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DOE OSTI2022

Glass Crystallization Constraints for WTP LAW Operations: Assessment of Isothermal Treatments on Crystal Formation

Much work has been done to expand the glass composition region available for operation of the Hanford Tank Waste Treatment and Immobilization Plant. This includes the development of updated glass property-composition models as well as constraints. This report supports this effort by suggesting constraints for avoiding excessive, and likely detrimental, crystallization during melter operation while processing advanced low-activity glasses. The constraints target Cassiterite and ZrO 2 -containing phases (ZCP, e.g., Baddeleyite and Zircon) that can form when melter temperatures drop below 1100 °C. These types of crystals were found to be potentially detrimental during processing as they are denser than low-activity waste glass melts; with densities of 6.95 g/cm 3 for Cassiterite and 5.68 g/cm 3 for Baddeleyite (the most prevalent ZCP). Compared to melt densities of approximately 2.65 g/cm 3 . Thus, they have the potential to form during melter idling and settle to the bottom of the melter or inside the melter. If the crystals are present in appreciable amounts, they can result in blockages of the pour-spout riser, which impacts glass pouring and melter operation. Additionally, SnO 2 and ZrO 2 are added to glass formulations to improve glass durability. Their precipitation from the melt may reduce overall glass durability. Using previously acquired results and results from testing during this effort, the following constraints (Table S.1) were determined and are recommended to reduce the risk of forming crystals of the types and concentrations that are likely detrimental to melter operation.

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DOE OSTI2024

Integrated Off-Gas System Tests on the DM1200 Melter with RPP-WTP LAW Sub-Envelope Bl Simulants, VSL-03R3851-1, Rev. 0 (Oct 2003)

The report documents melter and off-gas performance results obtained on the DM1200 melter during processing of LAW Sub-Envelope B1 feed. The principal objectives of the DM1200 melter testing were to demonstrate suitable processing and production rates for LAW B1 feed; characterize the glass product for elemental composition; measure elemental emission rates and decontamination factors (DFs) across the melter and off-gas treatment components; and provide additional data on the performance of the thermal catalytic oxidation and selective catalytic reduction (TCO/SCR) unit efficiency in treating organic emissions. The feed was spiked with organic compounds for part of the testing duration. All data were collected for use in engineering and system design purposes. No sampling and analysis to collect environmental data was performed during these tests.

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DOE OSTI2024

Regulatory Testing of WTP HL W Glasses for Compliance with Delisting Requirements, VSL-03R3780-1, Rev. 1

(Part of the data collected for this work and discussed in this report was subject to data quality and bias issues. All the affected tests have subsequently been repeated, as directed by the Waste Treatment Plant Project, and new statistical analyses have been performed on the revised data set. A subsequently-issued report supercedes this report and describes the revised data, together with the revised composition-property models (Kot et al. 2004). The reader should refer to the new report for discussion of the revised data set and composition-property (TCLP cadmium release) models. None of the data for the spike glasses, designed for Case 1 and Case 2 COPCs testing, were affected by this issue.)

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DOE OSTI2024

Integrated Off-Gas System Tests on the DM1200 Melter with RPP-WTP LAW Sub-Envelope C1 Simulants (Final Report)

The report documents melter and off-gas performance results obtained on the DM1200 during processing of LAW Sub-Envelope Cl feed. The principal objectives of the DM1200 melter testing were to demonstrate suitable processing and production rates for LAW Cl feed; characterize the glass product for elemental composition, the presence of organic compounds, and TCLP response for metals; and measure destruction and removal efficiencies (DREs) for organic compounds across the melter and off-gas treatment components. The feed was spiked with organic compounds for part of the testing duration. Data were collected for both process engineering needs and to support regulatory activities. The data needed for regulatory support were collected using EPA methods and independent data analyses and data checking were performed.

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DOE OSTI2016

INITIAL TESTING OF OFF-GAS RECYCLE CONDENSATE LIQUID FROM THE WTP LOW ACTIVITY WASTE VITRIFICATION PROCESS - 16432

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McCabe, D.↗

DOE OSTI2012

2020 Vision for Tank Waste Cleanup (One System Integration) - 12506

The mission of the Department of Energy's Office of River Protection (ORP) is to safely retrieve and treat the 56 million gallons of Hanford's tank waste and close the Tank Farms to protect the Columbia River. The millions of gallons of waste are a by-product of decades of plutonium production. After irradiated fuel rods were taken from the nuclear reactors to the processing facilities at Hanford they were exposed to a series of chemicals designed to dissolve away the rod, which enabled workers to retrieve the plutonium. Once those chemicals were exposed to the fuel rods they became radioactive and extremely hot. They also couldn't be used in this process more than once. Because the chemicals are caustic and extremely hazardous to humans and the environment, underground storage tanks were built to hold these chemicals until a more permanent solution could be found. The Cleanup of Hanford's 56 million gallons of radioactive and chemical waste stored in 177 large underground tanks represents the Department's largest and most complex environmental remediation project. Sixty percent by volume of the nation's high-level radioactive waste is stored in the underground tanks grouped into 18 'tank farms' on Hanford's central plateau. Hanford's mission to safely remove, treat and dispose of this waste includes the construction of a first-of-its-kind Waste Treatment Plant (WTP), ongoing retrieval of waste from single-shell tanks, and building or upgrading the waste feed delivery infrastructure that will deliver the waste to and support operations of the WTP beginning in 2019. Our discussion of the 2020 Vision for Hanford tank waste cleanup will address the significant progress made to date and ongoing activities to manage the operations of the tank farms and WTP as a single system capable of retrieving, delivering, treating and disposing Hanford's tank waste. The initiation of hot operations and subsequent full operations of the WTP are not only dependent upon the successful design and construction of the WTP, but also on appropriately preparing the tank farms and waste feed delivery infrastructure to reliably and consistently deliver waste feed to the WTP for many decades. The key components of the 2020 vision are: all WTP facilities are commissioned, turned-over and operational, achieving the earliest possible hot operations of completed WTP facilities, and supplying low-activity waste (LAW) feed directly to the LAW Facility using in-tank/near tank supplemental treatment technologies. A One System Integrated Project Team (IPT) was recently formed to focus on developing and executing the programs that will be critical to successful waste feed delivery and WTP startup. The team is comprised of members from Bechtel National, Inc. (BNI), Washington River Protection Solutions LLC (WRPS), and DOE-ORP and DOE-WTP. The IPT will combine WTP and WRPS capabilities in a mission-focused model that is clearly defined, empowered and cost efficient. The genesis for this new team and much of the 2020 vision is based on the work of an earlier team that was tasked with identifying the optimum approach to startup, commissioning, and turnover of WTP facilities for operations. This team worked backwards from 2020 - a date when the project will be completed and steady-state operations will be underway - and identified success criteria to achieving safe and efficient operations of the WTP. The team was not constrained by any existing contract work scope, labor, or funding parameters. Several essential strategies were identified to effectively realize the one-system model of integrated feed stream delivery, WTP operations, and product delivery, and to accomplish the team's vision of hot operations beginning in 2016: - Use a phased startup and turnover approach that will allow WTP facilities to be transitioned to an operational state on as short a timeline as credible. - Align Tank Farm (TF) and WTP objectives such that feed can be supplied to the WTP when it is required for hot operations. - Ensure immobilized waste and waste recycle streams can be received by the TF when required to support 2016 production of immobilized low-activity waste (ILAW). - Ensure the required baseline and additional funding is provided beginning in fiscal year 2011. - Modify TF and WTP contracts to adequately address this vision. The 2020 Vision provides a summary of strategies and key actions that optimize the approach to startup, commissioning, and turnover of WTP facilities. This vision focuses on the legally enforceable requirement to achieve the Consent Decree milestones of starting radioactive operations in 2019, and achieving initial WTP operations in 2022. (authors)

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DOE OSTI2016

Calcium Phosphate Constraints in HLW Glasses: Phosphate Liquidus Model

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 a national geological disposal facility for high-level nuclear waste. The ILAW and IHLW products must meet a variety of requirements before they can be accepted for disposal. Glass property-composition models will be used to control the vitrification process at the WTP to ensure that the glass meets product quality and processability requirements. The quality and the validity ranges of the property-composition models and the supporting database will greatly influence waste treatment operations, including the waste loading that is achievable in the glass for each waste composition. The current baseline models for operation of the WTP were developed under the Bechtel National, Inc. (BNI) WTP contract. These models were based on LAW and HLW glass property data over a range of compositions that was guided primarily by the WTP contract and the set of tanks specified therein. The HLW testing was directed towards waste streams from the then-planned early feed tanks for the WTP (i.e., AZ-101, AZ-102, C-106/AY-102, and C-104/AY-101). These wastes are high in iron (AZ-101, AZ-102, and C-106/AY-102) or thorium (C-104/AY-101). While the baseline models may be adequate for commissioning of the facility and processing of the specified tanks, refinements and extensions or augmentations of these models will be required to process the balance of the tank waste inventory. The overall mission of the WTP will require the immobilization of tank waste compositions that are variously dominated by mixtures of aluminum, chromium, bismuth, iron, phosphorous, zirconium, and sulfur compounds as waste-loading-limiting components. Further, the WTP contract includes minimum waste loading requirements that are generally rather modest while loadings significantly higher than those in the current baseline are likely achievable. In order to achieve these higher waste loadings and to expand the applicable composition regions, new models will be needed to support the optimized operation of the WTP. Since the development of the baseline WTP models, ORP directed a program of work at the Vitreous State Laboratory (VSL) to examine various approaches for optimization of the performance of the WTP, including increasing the waste loadings in the LAW and HLW glass products. That work involved HLW rich in Al, Al+Na, Cr, Bi, S, Zr, Sr, P and Fe, in contrast to old baseline models that were based mostly on HLW tanks that were high in Fe, with one other that was also high in Th. Glass property data collected under the ORP program were compiled and combined with data collected to develop the WTP models. The combined databases have been used to update pre-existing HLW composition models or to develop new models for properties such as Product Consistency Test (PCT) responses, spinel crystallization (one-percent crystal fraction temperature, T 1% ), melt viscosity, melt electrical conductivity, nepheline formation upon slow cooling (i.e., Canister Centerline Cooling [CCC]), and Toxicity Characteristic Leach Procedure (TCLP) Cd response. While spinel is typically the most commonly occurring phase in HLW glasses, other phases can be limiting depending on the waste and glass composition. For example, various phosphate phases can become important as the phosphorus content increases. Lithium phosphate crystallization can impact PCT releases of HLW glasses, while calcium phosphate phases forming in the cold-cap can deleteriously impact feed processing in the melter. At present, however, no models exist that relate glass composition and crystallization of phosphate phases in general and calcium phosphate in particular. The present work was therefore directed towards the initial development of such models. Future work may be directed at studying amorphous phase separation in high phosphate HLW glasses. Within the River Protection Project, feed compositions are projected using the Hanford Tank Waste Operations Simulator (HTWOS), a dynamic computer model that tracks the waste through storage, retrieval, feed staging, and treatment processes. A review of the HTWOS data shows that WTP will process 4106 batches of HLW glass for the overall mission (System Plan Rev. 6, ORP-11242), each with its own waste feed and glass composition. Some of the projected HTWOS feed batches are expected to have relatively high concentrations of phosphorous compared to typical HLW streams. In the 4106 batches of HLW for the overall WTP mission P 2 O 5 varies from 0.59 wt% to 13.00 wt%, with 95 batches containing at least 10 wt% P 2 O 5 . Occurrences of phosphate crystals have commonly been noted in glasses with high bismuth and phosphorus contents. In addition, recently collected data from a set of statistically designed HLW matrix glasses prepared and characterized to support enhancement of the HLW glass property-composition models identified apatite in a number of glass samples. However, the current HLW model for crystallization (one-percent crystal fraction temperature) is applicable only to spinel crystallization in glasses. Previous projections of waste loadings and glass volume (such as those in System Plan Rev. 6, ORP-11242) have used preliminary constraints for calcium phosphate crystallization that are based on the limited available data. Additional data and improved constraints or, preferably, models that relate glass composition to crystallization of phosphate-containing phases, are therefore needed to support HLW vitrification at the WTP. The present study focuses on the development of such a model based on data from previously characterized glasses and a set of newly fabricated glasses.

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DOE OSTI2018

Progress Updates for the Hanford Waste Treatment and Immobilization Plant Project - 18327

The Waste Treatment and Immobilization Plant (WTP) Project is vital to the U.S. Department of Energy's (DOE) mission to cleanup radioactive waste at the Hanford Site, located in southeastern Washington State. The overall WTP Project objective is to design, build, and commission the facilities and systems that will treat and immobilize approximately 56 million gallons of radioactive waste stored in Hanford's 177 underground storage tanks. The combination of technologies in the WTP makes it a first-of-a-kind facility at a scale larger than ever, built for radioactive waste processing. DOE is proceeding with its approach to complete the WTP Project in phases, which includes the following principal actions: - Completing construction of the Low-Activity Waste (LAW) Facility, Balance of Facilities (BOF), and Analytical Laboratory (LAB) (collectively referred to as LBL); - Implementing a direct-feed low-activity waste (DFLAW) process to treat low-activity waste independent of the Pretreatment (PT) Facility; - Resolving the technical issues associated with primarily the PT Facility; - Completing the design and construction of the High-Level Waste (HLW) and PT facilities to enable integrated WTP operations. In March 2016, a federal judge amended the 2010 Consent Decree 1 completion milestones for the Hanford WTP, which generally aligns with DOE's plans for completing the WTP facilities in sequence: - Complete LAW Facility hot commissioning: December 31, 2023; - Complete HLW Facility hot commissioning: December 31, 2033; - Complete PT Facility hot commissioning: December 31, 2033; - Achieve initial plant operations for the WTP: December 31, 2036. Having established milestones for completing the WTP facilities has enabled DOE to formally implement its plans for completing the WTP facilities in sequence, starting with the LAW Facility. In December 2016, DOE executed a contract modification and approved a change to the project's performance baseline to complete the LBL facilities and incorporate modifications needed to allow direct feed of low-activity waste to the LAW Facility. Significant progress has been made toward completing the design, construction, and planning for commissioning of the facilities needed to enable the DFLAW operations to commence as early as January 2022. In 2012, DOE partially suspended production work on the WTP's PT Facility and to a lesser degree the HLW Facility because of unresolved technical issues associated with those facilities. In September 2017, DOE acknowledged the WTP contractor had met all the criteria for full resumption of engineering, procurement, and construction (EPC) activities for the HLW Facility. By December 2017, DOE had completed the actions needed to resolve the six of the eight primary technical issues associated with the PT Facility, with the remaining two issues expected to be resolved in the first quarter of 2018. Although significant progress has been made to prepare for resuming production activities for the HLW and PT facilities, DOE has made the decision to constrain EPC work on those facilities in the near term based on DOE's higher priority of completing the WTP facilities needed to begin DFLAW operations. (authors)

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DOE OSTI2011

Evaluation of THOR TM Mineralized Waste Forms (Granular and Monolith) for the DOE Advanced Remediation Technologies (ART) Phase 2 Project

The U.S. Department of Energy's (DOE) Office of River Protection (ORP) is responsible for the retrieval, treatment, immobilization, and disposal of Hanford's tank waste. Currently there are approximately 56 million gallons of highly radioactive mixed wastes awaiting treatment. A key aspect of the River Protection Project (RPP) cleanup mission is to construct and operate the Waste Treatment and Immobilization Plant (WTP). The WTP will separate the tank waste into high-level and low-activity waste (LAW) fractions, both of which will subsequently be vitrified. The projected throughput capacity of the WTP LAW Vitrification Facility is insufficient to complete the RPP mission in the time frame required by the Hanford Federal Facility Agreement and Consent Order, also known as the Tri-Party Agreement (TPA), i.e. December 31, 2047. Therefore, Supplemental Treatment is required both to meet the TPA treatment requirements as well as to more cost effectively complete the tank waste treatment mission. The Supplemental Treatment chosen will immobilize that portion of the retrieved LAW that is not sent to the WTP's LAW Vitrification facility into a solidified waste form. The solidified waste will then be disposed on the Hanford site in the Integrated Disposal Facility (IDF). In addition, the WTP LAW Vitrification facility off-gas condensate known as WTP Secondary Waste (WTP-SW) will be generated and enriched in volatile components such as Cs-137, I-129, Tc-99, Cl, F, and SO 4 that volatilize at the vitrification temperature of 1150°C in the absence of a continuous cold cap. The current waste disposal path for the WTP-SW is to recycle it to the supplemental LAW treatment to avoid a large steady state accumulation in the pretreatment-vitrification loop. Fluidized Bed Steam Reforming (FBSR) offers a moderate temperature (700-750°C) continuous method by which LAW and/or WTP-SW wastes can be processed irrespective of whether they contain organics, nitrates, sulfates/sulfides, chlorides, fluorides, volatile radionuclides or other aqueous components. The FBSR technology can process these wastes into a crystalline ceramic (mineral) waste form. The mineral waste form that is produced by co-processing waste with kaolin clay in an FBSR process has been shown to be as durable as LAW glass. Monolithing of the granular FBSR product, which is one of the objectives of this current study, is being investigated to prevent dispersion during transport or burial/storage but is not necessary for performance. FBSR testing of a Hanford LAW simulant and a WTP-SW simulant at the pilot scale was performed by THOR Treatment Technologies, LLC at Hazen Research Inc. in April/May 2008. The Hanford LAW simulant was the Rassat 68 tank blend and the target concentrations for the LAW was increased by a factor of 10 for Sb, As, Ag, Cd, and Tl; 100 for Ba and Re (Tc surrogate); 1,000 for I; and 254,902 for Cs based on discussions with the DOE field office and the environmental regulators and an evaluation of the Hanford Tank Waste Envelopes A, B, and C. It was determined through the evaluation of the actual tank waste metals concentrations that some metal levels were not sufficient to achieve reliable detection in the off-gas sampling. Therefore, the identified metals concentrations were increased in the Rassat simulant processed by TTT at HRI to ensure detection and enable calculation of system removal efficiencies, product retention efficiencies, and mass balance closure without regard to potential results of those determinations or impacts on product durability response such as Toxicity Characteristic Leach Procedure (TCLP). A WTP-SW simulant based on melter off-gas analyses from Vitreous State Laboratory (VSL) was also tested at HRI in the 15-inch diameter Engineering Scale Test Demonstration (ESTD) dual reformer at HRI in 2008. The target concentrations for the Resource Conservation and Recovery Act (RCRA) metals were increased by 16X for Se, 29X for Tl, 42X for Ba, 48X for Sb, by 100X for Pb and Ni, 1000X for Ag, and 1297X for Cd to ensure detection by the analytic laboratory used for the demonstration and, as with the LAW simulant, without regard to potential impacts on product durability response such as TCLP. Details of the ESTD testing that was performed in April and May of 2008 are shown in Table 1 as the Operational Summary. The first eight tests were performed on LAW using a Denitration and Mineralization Reformer (DMR) temperature of 725°C and different ratios of clay:simulant of 675 g or 640 g of OptiKast clay per liter of simulant. The last four tests were performed on WTP-SW (originally referred to as LAW-Recycle) using a DMR temperature in the range of 680°C to 700°C with a mixture of 45/55 Sagger/OptiKast clay with 307 g clay/L simulant. The coal feed rates used in the FBSR processing are also shown as noted at the bottom of Table 1. It should be noted that the carbon feed rates are averaged over those periods.

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DOE OSTI2013

Improved Management of the Technical Interfaces Between the Hanford Tank Farm Operator and the Hanford Waste Treatment Plant - 13383

The Department of Energy (DOE) is constructing the Waste Treatment and Immobilization Plant (WTP) at the Hanford site in Washington to treat and immobilize approximately 114 million gallons of high level radioactive waste (after all retrievals are accomplished). In order for the WTP to be designed and operated successfully, close coordination between the WTP engineering, procurement, and construction contractor, Bechtel National, Inc. and the tank farms operating contractor (TOC), Washington River Protection Solutions, LLC, is necessary. To develop optimal solutions for DOE and for the treatment of the waste, it is important to deal with the fact that two different prime contractors, with somewhat differing contracts, are tasked with retrieving and delivering the waste and for treating and immobilizing that waste. The WTP and the TOC have over the years cooperated to manage the technical interface. To manage what is becoming a much more complicated interface as the WTP design progresses and new technical issues have been identified, an organizational change was made by WTP and TOC in November of 2011. This organizational change created a co-located integrated project team (IPT) to deal with mutual and interface issues. The Technical Organization within the One System IPT includes employees from both TOC and WTP. This team has worked on a variety of technical issues of mutual interest and concern. Technical issues currently being addressed include: - The waste acceptance criteria; - Waste feed delivery and the associated data quality objectives (DQO); - Evaluation of the effects of performing a riser cut on a single shell tank on WTP operations; - The disposition of secondary waste from both TOC and WTP; - The close coordination of the TOC double shell tank mixing and sampling program and the Large Scale Integrated Test (LSIT) program for pulse jet mixers at WTP along with the associated responses to the Defense Nuclear Facilities Safety Board (DNFSB) Recommendation 2010-2; - Development of a set of alternatives to the current baseline that involve aspects of direct feed, feed conditioning, and design changes. The One System Technical Organization has served WTP, TOC, and DOE well in managing and resolving issues at the interface. This paper describes the organizational structure used to improve the interface and several examples of technical interface issues that have been successfully addressed by the new organization. (authors)

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DOE OSTI2016

Progress Updates for the Hanford Waste Treatment and Immobilization Plant Project - 16281

The Waste Treatment and Immobilization Plant (WTP) Project is vital to the U.S. Department of Energy's (DOE) mission to clean up radioactive waste at the Hanford Site, located in southeastern Washington State. The overall WTP Project objective is to design, build, and commission the facilities and systems that will treat and immobilize approximately 56 million gallons of radioactive waste stored in Hanford's 177 underground storage tanks. The combination of technologies in the WTP makes it a first-of-a-kind facility at a scale larger than ever built for radioactive waste processing. The WTP includes several facilities that will contribute to waste processing: (1) the Pretreatment (PT) Facility, which is designed to receive waste retrieved from the Hanford tank farms and separate it into low-activity and high-level waste streams; (2) the Low-Activity Waste (LAW) Facility, which will vitrify the low-activity waste stream; (3) the High-Level Waste (HLW) Facility, which will vitrify the high-level waste stream; (4) the Analytical Laboratory (Lab), which will support both vitrification facilities' operations; and (5) the Balance of Facilities (BOF), which will provide industrial support capabilities and infrastructure, like electricity and steam, needed for WTP operations. In 2012, DOE suspended production work on the WTP's Pretreatment (PT) Facility and to a lesser degree the High-Level Waste (HLW) Facility because of unresolved technical issues associated with those facilities. DOE has established an approach that would facilitate immobilization of tank waste to begin as early as practicable without waiting for completion of work to resolve the technical issues associated with the PT and HLW Facilities. This approach enables LAW treatment to begin before the PT and HLW facilities are completed by transferring low activity waste directly from the Hanford tank farms to the LAW Facility - referred to as Direct Feed LAW (DFLAW). ORP has placed the highest priority on completing the Low Activity Waste Facility, Balance of Facilities, and Analytical Laboratory (collectively known as LBL) in support of the planned phased start to the Hanford Tank waste treatment mission. DOE has requested, and the WTP contractor has delivered contract modifications proposals for: (1) design of a permanent capability to accommodate DFLAW in WTP; (2) procurement and construction of modifications to enable DFLAW operations in WTP, and (3) completion of LBL work scope in the current contract through hot commissioning in a manner to accommodate a phased start toward completing the WTP mission. DOE is reviewing and approving contract modifications in a sequence and schedule that allows for an orderly completion of the LBL Facilities and to begin treating low-activity tank waste as soon as practicable. In August 2014, ORP authorized the WTP contractor to resume all engineering work necessary to finalize the design of the HLW Facility. Authorization for HLW equipment procurements and construction is forthcoming, based on conditions that must be satisfied for a full release of these activities, including completion of an update to the Preliminary Documented Safety Analysis. DOE has also established a comprehensive plan for resuming production activities for the PT Facility that is similar to the process established and implemented for the HLW Facility. Resolution of the technical issues and establishment of a revised safety basis are key prerequisites to resuming engineering, procurements, and construction. (authors)

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DOE OSTI2017

Progress Updates for the Hanford Waste Treatment and Immobilization Plant Project - 17275

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DOE OSTI2017

Implementing a Low Activity Waste Direct Feed Capability in the Hanford Waste Treatment Plant - 17277

The original design of the Waste Treatment and Immobilization Plant (WTP) requires that all waste be processed through the Pretreatment (PT) Facility in order to separate the low-activity waste and high-level waste streams. The U.S. Department of Energy (DOE) has developed a sequenced approach to completing the WTP Project, beginning with feeding some liquid waste directly to the Low-Activity Waste (LAW) Facility, bypassing the PT Facility. Sending low-activity waste from the tank farms to the LAW Facility is referred to as direct-feed LAW (DFLAW). Using this approach, low-activity waste will be pretreated in a Low-Activity Waste Pretreatment System (LAWPS) for cesium and solids separation to meet LAW Facility safety basis requirements and produce an acceptable low-activity waste product. The waste feed will then be transferred to the LAW Facility where it will be immobilized in glass, poured into stainless steel containers, and then transported by truck to the Integrated Disposal Facility, a mixed waste burial ground located in the Hanford 200-East Area. The primary driver for the DFLAW approach is to enable commissioning of the LAW Facility for low-activity waste processing prior to the completion and availability of the PT and High-Level Waste (HLW) facilities. As such, the functions intended to be provided to the LAW Facility by the PT Facility and the common functionality with the HLW Facility must be refined and modified to enable DFLAW operations. The DFLAW approach will provide necessary systems and facilities to replace these enabling PT Facility functions until the PT Facility is completed and commissioned. For example, liquid effluents from the LAW Facility, primarily melter offgas condensate, will be processed in a new effluent management facility (EMF) within the WTP footprint rather than sending the effluent back to the PT Facility for processing. During DFLAW operations approximately 3 785 m{sup 3} (1 million gallons) of double-shell tank (DST) waste will be delivered to WTP for treatment each year of operation, and nominally produce 21 metric tons of immobilized low-activity waste glass per day. The resultant freed space in the DSTs will support safe tank farm operation and staging of additional waste for treatment. In December 2016, DOE executed a contract modification and approved an incremental change to the project's performance baseline to complete the WTP facilities needed to allow direct feed of low-activity waste to the LAW Facility. The revised performance baseline supports completion and cold commissioning of the WTP facilities needed for DFLAW operations no later than August 2023. The design of modifications to WTP facilities needed to enable DFLAW operations is more that 60 percent complete. DOE approved the preliminary safety basis for DFLAW modifications to WTP based on the 30 percent design package in early 2016. Early construction work for DFLAW modifications to WTP began in mid-2015. Long-lead procurement actions for some of the more complex equipment needed for LAW Facility effluent treatment were initiated in early 2016. (authors)

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DOE OSTI2017

Transitioning from Construction to Startup for the Waste Treatment and Immobilization Plant's Low-Activity Waste Facility - 17284

The original design of the Waste Treatment and Immobilization Plant (WTP) required all waste be processed through the Pretreatment (PT) Facility in order to separate the low-activity waste and high-level waste streams. The U.S. Department of Energy (DOE), Office of River Protection (ORP) has developed a sequenced approach to completing the WTP Project, beginning with delivering some liquid waste directly to the Low-Activity Waste (LAW) Facility, bypassing the PT Facility. This operating configuration is referred to as direct-feed LAW (DFLAW). The primary driver for the DFLAW approach is to enable startup and commissioning of the LAW Facility for low-activity waste processing prior to the completion and availability of the PT and High-Level Waste facilities. In March 2016, a federal judge amended the Consent Decree between DOE and the State of Washington to require completion of hot commissioning for the LAW Facility no later than December 31, 2023. During the next few years ORP and the WTP contractor will transition the project from completion of construction to the startup and commissioning phase for the LAW Facility and the associated support facilities. The WTP contractor has developed an integrated management process to successfully conduct facility startup testing for the WTP facilities required to support DFLAW. The WTP contractor will also develop a commissioning plan and facility transition plan. These plans will describe the strategy; schedule; and requirements for safe, efficient, and sequential startup, commissioning, and transfer of the WTP facilities to an operations contractor. The WTP contractor has also established a strategy to achieve operational readiness for the facilities required to support DFLAW consistent with DOE O 425.1D, Verification of Readiness to Start Up or Restart Nuclear Facilities and DOE O 413.3B, Program and Project Management for the Acquisition of Capital Assets. ORP has established a strategy for oversight of the WTP contractor's startup, commissioning, and readiness activities. The strategy also encompasses ORP's own activities to achieve readiness. (authors)

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DOE OSTI2014

Laboratory Evaporation Testing Of Hanford Waste Treatment Plant Low Activity Waste Off-Gas Condensate Simulant

The Hanford Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) vitrification facility will generate an aqueous condensate recycle stream, LAW Off-Gas Condensate, from the off-gas system. The baseline plan for disposition of this stream 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. Alternate disposition of this stream would eliminate recycling of problematic components, and would enable de-coupled operation of the LAW melter and the Pretreatment Facilities. Eliminating this stream from recycling within WTP would also decrease the LAW vitrification mission duration and quantity of canistered glass waste forms. This LAW Off-Gas Condensate stream contains components that are volatile at melter temperatures and are problematic for the glass waste form. Because this stream recycles within WTP, these components accumulate in the Condensate stream, exacerbating their impact on the number of LAW glass containers that must be produced. Approximately 32% of the sodium in Supplemental LAW comes from glass formers used to make the extra glass to dilute the halides to be within acceptable concentration ranges in the LAW glass. Diverting the stream reduces the halides in the recycled Condensate and is a key outcome of this work. Additionally, under possible scenarios where the LAW vitrification facility commences operation prior to the WTP Pretreatment facility, identifying a disposition path becomes vitally important. This task examines the impact of potential future disposition of this stream in the Hanford tank farms, and investigates auxiliary evaporation to enable another disposition path. Unless an auxiliary evaporator is used, returning the stream to the tank farms would require evaporation in the 242-A evaporator. This stream is expected to be unusual because it will be very high in corrosive species that are volatile in the melter (chloride, fluoride, sulfur), will have high ammonia, and will contain carryover particulates of glass-former chemicals. These species have potential to cause corrosion of tanks and equipment, precipitation of solids, release of ammonia gas vapors, and scale in the tank farm evaporator. Routing this stream to the tank farms does not permanently divert it from recycling into the WTP, only temporarily stores it prior to reprocessing. Testing is normally performed to demonstrate acceptable conditions and limits for these compounds in wastes sent to the tank farms. The primary parameter of this phase of the test program was measuring the formation of solids during evaporation in order to assess the compatibility of the stream with the evaporator and transfer and storage equipment. The origin of this LAW Off-Gas Condensate stream will be the liquids from the Submerged Bed Scrubber (SBS) and the Wet Electrostatic Precipitator (WESP) from the LAW facility melter offgas system. The stream is expected to be a dilute salt solution with near neutral pH, and will likely contain some insoluble solids from melter carryover. The soluble components are expected to be mostly sodium and ammonium salts of nitrate, chloride, and fluoride. This stream has not been generated yet, and, thus, the composition will not be available until the WTP begins operation, but a simulant has been produced based on models, calculations, and comparison with pilot-scale tests. This report discusses results of evaporation testing of the simulant. Two conditions were tested, one with the simulant at near neutral pH, and a second at alkaline pH. The neutral pH test is comparable to the conditions in the Hanford Effluent Treatment Facility (ETF) evaporator, although that evaporator operates at near atmospheric pressure and tests were done under vacuum. For the alkaline test, the target pH was based on the tank farm corrosion control program requirements, and the test protocol and equipment was comparable to that used for routine evaluation of feed compatibility studies for the 242-A evaporator. One of the radionuclides that is volatile in the melter and expected to be in high concentration in this LAW Off-Gas Condensate stream is Technetium-99 (99Tc). Technetium will not be removed from the aqueous waste in the Hanford WTP, and will primarily end up immobilized in the LAW glass by repeated recycle of the off-gas condensate into the LAW melter. Other radionuclides that are also expected to be in appreciable concentrations in the LAW Off-Gas Condensate are 129I, 90Sr, 137Cs, and 241Am. The concentrations of these radionuclides in this stream will be much lower than in the LAW, but they will still be higher than limits for some of the other disposition pathways currently available. At this time, these scoping tests did not evaluate the partitioning of the radionuclides to the evaporator condensate, since ample data are available separately from other experience in the DOE complex. Results from the evaporation testing show that the neutral SBS simulant first forms turbidity at ~7.5X concentration, while the alkaline-adjusted simulant became turbid at ~3X concentration. The major solid in both cases was Kogarkoite, Na3FSO4. Sodium and lithium fluorides were also detected. Minimal solids were formed in the evaporator bottoms until a substantial fraction of liquid was removed, indicating that evaporation could minimize storage volume issues. Achievable concentration factors without significant insoluble solids were 17X at alkaline pH, and 23X at neutral pH. In both runs, significant ammonia carried over and was captured in the condenser with the water condensate. Results also indicate that with low insoluble solids formation in the initial testing at neutral pH, the use of Reverse Osmosis is a potential alternate method for concentrating the solution, although an evaluation is needed to identify equipment that can tolerate insoluble solids. Most of the ammonia remains in the evaporator bottoms during the neutral pH evaporation, but partitions to the condensate during alkaline evaporation. Disposition of both streams needs to consider the management of ammonia vapor and its release. Since this is an initial phase of testing, additional tasks related to evaporation methods are expected to be identified for development. These tasks likely include evaluation and testing of composition variability testing and evaluations, corrosion and erosion testing, slurry storage and immobilization investigations, and evaporator condensate disposition.

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DOE OSTI2014

Crystallization In High Level Waste (HLW) Glass Melters: Operational Experience From The Savannah River Site

processing strategy for the Hanford Tank Waste Treatment and Immobilization Plant (WTP). The basis of this alternative approach is an empirical model predicting the crystal accumulation in the WTP glass discharge riser and melter bottom as a function of glass composition, time, and temperature. When coupled with an associated operating limit (e.g., the maximum tolerable thickness of an accumulated layer of crystals), this model could then be integrated into the process control algorithms to formulate crystal tolerant high level waste (HLW) glasses targeting higher waste loadings while still meeting process related limits and melter lifetime expectancies. This report provides a review of the scaled melter testing that was completed in support of the Defense Waste Processing Facility (DWPF) melter. Testing with scaled melters provided the data to define the DWPF operating limits to avoid bulk (volume) crystallization in the un-agitated DWPF melter and provided the data to distinguish between spinels generated by K-3 refractory corrosion versus spinels that precipitated from the HLW glass melt pool. This report includes a review of the crystallization observed with the scaled melters and the full scale DWPF melters (DWPF Melter 1 and DWPF Melter 2). Examples of actual DWPF melter attainment with Melter 2 are given. The intent is to provide an overview of lessons learned, including some example data, that can be used to advance the development and implementation of an empirical model and operating limit for crystal accumulation for WTP. Operation of the first and second (current) DWPF melters has demonstrated that the strategy of using a liquidus temperature predictive model combined with a 100 °C offset from the normal melter operating temperature of 1150 °C (i.e., the predicted liquidus temperature (TL) of the glass must be 1050 °C or less) has been successful in preventing any detrimental accumulation of spinel in the DWPF melt pool, and spinel has not been observed in any of the pour stream glass samples. Spinel was observed at the bottom of DWPF Melter 1 as a result of K-3 refractory corrosion. Issues have occurred with accumulation of spinel in the pour spout during periods of operation at higher waste loadings. Given that both DWPF melters were or have been in operation for greater than 8 years, the service life of the melters has far exceeded design expectations. It is possible that the DWPF liquidus temperature approach is conservative, in that it may be possible to successfully operate the melter with a small degree of allowable crystallization in the glass. This could be a viable approach to increasing waste loading in the glass assuming that the crystals are suspended in the melt and swept out through the riser and pour spout. Additional study is needed, and development work for WTP might be leveraged to support a different operating limit for the DWPF. Several recommendations are made regarding considerations that need to be included as part of the WTP crystal tolerant strategy based on the DWPF development work and operational data reviewed here. These include: Identify and consider the impacts of potential heat sinks in the WTP melter and glass pouring system; Consider the contributions of refractory corrosion products, which may serve to nucleate additional crystals leading to further accumulation; Consider volatilization of components from the melt (e.g., boron, alkali, halides, etc.) and determine their impacts on glass crystallization behavior; Evaluate the impacts of glass REDuction/OXidation (REDOX) conditions and the distribution of temperature within the WTP melt pool and melter pour chamber on crystal accumulation rate; Consider the impact of precipitated crystals on glass viscosity; Consider the impact of an accumulated crystalline layer on thermal convection currents and bubbler effectiveness within the melt pool; Evaluate the impact of spinel accumulation on Joule heating of the WTP melt pool; and Include noble metals in glass melt experiments because of their potential to act as nucleation sites for spinel crystallization.

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DOE OSTI2014

LABORATORY OPTIMIZATION TESTS OF TECHNETIUM DECONTAMINATION OF HANFORD WASTE TREATMENT PLANT LOW ACTIVITY WASTE OFF-GAS CONDENSATE SIMULANT

The Hanford Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) vitrification facility will generate an aqueous condensate recycle stream (LAW Off-Gas Condensate) from the off-gas system. The baseline plan for disposition of this stream 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. Alternate disposition of this stream would eliminate recycling of problematic components, and would enable de-coupled operation of the LAW melter and the Pretreatment Facilities. Eliminating this stream from recycling within WTP would also decrease the LAW vitrification mission duration and quantity of glass waste. This LAW Off-Gas Condensate stream contains components that are volatile at melter temperatures and are problematic for the glass waste form. Because this stream recycles within WTP, these components accumulate in the Condensate stream, exacerbating their impact on the number of LAW glass containers that must be produced. Approximately 32% of the sodium in Supplemental LAW comes from glass formers used to make the extra glass to dilute the halides to acceptable concentrations in the LAW glass, and diverting the stream reduces the halides in the recycled Condensate and is a key outcome of this work. Additionally, under possible scenarios where the LAW vitrification facility commences operation prior to the WTP Pretreatment facility, identifying a disposition path becomes vitally important. This task examines the potential treatment of this stream to remove radionuclides and subsequently disposition the decontaminated stream elsewhere, such as the Effluent Treatment Facility (ETF), for example. The treatment process envisioned is very similar to that used for the Actinide Removal Process (ARP) that has been operating for years at the Savannah River Site (SRS), and focuses on using mature radionuclide removal technologies that are also compatible with longterm tank storage and immobilization methods. For this new application, testing is needed to demonstrate acceptable treatment sorbents and precipitating agents and measure decontamination factors for additional radionuclides in this unique waste stream. The origin of this LAW Off-Gas Condensate stream will be the liquids from the Submerged Bed Scrubber (SBS) and the Wet Electrostatic Precipitator (WESP) from the LAW melter off-gas system. The stream is expected to be a dilute salt solution with near neutral pH, and will likely contain some insoluble solids from melter carryover. The soluble components are expected to be mostly sodium and ammonium salts of nitrate, chloride, and fluoride. This stream has not been generated yet and will not be available until the WTP begins operation, but a simulant has been produced based on models, calculations, and comparison with pilot-scale tests. One of the radionuclides that is volatile and expected to be in greatest abundance in this LAW Off-Gas Condensate stream is Technetium-99 ({sup 99}Tc). Technetium will not be removed from the aqueous waste in the Hanford WTP, and will primarily end up immobilized in the LAW glass by repeated recycle of the off-gas condensate into the LAW melter. Other radionuclides that are low but are also expected to be in measurable concentration in the LAW Off-Gas Condensate are {sup 129}I, {sup 90}Sr, {sup 137}Cs, {sup 241}Pu, and {sup 241}Am. These are present due to their partial volatility and some entrainment in the off-gas system. This report discusses results of optimized {sup 99}Tc decontamination testing of the simulant. Testing examined use of inorganic reducing agents for {sup 99}Tc. Testing focused on minimizing the quantity of sorbents/reactants added, and minimizing mixing time to reach the decontamination targets in this simulant formulation. Stannous chloride and ferrous sulfate were tested as reducing agents to determine the minimum needed to convert soluble pertechnetate to the insoluble technetium dioxide. The reducing agents were tried with and without sorbents. The sorbents, hydroxyapatite and sodium oxalate, were expected to sorb the precipitated technetium dioxide and facilitate removal. The Phase 1 tests examined a broad range of conditions and used the initial baseline simulant. The Phase 2 tests narrowed the conditions based on Phase 1 results, and used a slightly modified simulant. Test results indicate that excellent removal of {sup 99}Tc was achieved using SnCl{sub 2} as a reductant, and was effective with or without sorption onto hydroxyapatite. This reaction worked even in the presence of air (which could oxidize the stannous ion) and at room temperature. This process was very effective at neutral pH, with a Decontamination Factor (DF) >199 in one hour with only 1 g/L of SnCl{sub 2}. Prior work had shown that it was much less effective at alkaline pH. The only deleterious effect observed was that the chromium co-precipitates with the {sup 99}c during the SnCl{sub 2} reduction. This effect was anticipated, and would have to be considered when managing disposition paths of this stream. Reduction using FeSO{sub 4} was not effective at removing {sup 99}Tc, but did remove the Cr. Chromium is present due to partial volatility and entrainment in the off-gas, and is highly oxidizing, so would be expected to react with reducing agents more quickly than pertechnetate. Testing showed that sufficient reducing agent must be added to completely reduce the chromium before the technetium is reduced and removed. Other radionuclides are also present in this off-gas condensate stream. To enable sending this stream to the Hanford ETF, and thereby divert it from the recycle where it impacts the LAW glass volume, several of these also need to be removed. Samples from optimized conditions were also measured for actinide removal in order to examine the effect of the Tc-removal process on the actinides. Plutonium was also removed by the SnCl{sub 2} precipitation process. Results of this separation testing indicate that sorption/precipitation is a viable concept and has the potential to decontaminate the {sup 99}Tc from the stream, allowing it to be diverted away from WTP and thus eliminating the impact of the recycled halides and sulfate on the LAW glass volume. Based on the results, a possible treatment scenario could involve the use of a reductive precipitation agent (SnCl{sub 2}) with or without sorbent at neutral pH to remove the Tc. Although hydroxyapatite was not necessary to effect the {sup 99}Tc removal, it may be beneficial in solid-liquid separations. Other testing will examine removal of the other radionuclides. This testing was the second phase of testing, which aimed at optimizing the process by examining the minimum amount of reductant needed and the minimum reaction time. Although results indicated that SnCl{sub 2} was effective, further work on a pH-adjusted Fe(SO{sub 4}) mixture are needed. Additional tasks are needed to examine removal of the other radionuclides, solid-liquid separation technologies, slurry rheology measurements, composition variability impacts, corrosion and erosion, and slurry storage and immobilization.

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DOE OSTI2013

One System Integrated Project Team: Retrieval and Delivery of Hanford Tank Wastes for Vitrification in the Waste Treatment Plant - 13234

The One System Integrated Project Team (IPT) was formed in late 2011 as a way for improving the efficiency of delivery and treatment of highly radioactive waste stored in underground tanks at the U.S. Department of Energy's (DOE's) 586-square-mile Hanford Site in southeastern Washington State. The purpose of the One System IPT is to improve coordination and integration between the Hanford's Waste Treatment Plant (WTP) contractor and the Tank Operations Contractor (TOC). The vision statement is: One System is a WTP and TOC safety-conscious team that, through integrated management and implementation of risk-informed decision and mission-based solutions, will enable the earliest start of safe and efficient treatment of Hanford's tank waste, to protect the Columbia River, environment and public. The IPT is a formal collaboration between Bechtel National, Inc. (BNI), which manages design and construction of the WTP for the U.S. Department of Energy's Office of River Protection (DOEORP), and Washington River Protection Solutions (WRPS), which manages the TOC for ORP. More than fifty-six (56) million gallons of highly radioactive liquid waste are stored in one hundred seventy-seven (177) aging, underground tanks. Most of Hanford's waste tanks - one hundred forty-nine (149) of them - are of an old single-shell tank (SST) design built between 1944 and 1964. More than sixty (60) of these tanks have leaked in the past, releasing an estimated one million gallons of waste into the soil and threatening the nearby Columbia River. There are another twenty-eight (28) new double-shelled tanks (DSTs), built from 1968 to 1986, that provide greater protection to the environment. In 1989, DOE, the U.S. Environmental Protection Agency (EPA), and the Washington State Department of Ecology (Ecology) signed a landmark agreement that required Hanford to comply with federal and state environmental standards. It also paved the way for agreements that set deadlines for retrieving the tank wastes and for building and operating the WTP. The tank wastes are the result of Hanford's nearly fifty (50) years of plutonium production. In the intervening years, waste characteristics have been increasingly better understood. However, waste characteristics that are uncertain and will remain as such represent a significant technical challenge in terms of retrieval, transport, and treatment, as well as for design and construction of WTP. What also is clear is that the longer the waste remains in the tanks, the greater the risk to the environment and the people of the Pacific Northwest. The goal of both projects - tank operations and waste treatment - is to diminish the risks posed by the waste in the tanks at the earliest possible date. About two hundred (200) WTP and TOC employees comprise the IPT. Individual work groups within One System include Technical, Project Integration and Controls, Front-End Design and Project Definition, Commissioning, Nuclear Safety and Engineering Systems Integration, and Environmental Safety and Health and Quality Assurance (ESH and QA). Additional functions and team members will be added as the WTP approaches the operational phase. The team has undertaken several initiatives since its formation to collaborate on issues: (1) alternate scenarios for delivery of wastes from the tank farms to WTP; (2) improvements in managing Interface Control Documents; (3) coordination on various technical issues, including the Defense Nuclear Facilities Nuclear Safety Board's Recommendation 2010-2; (4) deployment of the SmartPlant{sup R} Foundation-Configuration Management System; and (5) preparation of the joint contract deliverable of the Operational Readiness Support Plan. (authors)

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