Fluor Idaho's Technical and Programmatic Approach That Resolved the Problems with the Integrated Waste Treatment Unit - 19290
The Integrated Waste Treatment Unit (IWTU) is a facility designed to treat approximately 900,000 gallons of radioactive liquid waste, referred to as Sodium Bearing Waste (SBW). IWTU is a Fluidized Bed Steam Reforming process that will be used to treat the SBW to produce a granular sodium carbonate and sodium aluminate product. The product is planned to be managed as remote handled transuranic waste. Construction of the IWTU was completed in 2011 and Critical Decision 4 was achieved in 2012 with the expectation that the treatment of the SBW would be completed in 2012. However, process instabilities and equipment problems prevented the safe and reliable operation of the facility. All of the nonradiological tests of the IWTU had to be stopped prematurely because each time the IWTU was operated, the process would become unstable within a few days of initiating the operation. The instabilities were associated with the primary fluidized bed reaction vessel, the Denitration Mineralization Reformer (DMR). The instabilities included difficulties maintaining fluidization conditions and scale formation within the DMR. Design inadequacies and equipment reliability problems in other parts of the facility also hampered the testing the IWTU. The U.S. Department of Energy (DOE) awarded the Idaho Clean-up contract to Fluor Idaho (Fluor) in 2016. To resolve the issues with the IWTU, Fluor assembled a dedicated team to develop the technical and programmatic strategy to resolve the issues with the IWTU and get it operational. Fluor's approach has successfully resolved the primary issues with the IWTU. As a result of modifications of equipment and operating strategies implemented by Fluor, the core part of the IWTU process now works reliably when processing simulated Sodium Bearing Waste over a wide range of operating conditions. This paper describes Fluor's approach and summarize key steps in the process to resolve the issues with the IWTU. Fluor has used strong fundamentals including a first principles approach and unique program management techniques to solve the technical problems with the IWTU. The successful approach has provided renewed confidence in the IWTU process enabling the troubled project to move forward. Important factors in the success of the project include using a dedicated project team separate from the IWTU line organization, a Technical Review Group, the Chemistry Team and a diverse set of supporting contractors and National Laboratories. Fluor typically used multiple means to validate solutions before testing them in the IWTU. Fluor's successful full-scale demonstration runs of the IWTU confirm the process will reliably produce a compliant, treated waste product over a wide range of operating conditions.