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DOE OSTI2016

Cesium Isotherm Testing with Spherical Resorcinol-Formaldehyde Resin at High Sodium Concentrations

Washington River Protection Solutions (WRPS) is developing a Low-Activity Waste Pretreatment System (LAWPS) to provide low-activity waste (LAW) directly to the Hanford Tank Waste Treatment and Immobilization Plant (WTP) Low-Activity Waste Facility for immobilization. The pretreatment that will be conducted on tank waste supernate at the LAWPS facility entails filtration to remove entrained solids and cesium (Cs) ion exchange to remove Cs from the product sent to the WTP. Currently, spherical resorcinol-formaldehyde (sRF) resin (Microbeads AS, Skedsmokorset, Norway) is the Cs ion exchange resin of choice. Most work on Cs ion exchange efficacy in Hanford tank waste has been conducted at nominally 5 M sodium (Na). WRPS is examining the possibility of processing supernatant at high Na concentrations—up to 8 M Na—to maximize processing efficiency through the LAWPS. Minimal Cs ion exchange work has been conducted at 6 M and 8 M Na concentrations..

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DOE OSTI2016

Liquid Secondary Waste Grout Formulation and Waste Form Qualification

This report describes the results from liquid secondary waste (LSW) grout formulation and waste form qualification tests performed at Pacific Northwest National Laboratory (PNNL) for Washington River Protection Solutions (WRPS) to evaluate new formulations for preparing a grout waste form with high-sulfate secondary waste simulants and the release of key constituents from these grout monoliths. Specific objectives of the LSW grout formulation and waste form qualification tests described in this report focused on five activities: 1.preparing new formulations for the LSW grout waste form with high-sulfate LSW simulants and solid characterization of the cured LSW grout waste form; 2.conducting the U.S. Environmental Protection Agency (EPA) Method 1313 leach test (EPA 2012) on the grout prepared with the new formulations, which solidify sulfate-rich Hanford Tank Waste Treatment and Immobilization Plant (WTP) off-gas condensate secondary waste simulant, using deionized water (DIW); 3.conducting the EPA Method 1315 leach tests (EPA 2013) on the grout monoliths made with the new dry blend formulations and three LSW simulants (242-A evaporator condensate, Environmental Restoration Disposal Facility (ERDF) leachate, and WTP off-gas condensate) using two leachants, DIW and simulated Hanford Integrated Disposal Facility (IDF) Site vadose zone pore water (VZPW); 4.estimating the 99 Tc desorption K d (distribution coefficient) values for 99 Tc transport in oxidizing conditions to support the IDF performance assessment (PA); 5.estimating the solubility of 99 Tc(IV)-bearing solid phases for 99 Tc transport in reducing conditions to support the IDF PA.

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DOE OSTI2017

Support for HLW Direct Feed - Phase 2, VSL-15R3440-1

This report describes work performed to develop and test new glass and feed formulations originating from a potential flow-sheet for the direct vitrification of High Level Waste (HLW) with minimal or no pretreatment. In the HLW direct feed option that is under consideration for early operations at the Hanford Tank Waste Treatment and Immobilization Plant (WTP), the pretreatment facility would be bypassed in order to support an earlier start-up of the vitrification facility. For HLW, this would mean that the ultrafiltration and caustic leaching operations that would otherwise have been performed in the pretreatment facility would either not be performed or would be replaced by an interim pretreatment function (in-tank leaching and settling, for example). These changes would likely affect glass formulations and waste loadings and have impacts on the downstream vitrification operations. Modification of the pretreatment process may result in: (i) Higher aluminum contents if caustic leaching is not performed; (ii) Higher chromium contents if oxidative leaching is not performed; (iii) A higher fraction of supernate in the HLW feed resulting from the lower efficiency of in-tank washing; and (iv) A higher water content due to the likely lower effectiveness of in-tank settling compared to ultrafiltration. The HLW direct feed option has also been proposed as a potential route for treating HLW streams that contain the highest concentrations of fast-settling plutoniumcontaining particles, thereby avoiding some of the potential issues associated with such particles in the WTP Pretreatment facility [1]. In response, the work presented herein focuses on the impacts of increased supernate and water content on wastes from one of the candidate source tanks for the direct feed option that is high in plutonium.

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DOE OSTI2016

Enhanced LAW Glass Correlation - Phase 1

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 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. Acceptable glass formulations for vitrification of Hanford low activity waste (LAW) must meet a variety of product quality, processability, and waste loading requirements. To this end, The Vitreous State Laboratory (VSL) at The Catholic University of America (CUA) developed and tested a number of glass formulations during Part A, Part B1 and Part B2 of the WTP development program. The testing resulted in the selection of target glass compositions for the processing of eight of the Phase I LAW tanks. The selected glass compositions were tested at the crucible scale to confirm their compliance with ILAW performance requirements. Duramelter 100 (DM100) and LAW Pilot Melter tests were then conducted to demonstrate the viability of these glass compositions for LAW vitrification at high processing rates.

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DOE OSTI2015

Self-Flammability of Gases Generated by Hanford Tank Waste and the Potential of Nitrogen Inerting to Eliminate Flammability Safety Concerns

Through radiolytic and thermolytic reactions, Hanford tank wastes generate and retain a variety of gases, including hydrogen, nitrous oxide, methane (and other hydrocarbons), ammonia, and nitrogen. This gas generation can be expected to continue during processing in the Hanford Tank Waste Treatment and Immobilization Plant (WTP). The generation rates in the WTP will change from those for the in-situ tank waste because of different process temperatures, different dose rates produced by in-process changes in the proportions of solid and liquid, and dilution of the waste liquid. The flammability of the generated gas that is continuously released, and of any retained gas that might be released into a vessel headspace in quantity due to a spontaneous release, depends on the concentrations not only of the fuel gases—primarily hydrogen (H2), methane, other hydrocarbons, and ammonia—but of the oxidizer nitrous oxide (N2O). As a result of high concentrations of N2O, some gas mixtures are “self-flammable” (i.e., ignition can occur when no air is present because N2O provides the only oxidizer needed). Self-flammability could potentially reduce the effectiveness of using a nitrogen (N2) purge in the headspace as a flammability control, if its effects are not accounted for. A given amount of inertant gas (N2) can accommodate only a certain amount of a generated self-flammable gas before the mixture with inertant gas becomes flammable.

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DOE OSTI2017

FY2016 Update on ILAW Glass Testing for Disposal at IDF

This status report provides a FY2016 update on work performed to collect information on the corrosion behavior of LAW glasses to support the IDF PA. In addition to the development of the baseline operating envelope for the WTP, since 2003, VSL has developed a wide range of LAW formulations that achieve considerably higher waste loadings than the WTP baseline formulations.

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DOE OSTI2017

Liquid secondary waste: Waste form formulation and qualification

The Hanford Site Effluent Treatment Facility (ETF) currently treats aqueous waste streams generated during site cleanup activities. When the Hanford Tank Waste Treatment and Immobilization Plant (WTP) begins operations, including Direct Feed Low Activity Waste (DFLAW) vitrification, a liquid secondary waste (LSW) stream from the WTP will need to be treated. The volume of effluent for treatment at the ETF will increase significantly. The powdered salt waste form produced by the ETF will be replaced by a stabilized solidified waste form for disposal in Hanford’s Integrated Disposal Facility (IDF). Washington River Protection Solutions is implementing a Secondary Liquid Waste Immobilization Technology Development Plan to address the technology needs for a waste form and solidification process to treat the increased volume of waste planned for disposal at the IDF. Waste form testing to support this plan is composed of work in the near term to provide data as input to a performance assessment (PA) for Hanford’s IDF. In 2015, three Hanford Liquid Secondary Waste simulants were developed based on existing and projected waste streams. Using these waste simulants, fourteen mixes of Hanford Liquid Secondary Waste were prepared and tested varying the waste simulant, the water-to-dry materials ratio, and the dry materials blend composition.1 In FY16, testing was performed using a simulant of the EMF process condensate blended with the caustic scrubber—from the Low Activity Waste (LAW) melter—, processed through the ETF. The initial EMF-16 simulant will be based on modeling efforts performed to determine the mass balance of the ETF for the DFLAW.2 The compressive strength of all of the mixes exceeded the target of 3.4 MPa (500 psi) to meet the requirements identified as potential IDF Waste Acceptance Criteria in Table 1 of the Secondary Liquid Waste Immobilization Technology Development Plan.3 The hydraulic properties of the waste forms tested (hydraulic conductivity and water characteristic curves) were comparable to the properties measured on the Savannah River Site (SRS) Saltstone waste form. Future testing should include efforts to first; 1) determine the rate and amount of ammonia released during each unit operation of the treatment process to determine if additional ammonia management is required, then; 2) reduce the ammonia content of the ETF concentrated brine prior to solidification, making the waste more amenable to grouting, or 3) manage the release of ammonia during production and ongoing release during storage of the waste form, or 4) develop a lower pH process/waste form thereby precluding ammonia release.

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DOE OSTI2017

Solid secondary waste testing for maintenance of the Hanford Integrated Disposal Facility Performance Assessment - FY 2017

The Waste Treatment and Immobilization Plant (WTP) at Hanford is being constructed to treat 56 million gallons of radioactive waste currently stored in underground tanks at the Hanford site. Operation of the WTP will generate several solid secondary waste (SSW) streams including used process equipment, contaminated tools and instruments, decontamination wastes, high-efficiency particulate air filters (HEPA), carbon adsorption beds, silver mordenite iodine sorbent beds, and spent ion exchange resins (IXr) all of which are to be disposed in the Integrated Disposal Facility (IDF). An applied research and development program was developed using a phased approach to incrementally develop the information necessary to support the IDF PA with each phase of the testing building on results from the previous set of tests and considering new information from the IDF PA calculations. This report contains the results from the exploratory phase, Phase 1 and preliminary results from Phase 2. Phase 3 is expected to begin in the fourth quarter of FY17.

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DOE OSTI2018

Results from Phase 5 Study on Nepheline Formation in High-Level Waste Glasses Containing High Concentrations of Alumina

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DOE OSTI2018

K-3 Refractory Corrosion and Sulfate Solubility Model Enhancement (Final Report)

As higher waste loading LAW glasses are formulated, sulfate solubility and K-3 refractory corrosion are two properties that become increasingly constraining; however, WTP baseline models were not developed for these properties. In previous work for ORP, VSL/Atkins developed preliminary glass property-composition models that relate LAW glass composition to these two essential properties to support the implementation of the higher waste loading LAW glass formulations at the WTP. The development of the initial LAW glass property-composition models for K-3 refractory corrosion and sulfate solubility was completed in 2015. The present work scope focused on enhancement of these models and included augmentation of property-composition datasets for these two properties with newly available data, review of the updated datasets, and development of enhanced models.

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DOE OSTI2019

Solid-liquid Separation Testing for the Remediation of Hanford Waste Treatment Plant Low Activity Waste Melter Off-Gas Condensate

The Low Activity Waste (LAW) vitrification facility at the Hanford Waste Treatment and Immobilization Plant (WTP) will generate an aqueous condensate stream (LAW Off-Gas Condensate) from the off-gas system. The plan for disposition of this stream during Direct Feed LAW operations is to transfer it to the Effluent Management Facility (EMF), where it will be concentrated by evaporation and recycled to the LAW vitrification facility again. The primary reason to recycle this stream is so that the semi-volatile 99Tc isotope eventually becomes incorporated into the glass. However, this stream also contains non-radioactive salt components that are problematic in the melter, so diversion of this stream to another process would eliminate recycling of these salts and would enable simplified operation of the LAW melter and the Pretreatment Facilities. This diversion from recycling this stream within WTP would have the effect of decreasing the quantity of glass waste produced by allowing further increases in waste loading, resulting in a shortened LAW vitrification mission duration. The concept being tested here involves selectively removing the 99 Tc so that the decontaminated aqueous stream, with the problematic salts, can be disposed as a different waste form and avoid reprocessing through vitrification.

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DOE OSTI2019

Direct Feed Low-Activity Waste Physical Property and Analyte Measurement Reduction: Recommendations for Measurement Removal

Processing of low-activity waste feed will occur at the Hanford Tank Waste Treatment and Immobilization Plant (WTP). In support of plant operations, and per requirements from the WTP contract, feed sample analyses will occur at least 18,000 times per year generating over 7,000 liters of waste. The analytical measurements are often complicated by issues such as lack of standards, low concentrations, and difficult separations. Previous work has been completed to suggest removal of physical property and elemental analyses from required measurements and this document summarizes that work.

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DOE OSTI2019

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

Solid secondary waste materials expected to be generated during Hanford Waste Treatment and Immobilization Plant (WTP) operations were characterized (using representative materials) with respect to their ability to retain technetium-99 (Tc), iodine-129 (I), and mercury (Hg) as input to future updates to the Integrated Disposal Facility (IDF) performance assessments (PAs). The waste materials included granular activated carbon (GAC), silver mordenite (AgM), and high-efficiency particulate air (HEPA) filter media; all are used for removal of contaminants and radionuclides from the gaseous effluent treatment systems within the WTP. It is expected that the GAC and AgM will be mixed into a cementitious waste form in which the GAC and AgM particles will be blended/stabilized into the cementitious material. It is also expected that the HEPA filter media will be compacted and placed in a container that is then backfilled with a grout to macroencapsulate the medium. Here we report Kds for all waste materials of interest, examine the physical properties of grout specimens containing the waste materials, and provide solid-state characterization information to further understand the interaction of the waste materials with the encapsulating grout. The Kds are used in PA calculations that estimate contaminant release from the disposal site. Monolithic test specimens were prepared with the GAC and AgM mixed in either a Cast Stone grout formulation (8 weight percent [wt%] ordinary Portland cement [OPC], 45 wt% fly ash [FA], 47 wt% blast furnace slag [BFS]) or a Hanford grout mix 5 (HGM-5) formulation (25 wt% OPC, 75 wt% FA). As the specimens were being prepared, the fluid grout mixes were characterized for processing properties including flowability, set time, and the presence of free liquids during curing. After curing, compressive strengths of the waste forms were measured; the compressive strengths were above 2000 psi, easily exceeding the 500 psi minimum requirement. The cured waste forms were also characterized for their density, porosity, hydraulic conductivity, and water characteristic curve—all properties needed in PA calculations of radionuclide release from the waste forms in the IDF. Finally, EPA Method 1315 leach tests were conducted on the GAC and AgM waste materials encapsulated in the Cast Stone and HGM-5 grouts to determine the rate of release of contaminants from the waste forms. Effective diffusivities are provided, which can be used in future PA analyses of the disposal of these solid secondary waste materials.

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DOE OSTI2020

Technical Gaps in Hanford High-Level Waste Solids Settling Behavior and Settling Time Evaluation for Direct Feed High-Level Waste (DFHLW) Operations

Settling of high-level waste (HLW) solids in process vessels is a key conceptual process step in providing HLW feed directly to the Hanford Waste Treatment and Immobilization Plant (WTP) HLW Vitrification Facility. Direct Feed High-Level Waste (DFHLW) is a potential approach to initiating HLW vitrification prior to completing of the WTP Pretreatment Facility. Settling would be used with subsequent supernatant decant to concentrate HLW feed. To support planning for DFHLW, Washington River Protection Solutions (WRPS) requested support from the Pacific Northwest National Laboratory to evaluate the current data set available to predict the time needed for HLW solids to settle, to identify gaps in the understanding and predictive capability of HLW solids waste settling times, and to provide scoping estimates of the potential settling time. Eight technical gaps were identified for predicting settling times and characteristics of the formed sediment layers including: Gap 1: In-Tank Settling Rates Faster than Settling of Laboratory Samples, Gap 2: Effect of Sludge Leaching/Washing on Predicted Settling Times, Gap 3: Predicting Waste Settling from Waste Chemistry (Waste Type), Gap 4: Predicting Waste Settling from Particle Size and Density Distributions (PSDDs), Gap 5: Insufficient Laboratory and In-Tank Settling Data to Represent Hanford Waste, Gap 6: Methods for Real-Time, In-Tank Tracking of Settling, Gap 7: Prediction of Sediment Erosion Resistance as a Function of Settling Time, and Gap 8: Prediction of Sediment Solids Content as a Function of Settling Time. In addition to the data gaps, an overarching observation of the settling rate and settled layer data is the significant variation in behavior. At similar solids concentrations, settling rates can vary by as much as 3 orders of magnitude depending on the source waste tank, and significantly different settling rates are noted between laboratory and in situ tests for the same waste tank. The range of average solids concentration in existing HLW sediment, which may have been quiescent for decades, can vary from less than 7 wt% to greater than 74 wt% solids. The shear strengths (or yield stresses) measured on laboratory samples range from less than 27 Pa to greater than 6400 Pa. These variations can challenge process planning for the application of a settle/decant process for DFHLW. This report describes the significance of the gaps to the settle/decant process and presents uncertainties by way of examples. Potential technical approaches for resolving these gaps are described and the estimated difficulty in resolving these gaps is evaluated. Based on the significance of the gap and the difficulty of resolution, recommendations are made to address specific gaps. Scoping estimates of the potential settling times for DFHLW solids have been made based on the existing data set with its associated gaps. Depending on the process vessel depth and final sediment concentration, substantial fractions of the scoping estimate results for settling times for characterized HLW exceed the 2-week period that has been previously assumed for process planning. There is also significant disparity, potentially greater than a factor of 5000 difference, in the estimated settling times depending on process vessel depth and final sediment solid concentration. This variation in results underscores the significance of the identified gaps and uncertainties with respect to process planning for utilizing settle/decant operations for DFHLW.

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DOE OSTI2020

Iodine Flowsheet Status Report

A simplified flowsheet was developed to evaluate the impact of varied assumptions of I-129 decontamination factors on the overall I-129 material balance in the Direct Feed Low-Activity Waste (DFLAW) facility. The flowsheet allows inputs for I-129 feed and Decontamination Factors (DFs) for multiple DFLAW unit operations and provides information on I-129 partitioning to output streams. A series of 6 DFs were evaluated, including baseline DFs from a prior Waste Treatment and Immobilization Plant (WTP) study and refined values based on a Savannah River National Laboratory (SRNL) review. The Microsoft Excel flowsheet spreadsheet will be provided to WRPS to allow further evaluation of the impact of DF assumptions on output streams. The spreadsheet is not specific to iodine, the partitioning of any species can be estimated by entering the assumed DFs for each unit operation. Flowsheet outputs matched results from the prior WTP study and show that different assumptions for the DFs can greatly impact iodine partitioning to primary and secondary waste streams. Results from SRNL's baseline DF values suggest less than 50% of I-129 would be retained in glass versus the 96% when using the BNI DF values. In addition, the flowsheet demonstrated that more than 5 DFLAW operational cycles are required to achieve a steady-state of I-129 to the primary waste stream. It is not possible with the data available to determine whether the BNI approach or the approach taken in this study will be a better match for the iodine partitioning once the LAW facility begins operation.

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DOE OSTI2019

X-Ray Diffraction and Product Consistency Test Results for the Phase 6 Study of Nepheline Formation in High-Level Waste Glasses

Hanford high-level waste (HLW) contains relatively high concentrations of Al 2 O 3 . A major constraint limiting the waste loading of high-Al 2 O 3 glasses is nepheline (nominally NaAlSiO 4 ) formation upon slow cooling of HLW glasses after melts are poured into steel canisters. The model currently planned to be used at the Hanford Waste Treatment and Immobilization Plant (WTP) for avoiding nepheline formation is too conservative and drastically limits waste loading. To increase operational flexibility and effectively operate the WTP, the effects of glass composition on glass properties must be determined and glass property-composition models must be developed. Determining the impacts of glass composition on nepheline formation and the effects of nepheline on Product Consistency Test (PCT) response is an important part of this effort. As a part of this effort, data related to the Hanford high-Al 2 O 3 HLW composition region was generated to supplement existing data for model development. Twenty glasses were fabricated, heat treated, and analyzed for crystallinity and PCT response. The heat treatment was designed to mimic the canister centerline cooling (CCC) profile of Hanford HLW glass canisters. It was found that only 6 of the 20 prepared glasses (#4, #7, #8, #10, #19, and #20) formed nepheline upon heat treatment. All glasses except for one (#19) precipitated spinel upon quenching and no glasses contained nepheline upon quenching. Of the 20 glasses, the PCT-normalized boron release of the quenched glasses and all but five of the CCC glasses satisfied the environmental assessment glass benchmark value (16.695 g/L). The CCC glass samples that exceeded the limit were #8 (48.21 g/L), #10 (19.77 g/L), #13 (20.17 g/L), #19 (60.85 g/L), and #20 (61.08 g/L). Those glasses coincide with the highest amounts of nepheline found in the CCC glasses, except for #13, which did not form nepheline after CCC.

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DOE OSTI2020

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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DOE OSTI2016

Results from Phase 1, 2, and 3 Studies on Nepheline Formation in High-Level Waste Glasses Containing High Concentrations of Alumina

The composition of Hanford high-level waste (HLW) is dominated by relatively high concentrations of Al 2 O 3 . A major constraint limiting the waste loading of high-Al 2 O 3 glasses is nepheline (nominally NaAlSiO 4 ) formation upon slow cooling of HLW glasses after melts are poured into canisters. The model currently planned to be used at the Hanford Tank Waste Treatment and Immobilization Plant (WTP) for avoiding nepheline formation is too conservative and drastically limits waste loading. To increase loadings of high-Al 2 O 3 waste at the WTP, the effects of glass composition on glass properties must be determined and glass property-composition models must be developed. An important task of this effort is determining the impacts of glass composition on nepheline formation and the effects of nepheline on Product Consistency Test (PCT) response.

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