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Product consistency test results for the LAW Phase 4 gases

In this report, the Savannah River National Laboratory provides chemical analysis of Product Consistency Test (PCT) leachates from a series of simulated nuclear waste glasses fabricated at the Pacific Northwest National Laboratory (PNNL). The series included quenched and canister-centerline cooled (CCC) versions of the glasses. The resulting data will be used in the development of enhanced property/composition models for waste vitrification at Hanford. For some of the glass leachates, minor scatter among the triplicate values of some analytes were observed. For other leachates, there were more significant differences among the triplicate values. A review of the PCT data noted that there was little difference between the normalized values based on targeted or measured glass composition. Several of the study glasses have normalized concentration of element “i” (NCi) values that are greater than the Hanford Tank Waste Treatment and Immobilization Plant immobilized low-activity waste constraint of 4 g/L for boron (B), sodium (Na), and silicon (Si). The results of these glasses will help ensure the ability of advanced glass performance models to appropriately predict acceptable compositions. For the study glasses with NCi values exceeding 4 g/L, the CCC heat treatment samples had generally lower NCi values than quenched samples. The samples of the Environmental Assessment (EA) reference glass included with each PCT set had generally consistent NCi values. The release rates for boron (B), potassium (K), lithium (Li), sodium (Na), and silicon (Si) were highly correlated for the study glasses.

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Enhanced Hanford Low-Activity Waste Glass Property Data Development (Phase 3)

This work was performed for the U.S. Department of Energy (DOE) Office of River Protection (ORP) to provide expert evaluation and experimental work in support of the River Protection Project vitrification technology development1. The long-term objective of this work is to expand the property-composition database for Hanford site low-activity waste (LAW) glasses and property-composition models to cover the balance of the mission for the Hanford Waste Treatment and Immobilization Plant (WTP). When this effort is complete, enhanced LAW glass property-composition models will be developed.

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Development and Characterization of Cementitious Waste Forms for Immobilization of Granular Activated Carbon, Silver Mordenite, and HEPA Filter Media Solid Secondary Waste

At the Department of Energy’s Hanford site, over 53 million gallons of chemically complex and radioactive wastes have been stored in 177 underground tanks. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is under construction and is designed to treat and immobilize these wastes. During operations of WTP, solid secondary wastes (SSWs) will be generated as a result of waste treatment, vitrification, off-gas management, and supporting process activities. SSW treatment processes and resulting disposal pathways for the final disposition form of the SSW are needed to support direct feed low activity waste (DFLAW) operations and facilitate continued operation of WTP. The SSWs produced through WTP operations are expected to include used process equipment, contaminated tools and instruments, decontamination wastes, high-efficiency particulate air (HEPA) filters, carbon absorption beds (granular activated carbon, GAC), silver mordenite (AgM) and spent ion-exchange resins. These waste streams are planned to be immobilized in a cementitious waste form and disposed of either as stabilized/blended (non-debris) or encapsulated (debris) in a cementitious waste form. Accordingly, cementitious waste forms from these streams were included in the 2017 Integrated Disposal Facility (IDF) Performance Assessment (PA). The input data used to represent these SSW forms in the 2017 IDF PA involved many assumptions and associated uncertainties. This data limitation was due to the lack of material- and site-specific data available for representative SSW materials in cementitious matrices. To verify the assumed values used in the IDF PA and fill this limitation in available data, Washington River Protection Solutions, LLC (WRPS), has initiated a program targeted toward gathering site specific data relevant to Hanford SSW disposal. The work within this report is a continuation of this ongoing program.

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IER-519 CED-2: Final Design for Thermal/Epithermal eXperiments (TEX) with Absorbers to Provide Validation Benchmarks for Hanford Tank Farms

The Hanford tank farms contain 56 million gallons of waste across 177 tanks. The primary criticality safety concern for the waste is the plutonium inventory in waste solids – approximately 670 kg in total. Criticality safety analysis credits the absorption and dilution properties of the large quantities of other elements (aluminum, chromium, iron, manganese, nickel, silicon, sodium, and zirconium) present in the waste. Of these, iron and manganese are by far the most significant neutron absorbers, particularly for the waste compositions of highest criticality safety concern. The criticality safety analyses at the Hanford Waste Treatment and Vitrification Plant (WTP) and the Savannah River tank farms also credit iron and manganese as the primary neutron absorbers to demonstrate subcriticality.

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Ion Exchange Processing of AP-105 Hanford Tank Waste through Crystalline Silicotitanate in a Staged 2- then 3-Column System

The U.S. Department of Energy (DOE) is working to expedite processing of Hanford tank waste supernate at the Hanford Waste Treatment and Immobilization Plant (WTP). To support this goal, Washington River Protection Solutions, LLC (WRPS, Richland, WA) is designing a system for suspended solids and cesium (Cs/ 137 Cs) removal from Hanford tank waste supernate. The effluent will then be sent to the WTP Low-Activity Waste (LAW) Facility for vitrification. The Cs removal is critical for eliminating the high dose rate associated with 137 Cs and facilitating a contact maintenance philosophy for the LAW Facility. The maximum 137 Cs concentration in the LAW sent to the WTP is targeted to be below the 3.18E-5 Ci 137 Cs/mole of Na waste acceptance criteria (WAC) limit. The filtration and ion exchange systems will be placed near the Hanford tanks and are collectively termed the Tank Side Cesium Removal (TSCR) system.

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Crystalline Silicotitanate Batch Contact Testing with Ba, Ca, Pb, and Sr

Washington River Protection Solutions is working to support initial production of immobilized low-activity waste (LAW) by feeding Hanford tank supernate from tank farms to the Hanford Waste Treatment and Immobilization Plant (WTP) LAW Facility. This goal incorporates the design of a Tank Side Cesium Removal system, which filters tank waste supernate to remove suspended solids and then removes Cs by processing it through crystalline silicotitanate (CST) ion exchange media manufactured by Honeywell UOP, LLC. The 137 Cs-depleted product is intended to be sent to the WTP for vitrification. Processing of actual tank waste supernate showed effectively complete uptake of Sr and Ba by CST and significant uptake of Ca. Further, Campbell et al. (2019) analyzed CST post-column testing and found significant (>1E-2 mmoles/g) uptake of Ca and Pb along with some Ba, Cd, Fe, Sr, and U. This led to concern that selected metals, particularly the +2 cations, Ca, Sr, Ba, and Pb may be consuming Cs exchange sites and possibly reducing CST capacity for Cs. Exchange of +2 cations was assumed to be associated with the M(OH) + species for the metal (M) ion in the caustic solution. A series of batch contact testing was conducted to evaluate the exchange behavior of Ba, Ca, Pb, and Sr onto CST. The Cs exchange behavior was also tested as a benchmark for direct comparisons. The CST was provided in the sodium form by Honeywell UOP, as IONSIV TM R9140-B, Lot 2002009604, 18 x 50 mesh. A <30-mesh aliquot was collected to match the sieve fraction expected for use in upcoming small column test configurations. Kinetic exchange rate and isotherms were measured at metal concentrations benchmarked from the AP-107 tank waste feed composition and as limited by the metal solubility in the alkaline solution. Two simplified matrices were tested: 1) 1.0 M NaOH/4.6 M NaNO 3 and 2) 0.1 M NaOH/5.5 M NaNO 3 ; these matrices represented the expected 5.6 M Na concentration of process feed and served to address the hydroxide concentration effect on exchange behavior.

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Hanford Supplemental Low Activity Waste Simulant Evaporation Testing for Removal of Organics

The Hanford site has approximately 56 million gallons of radioactive waste stored in 177 underground storage tanks. The Hanford Waste Treatment and Immobilization Plant (WTP) is being built to treat and immobilize the tank waste. The baseline method for immobilization of Low Activity Waste (LAW) is vitrification, but additional immobilization capacity is likely needed to supplement the initial melters. An alternative cementitious waste form is being investigated for that future supplemental immobilization method. However, one impediment to a cementitious waste form is the presence of Land Disposal Restricted (LDR) organic chemicals in tank waste. Developing a method to remove the organics would eliminate that impediment to permit possible use of a cementitious waste form. Savannah River National Laboratory (SRNL) performed testing to examine evaporation as a method to remove some prevalent organics from the Supplemental LAW (SLAW) stream. Samples of product streams from the evaporation were analyzed to determine partitioning of the organics. Modeling was also performed to determine if the experimental and modeling results matched. A description of the experimental details, equipment, and results of that testing are included in this report.The work is intended to inform future SLAW flowsheet development activities and gather useful data about the partitioning of constituents through a possible SLAW feed evaporator.

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Characterization of the Sulfur-Saturated Melt Versions of the LAW Phase 4 Glasses

In this report, results are provided from the analyses of a series of sulfur-saturated melt versions of simulated nuclear waste glasses, and chemical analysis of the wash solution resulting from the preparation of these glasses. The glasses were selected and fabricated by the Pacific Northwest National Laboratory as part of a broader study of the influence of glass composition on chemical durability, sulfur retention, and other properties. The resulting data will be used in the development of enhanced property/composition models for waste vitrification at Hanford. Chemical analyses were performed on a representative sample of each of the sulfur-saturated versions of the quenched glasses to allow for comparisons with the targeted compositions, as well as the measured compositions of the quenched glasses. The measured concentrations of chlorine, and fluorine were below the targeted values for most of the study glasses, likely because of volatility during the multiple melting steps. The measured concentrations of B 2 O 3 , K 2 0, and Li 2 0 were generally low relative to the targeted values. As expected, the measured concentrations of SO 3 in most of the glasses were higher than targeted due to the use of the sulfur saturation method in fabricating these glasses. The wash solutions contained mainly sodium and sulfur, with moderate concentrations of potassium.

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Long-Term PCT of ILAW Glasses (Final Report FY2020)

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 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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ILAW Glass Ion-Exchange Rate Testing (Final Report FY2020)

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 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.

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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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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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Performance Criteria for Capture and/or Immobilization Technologies (Revision 1)

The capture and subsequent immobilization of regulated volatile radionuclides from the off-gas streams of a used nuclear fuel (UNF) reprocessing facility has been a topic of substantial research interest for the US Department of Energy and its international counterparts. Removal of specific radionuclides from the plant effluent streams before discharge to the environment is required to meet regulations set forth by the US Environmental Protection Agency. Upon removal, the radionuclides, as well as associated sorbents that cannot be regenerated in a cost-effective manner, are destined for conversion to a waste form. Research in separation and capture methodologies has included a wide range of technology types, and studies of waste forms are correspondingly diverse. In considering the future development and implementation of both sorbents and waste forms, it is necessary to identify benchmark measures of performance to objectively evaluate each sorbent system or waste form. Sets of performance criteria and associated metrics have been developed for sorbent and waste form evaluation. These criteria address physical, radiological, and chemical characteristics, technical practicality, technical maturity, cost, and, for sorbents, system performance. The criteria and metrics appear to be robust and should be applicable despite the eventual waste classification (as either high- or low-level waste). They are flexible enough to address both aqueous reprocessing and electrochemical reprocessing of UNF. These criteria sets can serve as tools to evaluate performance at multiple stages within the development process, and in this revision (Revision 1) they have been used to assess technologies relating to krypton/xenon separations and iodine capture from off-gas streams arising from UNF reprocessing. Assessment of krypton/xenon separations using engineered forms of two zeolite minerals (silver mordenite and hydrogen mordenite in a polyacrylonitrile-based binder [AgZ-PAN/HZ-PAN]) found that the zeolite-based separation is relatively advanced in its development, but several key issues require resolution. First, desorption processes for both krypton and xenon require refinement to provide an understanding of the product purity that can be achieved. Second, adsorption rate data is needed in order to calculate the bed depth required for effective separation. Finally, it is strongly recommended that a technical review of krypton/xenon separation by AgZ-PAN/HZ-PAN be performed to synergize available data and assess the cost savings and operational benefits that may be realized from implementation of this technology. Assessment of metal organic frameworks (MOFs) for their use in the separation of krypton/xenon found that the ideal separation would be performed using a single-column system with a MOF selective for krypton over xenon. A robust research effort should work to identify a krypton-selective MOF designed to operate at temperatures of approximately 0°C or higher, which could be preferred over cryogenic krypton/xenon capture for used fuel reprocessing off-gas streams. In the case of the CaSDB-MOF (the most well-understood xenon sorbent to date), two issues are judged of high importance. First, xenon breakthrough capacity for the CaSDB-MOF in prototypical conditions should be determined. Preliminary research indicates that breakthrough may be near immediate, presenting a substantial obstacle in separative system design. Second, development of desorption methodology should be performed to determine regeneration time, energy requirements, and the product stream composition. Silver-based sorbents (AgZ and AgAero) for use in iodine capture from the dissolver off-gas were evaluated against the established criteria. These sorbents are significantly better understood for this application as a result of research efforts over the past decade. The potential implementation of AgAero at a large scale is hindered by its physical degradation by components of the dissolver off-gas stream. Less is known about the adsorption of iodine by these sorbents from other off-gas streams in the plant. Initial experimental efforts have been closely coordinated in an effort to understand organic iodine (such as would be found in the vessel off-gas) adsorption by AgZ and AgAero. Future work should expand this experimental program, and analysis of other reprocessing facility off-gas streams such as the vitrification off-gas stream should be conducted to better understand other potential applications for iodine sorbents. A review of iodine waste form development shows that this area is diverse and that multiple promising waste forms have been identified for the immobilization of radioactive iodine. Efforts related to the direct conversion of iodine sorbents (including AgZ and AgAero) should be continued because of the advantages of direct conversion in a waste management strategy and other sorbents should continue to be advanced as merited.

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Modeling of Glycolate Destruction in the Recycle Collection Tank

The Savannah River Site’s DWPF is being upgraded with the introduction of the NG flowsheet. Glycolic acid has been shown to be a superior alternative to formic acid for sludge processing. The new flowsheet improves or maintains necessary parameters such as 1) reduction of mercury, 2) adjustment of feed rheology, 3) pH stability, and 4) adjustment of melter oxidation/reduction potential. Further, the use of glycolic acid virtually eliminates the potential for catalytic hydrogen generation in DWPF processing DWPF process condensates are collected and returned to the Savannah River Site (SRS) CSTF. The RCT collects off-gas condensate during chemical processing, vitrification, and other unit operations performed in DWPF and is the singular return vessel delivering recycle effluent back to CSTF. Each batch of recycle will have a small amount of glycolate from chemical processing and melter off-gas condensates. To avoid potential flammability issues due to thermolysis of glycolate in the CSTF, Savannah River National Laboratory (SRNL) provided to Savannah River Remediation (SRR) at their request a Task Technical and Quality Assurance Plan (TTQAP) to quantify and mitigate glycolate returns via DWPF’s recycle stream. The request included testing of a process to oxidize glycolate and other organic species that are responsible for hydrogen generation from thermolysis. Following that work SRR provided a Task Technical Request (TTR) that requested process modeling. In 2021 a TTQAP was issued to cover the modeling work. Modeling draws data from laboratory scale studies using chemical simulants and radioactive waste samples. Chemical kinetic modeling was performed to evaluate the feasibility of using sodium permanganate to destroy glycolate in the RCT. The results from the laboratory studies were summarized in a series of reports. Reference 9 is a report of lab scale processing of actual DWPF Slurry Mix Evaporate Condensate Tank (SMECT) and Offgas Condensate Tank (OGCT) samples in the SRNL Shielded Cells. Tests at caustic conditions demonstrated sodium permanganate was effective in converting glycolate to oxalate, and permanganate (Mn 7+ ) is reduced to manganate (Mn 6+ ) with no significant formation of carbon dioxide or carbonate. Equation (1) was found to best describe the observed reaction of glycolate with permanganate under nominal (60 to 145 mg/L in RCT) glycolate entrainment conditions.

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Composition Measurements of the LAW Phase 5 Glasses

This report provides the results from the chemical analyses of glass compositions for the Low-Activity Waste Phase 5 study glasses, a series of simulated nuclear waste glasses fabricated at Pacific Northwest National Laboratory. These data will be used in the development of enhanced property/composition models for waste glass vitrification at Hanford. Chemical analyses were performed on a representative sample of each of the quenched glasses to allow for comparisons with targeted compositions. The relative differences between the targeted and measured concentrations of CaO, Cl - , K 2 O, Li 2 O, and SO 3 for some of the glasses were greater than 10%. Several of these glass samples were rerun to verify original measurements; however, there were no significant changes in the measurements to indicate errors in preparation or analysis of the samples. These results can be used in further characterization of this series of glasses, including the normalization of Product Consistency Test results.

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Product Consistency Test Results for the LAW Phase 5 Glasses

This report provides the results of the Vapor Hydration Test solutions and the Product Consistency Test leachates from the Low-Activity Waste Phase 5 glasses, a series of simulated nuclear waste glasses fabricated at the Pacific Northwest National Laboratory. The series included quenched and canister-centerline cooled versions of the glasses. These data will be used in the development of enhanced property/composition models for waste glass vitrification at Hanford. Several of the blanks had detectable amounts of sodium and/or silicon. The measured concentrations (mg/L) of boron, sodium, and silicon for the low-activity test reference material glass included with the Product Consistency Tests were much lower than the expected low-activity test reference material test results. A review of the Product Consistency Test data indicated that there was generally little difference between the normalized values based on targeted or measured glass composition. Heat treatment had various impacts on the normalized concentration values. Most of the glasses had NC B , NC Na , and NC Si values that were greater than the Hanford Tank Waste Treatment and Immobilization Plant low-activity waste constraint of 4 g/L. The release rates for boron, sodium, and silicon were highly correlated for the study glasses.

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Maximum Cs-137 Curie Loading onto Crystalline Silicotitanate for the Documented Safety Analysis of the Tank Side Cesium Removal Platform

The Tank Side Cesium Removal (TSCR) system is currently being constructed to process Hanford tank waste supernates for vitrification. TSCR incorporates a filtration system and cesium (Cs) removal system using columns filled with crystalline silicotitanate (CST) ion exchanger, produced by Honeywell UOP, LLC. The documented safety analysis (DSA) developed for TSCR limits a single column curie loading to 141,600 Ci; given a 137 Cs isotopic mass fraction of 20% and the planned CST bed size of a TSCR column, this equates to 0.10 mmole Cs per g CST. Factors that influence 137Cs loading onto the CST include, but are not limited to, CST production lot (different production lots behave differently), contact temperature, contact duration, 137Cs mass fraction, and competitors in the tank waste feed. Seventeen tank waste feeds (compositions) were identified by Washington River Protection Solutions to be processed through TSCR. These feed compositions were used to develop a simulant (referred to herein as Stage 1) that would provide an upper bound to the Cs loading onto CST based on maximizing the Cs/Na activity coefficient ratios in solution while maintaining Na at no less than 5.0 M. Building upon this Stage 1 simulant, a series of four additional simulants were developed based on the cationic/anionic species that impact Cs exchange, with each successive formulation relaxing one or more matrix component concentration constraints as show in Table S.1

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Composition Measurements of the LAW ALG Glasses

This report provides the results from the chemical analyses of glass compositions for the Low-Activity Waste Algorithm study glasses, a series of simulated nuclear waste glasses designed and fabricated at Pacific Northwest National Laboratory. These data will be used in the development, validation, and implementation of enhanced property/composition models for waste glass vitrification at Hanford.

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