Engineering topics
Stone, M
Publications and source records attributed to Stone, M.
IMPACT OF THE SMALL COLUMN ION EXCHANGE PROCESS ON THE DEFENSE WASTE PROCESSING FACILITY - 12112
The Savannah River Site (SRS) is investigating the deployment of a parallel technology to the Salt Waste Processing Facility (SWPF, presently under construction) to accelerate high activity salt waste processing. The proposed technology combines large waste tank strikes of monosodium titanate (MST) to sorb strontium and actinides with two ion exchange columns packed with crystalline silicotitanate (CST) resin to sorb cesium. The new process was designated Small Column Ion Exchange (SCIX), since the ion exchange columns were sized to fit within a waste storage tank riser. Loaded resins are to be combined with high activity sludge waste and fed to the Defense Waste Processing Facility (DWPF) for incorporation into the current glass waste form. Decontaminated salt solution produced by SCIX will be fed to the SRS Saltstone Facility for on-site immobilization as a grout waste form. Determining the potential impact of SCIX resins on DWPF processing was the basis for this study. Accelerated salt waste treatment is projected to produce a significant savings in the overall life cycle cost of waste treatment at SRS.
DWPF FLOWSHEET STUDIES WITH SIMULANT TO DETERMINE THE IMPACT OF NEXT GENERATION SOLVENT ON THE CPC PROCESS AND GLASS FORMULATION
As a part of the Actinide Removal Process (ARP)/Modular Caustic Side Solvent Extraction Unit (MCU) Life Extension Project, a next generation solvent (NGS), a new strip acid, and modified monosodium titanate (mMST) will be deployed. The NGS is comprised of four components: 0.050 M MaxCalix (extractant), 0.50 M Cs-7SB (modifier), 0.003 M guanidine-LIX-79, with the balance ({approx}74 wt%) being Isopar{reg_sign} L. The strip acid will be changed from dilute nitric acid to dilute boric acid (0.01 M). Because of these changes, experimental testing with the next generation solvent and mMST was required to determine the impact of these changes in 512-S and Defense Waste Processing Facility (DWPF) operations, as well as Chemical Process Cell (CPC), glass formulation activities, and melter operations. Because of these changes, experimental testing with the next generation solvent and mMST is required to determine the impact of these changes. A Technical Task Request (TTR) was issued to support the assessments of the impact of the next generation solvent and mMST on the downstream DWPF flowsheet unit. The TTR identified five tasks to be investigated: (1) CPC Flowsheet Demonstration for NGS; (2) Solvent Stability for DWPF CPC Conditions; (3) Glass Formulation Studies; (4) Boron Volatility and Melt Rate; and (5) CPC Flowsheet Demonstration for mMST.
PARTITIONING OF GADOLINIUM IN THE CHEMICAL PROCESSING CELL
A combination of short-term beaker tests and longer-duration Sludge Receipt and Adjustment Tank (SRAT) simulations were performed to investigate the relative partitioning behaviors of gadolinium and iron under conditions applicable to the Chemical Processing Cell (CPC). The testing was performed utilizing non-radioactive simple Fe-Gd slurries, non-radioactive Sludge Batch 6 simulant slurries, and a radioactive real-waste slurry representative of Sludge Batch 7 material. The testing focused on the following range of conditions: (a) Fe:Gd ratios of 25-100; (b) pH values of 2-6; (c) acidification via addition of nitric, formic, and glycolic acids; (d) temperatures of {approx}93 C and {approx}22 C; and (e) oxalate concentrations of <100 mg/kg and {approx}10,000 mg/kg. The purpose of the testing was to provide data for assessing the potential use of gadolinium as a supplemental neutron poison when dispositioning excess plutonium. Understanding of the partitioning behavior of gadolinium in the CPC was the first step in assessing gadolinium's potential applicability. Significant fractions of gadolinium partitioned to the liquid-phase at pH values of 4.0 and below, regardless of the Fe:Gd ratio. In SRAT simulations targeting nitric and formic acid additions of 150% acid stoichiometry, the pH dropped to a minimum of 3.5-4.0, and the maximum fractions of gadolinium and iron partitioning to solution were both {approx}20%. In contrast, in a SRAT simulation utilizing a nitric and formic acid addition under atypical conditions (due to an anomalously low insoluble solids content), the pH dropped to a minimum of 3.7, and the maximum fractions of gadolinium and iron partitioning to solution were {approx}60% and {approx}70%, respectively. When glycolic acid was used in combination with nitric and formic acids at 100% acid stoichiometry, the pH dropped to a minimum of 3.6-4.0, and the maximum fractions of gadolinium and iron partitioning to solution were 60-80% and 3-5%, respectively. Thus, the presence of glycolic acid increased dissolution of gadolinium, but decreased dissolution of iron. In beaker tests, the fractions of gadolinium partitioning to solution were all less than the minimum detection limits at pH 6, on the order of a few percent at pH 4, and ranging from 70-90% at pH 2. In contrast, the fractions of iron partitioning to solution were all less than the minimum detection limits at pH 6, {le} 0.04% at pH 4, and {le} 0.9% at pH 2. A possible explanation for the small magnitude of these fractions (as compared to the fractions observed in the SRAT simulations) was incomplete equilibrium, due to the short duration (30 minutes) of the beaker tests. As demonstrated by the SRAT simulations, the typical partitioning equilibration time was on the order of hours. The Fe:Gd ratio appeared to impact the extent of liquid-phase conditions under certain conditions, although the exact relationship was not clear. Temperature impacts on the liquid-phase gadolinium concentrations were modest, with liquid phase concentrations typically increasing about 25% as temperatures rose from {approx}22 C to {approx}93 C. The presence of high concentrations of oxalate did not appear to change the liquid-phase gadolinium concentrations - however, it did increase the liquid-phase iron concentrations (from being undetectable to being detectable but still minor). Additional gadolinium partitioning testing is recommended. Of greatest usefulness will be SRAT simulations focusing on a wider range of acid addition scenarios and alternate sludge compositions, particularly those specific to future sludge batches where addition of excess plutonium is being considered.
GLYCOLIC-FORMIC ACID FLOWSHEET FINAL REPORT FOR DOWNSELECTION DECISION
Flowsheet testing was performed to develop the nitric-glycolic-formic acid flowsheet (referred to as the glycolic-formic flowsheet throughout the rest of the report) as an alternative to the nitric/formic flowsheet currently being processed at the DWPF. This new flowsheet has shown that mercury can be removed in the Sludge Receipt and Adjustment Tank (SRAT) with minimal hydrogen generation. All processing objectives were also met, including greatly reducing the Slurry Mix Evaporator (SME) product yield stress as compared to the baseline nitric/formic flowsheet. Forty-six runs were performed in total, including the baseline run and the melter feed preparation runs. Significant results are summarized. The baseline nitric/formic flowsheet run, using the SB6 simulant produced by Harrell was extremely difficult to process successfully under existing DWPF acceptance criteria with this simulant at the HM levels of noble metals. While nitrite was destroyed and mercury was removed to near the DWPF limit, the rheology of the SRAT and SME products were well above design basis and hydrogen generation far exceeded the DWPF SRAT limit. In addition, mixing during the SME cycle was very poor. In this sense, the nitric/glycolic/formic acid flowsheet represents a significant upgrade over the current flowsheet. Mercury was successfully removed with almost no hydrogen generation and the SRAT and SME products yield stresses were within process limits or previously processed ranges. The glycolic-formic flowsheet has a very wide processing window. Testing was completed from 100% to 200% of acid stoichiometry and using a glycolic-formic mixture from 40% to 100% glycolic acid. The testing met all processing requirements throughout these processing windows. This should allow processing at an acid stoichiometry of 100% and a glycolic-formic mixture of 80% glycolic acid with minimal hydrogen generation. It should also allow processing endpoints in the SRAT and SME at significantly higher total solids content and may be effective at acid stoichiometries below 100%, although no testing was performed below 100% acid stoichiometry. There are several issues related to the development of the glycolic-formic flowsheet. First, the measurement of anions using the new glycolate anion procedure likely needs to be optimized to improve the accuracy of the anions important to DWPF processing and REDOX prediction. Second, the existing REDOX equation with an added term for glycolate did not accurately predict the glass REDOX for the glycolic-formic flowsheet. Improvement of the anion measurement or modification of the REDOX methodology or equation may be necessary to improve the REDOX prediction. Last, the glycolic-formic flowsheet dissolves a number of metals, including iron. This leads to a thinner slurries but also dissolves up a portion of the iron, which is currently used for criticality control. It is recommended that DWPF continue to support development of the glycolic-formic flowsheet. This flowsheet meets or outperforms the baseline flowsheet in off-gas generation, mercury removal, product rheology and general ease of processing. Additional testing is in progress to demonstrate the effectiveness of the nitric-glycolic-formic flowsheet in processing a wide sludge processing window using the matrix sludge simulants.
GLYCOLIC - FORMIC ACID FLOWSHEET DEVELOPMENT
Flowsheet testing was performed to further develop the nitric/glycolic/formic acid flowsheet as an alternative to the nitric/formic flowsheet currently being processed at the DWPF. This new flowsheet has shown that mercury can be removed in the Sludge Receipt and Adjustment Tank (SRAT) with minimal hydrogen generation. All other processing objectives were also met, including greatly reducing the Slurry Mix Evaporator (SME) product yield stress as compared to the baseline nitric/formic flowsheet. Eight runs were performed in total, including the baseline run. The baseline nitric/formic flowsheet run was extremely difficult to process under existing DWPF acceptance criteria with this simulant at the HM levels of noble metals. While nitrite was destroyed and mercury was removed to near the DWPF limit, the rheology of the SRAT and SME products were well above design basis and hydrogen generation far exceeded the DWPF limit. In addition, mixing during the SME cycle was very poor. In this sense, the nitric/glycolic/formic acid flowsheet represents a significant upgrade over the current flowsheet. In the nitric/glycolic/formic flowsheet runs, mercury was successfully removed with almost no hydrogen generation and the SRAT and SME products yield stresses were within process limits or previously processed ranges. It is recommended that DWPF continue to support development of the nitric/glycolic/formic flowsheet. Although experience is limited at this time, this flowsheet meets or outperforms the current flowsheet in many regards, including off-gas generation, mercury removal, product rheology and general ease of processing. Additional flowsheet testing will allow for a more thorough understanding of the chemistry and effectiveness of the flowsheet over a range of sludge compositions and formic/glycolic ratios. This testing will also show whether the REDOX and metal solubility concerns with this change in the flowsheet can be addressed by just adjusting the volumes of glycolic acid added. The outstanding issues regarding the glycolic/formic flowsheet include increasing understanding of the impact on glass REDOX control and increased metal solubility, particularly iron, during processing. Additionally, evaluations of the utility of the flowsheet over varying sludge compositions should be completed to ensure flowsheet robustness. Work has already been initiated to further understand the REDOX and iron solubility areas.
PRELIMINARY EVALUATION OF DWPF IMPACTS OF BORIC ACID USE IN CESIUM STRIP FOR SWPF AND MCU
A new solvent system is being evaluated for use in the Modular Caustic-Side Solvent Extraction Unit (MCU) and in the Salt Waste Processing Facility (SWPF). The new system includes the option to replace the current dilute nitric acid strip solution with boric acid. To support this effort, the impact of using 0.01M, 0.1M, 0.25M and 0.5M boric acid in place of 0.001M nitric acid was evaluated for impacts on the DWPF facility. The evaluation only covered the impacts of boric acid in the strip effluent and does not address the other changes in solvents (i.e., the new extractant, called MaxCalix, or the new suppressor, guanidine). Boric acid additions may lead to increased hydrogen generation during the SRAT and SME cycles as well as change the rheological properties of the feed. The boron in the strip effluent will impact glass composition and could require each SME batch to be trimmed with boric acid to account for any changes in the boron from strip effluent additions. Addition of boron with the strip effluent will require changes in the frit composition and could lead to changes in melt behavior. The severity of the impacts from the boric acid additions is dependent on the amount of boric acid added by the strip effluent. The use of 0.1M or higher concentrations of boric acid in the strip effluent was found to significantly impact DWPF operations while the impact of 0.01M boric acid is expected to be relatively minor. Experimental testing is required to resolve the issues identified during the preliminary evaluation. The issues to be addressed by the testing are: (1) Impact on SRAT acid addition and hydrogen generation; (2) Impact on melter feed rheology; (3) Impact on glass composition control; (4) Impact on frit production; and (5) Impact on melter offgas. A new solvent system is being evaluated for use in the Modular Caustic-Side Solvent Extraction Unit (MCU) and in the Salt Waste Processing Facility (SWPF). The new system includes the option to replace the current dilute nitric acid strip solution with boric acid. To support this effort, the impact of using 0.01M, 0.1M, 0.25M and 0.5M boric acid in place of 0.001M nitric acid was evaluated for impacts on the DWPF facility. The evaluation only covered the impacts of boric acid in the strip effluent and does not address the other changes in solvents (i.e., the new extractant, called MaxCalix, or the new suppressor, guanidine). Experimental testing with the improved solvent is required to determine the impact of any changes in the entrained solvent on DWPF processing.