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DOE OSTI2024

Experience with Noble Metals During HLW Vitrification at FZK, Germany (Rev. 0)

The noble metals ruthenium (Ru), rhodium (Rh), and palladium (Pd) are present to various extents in defense and commercial high-level nuclear waste streams. Usually, their concentrations are higher in commercial waste. Ru, Rh, and Pd are sparingly soluble in silicate glass melts and they therefore form separate metal, oxide, or other phases. These phases are generally denser than the glass melt and tend to sediment to the bottom of the melter, where they form a "sludge" layer. Since the sludge layer has a higher electrical conductivity than the molten glass, accumulation of sludge can ultimately lead to electrical disruption of the operation of the melter. In addition, the sludge reduces the melt volume, which also changes the operational characteristics of the melter.

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DOE OSTI2024

Modeling the Behavior of Noble Metals During HLW Vitrification in the DM1200 Melter

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DOE OSTI2023

Phosphate and Fluoride Processing Options for Hanford Sludge

The Direct Feed High-Level Waste (DFHLW) strategy represents an alternative flowsheet to bypass the Hanford Waste Treatment and Immobilization Plant (WTP) Pretreatment Facility. Key processing functions previously captured during baseline pretreatment operations include leaching and washing prior to solids concentration and should be considered in the new DFHLW flowsheet to maximize waste feed loading, minimize high-level waste (HLW) volume, and mitigate corrosion challenges associated with vitrification of high phosphate and fluoride concentrations. The effectiveness and efficiency of sludge washing can have a substantial impact on DST space and mission duration. Two target species that benefit significantly from washing are phosphate and fluoride. Commonly present in many high-level wastes at Hanford, phosphate and fluoride are found predominately in the form of salt precipitates and can have adverse and detrimental effects on glass waste loading. Additionally, fluoride produces melter off-gas that creates corrosion risks in the off-gas system piping. Determining the solubilities of fluoride and phosphate salts, as well as the dissolution kinetics under potential HLW processing conditions will help to mitigate future operational risks and mature flowsheet technical bases.

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DOE OSTI2021

Melting rate correlation with batch properties and melter operating conditions during conversion of nuclear waste melter feeds to glasses

The rate of conversion of nuclear waste melter feed to glass is affected by the selection of melter feed materials and by melter design and operation. The melting rate correlation (MRC) is an equation that relates the glass production rate with two types of variables: (1) feed and melt properties: conversion heat, cold-cap bottom temperature, and glass melt viscosity; and (2) melter design and operation parameters: melter geometry, melter operating temperature, and gas bubbling rate. The MRC shows good agreement for an extended melting-rate data set of high-level waste (HLW) melter feeds and a data set generated for low-activity waste (LAW) melter feeds. Laboratory observation of heated melter feed samples is often used to assess the cold-cap bottom temperature of HLW melter feeds (moderately foaming feeds), but this technique appears inadequate for LAW melter feeds (vigorously foaming feeds). For LAW feeds, an adequate assessment of the cold-cap bottom temperature was achieved using evolved gas analysis, which allows identification of the collapse of primary foam for oxidized feeds. This assessment shows that the cold-cap bottom temperature for vigorously foaming LAW feeds is higher than that for moderately foaming HLW feeds. When the results of MRC are compared, LAW feeds are generally less sensitive to the bubbling rate and melt viscosity, and more sensitive to the cold-cap bottom temperature than HLW feeds. The MRC qualifies as a promising tool to support the selection of melter feed materials and melter operating conditions, which is determined from expensive independent scaled melter experiments, and sophisticated mathematical models.

Lee, Seung Min↗

DOE OSTI2023

Waste Glass Property Database and Data Qualification Plan

The U.S. Department of Energy vitrification facilities currently employ glass property-composition models to ensure processability of waste streams and acceptability of the final glass products. The efficiency (e.g., process flexibility, reduced down time, and reduced cost) of waste vitrification is directly tied to the size of the waste processing envelope. To increase the size of the processing envelope, a larger database was developed. The database will improve the prediction accuracy of glass properties, leading to higher waste loadings, higher waste throughput, broader process flexibility, and reduced mission life. Some of the data in this expanded database has insufficient quality assurance (QA) rigor for use in nuclear facility operation and glass qualification. A plan was developed to qualify high-value data under the appropriate QA rigor for use at the Hanford Waste Treatment and Immobilization Plant’s High-Level Waste (HLW) Facility. This qualification plan first compares the data coverage over the composition region of interest to Hanford HLW by property. Those studies that significantly improve the data coverage in the Hanford HLW glass composition region were prioritized for qualification activities. Qualification methods including QA equivalence, peer review, data corroboration, and confirmatory testing have been assigned to each high-priority study.

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DOE OSTI2026

Modeling glass degradation and release of radionuclides from vitrified waste for performance assessment simulations

The release of radionuclides initially encapsulated in a slowly degrading solid waste form and contained in an eventually corroding canister defines the source term for numerical simulations for the assessment of a geologic repository for high-level radioactive waste. While the details of waste degradation, canister corrosion, and dissolution and mobilization of the radionuclides in pore water include complex chemical reaction and transport processes that are coupled to the thermal, hydrological, microbiological, and mechanical conditions in the repository, the source-term model suitable for use in a numerical performance assessment model should be a defensible abstraction of these mechanisms. We developed a radiological source-term model and implemented it into a non-isothermal flow and transport simulator. While the proposed source-term model is applicable to various waste forms, canister systems, and disposal concepts, we specifically considered radionuclide releases from vitrified high-level waste placed in a cylindrical canister disposed in a deep vertical borehole repository. In this model, waste degradation is a function of temperature, and it can be adjusted to evaluate the influence of and propagate uncertainties in pH, passivation reactions, and chemical conditions as well as geometrical factors. The time-dependent, congruent release of safety-relevant radionuclides present in the decaying inventory is then calculated. Finally, the radionuclides are mobilized by diffusive and advective transport according to the thermo-hydraulic conditions prevailing in the near field of the repository, from where they migrate through the geosphere to the accessible environment. We examine the influence of the source-term model’s parameters on performance assessment calculations through sensitivity and uncertainty propagation analyses, identifying influential factors and confirming the upper bound of their impact. These considerations align with the overarching goal of repository design, which is to demonstrate that engineered and natural barriers can collectively delay radionuclide migration for timescales far exceeding human planning, thereby providing multiple, redundant barriers against environmental contamination.

iTOUGH2↗

DOE OSTI2021

FY2021 ILAW Glass Ion-Exchange Rate Testing

Approximately 54 to 56 million gallons of radioactive 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 of in an engineered facility – the Integrated Disposal Facility (IDF) – 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 before they can be accepted for disposal. To capitalize on the success of the FY19 and FY20 Atkins/VSL test results on six glasses, Washington River Protection Solutions, LLC (WRPS) has contracted with Atkins/VSL to collect IEX data on four more ILAW glasses using PFT, the results of which are the subject of the present report. The work described herein was performed according to a Test Plan that is responsive to the corresponding WRPS scope of work.

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DOE OSTI2021

FY2021 Long-Term PCT of ILAW Glasses

Approximately 54 to 56 million gallons of radioactive 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 a near-surface engineered facility – the Integrated Disposal Facility (IDF) – on the Hanford site, while the IHLW product is designed for deep geological disposal in a national 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 objective of the work described in this report is to perform testing, data collection, and analyses for the ILAW glass product for subsequent use in the performance assessment (PA) of the IDF to assess potential environmental risks associated with long-term storage.

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DOE OSTI2021

Demonstration of Defense Waste Processing Facility (DWPF) Higher Fissile Content Glass

The Accelerated Basin De-inventory (ABD) Program has been proposed as an alternative for future spent nuclear fuel (SNF) and nuclear material processing at the Savannah River Site (SRS). This approach would change the baseline H-Canyon (HCAN), Concentrate, Storage, and Transfer Facility (CSTF), and Defense Waste Processing Facility (DWPF) operations. The ABD Program would require that all domestic and foreign research reactor SNF currently at SRS be dissolved, stored, and then transferred to CSTF without the recovery of uranium. Preliminary assessments in the ABD Program plan have shown that ~5000 extra SRS high-level waste (HLW) canisters would be produced if the fissile mass loading remains at the current 897 g/m 3 limit; however, increasing the limit to 2500 g/m 3 would result in ~520 extra canisters. Thus, the ABD Program plan requires an increase of the DWPF fissile mass loading limit to 2500 g/m 3 to minimize canister production. DWPF considers the following isotopes in the calculation of fissile mass loading: U-233, U-235, Pu-239 and Pu-241.

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DOE OSTI2025

Evaluation of desiccation cracking characteristics of inorganic micro-fiber-reinforced engineered barrier material (IMEBM) for geological repository

Abstract Buffer material is crucial for the engineering barrier system to dispose of high-level radioactive waste in a geological repository. A reliable buffer material should be able to maintain good sealing characteristics and minimize desiccation cracking. In this study, the effectiveness of inorganic fiber-reinforced engineering barrier material in reducing desiccation cracks in bentonite was evaluated via desiccation tests, image analysis, and air permeability tests. The effects of fiber type (E-glass fiber and basalt fiber) and fiber content (0.0%, 0.5%, 1.0%, 1.5%, 3.0%, and 5.0% of dry weight of the bentonite) on the development of desiccation cracks in the fiber–bentonite mixtures with the same given initial moisture content were evaluated. The results indicated that the addition of fibers could significantly reduce the crack size and area in bentonite during the drying. Basalt fibers showed a slightly better reinforcement effect than E-glass fibers when the fiber content was lower than 3.0%. The addition of fibers prevented the development of penetrating cracks and significantly reduced the permeability of the bentonite after drying. The permeabilities of basalt fiber- and E-glass fiber-reinforced bentonite composites with 3% reinforcement were 5.81 × 10 –11 m 2 and 7.24 × 10 –11 m 2 , respectively, which were 64 and 51 times smaller than that of pure bentonite. X-ray–CT observation of the internal structure of the samples after drying showed that the addition of fibers significantly changed the crack morphology and potentially increased the tortuosity.

Feng, Yuan↗

DOE OSTI2020

Managing Hanford's Direct Feed Low Activity Waste Program - 20002

The Office of River Protection (ORP) is responsible for the management and completion of the River Protection Project (RPP) mission, which comprises both the Hanford Site tank farms operations and the completion and operation of the Waste Treatment and Immobilization Plant Project. The RPP mission is to safely retrieve, treat, and immobilize Hanford's high-level and low-activity tank waste and close the tank farms to protect the Columbia River. The Direct-Feed Low-Activity Waste (DFLAW) Program is a major subset of the overall RPP mission, providing disposition of low-activity waste. The scope is to retrieve, treat, and immobilize the low-activity waste at the Low-Activity Waste Facility. DFLAW will begin operations no later than December 2023. The DFLAW Program overarches a suite of individual projects, activities, and infrastructure upgrades. The major projects and activities include multiple contractors under both ORP and the Richland Operations Office, underscoring the need for effective integration, coordination, and collaboration. The objectives of the DFLAW Program leadership team are to: - Effectively coordinate and integrate the projects that comprise the DFLAW Program - Manage the interfaces between the projects so that the integrated DFLAW Program is completed successfully - Ensure the DFLAW portfolio of projects operate as required without gaps or conflicts at the interfaces. DOE is accomplishing these objectives through a newly established leadership model that integrates the DOE and contractor work streams and promotes a teamwork model to enable collaborative success. Long considered one of the most formidable cleanup challenges at Hanford, the Department of Energy and its contractors are on the verge of achieving a cleanup commitment that has been decades in the making. DOE is preparing to vitrify (turn to glass) Hanford's chemical and radioactive tank waste using the DFLAW process. The Modified Consent Decree milestone for completing hot commissioning of the Hanford Site's Low- Activity Waste Facility is Dec. 31, 2023. While this milestone may seem distant under normal project management circumstances, it is a relatively short period of time for the operational and cultural transformation necessary to successfully begin treating tank waste at Hanford. Direct feed means separating the waste at a tank farm to remove the more radioactive portion (i.e., solids and cesium) so that the resulting low-activity (less radioactive) waste can be fed directly to the Waste Treatment and Immobilization Plant's Low-Activity Waste Facility. Starting DFLAW will require a singular, intensive leadership focus, along with a sustained, collective commitment to excellence and teamwork by the Department and its contractors. Major upgrades to Hanford's infrastructure will occur prior to startup. Supporting DFLAW operations requires significant integration between the DFLAW facilities - the Waste Treatment Plant, Hanford's tank farms, effluent treatment facilities, disposal facilities - and between all of the site contractors to achieve success. (authors)

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DOE OSTI2021

Recent Advances in Corrosion Science Applicable To Disposal of High-Level Nuclear Waste

High level radioactive waste is accumulating at temporary storage locations around the world and will eventually be placed in deep geological repositories. Many different types of geological formation are under consideration, but all will eventually allow water to contact the metallic waste containers considering that the period of performance required to allow sufficient decay of dangerous radionuclides is on the order of 105 – 106 years. Corrosion of the containers and waste forms in the aqueous repository environment is therefore a concern. This review describes the recent advances of the field of materials corrosion based on the work of the Center for Performance and Design of Nuclear Waste Forms and Containers (WastePD) to address the issues associated with the long-term performance assessment and the design of materials with improved performance, where performance is defined as resistance to aqueous corrosion. Glass, crystalline ceramics, and metals are discussed separately, and then the near field interactions of these different materials classes are addressed. Recommendations for future directions are provided.

Frankel, Gerald↗

DOE OSTI2024

Thermo-rheological snapshot of melter feed conversion to glass

Slurry feed charged into an electric melter creates a layer of reacting and melting material (termed cold cap) that floats on the surface of molten glass. The rheological behavior of heated melter feed affects the spreading of slurry at the top of the cold cap and the stability of the primary foam, affecting cold-cap coverage and melter plenum temperatures. The apparent viscosity of a high-alumina high-level waste melter feed was assessed by thermomechanical analysis, high-temperature viscometer, and the hot stage microscopy method, yielding viscosity estimates from ≈10 7.5 Pa s at 550°C to ≈10 2.5 Pa s at 1050°C. As the temperature of feed materials increased, their state changed from rigid solid to dilatant fluid, to pseudoplastic bubbly liquid with dissolving solids, to fully developed foam, and finally to Newtonian glass melt.

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DOE OSTI2025

Adsorptive Capture of Iodide by Metal-Organic Framework from Off-Gas Condensate Simulate

Millions of gallons of liquid nuclear wastes generated due to nuclear weapon development during the Cold War are in tank storage at several Department of Energy (DOE) sites across the country. DOE is responsible for disposal of the tank nuclear waste and clean-up of the contaminated sites. These efforts are complex and challenging technically and are costly financially, with the predicted overall cost reaching $377 billion over the next few decades [1]. The current practice of nuclear waste treatment and tank closure is to separate high-level waste (HLW) and low-level waste (LLW) [2]. The HLW is then vitrified into a borosilicate-based glass waste form [3], while the LLW is immobilized into cementitious grout or vitrified into glass [4]. However, these treatment processes have met unsolved technical problems

Jiang, Junhua [Savannah River National Laboratory ↗

DOE OSTI2022

Follow-on Report of Analysis of Approaches to Supplemental Treatment of Low-Activity Waste at the Hanford Nuclear Reservation (Vol. I)

The Hanford Site, in southeast Washington State, is preparing to disposition approximately 56,000,000 gallons (56 Mgal) of radioactive and chemically hazardous wastes currently stored in underground tanks at the site. Tank wastes will be divided into a high-activity fraction and a low-activity fraction for subsequent treatment and disposition. A waste processing and treatment facility, the Waste Treatment and Immobilization Plant (WTP), will include the high-level waste (HLW) vitrification facility (WTP HLW Vitrification Facility) for immobilizing the high-activity fraction and a low-activity waste (LAW) vitrification facility (WTP LAW Vitrification Facility) for immobilizing the low-activity fraction. Both facilities will use vitrification technology to immobilize the Hanford tank wastes in a glass waste form. The volume of LAW to be treated and disposed of following waste retrieval and WTP operations will exceed the planned processing capacity of the WTP LAW Vitrification Facility. ORP-11242,-River Protection Project System Plan, estimates a shortfall in LAW treatment capacity of approximately 56 Mgal, approximately 50% of the projected LAW volume. To maintain the planned tank waste processing mission schedule, the U.S. Department of Energy (DOE) will require additional LAW treatment capacity (termed “supplemental LAW”) external to the WTP process. LAW must be solidified by a treatment technology before the waste can be permanently disposed of in an approved DOE on-site disposal facility or a commercial (state or U.S. Nuclear Regulatory Commission [NRC-licensed]) off-site mixed low-level waste disposal facility. A decision on the approach to supplemental LAW treatment, processing, and disposal has not yet been made

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DOE OSTI2023

Follow-on Report of Analysis of Approaches to Supplemental Treatment of Low–Activity Waste at the Hanford Nuclear Reservation (Volumes I & II)

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DOE OSTI2023

Follow-On Report of Analysis of Approaches to Supplemental Treatment of Low-Activity Waste at the Hanford Nuclear Reservation (Volumes I & II)

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DOE OSTI2024

Improving Efficiency of DWPF Operations via Automating Process Calculations and Vitrifying High-Curie Feed- 24529

The Liquid Waste Organization (LWO) at the Savannah River Site (SRS) uses a “Power As One®” motto to process and dispose of radioactive waste. The Defense Waste and Processing Facility (DWPF) treats the high-level waste through a process of vitrification. The DWPF receives three incoming waste streams that are added to the Sludge Receipt and Adjustment Tank (SRAT): sludge, Monosodium Titanate/Sludge Solids (MST/SS), and Strip Effluent (SE). The liquid waste is mixed with pre-fabricated frit and treated with high temperatures in the melter prior to being poured into stainless steel canisters. The liquid cools to form solid glass within these canisters that are suitable for long-term storage and disposal. Savannah River Mission Completion (SRMC), the SRS liquid waste contractor for the U.S. Department of Energy, has implemented several facility improvements to further enhance the operations to support the Liquid Waste Operation (LWO) mission. Two of these operational enhancements include implementing the electronic Material Tracking Program Calculator (eMTPC)software and increasing the DWPF canister heat rate limit.

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