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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Creating a Salt Batch: Challenges and Lessons Learned

CONCLUSION • The overall Salt Batch system has been honed through each iteration of the process • Increased communication across facilities and work groups has enabled the salt team to react swiftly to emergent items and identify improvement opportunities • Even the best plans require backup options – Emergent items can appear at any time during the process – Flexibility to adapt to the unexpected is a must-have team mindset • To date, every salt batch compiled has been qualified and approved as feed for SWPF – No feed break has occurred between the Tank Farm and SWPF

Goldblatt, Joshua B. [Savannah River National Labo↗
DOE OSTI2024

Summary of Savannah River Site FY23 Salt Waste Qualification Data

The Savannah River National Laboratory (SRNL) analyzed samples from Savannah River Site (SRS) Waste Tanks 41H and 21H to support qualification of Salt Waste Processing Facility (SWPF) Waste Batches 8 and 9 for processing (the FY23 Salt Batch Qualification samples). These Tanks (i.e. 41H and 21H) are blend tanks for feed to SWPF. None of the samples displayed any unusual or unexpected characteristics such as large amounts of solids, floating solids, or unusual color. Characterization of these samples confirmed similar chemical composition and characteristics to previous salt waste batches. The results for Batches 8 and 9 were provided by SRNL to Savannah River Mission Completion (SRMC), the Liquid Waste Operations subcontractor at SRS, as External Sample Results (Laboratory Information Management System (LIMS)) Reports. Additionally, a separate technical memo was issued by SRNL to report re-test data for Batch 8 for Cs-137 for filtered samples only which were run at the request of SWPF. For Batch 9, a set of samples was also analyzed in parallel by the SWPF-Analytical Laboratory (SWPF-AL). The SWPF-AL data is included herein for comparison with the SRNL data where applicable. The analytical results (both rapid, typically 4 weeks, and long term, typically 8 weeks) for Batches 8 and 9 are now summarized and discussed in this technical report.

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DOE OSTI2025

Summary of Savannah River Site FY24 Salt Waste Qualification Data

Savannah River Mission Completion (SRMC), the Liquid Waste Operations subcontractor at SRS, and Savannah River National Laboratory (SRNL) analyzed samples from Savannah River Site (SRS) Waste Tanks 21H, 41H, and 42H to support qualification of Salt Waste Processing Facility (SWPF) Waste Batches 10, 11, 12, and 13 for processing (the FY24 Salt Batch Qualification samples). These Tanks (i.e. 21H, 41H and 42H) are blend tanks for feed to SWPF. This report focuses on the characterization of the Salt Batch Qualification sub-samples (i.e., any adjustments after qualification or as a part of processing are documented elsewhere). None of the samples displayed any unusual or unexpected characteristics such as large amounts of solids, floating solids, or unusual color. Characterization of these samples confirmed similar chemical composition and characteristics to previous salt waste batches. The analytical results (both rapid, typically 4 weeks, and long-term, typically 8 weeks) for Salt Batches 10, 11, 12, and 13 are now summarized and discussed in this technical report. SRMC-Analytical Laboratory (SRMC-AL), for the first time, provided all the short-term analyses data used in the qualification evaluations of SWPF Salt Batches 10, 11, 12, and 13. These SRMC short-term results are presented along with the results for the long-term analyses provided by SRNL.

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DOE OSTI2021

X-ray diffraction and scanning electron microscope characterizations of the salt waste processing facility tank 101 and tank 104 solid samples

The “as-received” Salt Waste Processing Facility (SWPF) Tank 101 and two Tank 104 samples (pre-wash and washed solids) have been characterized using x-ray diffraction (XRD) and scanning electron microscope/energy dispersive x-ray (SEM/EDX) techniques to address the concerns for the existence of solids, which may interfere with the operational performance of the SWPF crossflow filtration process.

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DOE OSTI2023

Characterization of the Soluble and Insoluble Portions of Solids from the Salt Waste Processing Facility Tank 201 and Tank 202 Samples

The Salt Waste Processing Facility (SWPF) Tank 201 and Tank 202 samples have been characterized using X-ray diffraction (XRD), scanning electron microscope/energy dispersive x-ray (SEM/EDX), particle size analysis (PSA-Microtrac), Fourier transform-infrared (FT-IR) and nuclear magnetic resonance ( 1 H NMR) spectroscopic techniques to characterize and identify organic and inorganic components in Tanks 201 and 202 as part of efforts to understand the problems occurring at SWPF due to the presence of solids in the recovered solvent.

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DOE OSTI2020

Tank 49H Solids Disturbance Analysis

Tank 49H will serve as the feed tank for the Salt Waste Processing Facility (SWPF). Transfers into Tank 49H may disturb solids that have settled to the bottom of the tank, resulting in feed that may exceed the insoluble solids content limit of 1200 mg/L from the SWPF Waste Acceptance Criteria (WAC). During a transfer into Tank 49H, material that free falls from the Tank 49H B4 downcomer and passes through the supernate could potentially disturb the solids on the bottom of the tank and scour or suspend solids from a settled solids layer or turbid region. The scope of this task is to perform fluid flow analysis to determine the impact of a “plunging jet” through the B4 downcomer on solids in Tank 49H and to determine a minimum liquid level to be maintained in Tank 49H prior to transfers that will minimize disturbing the solids and exceeding the SWPF WAC limits for insoluble solids carryover to SWPF.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Tank 49H solids disturbance analysis

Tank 49H serves as the feed tank for the Salt Waste Processing Facility (SWPF). Transfers into Tank 49H may disturb any solids that have settled to the bottom of the tank, resulting in feed that may exceed the insoluble solids content limit of 1,200 mg/L of the SWPF Waste Acceptance Criteria (WAC). During a transfer into Tank 49H, material that free falls into Tank 49H through a downcomer could potentially disturb any solids on the bottom of the tank and scour or suspend solids from a settled solids layer or turbid region. A previous analysis and report evaluated the potential to disturb solids when transferring into Tank 49H through the B4 riser and recommended a minimum tank level of 120 inches to prevent disturbing any solids in the bottom of the tank. The scope of this task is to perform additional fluid flow analysis to determine whether accounting for disturbed particle settling and particle mixing and dispersion during transfer could allow the minimum liquid level to be reduced below 120 inches. The analysis utilized models from the technical literature to calculate the size and shape of the “plunging jet” as a function of input parameters such as initial velocity, initial jet diameter, elevation of the initial jet, liquid level in the tank, and solids depth. The analysis relied on the M-Star® simulations performed for the previous analysis to provide bounding estimates of the amount of solid particles disturbed and used the MStar® software to calculate the dispersion and mixing of the disturbed solids with other liquid in the tank as the solids are transported to the transfer pump. The analysis showed that with a solid particle size of 5 micron or less, a liquid level of 120 inches should be maintained to prevent significant disturbance of the solid layer at the bottom of Tank 49H.

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DOE OSTI2026

Characterization of Precipitate Reactor Feed Tank (PRFT) Batches 44 and 49 from the Defense Waste Processing Facility (DWPF)

The Savannah River Site (SRS) Defense Waste Processing Facility (DWPF) processes a Monosodium Titanate/Sludge Solids (MST/SS) waste stream received from the Salt Waste Processing Facility (SWPF) via the Precipitate Reactor Feed Tank (PRFT). During processing, DWPF is required to provide evidence of compliance with the Waste Acceptance Product Specifications (WAPS). Savannah River Mission Completion (SRMC) has requested Savannah River National Laboratory (SRNL) to analyze PRFT samples representing each SWPF salt batch for thirty-two radionuclides. Additionally, elemental analysis of PRFT slurry and MST/SS solids was performed to aid SRMC in further refinement of the inputs and assumptions used in future frit development and Material Tracking Program calculations. The analyses of PRFT Batches 44 and 49, which correspond to material from the processing of Salt Batches (StB) 12 and 11, respectively, are reported herein. The unwashed dried solids of the PRFT Batches 44 and 49 are predominately MST, ~63-59% MST. The two batches have a much higher amount of Fe, Mn, and Ni compared to all previous batches. For Batch 44 this appears to be due to the use of a sludge simulant filter aid during processing of StB 12 and for Batch 49, it is possibly due to the larger amount of insoluble solids for StB 11 in comparison to all previous salt batches. Like previous PRFT batches, a significant amount of the unwashed dried solids are alkaline earth metals. The total sulfate, in mg/kg of slurry, for PRFT Batches 44 and 49 is 119 and 139, respectively, which is well below the current sulfate concentration used in Material Tracking Program calculations and is in agreement with DWPF laboratory sulfate measurements.

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DOE OSTI2024

Characterization of Precipitate Reactor Feed Tank (PRFT) Batches 15, 22, and 26 from the Defense Waste Processing Facility (DWPF)

The Savannah River Site (SRS) Defense Waste Processing Facility (DWPF) processes a Monosodium Titanate/Sludge Solids (MST/SS) waste stream received from the Salt Waste Processing Facility (SWPF) via the Precipitate Reactor Feed Tank (PRFT). During processing, DWPF is required to provide evidence of compliance with the Waste Acceptance Product Specifications (WAPS) to ensure acceptance of their vitrified high-level waste (HLW) into the Civilian Radioactive Waste Management System. Production Records must document the constituents of the MST/SS material in the PRFT from each salt batch (StB) processed at SWPF. Savannah River Mission Completion (SRMC) has requested Savannah River National Laboratory (SRNL) to analyze PRFT samples representing each SWPF salt batch for thirty-two radionuclides. Additionally, elemental analysis of PRFT slurry and MST/SS solids was performed to aid SRMC in further refinement of the inputs and assumptions used in future frit development and Material Tracking Program calculations. The analyses of PRFT Batches 15, 22, and 26, which corresponds to material from the processing of StB4, StB5, and StB7, respectively, are reported herein. The unwashed dried solids of the PRFT batches were found to be 86-87% MST. Additionally, the total sulfur values are well below the assumed 982 mg of sulfate/kg of PRFT slurry used in Material Tracking Program calculations.

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DOE OSTI2021

Tank 49H Solids Disturbance Analysis

Tank 49H will serve as the feed tank for the Salt Waste Processing Facility (SWPF). Transfers into Tank 49H may disturb solids that have settled to the bottom of the tank, resulting in feed that may exceed the insoluble solids content limit of 1,200 mg/L from the SWPF Waste Acceptance Criteria (WAC). During a transfer into Tank 49H, material that free falls into Tank 49H through a downcomer and passes through the supernate could potentially disturb the solids on the bottom of the tank and scour or suspend solids from a settled solids layer or turbid region. A previous analysis and report evaluated the potential to disturb solids when transferring into Tank 49H through the B4 riser and recommended a minimum tank level of 120 inches to prevent disturbing any solids in the bottom of the tank. The scope of this task is to perform additional fluid flow analysis to determine the impact of a “plunging jet” through the C3 downcomer on solids in Tank 49H and to determine a minimum liquid level to be maintained in Tank 49H prior to transfers that will minimize disturbing the solids and exceeding the SWPF WAC limits for insoluble solids carryover to SWPF since the C3 riser downcomer is at a lower elevation and farther away from the B5 transfer pump than the B4 downcomer.

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

Tank 49H Solids Disturbance Analysis

Tank 49H will serve as the feed tank for the Salt Waste Processing Facility (SWPF). Transfers into Tank 49H may disturb solids that have settled to the bottom of the tank, resulting in feed that may exceed the insoluble solids content limit of 1,200 mg/L from the SWPF Waste Acceptance Criteria (WAC). During a transfer into Tank 49H, material that free falls into Tank 49H through a downcomer and passes through the supernate could potentially disturb the solids on the bottom of the tank and scour or suspend solids from a settled solids layer or turbid region. A previous analysis and report evaluated the potential to disturb solids when transferring into Tank 49H through the B4 riser and recommended a minimum tank level of 120 inches to prevent disturbing any solids in the bottom of the tank. The scope of this task is to perform additional fluid flow analysis to determine the impact of a “plunging jet” through the C3 downcomer on solids in Tank 49H and to determine a minimum liquid level to be maintained in Tank 49H prior to transfers that will minimize disturbing the solids and exceeding the SWPF WAC limits for insoluble solids carryover to SWPF since the C3 riser downcomer is at a lower elevation and farther away from the B5 transfer pump than the B4 downcomer.

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

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

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

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DOE OSTI2023

Investigation of Potential Routes for Titanium and Mercury Concentrations within Salt Waste Processing Facility

Savannah River National Laboratory (SRNL) has been requested by Savannah River Mission Completion (SRMC)/ Salt Waste Processing Facility (SWPF) personnel to investigate the potential routes for titanium and mercury accumulations within the SWPF Flowsheet. The first part of this work examined how various forms of mercury can migrate through the solvent extraction system. This entailed single stage distribution tests, a multi-stage Extraction-Scrub-Strip (ESS) test, and a detailed speciation analysis of several salt batch feed samples.

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DOE OSTI2021

Increased Fissile Loading Flowsheet Review

A request was made by H-Canyon Process Engineering to assess the impact of blending dissolved, neutralized Spent Nuclear Fuel (SNF) with future sludge batches and their impact on downstream processing facilities including the Concentration, Storage and Transfer Facilities (CSTF), the Salt Waste Processing Facility (SWPF), the Defense Waste Processing Facility (DWPF), Saltstone, and the Effluent Treatment Facility (ETF). The purpose of this change is to accelerate the deinventory of SNF which is currently stored in the L-Area Disassembly Basin. The addition of SNF increases the mass of fissiles in each future sludge batch, due to their high enrichment. This high enrichment has the potential to complicate the programs to eliminate criticality events in the downstream processing facilities and will increase the number of canisters produced by DWPF because of the SNF mass increase. A separate report addressed the impacts to glass. The review and subsequent calculations were based on average predicted compositions of Accelerated Basin Deinventory (ABD) slurry, average compositions for predicted future sludge batches, average past salt batches and average past recycle batches to predict the feeds that will be processed in SWPF, DWPF, Saltstone, the 2H evaporator and ETF. Each of the processes was evaluated for potential issues.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

An Assessment of the Materials of Construction for the Transfer Lines and Unit Operations Equipment Associated with the Recycle Diversion Process

The Defense Waste Processing Facility (DWPF) processes and vitrifies radioactive waste that it receives from the Concentration, Storage, and Transfer Facility (CSTF) and Salt Waste Processing Facility (SWPF). As a result of the evaporation of water during both the melter feed preparation and the melter feed vitrification steps in DWPF, a recycle waste stream is generated, neutralized, and sent back to the CSTF. The recycle waste is a dilute water stream originating from the collection of condensate liquids containing some minor sludge and frit solids and other waste components primarily resulting from entrainment into the condensate during foam-over events. The recycle stream volume is significant and is expected to approach 3 million gallons per year once the SWPF reaches full operation. Diverting the bulk of the recycle waste stream from the CSTF is essential for the eventual closure of the waste tanks, and hence the completion of the SRS liquid waste mission.

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DOE OSTI2024

Investigation of Mercury Compound Partitioning Through the Solvent Extraction System

Savannah River National Laboratory (SRNL) has been requested by Savannah River Mission Completion (SRMC)/ Salt Waste Processing Facility (SWPF) personnel to investigate the potential routes for titanium and mercury accumulations within the SWPF Flowsheet. This report documents work performed to examine how various forms of mercury can migrate through the multiple flowsheets of a solvent extraction system. This entailed 29 single stage distribution tests, a multi-stage Extraction-Scrub-Strip (ESS) test, and a detailed speciation analysis of several salt batch feed samples.

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DOE OSTI2021

An Evaluation of the Impact of Glycolate and Glycolate Mitigation on the Defense Waste Processing Facility Recycle Diversion Project Flowsheet

The Savannah River Site (SRS) Defense Waste Processing Facility (DWPF) processes radioactive High Level Waste (HLW) sludge solids from the Concentration, Storage, and Transfer Facilities (CSTF); which includes the SRS Tank Farm and Evaporator facilities, and a concentrated Cs-137 laden stream and a Monosodium Titanate (MST) and sludge solids stream from the SRS Salt Waste Processing Facility (SWPF). The waste is chemically adjusted with acids and reductant (currently with 50 wt.% nitric acid and ~90 wt.% formic acid, but eventually formic acid will be substituted with ~70 wt.% glycolic acid), and frit is added so that a durable, borosilicate glass waste form can be produced when the material is vitrified in the melter. As a result of the evaporation of water during both the melter feed preparation and the melter feed vitrification steps in DWPF, a recycle waste stream is generated, neutralized, and sent back to the CSTF. The recycle waste is a dilute aqueous stream originating from the collection of condensate liquids containing some minor sludge, MST, and frit solids and other waste components resulting from melter feed entrainment during foamover events and transfer of volatile species into the condensate. The recycle stream volume is significant and is expected to approach 3 million gallons per year once SWPF reaches full operation, requiring the use of multiple large CSTF tanks for storage. The recycle waste is currently collected in the SRS Tank Farm and periodically evaporated in the 242-16H (2H) Evaporator to conserve storage space.

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DOE OSTI2023

Measurement Acceptance Region (MAR) Assessment Results Based on Confirmation Sample Sludge Batch 10 Projections

The Defense Waste Processing Facility (DWPF) is currently preparing to initiate processing of Sludge Batch 10 (SB10), which is comprised of material from Tanks 11H, 13H, 15H, 26F, 40H (heel only), and Alternate Feed Stock-2 and Sodium Reactor Experiment material from H-Canyon. Frit 473 was recommended for sludge-only (SO) and coupled processing with the Salt Waste Processing Facility (SWPF) based on previous assessments of SB10 projections with the DWPF Product Composition Control System (PCCS) glass property models and their associated Measurement Acceptance Region (MAR) constraints. Savannah River Mission Completion (SRMC) subsequently pursued Wash Cycle Y to further reduce the total sulfur in the sludge batch and increase processing flexibility at DWPF. In October 2022, SRMC System Planning provided an updated SB10 Tank 40H blend baseline projection based on the Tank 51 confirmation sample results. Due to the reduced Na concentration relative to previous SB10 projections, two additional projections based on the addition of 7,000 gallons of caustic were provided in November 2022.

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