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DOE OSTI2021

Case Study: Hybrid Carbon Conversion Using Low-Carbon Energy Sources in Coal-Producing States

The demand for more carbon efficient power sources and a decrease in natural gas prices has decreased the desire for coal power. This decrease in demand has led to massive job losses in coal mining regions over the past decade. The purpose of this project is to develop a hybrid energy system utilizing both a coal power plant and advanced reactor, which is competitive with natural gas by improving on profitability and decreasing carbon emissions. This report details the problem with a summary of the impact on the coal industry and the availability of renewable energy sources in the Appalachian region. Because of the geography of the region, variable renewable energy sources are not available without significant size and siting restrictions. However, biomass in the form of wood waste is abundant and can be used as a carbon neutral energy source. Combining biomass and coal processing, in addition to thermal power plants, can increase system profits and efficiency by providing peaking power and conversion opportunities for secondary markets. The electric load is based on publicly available demand data from Appalachian Power, which services the western Virginia and southern West Virginia in the Appalachian region. The demand information is combined by service, normalized, and scaled to an average demand of 1000 kW, which will be the basis for sizing the hybrid energy system. A traditional screening curve analysis for a coal plant and advanced reactor shows that the least cost design varies significantly based on the assumed discount rate and capital recovery period. An optimization program to size the design in TEAL based on the load curve gives 10 optimal designs, all with a negative resulting net present value (NPV) and a coal plant capacity of less than 15%. Including profits from selling captured carbon at a flat rate results in a positive NPV; however, the coal capacity factor only increases to about 40%. There are limitations with this optimization as well since the price of CO2 is likely to decrease as more is sold to the conversion market. The suggested design will combine coal power, an advanced reactor, and coal and biomass coprocessing to produce a variety of products that can be sold to the conversion market while increasing system efficiency. The analysis of conversion pathways for coal and biomass reveals that multiple options will need to be included in the analysis to produce the optimal system design. Three systems will be optimized and compared to determine the best design based on the figures of merit of total NPV and cost of carbon avoided. The first system will include a coal power plant and an advanced reactor that will sell electricity to the grid to meet demand and sell captured carbon to the conversion market. The second system adds a high-temperature steam electrolysis plant, which will utilize electricity during times of low demand to produce hydrogen and sell it to the conversion market. The third system adds biomass and coal processing with options for hydrocarbon oils, syngas to be produced for the conversion market, and electricity generation to power components within the system or provide peaking power. This analysis will be based on a new approach that combines traditional screening curve methods with a dispatch algorithm that optimizes the system based on the opportunity cost of different production options. The resulting optimization algorithm should provide results with less processing time than HERON’s decision tree method. The results from this analysis will determine an optimal design and reinforce the benefits of coal power when used in a hybrid energy system. The initial results show that the addition of a secondary market for carbon sales could result in a positive NPV and increases the capacity factor of the coal plant as compared to a design with only sales to the electricity market. The addition of more markets and additional coal consumption from biomass coprocessing could increase NPV further, replace carbon in other markets through the sale of biomass-derived hydrocarbons, and demonstrate the value of coal power technology.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Measurement of Iodine, Iodide, and Iodate in Hanford Tank Waste: Technology Transfer from PNNL to Hanford 222-S Laboratory

This report summarizes the measurement of the inorganic chemical forms of iodine in Hanford tank waste. The Hanford tank wastes have roughly a part per million iodine. Part of the iodine is the long-lived beta emitter 129I, and the rest is stable 127I. Because tank waste iodine is radioactive and radiotoxic, its chemical form must be known so that its behavior in the vitrification process can be reliably known and anticipated in various waste streams (glass, secondary liquid and solid waste, and offgas emissions) at Hanford. Iodine in tank wastes exists in the inorganic chemical forms iodide and iodate (and possibly also periodate) and also as organic forms such as alkyl iodides. The measurement of organic iodides is very different from the measurement of inorganic forms and is outside the scope of this report. The inorganic chemical forms are chemically separated, in sequence, from the raw tank waste using solvent extractions and several redox reactions, then measured by ICP-MS. The inorganic chemical forms of iodine are chemically reactive, and so is the tank waste. The chemistry must be carefully designed to avoid unintended reactions that could convert one form of iodine to another during the analysis, which would skew the data and report iodine in the wrong chemical form. This iodine analysis, developed at PNNL, is being transferred to the DOE 222-S Laboratory on the Hanford Site, in Washington State, for implementation during waste processing operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Uncertainty propagation and sensitivity analysis for constrained optimization of nuclear waste vitrification

Abstract The vitrification of high‐level waste (HLW) by heating a mixture of glass‐forming chemicals (GFCs) with the waste can be improved using a constrained optimization problem. This study explores how different uncertainty propagation (UP) methods implemented with the optimization process can affect the glass formulation of nuclear waste glasses. UP is the effort of propagating uncertain inputs through a system to understand and quantify output distributions. Uncertainty intervals are crafted from output distributions to inform the optimization algorithm. UP is often implemented with Monte Carlo (MC) sampling for large nonlinear systems, which can be difficult to implement within a constrained optimization algorithm that requires derivative information. Other UP methods often used for optimization under uncertainty (OUU) can be designed to work within an established constrained optimization framework. Methods of UP are evaluated in this study including iterative sampling approaches, first‐order approximations, and surrogate modeling with machine learning (ML). A method of dimensional reduction based on global sensitivity analysis is introduced to support the UP methods for the large dimensionality of the problem. Analytical UP methods able to achieve similar optimums 10 times faster than the baseline MC approach, and produce 93.9% similar output distributions are reported.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Evaluation of High Level Waste Sludge Processing Behavior

The U.S. Department of Energy’s (DOE) Hanford Site has 177 underground storage tanks that contain wastes from past nuclear fuel reprocessing and waste-management operations. Over 20% of this waste is in the form of an insoluble sludge that will require slurry modification before its transfer to the Waste Treatment and Immobilization Plant (WTP). Specific WTP acceptance criteria for waste feed delivery describe the physical and chemical characteristics of the waste that must be met before the waste is transferred to the WTP. One challenging requirement relates to the undissolved solids (UDS) composition in a waste feed because the waste contains solid particles that settle, and their concentration and relative proportion can change during the transfer of the waste in individual batches. A key uncertainty is the ability to transfer and mix wastes with large variations in UDS concentrations and resulting settling rates. To address this uncertainty, a number of small scale mixing and settling tests have been conducted to determine the mobilization performance of variable chemistry simulants. Comparison of the size and density of the particulate for each simulant to that of southeast area Hanford sludge was made using metrics for particle mobilization, suspension, settling, and pipeline transfer where dependance on particle size and density may be different, including: 1. Settling velocity, 2. Critical shear stress for erosion, 3. Just-suspended impeller speed, and 4. Pipeline critical transport velocity. Existing high-level waste sludge data has shown the effect that increasing Al concentration has on resulting settled solids. This differential settling of particles in the sludge has the possibility of resulting in solids segregation during feed preparation and uneven particle distribution during pipeline transportation or mixer jet pump operations. Understanding the predictive capabilities of HLW solids settling and transport as well as potential remedies for addressing disparate sludge behaviors can help provide technical guidance during HLW flowsheet planning.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

The Utility of Waste Tank Historical Reviews in Bulk Waste Removal Operations at the Savannah River Site – 25271

SRMC is actively working to remove, treat, and dispose radioactive waste generated by the separation facilities at SRS since their initial operations in the 1950s. The separation facilities at SRS have produced nuclear materials for a variety of purposes, particularly national defense, and continue to support the disposition of spent fuel through the Accelerated Basin Deinventory program. In almost 70 years of operation, nearly 625,000 m3 (165 million gallons) of radioactive waste have been generated and transferred to the tank farm facilities at SRS [1]. As a result of volume reduction (e.g., evaporation) and waste solidification (e.g., vitrification), approximately 127,000 m3 (33.5 million gallons) of material remain as of June 30, 2024 [2]. This liquid waste has since been stored in 51 large underground waste tanks present on the site. These waste tanks may contain up to 4,921 m3 (1.3 million gallons) of radioactive waste each in the form of saltcake or sludge. SRMC’s contract is to treat and dispose of this waste, clean the tanks, and operationally close them. To date, 8 of the 51 waste tanks have been operationally closed. Waste retrieval and tank closure activities are ongoing in an additional 17 tanks through either operations in the field or in design [3].

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Development of a stoichiometric magnesium potassium phosphate cement (MKPC) for the immobilization of powdered minerals

Ordinary Portland Cement (OPC)-based materials are not systematically adapted for immobilizing industrial hazardous waste, e.g. for aluminium powder or plutonium waste sludge. In such case, Magnesium Potassium Phosphate Cements (MKPC) represent an interesting alternative. }The originality of this research is to develop a formulation of a MKPC paste for hazardous waste immobilization, which incorporates a maximum amount of such waste, preferably in powdered form. To this purpose, a stoichiometric MKPC paste is selected, and its properties are improved by powdered waste addition. }Firstly, the physico-chemical mechanisms generating expansion in stoichiometric MKPC paste are analyzed. Swelling is attributed to a pH gradient in the paste, due to the progressive sedimentation of MgO particles in the fresh mix. }Secondly, over-stoichiometric MgO is replaced by varying amounts of minerals simulating the waste, of different mineralogy and granulometry, in order to achieve sufficient workability and no swelling. An optimal formulation is proposed, which incorporates powdered fly ash at a fine-to-cement mass ratio (F/C) of 1. Its mechanical performance and endogenous dimensional changes are comparable to typical over-stoichiometric pastes, and they stabilize between 7 and 28 days.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Evaluation of Technologies to Mitigate the Presence of Gaseous Elemental Mercury in Waste Disposal Containers

A study was conducted to evaluate sorbent technologies that can mitigate the presence of elemental mercury (Hg⁰) in waste containers for mercury-contaminated debris (MCD). Decontamination and demolition (D&D) activities at the Y-12 National Security Complex (Y-12) and other U.S. Department of Energy (DOE) Oak Ridge Reservation (ORR) facilities generate MCD requiring offsite disposal. The debris is packaged in appropriate waste containers and may be temporarily stored onsite prior to transport for treatment and/or disposal. During transportation of loads that had no visible liquid Hg at the point of origin, temperature changes can cause Hg⁰ to evaporate, condense, and form droplets on container walls. Furthermore, vibration during transportation could cause beads of Hg to be released from the debris, container walls, and ceiling, resulting in pools of liquid Hg⁰ on the container floor. Waste acceptance criteria (WAC) limitations for commercial disposal facilities, the Nevada National Security Site (NNSS), and ORR mixed low-level waste landfills prohibit the presence of any free liquids in containers identified as a solid waste form. Potential solutions to mitigate the presence of residual liquids that could be formed through vapor condensation include the use of sorbents or similar materials to capture and stabilize volatile Hg⁰ vapors and thus ensure compliance with landfill WAC requirements. This report summarizes data from small-scale laboratory experiments conducted to evaluate sorbent materials for Hg⁰ vapor suppression and sorption of liquid Hg⁰ that could form under relevant transportation and disposal conditions. A series of experiments was conducted to evaluate commercial sorbent materials and their effectiveness for Hg⁰ sorption across a temperature range from 19.4°C to 60°C. The impact of residual moisture on sorption was investigated under relevant conditions, and leaching tests were performed to assess the stability of Hg⁰ captured sorbent materials. The results provide estimates for sorbent quantities needed for a given Hg⁰ mass loading based on experimental results exposing sorbents to gaseous and liquid Hg⁰ at various mass ratios. Overall, sorbents that were most effective for Hg⁰ vapor suppression were brominated activated carbons, mackinawite-based sorbents coated on vermiculite, and sulfur-modified granular activated carbon. Elevated temperatures and moisture conditions did not result in significant increases of Hg⁰ headspace concentrations, and the materials also demonstrated high sorption capacities for the sorption of liquid Hg⁰.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Off-Gas Design and Testing from Advanced Chlorination Process

Chlorination of Zr alloy cladding with sulfur-chloride reagents is being considered as a means of separating the main metal from alloying elements, imbedded U, actinides, and fission and activation products to purify the Zr. This would allow the Zr to be disposed of as low-level nuclear waste or possibly be recycled. A multistage process was developed that involves several steps and waste streams. Recycling of sulfur-chloride reagents S 2 Cl 2 and SOCl 2 is planned to minimize the waste stream. The generation of off-gas and entrainment of volatiles is anticipated to be minimized. However, given the complex nature of spent nuclear fuel (SNF), some volatile components will be generated, including the solvents themselves; Cl 2 used for the regeneration of S 2 Cl 2 ; volatile fission product chlorides, such as Sb and 3 H; and chlorinated alloying components, such as Sn, Nb, Fe, and Mo. This report discusses the chemical phenomena that might give rise to volatile species and their planned capture. The volatility of the transition metals will depend on their oxidation state and the compounds that are formed, such as Zr tritide. Loading radionuclides in the process off-gas will depend on the inputs to the process. For instance, processing separated Zr to reduce waste will have a much lower loading of radionuclides than if alternative chlorination were used for decladding SNF. Much of the volatile process streams will be part of the solvent recycling, which may involve online scrubbing. Generally, a caustic scrubber should be included in the off-gas to remove acidic vapors (e.g., Cl 2 , SOCl 2 ). The decontamination procedures for removing these species could involve pretreatment (i.e., heating) options or reduction by contact with H 2 . This report discusses these options along with a framework for testing these alternatives in future experiments. Technologies for off-gas capture will leverage those developed in the Materials Recovery and Waste Forms program.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

200-IA-1 Operable Unit Ecological Risk Screen

The purpose of this environmental calculation file (ECF) is to document the assumptions, inputs, methodology, equations, and results of a screening level ecological risk assessment (SLERA) conducted for eight of 12 representative waste sites within the newly formed 200 IA-1 Operable Unit (OU); the remaining four waste sites lacked soil data within the shallow vadose zone and were not further evaluated. The SLERA was conducted to evaluate ecological receptor exposure and potential risk using soil data for radionuclides and nonradionuclides occurring within the shallow vadose zone (0 to 15 ft) soil of the OU. The representative Hanford ecological receptors evaluated are: plants, soil invertebrates, California quail (Callipepla californica), Meadowlark (Sturnella neglecta), Killdeer (Charadrius vociferus), Red-tailed hawk (Buteo jamaicensis), Great Basin pocket mouse (Perognathus parvus), Deer mouse (Peromyscus maniculatus), Grasshopper mouse (Onychomys leucogaster), and badger (Taxidea taxus). During the SLERA, detected soil sample results from the shallow vadose zone were used to calculate Hazard Quotients (HQs) for nonradionuclides and Sum of Fractions (SOF) for radionuclides. The results of this SLERA support the preparation of DOE/RL-2020-51, 200-IA-1 Operable Unit Focused Feasibility Study.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2003

Partitioning of Inorganic Elements Consumed by Humans Between the Various Fractions of Human Wastes: A Review and Analysis of Existing Literature

The nutritional requirements of humans and astronauts are well defined and show consistency, but the same cannot be said of human wastes. Nutrients taken up by humans can be considered to fall into two major categories - organic and inorganic fractions. Carbon, hydrogen, oxygen, nitrogen and sulfur are elements that are associated with the organic fraction. These elements are taken up in large amounts by humans and when metabolized released in wastes often in gaseous forms or as water. On the other hand, a large number of the elements are simply exchanged and can be accounted for in the liquid and solid wastes of humans. These elements fall into three major categories - cationic macroelements (e.g. Ca, K, Na, Mg and Si), anionic macroelements (e.g P, S and Cl), 17 essential microelements, (e.g. Fe, Mn, Cr, Co, Cu, Zn, Se and Sr). When provided in the recommended concentrations to an adult human, these elements should not normally accumulate in humans, but will be excreted in the different human wastes. Knowledge of the partitioning of these elements between the different human waste fractions is fundamental to understanding (a) how these elements can be recovered for reuse in space habitats, and (b) to developing the processors for waste management. The current literature is exhaustive but sometimes also conflicting. We have used the existing knowledge of nutrition and waste from medical literature and NASA documentation to develop a consensus to typify and chemically characterize the various human wastes. The partitioning of these elements has been developed into a functional model.

Wignarajah, K.↗

DOE OSTI2023

Multi-modal chemical characterization of highly viscous submicrometer organic particles

Distinguishing highly viscous organic particles within complex mixtures of atmospheric aerosol and accurate descriptions of their composition, size distributions, and mixing states are challenges at the forefront of aerosol measurement science and technology. Here, we present results obtained from complementary single-particle measurement techniques employed for the in-depth characterization of highly viscous particles. In this study, we demonstrate advantages and synergy of this multi-modal particle characterization approach based on the analysis of individual viscous particles formed in the air-discharged waste produced by a common sewer pipe rehabilitation technology. Using oil immersion flow microscopy, we investigate particle size distributions and morphology of colloidal components present in field-collected aqueous waste condensates. We compare these results with corresponding measurements of viscous particles formed in drying droplets of the aerosolized discharged waste. The colloidal components and viscous particles were found to be approximately 10 µm and 0.5 µm, respectively. The aerosolized viscous particles exhibited a spherical morphology, while the colloidal particles appeared noticeably fractal, resembling fragments of a cured composite material. Chemical imaging of the viscous particles collected on substrates was performed using scanning electron microscopy and soft X-ray spectro-microscopy techniques. Through these methods, comprehensive description of these particles emerged, confirming their high solid-like viscosity, wide-ranging sizes, diverse carbon speciation with high degrees of oxygenation, and high organic volume fractions. The aerosolized viscous particles were further characterized using high-throughput single particle mass spectrometry. This technique provides real-time measurements of composition, size, and morphological metrics for large numbers of individual particles, enabling the identification of their distinct mass spectrometric signatures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Sludge Processing Options for early HLW Treatment at Hanford

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Numerical modeling of Joule heated ceramic melter

Computational fluid dynamics and heat transfer models of waste glass melters are being developed to support the vitrification campaign at the Waste Treatment and Immobilization Plant (WTP) as part of the United States nuclear waste stewardship and environmental protection programs. The WTP mission aims to achieve the stable and durable processing of vitrified waste in the safest, most efficient, and economical manner possible. Hanford’s tank waste is far more complex and varied than the waste treated by other vitrification facilities and both startup and long-term operational challenges are likely to be even greater than prior experience has shown. There are thousands of different waste compositions, which makes processing the waste a complex and challenging task. Models of test melters, pilot-scale, and full-scale melters have been developed to provide understanding and insight into the various physical and chemical phenomena occurring during vitrification. So the results of these modeling activities will be used to support the WTP operations to process legacy nuclear waste into a stable form for disposal.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1975

Energy recovery from solid waste. Volume 1: Summary report

A systems analysis of energy recovery from solid waste which demonstrates the feasibility of several processes for converting solid waste to an energy form is presented. The social, legal, environmental, and political factors are considered and recommendations made in regard to legislation and policy. A technical and economic evaluation of available and developing energy-recovery processes is given with emphasis on thermal decomposition and biodegradation. A pyrolysis process is suggested. The use of prepared solid waste as a fuel supplemental to coal is considered to be the most economic process for recovery of energy from solid waste. Markets are discussed with suggestions for improving market conditions and for developing market stability. A decision procedure is given to aid a community in deciding on its options in dealing with solid waste.

Source record↗

NASA NTRS1975

Energy recovery from solid waste. Volume 2: Technical report

A systems analysis of energy recovery from solid waste demonstrates the feasibility of several current processes for converting solid waste to an energy form. The social, legal, environmental, and political factors are considered in depth with recommendations made in regard to new legislation and policy. Biodegradation and thermal decomposition are the two areas of disposal that are considered with emphasis on thermal decomposition. A technical and economic evaluation of a number of available and developing energy-recovery processes is given. Based on present technical capabilities, use of prepared solid waste as a fuel supplemental to coal seems to be the most economic process by which to recover energy from solid waste. Markets are considered in detail with suggestions given for improving market conditions and for developing market stability. A decision procedure is given to aid a community in deciding on its options in dealing with solid waste, and a new pyrolysis process is suggested. An application of the methods of this study are applied to Houston, Texas.

Huang, C. J.↗

DOE OSTI2024

Biological Upcycling of Plastics Waste

Plastic wastes accumulate in the environment, impacting wildlife and human health and representing a significant pool of inexpensive waste carbon that could form feedstock for the sustainable production of commodity chemicals, monomers, and specialty chemicals. Current mechanical recycling technologies are not economically attractive due to the lower-quality plastics that are produced in each iteration. Thus, the development of a plastics economy requires a solution that can deconstruct plastics and generate value from the deconstruction products. Biological systems can provide such value by allowing for the processing of mixed plastics waste streams via enzymatic specificity and using engineered metabolic pathways to produce upcycling targets. We focus on the use of biological systems for waste plastics deconstruction and upcycling. We highlight documented and predicted mechanisms through which plastics are biologically deconstructed and assimilated and provide examples of upcycled products from biological systems. Additionally, we detail current challenges in the field, including the discovery and development of microorganisms and enzymes for deconstructing non–polyethylene terephthalate plastics, the selection of appropriate target molecules to incentivize development of a plastic bioeconomy, and the selection of microbial chassis for the valorization of deconstruction products.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

EBS Task Force: Task 9/FEBEX Modeling Final Report: Thermo-Hydrological Modeling with PFLOTRAN

This report outlines Sandia National Laboratories modeling studies applied to Stage 1 and Stage 2 of the Full-scale Engineered Barriers Experiment in Crystalline Host Rock (FEBEX) in situ test for the SKB EBS Task Force Task 9. The FEBEX test was a full-scale test conducted over ~18 years at the Grimsel, Switzerland Underground Research Laboratory (URL) managed by NAGRA. It involved emplacing simulated waste packages, in the form of welded cylindrical heaters, inside a tunnel in crystalline granitic rock and surrounded by a bentonite barrier and cement plug. Sensors emplaced within the bentonite monitored the wetting-up, heating, and drying out of the bentonite barrier, and the large resulting data set provides an excellent opportunity for validation of multiphysics Thermal-Hydrological (TH), Thermal-Hydrologic-Chemical (THC), and Thermal-Hydrological-Mechanical (THM) modeling approaches for underground nuclear waste storage and the performance of engineered bentonite barriers. The present status of the EBS Task Force is finalizing Task 9, which follows years of modeling studies of the FEBEX test, by many notable modeling teams (Gens et al., 2009; Sanchez et al. 2010; 2012; Samper et al., 2018). These modeling studies generally use two-dimensional axisymmetric meshes, ignoring threedimensional effects, gravity and asymmetric wetting and dry out of the bentonite engineered barrier. This study investigates these effects with use of the PFLOTRAN THC code with massively parallel computational methods in modeling FEBEX Stage 1 and Stage 2 results. The PFLOTRAN numerical code is an open source, state-of-the-art, massively parallel subsurface flow and reactive transport code operating in a high-performance computing environment (Hammond et al., 2014). Section 2 describes the applied partial differential equations describing mass, momentum and energy balance used in this study, considerations derived by assuming phase equilibrium between gas and liquid phases, constitutive equations for granite, cement plug, and bentonite domains, and specific approaches for use inthe PFLOTRAN code. Section 3 describes the geometry, meshing, and model set-up. Section 4 describes modeling results, Section 5 compares modeling results to field testing data, and Section 6 gives conclusions. The Appendix provides detailed information required by the EBSTask Force for final reporting.

42 ENGINEERING↗

NASA NTRS1982

Process for the production of ultrahigh purity silane with recycle from separation columns

Tri- and dichlorosilanes formed by hydrogenation in the course of the reaction of metallurgical silicon, hydrogen and recycle silicon tetrachloride are employed as feed into a separation column arrangement of sequential separation columns and redistribution reactors which processes the feed into ultrahigh purity silane and recycle silicon tetrachloride. A slip stream is removed from the bottom of two sequential columns and added to the recycle silicon tetrachloride process stream causing impurities in the slip streams to be subjected to reactions in the hydrogenation step whereby waste materials can be formed and readily separated.

Coleman, Larry M.↗