRNL) that is similar to equipment used in the SRNL work during qualification of waste feed for the Defense Waste Processing Facility (DWPF) and other waste treatment facilities at the Savannah River Site. It is not expected that the exact equipment used during this testing will be used during the waste feed qualification testing for WTP, but functionally similar equipment will be used such that the techniques demonstrated would be applicable. For example, the mixing apparatus could use any suitable mixer capable of being remoted and achieving similar mixing speeds to those tested.

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RPP-PRT-58489, Revision 1, One Systems Consistent Safety Analysis Methodologies Report. 24590-WTP-RPT-MGT-15-014

In 2012, One System Nuclear Safety performed a comparison of the safety bases for the Tank Farms Operations Contractor (TOC) and Hanford Tank Waste Treatment and Immobilization Plant (WTP) (RPP-RPT-53222 / 24590-WTP-RPT-MGT-12-018, “One System Report of Comparative Evaluation of Safety Bases for Hanford Waste Treatment and Immobilization Plant Project and Tank Operations Contract”), and identified 25 recommendations that required further evaluation for consensus disposition. This report documents ten NSSC approved consistent methodologies and guides and the results of the additional evaluation process using a new set of evaluation criteria developed for the evaluation of the new methodologies.

61 RADIATION PROTECTION AND DOSIMETRY↗

Evaluation of Immobilizing Secondary Waste from a Proposed Treatment Process for Hanford WTP LAW Melter Condensate

The off-gas system in the Low Activity Waste (LAW) vitrification facility at the Hanford Waste Treatment and Immobilization Plant (WTP) will generate an aqueous condensate recycle stream. Two unit operations generate this condensate, a Submerged Bed Scrubber and a Wet Electrostatic Precipitator (LAW SBSWESP condensate). The expected disposition of this stream during baseline operations is to send it to the WTP Pretreatment Facility, where it will be blended with LAW, concentrated by evaporation and recycled to the LAW vitrification facility again. The primary reason to recycle this stream is to immobilize the semivolatile 99 Tc isotope into the glass. During the Direct Feed Low Activity Waste (DFLAW) portion of the mission, the condensate is sent to the Effluent Management Facility (EMF) where it is evaporated then recycled to the LAW facility where the evaporated condensate is combined with the LAW feed from the pretreatment system.

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DFLAW Glass and Feed Qualifications to Support WTP Start-Up and Flow-Sheet Development (Final Report, Rev. 0)

In each test, a distinct feed composition was used to determine the effects of feed composition changes on the retention of technetium and other species as detailed in the Test Plan for this work. Key operating parameters such as the glass temperature (nominally 1150°C) were held constant to investigate the effect of each new feed composition on the retention of technetium. The processing rate was maintained at ≈2,250 kg/m 2 /day of glass, which corresponds to the “stretch-goal” rate of 22.5 MT/day specified by ORP for the WTP LAW melter, or ≈2,000 kg/m 2 /day of glass, which corresponds to the enhanced baseline specified by ORP for the WTP LAW melter (as compared to the nominal 1500 kg/m 2 /day). The bubbling rate was adjusted to achieve a near-complete cold-cap (90-100% of melt surface covered with feed). Quantitative measurements of glass production rates, melter operating conditions (temperatures, pressures, power, flows, etc.), gaseous emissions by Fourier Transform Infrared Spectroscopy (FTIR), and particulate emissions using Environmental Protection Agency (EPA) methods were made for each test. Discharged and melt pool glass samples were inspected for formation of any salt phases and analyzed for chemical composition, including technetium content. Samples of the process fluids from each of the off-gas treatment system components were collected and analyzed. Following each test, the off-gas system was partially disassembled and extensively sampled for any residual feed components residing within the off-gas system. Sampling and analysis during and subsequent to each test was intended to be sufficient for supporting a mass balance for all constituents of interest and particularly technetium, rhenium, iodine, sulfur, chlorine, and fluorine. Additional sampling and analysis of evaporator concentrates and condensates was conducted for various organic compounds.

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DFLAW Glass and Feed Qualifications for AP-107 to Support WTP Start-Up and Flow-Sheet Development (VSL-18R4500-1, Rev 0)

About 50 million gallons of high-level mixed waste is currently stored in underground tanks at The United States Department of Energy’s (DOE’s) Hanford site in the State of Washington. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) will provide DOE’s Office of River Protection (ORP) with a means of treating this waste by vitrification for subsequent disposal. The tank waste will be separated into low- and high-activity waste fractions, which will then be vitrified respectively into Immobilized Low Activity Waste (ILAW) and Immobilized High Level Waste (IHLW) products. The ILAW product will be disposed in an engineered facility on the Hanford site while the IHLW product is designed for acceptance into the national deep geological disposal facility for high-level nuclear waste. The ILAW and IHLW products must meet a variety of requirements with respect to protection of the environment before they can be accepted for disposal. The Low Activity Waste (LAW) at Hanford will be vitrified in a Joule Heated Ceramic Melter (JHCM) to produce a stable product for safe disposal. Although present in relatively small amounts, a few key constituents in the LAW streams play particularly important roles. Sulfur, chlorine, and fluorine can have significant impacts on LAW glass formulation and waste loadings, while technetium and iodine are important for waste form performance, with technetium being the constituent of most concern with respect to waste disposal in the Integrated Disposal Facility (IDF). The IDF is designed to accept ILAW, secondary waste associated with ILAW production, and other on-site Hanford Non-Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) waste. As a result of volatilization of these species during the vitrification process, they are also present in significant amounts in the liquid effluents from the off-gas treatment system. Understanding the fraction of each constituent incorporated in the LAW glass or in WTP liquid effluents is critical for assessing the performance of waste forms to be disposed in the IDF. Liquid effluents from the LAW vitrification process that are not recycled will likely be solidified to produce a secondary waste form that is not as chemically durable as glass. Therefore, understanding partitioning of the key constituents between the glass and non-glass waste forms is a significant factor in the Performance Assessment (PA) for the Hanford IDF. Clearly, it is preferable to incorporate as much of the technetium into the glass as possible because of the superior chemical durability of that waste form. The objective of the present work is to improve the understanding of the partitioning of technetium and other key waste constituents between the glass and non-glass waste forms.

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Recommendations for Reduction in Radionuclide Analyte Analysis in Support of WTP Operations

In support of Hanford Tank Waste Treatment and Immobilization Plant (WTP) direct feed low-activity waste operations, this document seeks to provide a discussion on currently required radionuclide sample analyses and which, if any, are planned but may not be needed. The total number of analyses is more than 10,000 per year and, often, this analytical endeavor is difficult due to troublesome components. Such components cause issues due to low concentrations, difficulty of analysis, lack of standards, or other reasons. One of the main goals is to remove onerous or troublesome components that are present in low enough concentrations to not pose a threat of the resulting waste form being non-compliant if not measured. Additionally, if it can be demonstrated that the large number of analyses is not needed, then that will save hold times in operations, decrease the amount of money required for operations, and reduce potential exposure for plant staff or researchers. Suggestions are provided for radionuclide analytes that may not be needed and can be safely estimated from process knowledge documented in the best basis inventory. The analytes recommended for removal were determined via calculations using batch feed estimates from the Tank Utilization Assessment of 2013. Approximately 750 feed estimates, representing waste compositions throughout the lifetime of the Hanford mission, were analyzed, and radionuclide concentrations were compared against established reporting and contractual limits as specified in the WTP contract. Analytes that were found to be consistently below the limits include many transuranic radionuclides and other radionuclides present in the waste in small concentrations. A total of 23 of the 44 radionuclides in the batch estimates were not significant in all batch feeds.

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Development And Initial Testing Of Off-Gas Recycle Liquid From The WTP Low Activity Waste Vitrification Process - 14333

The Waste Treatment and Immobilization Plant (WTP) process flow was designed to pre-treat feed from the Hanford tank farms, separate it into a High Level Waste (HLW) and Low Activity Waste (LAW) fraction and vitrify each fraction in separate facilities. Vitrification of the waste generates an aqueous condensate stream from the off-gas processes. This stream originates from two off-gas treatment unit operations, the Submerged Bed Scrubber (SBS) and the Wet Electrospray Precipitator (WESP). Currently, the baseline plan for disposition of the stream from the LAW melter is to recycle it to the Pretreatment facility where it gets evaporated and processed into the LAW melter again. If the Pretreatment facility is not available, the baseline disposition pathway is not viable. Additionally, some components in the stream are volatile at melter temperatures, thereby accumulating to high concentrations in the scrubbed stream. It would be highly beneficial to divert this stream to an alternate disposition path to alleviate the close-coupled operation of the LAW vitrification and Pretreatment facilities, and to improve long-term throughput and efficiency of the WTP system. In order to determine an alternate disposition path for the LAW SBS/WESP Recycle stream, a range of options are being studied. A simulant of the LAW Off-Gas Condensate was developed, based on the projected composition of this stream, and comparison with pilot-scale testing. The primary radionuclide that vaporizes and accumulates in the stream is Tc-99, but small amounts of several other radionuclides are also projected to be present in this stream. The processes being investigated for managing this stream includes evaporation and radionuclide removal via precipitation and adsorption. During evaporation, it is of interest to investigate the formation of insoluble solids to avoid scaling and plugging of equipment. Key parameters for radionuclide removal include identifying effective precipitation or ion adsorption chemicals, solid-liquid separation methods, and achievable decontamination factors. Results of the radionuclide removal testing indicate that the radionuclides, including Tc-99, can be removed with inorganic sorbents and precipitating agents. Evaporation test results indicate that the simulant can be evaporated to fairly high concentration prior to formation of appreciable solids, but corrosion has not yet been examined.

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The WTP Immobilized LAW Formulation Algorithm: Recent Efforts Toward Software Development - 17342

The immobilized low-activity waste (ILAW) product from WTP must meet certain requirements and processing constraints. The strategy for controlling ILAW product composition uses the ILAW formulation algorithm. This algorithm is approved by the DOE Office of River Protection (ORP) for use in calculating melter feed recipes that will produce acceptable ILAW product during Low-Activity Waste (LAW) Facility commissioning. The calculations performed by the algorithm have been demonstrated using a sophisticated spreadsheet, but this spreadsheet is not expected to support continuous operation. Efforts are underway to develop software that will support glass formulation during operation. Recent work toward software development includes an examination of assumptions made in the algorithm about expected LAW Facility operation, and spreadsheet calculations to formulate glass for potential LAW compositions under the direct feed LAW (DFLAW) strategy that ORP has adopted. The documentation of the ILAW algorithm is the planned basis for software development. However, some assumptions made in the current algorithm's mass balance logic do not match the matured design and expected operation of the LAW Facility. A self-assessment effort evaluated the validity of these assumptions by reviewing design documents, in order to identify opportunities to align the algorithm's mass balance logic with the matured design and ensure that the developed software supports continuous LAW Facility operation. Several improvement opportunities were identified and are discussed. The results of ILAW algorithm calculations to formulate glass for eighteen challenging LAW compositions indicate that the current WTP baseline LAW glass models are sufficiently robust to accommodate DFLAW. (authors)

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Initial Testing of Off-Gas Recycle Condensate Liquid from the WTP Low Activity Waste Vitrification Process - 16432

The Waste Treatment and Immobilization Plant (WTP) under construction at the Hanford site is designed to treat and immobilize the inventory of High-Level Waste stored in the 177 underground storage tanks. The WTP process flow was designed to pre-treat this waste, separating it into High Level Waste (HLW) and Low Activity Waste (LAW) fractions for vitrification. Vitrification of the waste generates a condensate stream from the off-gas processes originating from two off-gas treatment unit operations, the Submerged Bed Scrubber (SBS) and the Wet Electrostatic Precipitator (WESP). The baseline plan for disposition of the stream from the LAW melter is to recycle it to the Pretreatment facility where it gets evaporated and processed through the LAW melter again. If the Pretreatment facility is unavailable, this baseline disposition pathway is not viable. Additionally, chloride, fluoride, and sulfate are partially volatile in the melter, accumulating to high concentrations while recycling and impacting the glass waste loading and facility throughput. The primary radionuclide that volatizes and accumulates is {sup 99}Tc. The long half-life and environmental mobility of {sup 99}Tc complicates disposal options for this secondary aqueous waste stream. This task is investigating {sup 99}Tc removal to examine the potential for diverting this stream to an alternate disposition path and avoiding impacting the glass waste loading. Separation methods for {sup 99}Tc have focused on using inorganic precipitation agents that can remove it by reducing it from soluble pertechnetate ion, with a +7 oxidation state, to insoluble technetium dioxide in the +4 oxidation state. Stannous chloride (SnCl{sub 2}) has been found highly effective at causing the reduction and precipitating {sup 99}Tc for removal, but it also precipitates other components. The primary competitor that precipitates is chromium, which consumes the redox activity of the Sn(II), causing addition of more of the SnCl{sub 2}. Research has examined the optimum quantity of SnCl{sub 2}, mixing time, and the impact of other redox-active species. It is also important to know the stability of the precipitated {sup 99}Tc in process conditions, since it is expected it will eventually be re-oxidized by oxygen and dissolve. This work is expected to determine if a {sup 99}Tc removal step could be used to decontaminate the bulk of this stream, and make it suitable for other disposal paths so that the chloride, fluoride, and sulfate can be diverted away from the glass melter. (authors)

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Transitioning from Construction to Startup at WTP from a Plant Engineering Perspective - 16461

The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is a one-of-a-kind facility being designed, built and commissioned for the U.S. Department of Energy by Bechtel National, Inc. and principal subcontractor URS to solidify liquid radioactive waste stored in underground tanks at the Hanford Site. WTP consists of 20 infrastructure facilities and structures, known as Balance of Facilities, designed to support the Plant's four major facilities - Pretreatment Facility, High-Level Waste Vitrification Facility, Low-Activity Waste Vitrification Facility and the Analytical Laboratory. As construction moves toward startup and commissioning, a turnover process facilitates the transition of facilities and systems between organizations. The transition from Construction is initiated by an approved Design Completion List, which documents that design and construction have been completed, and the facility or system is ready for startup testing. Qualified individuals perform an inspection to ensure the facility or system has been constructed per the design during an eight-week engineering walk-down. During this phase in turnover, Plant Engineering personnel are responsible for updating and maintaining the Master Equipment List, developing spare parts recommendations, developing and issuing instrument calibration data sheets, evaluating temporary modifications, and supporting plant operations and maintenance activities. As of 2015, two electrical switchgear buildings and the non-radioactive liquid waste disposal system have been turned over from Construction to Startup. This paper discusses the turnover process, organizational interfaces, and experiences from a Plant Engineering perspective. (authors)

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Technetium Retention in WTP LAW Glass with Recycle Flow-Sheet: DMIO Melter Testing

Melter tests were conducted to determine the retention of technetium and other volatiles in glass while processing simulated Low Activity Waste (LAW) streams through a DM10 melter equipped with a prototypical off-gas system that concentrates and recycles fluid effluents back to the melter feed. To support these tests, an existing DM10 system installed at Vitreous State Laboratory (VSL) was modified to add the required recycle loop. Based on the Hanford Tank Waste Treatment and Immobilization Plant (WTP) LAW off-gas system design, suitably scaled versions of the Submerged Bed Scrubber (SBS), Wet Electrostatic Precipitator (WESP), and TLP vacuum evaporator were designed, built, and installed into the DM10 system. Process modeling was used to support this design effort and to ensure that issues associated with the short half life of the 99m Tc radioisotope that was used in this work were properly addressed and that the system would be capable of meeting the test objectives. In particular, this required that the overall time constant for the system was sufficiently short that a reasonable approach to steady state could be achieved before the 99m Tc activity dropped below the analytical limits of detection. The conceptual design, detailed design, flow sheet development, process model development, Piping and Instrumentation Diagram (P&ID) development, control system design, software design and development, system fabrication, installation, procedure development, operator training, and Test Plan development for the new system were all conducted during this project. The new system was commissioned and subjected to a series of shake-down tests before embarking on the planned test program. Various system performance issues that arose during testing were addressed through a series of modifications in order to improve the performance and reliability of the system. The resulting system provided a robust and reliable platform to address the test objectives.

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Phase 2 testing results of immobilization of WTP effluent management facility vaporator bottoms simulant

The Hanford Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) vitrification facility will generate an aqueous condensate recycle stream (LAW Melter Off-Gas Condensate) from the primary off-gas system. This work examined three waste form formulations based on previous testing with related simulants: 8 wt% ordinary portland cement (OPC), 47 wt% blast furnace slag (BFS), 45 wt% fly ash (FA) known as Cast Stone formulation; 20 wt% Aquaset® II-GH and 80 wt% BFS; 20 wt% OPC and 80 wt% BFS. These tests successfully produced one waste form that set within five days (Cast Stone formulation); however the other two formulations, Aquaset® II-GH/BFS and OPC/BFS, took approximately eight and fourteen days to set, respectively.

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Ammonia Remediation in Hanford WTP Liquid Secondary Waste

The Hanford Site Effluent Treatment Facility (ETF) treats aqueous waste streams; some of these waste streams have high concentrations of ammonium ion. When the WTP begins operation the ETF LSW is slated to be stabilized by grouting prior to disposal. During stabilization of such waste by grouting the pH would rise considerably, leading to the evolution of ammonia gas. Such an ammonia release would require engineering controls to assure worker and environmental safety. The primary objective of this work was to perform a parametric study of the efficacy of ammonia destruction from solution using sodium nitrite addition under varying conditions that expands upon previous work.

54 ENVIRONMENTAL SCIENCES↗

Regulatory Spike Testing of RPP-WTP LAW and HLW Glasses for Compliance with Land Disposal Restrictions, VSL-03R3760-1, Rev. 1

The United States Department of Energy’s (DOE’s) Hanford site is the current location of storage of about 50 million gallons of mixed waste. This waste is stored in underground tanks at the Hanford site and is both a listed and characteristic waste, as defined in 40 CFR Part 261, and a dangerous waste according to Chapter 173-303 of the Washington Administrative Code (WAC). The waste is also subject to the Land Disposal Restrictions (LDR) (40 CFR Part 268 and WAC 173-303-140). The River Protection Project - Waste Treatment Plant (RPP-WTP) will provide DOE with a means for treating this waste by vitrification (for subsequent disposal). The tank waste will be partitioned into low and high activity fractions, which will then be vitrified respectively into Immobilized Low Activity Waste (ILAW) and Immobilized High Level Waste (IHLW) products. The ILAW product will be disposed of in an engineered facility on the Hanford site while the IHLW product will be directed to the national deep geological disposal facility for high level nuclear waste. The ILAW and IHLW products must meet a variety of requirements with respect to protection of the environment.

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