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DOE OSTI2014

FY13 Glycolic-Nitric Acid Flowsheet Demonstrations of the DWPF Chemical Process Cell with Simulants

Savannah River Remediation is evaluating changes to its current Defense Waste Processing Facility flowsheet to replace formic acid with glycolic acid in order to improve processing cycle times and decrease by approximately 100x the production of hydrogen, a potentially flammable gas. Higher throughput is needed in the Chemical Processing Cell since the installation of the bubblers into the melter has increased melt rate. Due to the significant maintenance required for the safety significant gas chromatographs and the potential for production of flammable quantities of hydrogen, eliminating the use of formic acid is highly desirable. Previous testing at the Savannah River National Laboratory has shown that replacing formic acid with glycolic acid allows the reduction and removal of mercury without significant catalytic hydrogen generation. Five back-to-back Sludge Receipt and Adjustment Tank (SRAT) cycles and four back-to-back Slurry Mix Evaporator (SME) cycles were successful in demonstrating the viability of the nitric/glycolic acid flowsheet. The testing was completed in FY13 to determine the impact of process heels (approximately 25% of the material is left behind after transfers). In addition, back-to-back experiments might identify longer-term processing problems. The testing was designed to be prototypic by including sludge simulant, Actinide Removal Product simulant, nitric acid, glycolic acid, and Strip Effluent simulant containing Next Generation Solvent in the SRAT processing and SRAT product simulant, decontamination frit slurry, and process frit slurry in the SME processing. A heel was produced in the first cycle and each subsequent cycle utilized the remaining heel from the previous cycle. Lower SRAT purges were utilized due to the low hydrogen generation. Design basis addition rates and boilup rates were used so the processing time was shorter than current processing rates.

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DOE OSTI2013

Material compatibility evaluation for DWPF nitric-glycolic acid-literature review

Glycolic acid is being evaluated as an alternative for formic and nitric acid in the DWPF flowsheet. Demonstration testing and modeling for this new flowsheet has shown that glycolic acid and glycolate has a potential to remain in certain streams generated during the production of the nuclear waste glass. A literature review was conducted to assess the impact of glycolic acid on the corrosion of the materials of construction for the DWPF facility as well as facilities downstream which may have residual glycolic acid and glycolates present. The literature data was limited to solutions containing principally glycolic acid.

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NASA NTRS1986

Photolysis products of CO, NH3 aND H2O and their significance to reactions on interstellar grains

With the increase in evidence that interstellar grains are the basic building blocks of comets and with the realization that comet collisions with the earth have probably occured at a much higher frequency than earlier assumed it may be presumed that interstellar dust chemistry played an important role in the early chemistry of the earth. As a part of the study of the photochemical processes taking place on interstellar grains the photolysis of mixtures of CO, NH3 and H2O was performed at 10 K, 77K and 298K. The reaction products were determined by GC/MS and HPLC analysis to be lactic acid, glycolic acid, hydroxyacetamide, urea, biuret, oxamic acid, oxamide, glyceric acid and glyceramide. Ethylene glycol and glycerol were also detected but is is not clear at present whether these are true photoproducts or contaminants. The mechanism of formation of these molecules are discussed as well as their possible significance to the origins of life.

Ferris, J. P.↗

DOE OSTI2016

Implementation of flowsheet change to minimize hydrogen and ammonia generation during chemical processing of high level waste in the Defense Waste Processing Facility

Testing was completed to develop a chemical processing flowsheet for the Defense Waste Processing Facility (DWPF), designed to vitrify and stabilize high level radioactive waste. DWPF processing uses a reducing acid (formic acid) and an oxidizing acid (nitric acid) to rheologically thin the slurry and complete the necessary acid base and reduction reactions (primarily mercury and manganese). Formic acid reduces mercuric oxide to elemental mercury, allowing the mercury to be removed during the boiling phase of processing through steam stripping. In runs with active catalysts, formic acid can decompose to hydrogen and nitrate can be reduced to ammonia, both flammable gases, due to rhodium and ruthenium catalysis. Replacement of formic acid with glycolic acid eliminates the generation of rhodium- and ruthenium-catalyzed hydrogen and ammonia. In addition, mercury reduction is still effective with glycolic acid. Hydrogen, ammonia and mercury are discussed in the body of the report. Ten abbreviated tests were completed to develop the operating window for implementation of the flowsheet and determine the impact of changes in acid stoichiometry and the blend of nitric and glycolic acid as it impacts various processing variables over a wide processing region. Three full-length 4-L lab-scale simulations demonstrated the viability of the flowsheet under planned operating conditions. The flowsheet is planned for implementation in early 2017.

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DOE OSTI2019

Historical Scaling Performance from Laboratory to Full Scale for The Defense Waste Processing Facility's Chemical Process Cell

The Defense Waste Processing Facility (DWPF) is planning to modify the chemical processing flowsheet by replacing formic acid with glycolic acid in the Chemical Process Cell (CPC) Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME). The replacement of formic acid with glycolic acid virtually eliminates the CPC’s largest flammability hazards, catalytic hydrogen and ammonia.

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DOE OSTI2012

Glycolic-Nitric Acid Flowsheet Demonstration of the DWPF Chemical Processing Cell with Matrix Simulants and Supernate

Savannah River Remediation (SRR) is evaluating changes to its current DWPF flowsheet to improve processing cycle times. This will enable the facility to support higher canister production while maximizing waste loading. Higher throughput is needed in the CPC since the installation of the bubblers into the melter has increased melt rate. Due to the significant maintenance required for the DWPF gas chromatographs (GC) and the potential for production of flammable quantities of hydrogen, reducing or eliminating the amount of formic acid used in the CPC is being developed. Earlier work at Savannah River National Laboratory has shown that replacing formic acid with an 80:20 molar blend of glycolic and formic acids has the potential to remove mercury in the SRAT without any significant catalytic hydrogen generation. This report summarizes the research completed to determine the feasibility of processing without formic acid. In earlier development of the glycolic-formic acid flowsheet, one run (GF8) was completed without formic acid. It is of particular interest that mercury was successfully removed in GF8, no formic acid at 125% stoichiometry. Glycolic acid did not show the ability to reduce mercury to elemental mercury in initial screening studies, which is why previous testing focused on using the formic/glycolic blend. The objective of the testing detailed in this document is to determine the viability of the nitric-glycolic acid flowsheet in processing sludge over a wide compositional range as requested by DWPF. This work was performed under the guidance of Task Technical and Quality Assurance Plan (TT and QAP). The details regarding the simulant preparation and analysis have been documented previously.

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DOE OSTI2012

Glycolic-Nitric Acid Flowsheet Demonstration of the DWPF Chemical Process Cell with Sludge and Supernate Simulants

Savannah River Remediation (SRR) is evaluating changes to its current Defense Waste Processing Facility (DWPF) flowsheet to improve processing cycle times. This will enable the facility to support higher canister production while maximizing waste loading. Higher throughput is needed in the Chemical Process Cell (CPC) since the installation of the bubblers into the melter has increased melt rate. Due to the significant maintenance required for the DWPF gas chromatographs (GC) and the potential for production of flammable quantities of hydrogen, reducing or eliminating the amount of formic acid used in the CPC is being developed. Earlier work at Savannah River National Laboratory has shown that replacing formic acid with an 80:20 molar blend of glycolic and formic acids has the potential to remove mercury in the SRAT without any significant catalytic hydrogen generation. This report summarizes the research completed to determine the feasibility of processing without formic acid. In earlier development of the glycolic-formic acid flowsheet, one run (GF8) was completed without formic acid. It is of particular interest that mercury was successfully removed in GF8, no formic acid at 125% stoichiometry. Glycolic acid did not show the ability to reduce mercury to elemental mercury in initial screening studies, which is why previous testing focused on using the formic/glycolic blend. The objective of the testing detailed in this document is to determine the viability of the nitric-glycolic acid flowsheet in processing sludge over a wide compositional range as requested by DWPF. This work was performed under the guidance of Task Technical and Quality Assurance Plan (TT&QAP). The details regarding the simulant preparation and analysis have been documented previously.

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DOE OSTI2010

GLYCOLIC - FORMIC ACID FLOWSHEET DEVELOPMENT

Flowsheet testing was performed to further develop the nitric/glycolic/formic acid flowsheet as an alternative to the nitric/formic flowsheet currently being processed at the DWPF. This new flowsheet has shown that mercury can be removed in the Sludge Receipt and Adjustment Tank (SRAT) with minimal hydrogen generation. All other processing objectives were also met, including greatly reducing the Slurry Mix Evaporator (SME) product yield stress as compared to the baseline nitric/formic flowsheet. Eight runs were performed in total, including the baseline run. The baseline nitric/formic flowsheet run was extremely difficult to process under existing DWPF acceptance criteria with this simulant at the HM levels of noble metals. While nitrite was destroyed and mercury was removed to near the DWPF limit, the rheology of the SRAT and SME products were well above design basis and hydrogen generation far exceeded the DWPF limit. In addition, mixing during the SME cycle was very poor. In this sense, the nitric/glycolic/formic acid flowsheet represents a significant upgrade over the current flowsheet. In the nitric/glycolic/formic flowsheet runs, mercury was successfully removed with almost no hydrogen generation and the SRAT and SME products yield stresses were within process limits or previously processed ranges. It is recommended that DWPF continue to support development of the nitric/glycolic/formic flowsheet. Although experience is limited at this time, this flowsheet meets or outperforms the current flowsheet in many regards, including off-gas generation, mercury removal, product rheology and general ease of processing. Additional flowsheet testing will allow for a more thorough understanding of the chemistry and effectiveness of the flowsheet over a range of sludge compositions and formic/glycolic ratios. This testing will also show whether the REDOX and metal solubility concerns with this change in the flowsheet can be addressed by just adjusting the volumes of glycolic acid added. The outstanding issues regarding the glycolic/formic flowsheet include increasing understanding of the impact on glass REDOX control and increased metal solubility, particularly iron, during processing. Additionally, evaluations of the utility of the flowsheet over varying sludge compositions should be completed to ensure flowsheet robustness. Work has already been initiated to further understand the REDOX and iron solubility areas.

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DOE OSTI2020

Impacts of the Addition of Sodium Reactor Experiment (SRE) and DR-3 Fuel from H-Canyon to Tank 40 on Acid Stoichiometry and Hydrogen Production

H-Canyon plans to discard Sodium Reactor Experiment (SRE) material that is currently stored in Tanks 16.3 and 16.4. Savannah River Remediation (SRR) determined that a portion of the SRE material can be added to Sludge Batch 9 (SB9) in Tank 40 and the remainder will be added to Sludge Batch 10 (SB10) that is currently being prepared in Tank 51. A processing flowsheet for both the nitric-formic acid flowsheet and the nitric-glycolic acid flowsheet were previously developed for SB9 sludge-only and coupled operation with the Actinide Removal Process – Modular Caustic Side Solvent Extraction Unit (ARP-MCU) and the Salt Waste Processing Facility (SWPF). Due to the compositional change in Tank 40 after the addition of SRE material, it is necessary to determine the influence on the acid stoichiometry operating window and hydrogen production for SB9 processing. An assessment was completed to address the influence of an addition of SRE and DR-3 Fuel from H-Canyon on the chemistry of Tank 40, the defined acid stoichiometry window (with and without SWPF streams) for the nitric-formic and nitric-glycolic acid flowsheets, and the resulting influence of the hydrogen production. Hydrogen production during the SRAT/SME cycles consists of thermolytic, radiolytic, and catalytic hydrogen. For the nitric-formic acid flowsheet, catalytic hydrogen dominates the hydrogen production during DWPF operation mode for the SRAT and SME vessels. This report was written to summarize that assessment. No SRNL testing is needed prior to adding up to 7,100 additional gallons of SRE and DR-3 Fuel from H-Canyon to Tank 40. Also, the addition of SRE will not exceed the Shielded Cells reported values for catalytic hydrogen for either the nitric-formic acid flowsheet (Technical Safety Requirement (TSR) limit of 0.15 lb/h) or the nitric-glycolic acid flowsheet (TSR limit 0.024 lb/h). The addition of the ARP stream from SWPF and the use of the nitric-glycolic acid flowsheet are both expected to decrease hydrogen generation, leading to a larger safety margin in the CPC.

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DOE OSTI2011

GLYCOLIC-FORMIC ACID FLOWSHEET FINAL REPORT FOR DOWNSELECTION DECISION

Flowsheet testing was performed to develop the nitric-glycolic-formic acid flowsheet (referred to as the glycolic-formic flowsheet throughout the rest of the report) as an alternative to the nitric/formic flowsheet currently being processed at the DWPF. This new flowsheet has shown that mercury can be removed in the Sludge Receipt and Adjustment Tank (SRAT) with minimal hydrogen generation. All processing objectives were also met, including greatly reducing the Slurry Mix Evaporator (SME) product yield stress as compared to the baseline nitric/formic flowsheet. Forty-six runs were performed in total, including the baseline run and the melter feed preparation runs. Significant results are summarized. The baseline nitric/formic flowsheet run, using the SB6 simulant produced by Harrell was extremely difficult to process successfully under existing DWPF acceptance criteria with this simulant at the HM levels of noble metals. While nitrite was destroyed and mercury was removed to near the DWPF limit, the rheology of the SRAT and SME products were well above design basis and hydrogen generation far exceeded the DWPF SRAT limit. In addition, mixing during the SME cycle was very poor. In this sense, the nitric/glycolic/formic acid flowsheet represents a significant upgrade over the current flowsheet. Mercury was successfully removed with almost no hydrogen generation and the SRAT and SME products yield stresses were within process limits or previously processed ranges. The glycolic-formic flowsheet has a very wide processing window. Testing was completed from 100% to 200% of acid stoichiometry and using a glycolic-formic mixture from 40% to 100% glycolic acid. The testing met all processing requirements throughout these processing windows. This should allow processing at an acid stoichiometry of 100% and a glycolic-formic mixture of 80% glycolic acid with minimal hydrogen generation. It should also allow processing endpoints in the SRAT and SME at significantly higher total solids content and may be effective at acid stoichiometries below 100%, although no testing was performed below 100% acid stoichiometry. There are several issues related to the development of the glycolic-formic flowsheet. First, the measurement of anions using the new glycolate anion procedure likely needs to be optimized to improve the accuracy of the anions important to DWPF processing and REDOX prediction. Second, the existing REDOX equation with an added term for glycolate did not accurately predict the glass REDOX for the glycolic-formic flowsheet. Improvement of the anion measurement or modification of the REDOX methodology or equation may be necessary to improve the REDOX prediction. Last, the glycolic-formic flowsheet dissolves a number of metals, including iron. This leads to a thinner slurries but also dissolves up a portion of the iron, which is currently used for criticality control. It is recommended that DWPF continue to support development of the glycolic-formic flowsheet. This flowsheet meets or outperforms the baseline flowsheet in off-gas generation, mercury removal, product rheology and general ease of processing. Additional testing is in progress to demonstrate the effectiveness of the nitric-glycolic-formic flowsheet in processing a wide sludge processing window using the matrix sludge simulants.

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DOE OSTI2017

Impact of Glycolate Anion on Aqueous Corrosion in DWPF and Downstream Facilities

36 MATERIALS SCIENCE↗

DOE OSTI2017

Impact of Glycolate Anion on Aqueous Corrosion in DWPF and Downstream Facilities

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DOE OSTI2011

GLYCOLIC-FORMIC ACID FLOWSHEET SLUDGE MATRIX STUDY

Testing was completed to demonstrate the viability of the newly developed glycolic acid/formic acid flowsheet on processing in the Defense Waste Processing Facility's (DWPF) Chemical Process Cell (CPC). The Savannah River National Laboratory (SRNL) initiated a sludge matrix study to evaluate the impact of changing insoluble solid composition on the processing characteristics of slurries in DWPF. Four sludge simulants were prepared to cover two compositional ranges in the waste. The first was high iron/low aluminum versus low iron/high aluminum (referred to as HiFe or LoFe in this report). The second was high calcium-manganese/low nickel, chromium, and magnesium versus low calcium-manganese/high nickel, chromium, and magnesium (referred to as HiMn or LoMn in this report). These two options can be combined to form four distinct sludge compositions. The sludge matrix study called for testing each of these four simulants near the minimum acid required for nitrite destruction (100% acid stoichiometry) and at a second acid level that produced significant hydrogen by noble metal catalyzed decomposition of formic acid (150% acid stoichiometry). Four simulants were prepared based on the four possible combinations of the Al/Fe and Mn-Ca/Mg-Ni-Cr options. Preliminary simulant preparation work has already been documented. The four simulants were used for high and low acid testing. Eight planned experiments (GF26 to GF33) were completed to demonstrate the viability of the glycolic-formic flowsheet. Composition and physical property measurements were made on the SRAT product. Composition measurements were made on the condensate from the Mercury Water Wash Tank (MWWT), Formic Acid Vent Condenser (FAVC), ammonia scrubber and on SRAT samples pulled throughout the SRAT cycle. Updated values for formate loss and nitrite-tonitrate conversion were found that can be used in the acid calculations for future sludge matrix process simulations with the glycolic acid/formic acid flowsheet. Preliminary results of the initial testing indicate: (1) Hydrogen generation rate was very low throughout all SRAT cycles. (2) The mercury concentration of the SRAT product was below the 0.8 wt% limit in all runs. (3) Nitrite in the SRAT product was <100 mg/kg for all runs. (4) Foaminess was not an issue using the nominal antifoam addition strategy in these tests. (5) The high aluminum sludges (LoFe, HM type sludges) were much more viscous than the Hi Fe sludges. At 100% acid stoichiometry, the SRAT products from the high aluminum sludges were very viscous but at 150% acid stoichiometry, the SRAT products from the high aluminum sludges were very thin. This makes the glycolic acid/formic acid flowsheet an improvement for processing more viscous sludges. (6) The pH of the SRAT products was from 2.7-3.1 for the 150% acid stoichiometry runs and 5.1-6.1 for the 100% acid stoichiometry runs, significantly lower than is typical of the baseline nitric acid/formic acid flowsheet.

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DOE OSTI2015

Impact of glycolate anion on aqueous corrosion in DWPF and downstream facilities

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DOE OSTI2016

Interim glycol flowsheet reduction/oxidation (redox) model for the Defense Waste Processing Facility (DWPF)

Control of the REDuction/OXidation (REDOX) state of glasses containing high concentrations of transition metals, such as High Level Waste (HLW) glasses, is critical in order to eliminate processing difficulties caused by overly reduced or overly oxidized melts. Operation of a HLW melter at Fe +2 /ΣFe ratios of between 0.09 and 0.33, a range which is not overly oxidizing or overly reducing, helps retain radionuclides in the melt, i.e. long-lived radioactive 99 Tc species in the less volatile reduced Tc 4+ state, 104 Ru in the melt as reduced Ru +4 state as insoluble RuO 2 , and hazardous volatile Cr 6+ in the less soluble and less volatile Cr +3 state in the glass. The melter REDOX control balances the oxidants and reductants from the feed and from processing additives such as antifoam. Currently, the Defense Waste Processing Facility (DWPF) is running a formic acid-nitric acid (FN) flowsheet where formic acid is the main reductant and nitric acid is the main oxidant. During decomposition formate and formic acid releases H 2 gas which requires close control of the melter vapor space flammability. A switch to a nitric acid-glycolic acid (GN) flowsheet is desired as the glycolic acid flowsheet releases considerably less H 2 gas upon decomposition. This would greatly simplify DWPF processing. Development of an EE term for glycolic acid in the GN flowsheet is documented in this study.

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DOE OSTI2012

Formic Acid Free Flowsheet Development To Eliminate Catalytic Hydrogen Generation In The Defense Waste Processing

The Defense Waste Processing Facility (DWPF) processes legacy nuclear waste generated at the Savannah River Site (SRS) during production of plutonium and tritium demanded by the Cold War. The nuclear waste is first treated via a complex sequence of controlled chemical reactions and then vitrified into a borosilicate glass form and poured into stainless steel canisters. Converting the nuclear waste into borosilicate glass canisters is a safe, effective way to reduce the volume of the waste and stabilize the radionuclides. Testing was initiated to determine whether the elimination of formic acid from the DWPF's chemical processing flowsheet would eliminate catalytic hydrogen generation. Historically, hydrogen is generated in chemical processing of alkaline High Level Waste sludge in DWPF. In current processing, sludge is combined with nitric and formic acid to neutralize the waste, reduce mercury and manganese, destroy nitrite, and modify (thin) the slurry rheology. The noble metal catalyzed formic acid decomposition produces hydrogen and carbon dioxide. Elimination of formic acid by replacement with glycolic acid has the potential to eliminate the production of catalytic hydrogen. Flowsheet testing was performed to develop the nitric-glycolic acid flowsheet as an alternative to the nitric-formic flowsheet currently being processed at the DWPF. This new flowsheet has shown that mercury can be reduced and removed by steam stripping in DWPF with no catalytic hydrogen generation. All processing objectives were also met, including greatly reducing the Slurry Mix Evaporator (SME) product yield stress as compared to the baseline nitric/formic flowsheet. Ten DWPF tests were performed with nonradioactive simulants designed to cover a broad compositional range. No hydrogen was generated in testing without formic acid.

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DOE OSTI2014

Corrosion impact of reductant on DWPF and downstream facilities

Glycolic acid is being evaluated as an alternate reductant in the preparation of high level waste for the Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS). During processing, the glycolic acid is not completely consumed and small quantities of the glycolate anion are carried forward to other high level waste (HLW) facilities. The impact of the glycolate anion on the corrosion of the materials of construction throughout the waste processing system has not been previously evaluated. A literature review had revealed that corrosion data in glycolate-bearing solution applicable to SRS systems were not available. Therefore, testing was recommended to evaluate the materials of construction of vessels, piping and components within DWPF and downstream facilities. The testing, conducted in non-radioactive simulants, consisted of both accelerated tests (electrochemical and hot-wall) with coupons in laboratory vessels and prototypical tests with coupons immersed in scale-up and mock-up test systems. Eight waste or process streams were identified in which the glycolate anion might impact the performance of the materials of construction. These streams were 70% glycolic acid (DWPF feed vessels and piping), SRAT/SME supernate (Chemical Processing Cell (CPC) vessels and piping), DWPF acidic recycle (DWPF condenser and recycle tanks and piping), basic concentrated recycle (HLW tanks, evaporators, and transfer lines), salt processing (ARP, MCU, and Saltstone tanks and piping), boric acid (MCU separators), and dilute waste (HLW evaporator condensate tanks and transfer line and ETF components). For each stream, high temperature limits and worst-case glycolate concentrations were identified for performing the recommended tests. Test solution chemistries were generally based on analytical results of actual waste samples taken from the various process facilities or of prototypical simulants produced in the laboratory. The materials of construction for most vessels, components and piping were not impacted with the presence of glycolic acid or the impact is not expected to affect the service life. However, the presence of the glycolate anion was found to affect corrosion susceptibility of some materials of construction in the DWPF and downstream facilities, especially at elevated temperatures. The following table summarizes the results of the electrochemical and hot wall testing and indicates expected performance in service with the glycolate anion present.

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DOE OSTI2020

Influence of Glycolate Anion on Aqueous Corrosion in DWPF and Downstream Facilities – SCC Testing

Glycolic acid is being evaluated as an alternate reductant in the preparation of High Level Waste for the Defense Waste Processing Facility (DWPF) at the Savannah River Site (SRS). During processing, the glycolic acid may not be completely consumed with small quantities of the glycolate anion being carried forward to waste facilities. The SRS liquid waste contractor requested an assessment of the influence of the glycolate anion on the corrosion of the materials of construction (MoC) throughout the waste processing system since this concern had not been previously evaluated. The influence of glycolic acid on the occurrence of stress corrosion cracking (SCC) had not been evaluated specifically in the previous testing. The present testing used electrochemical and coupon immersion testing to assess this influence. Additionally, the primary guidance on corrosion for operating DWPF with a formate-based flowsheet is based on testing that utilized test solutions with a small number of constituents. Recent testing used more complex solutions based on flowsheet development for DWPF. Additional electrochemical tests were also conducted to assess the influence of this difference on test results.

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