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At least 775 records · Page 43

Battery metal recycling by flash Joule heating

The staggering accumulation of end-of-life lithium-ion batteries (LIBs) and the growing scarcity of battery metal sources have triggered an urgent call for an effective recycling strategy. However, it is challenging to reclaim these metals with both high efficiency and low environmental footprint. We use here a pulsed dc flash Joule heating (FJH) strategy that heats the black mass, the combined anode and cathode, to >2100 kelvin within seconds, leading to ~1000-fold increase in subsequent leaching kinetics. There are high recovery yields of all the battery metals, regardless of their chemistries, using even diluted acids like 0.01 M HCl, thereby lessening the secondary waste stream. The ultrafast high temperature achieves thermal decomposition of the passivated solid electrolyte interphase and valence state reduction of the hard-to-dissolve metal compounds while mitigating diffusional loss of volatile metals. Life cycle analysis versus present recycling methods shows that FJH significantly reduces the environmental footprint of spent LIB processing while turning it into an economically attractive process

36 MATERIALS SCIENCE↗

Summary of Savannah River Site FY23 Salt Waste Qualification Data

The Savannah River National Laboratory (SRNL) analyzed samples from Savannah River Site (SRS) Waste Tanks 41H and 21H to support qualification of Salt Waste Processing Facility (SWPF) Waste Batches 8 and 9 for processing (the FY23 Salt Batch Qualification samples). These Tanks (i.e. 41H and 21H) are blend tanks for feed to SWPF. None of the samples displayed any unusual or unexpected characteristics such as large amounts of solids, floating solids, or unusual color. Characterization of these samples confirmed similar chemical composition and characteristics to previous salt waste batches. The results for Batches 8 and 9 were provided by SRNL to Savannah River Mission Completion (SRMC), the Liquid Waste Operations subcontractor at SRS, as External Sample Results (Laboratory Information Management System (LIMS)) Reports. Additionally, a separate technical memo was issued by SRNL to report re-test data for Batch 8 for Cs-137 for filtered samples only which were run at the request of SWPF. For Batch 9, a set of samples was also analyzed in parallel by the SWPF-Analytical Laboratory (SWPF-AL). The SWPF-AL data is included herein for comparison with the SRNL data where applicable. The analytical results (both rapid, typically 4 weeks, and long term, typically 8 weeks) for Batches 8 and 9 are now summarized and discussed in this technical report.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Evaluation of the Potential for Precipitation of Solids during Storage of Non-Aluminum SNF Solutions

Non-aluminum clad spent nuclear fuels (NASNF) stored in the L-Area basin will be dissolved in H-Canyon using the 6.3D electrolytic dissolver. The solutions will be stored in either the hot or warm canyon until the preparation of a sludge batch for the Defense Waste Processing Facility. Spent nuclear fuel solutions could be stored for 1-2 years before transfer to the H-Area Tank Farm depending on the interval between sludge batches. The solution level in the storage tanks will be maintained; therefore, precipitation of solids due to evaporation is not an issue. However, the precipitation of solids from completely dissolved SNF due to solution instabilities has been observed during intermediate storage of solutions generating hydrated oxides.The presence of fissile material in these solids is generally associated with zirconium molybdate, which is known to act as a host lattice for Pu and can carry the actinides upon precipitation. The formation of zirconium molybdate solids which carry fissile material is a potential concern for the storage of NASNF solutions. To address this concern, the Savannah River National Laboratory performed a literature review to identify knowledge gaps which may require experimental work to determine if the formation of solids is a concern during storage of these solutions. Based on the literature review, the precipitation of zirconium molybdate solids from the Campaign 1 NASNF solutions during intermediatestorage is expected. This conclusion is supported by the identification of zirconium molybdate solids found on the H-Canyon 6.1D Dissolver MK-12 insert spacer. The formation of the zirconium molybdate solids is attributed to hydrolysis and radiolytic processes in the nitric acid solution. As the molybdate solids form, U and Pu can substitute for Zr in the crystal lattice resulting in co-precipitation. Generally, the Pu substitutes directly into the crystal lattice during precipitation while the U associated with the molybdate solids more likely absorbs from the solution. The U in the NASNF solutions is present as uranyl nitrate, a 2+ cation which will not substitute as easily into the molybdate crystal lattice for the Zr 4+ ion.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Evaluating the feasibility of biological waste processing for long term space missions

Recycling waste products during orbital (e.g., International Space Station) and planetary missions (e.g., lunar base, Mars transit mission, Martian base) will reduce storage and resupply costs. Wastes streams on the space station will include human hygiene water, urine, faeces, and trash. Longer term missions will contain human waste and inedible plant material from plant growth systems used for atmospheric regeneration, food production, and water recycling. The feasibility of biological and physical-chemical waste recycling is being investigated as part of National Aeronautics and Space Administration's (NASA) Advanced Life Support (ALS) Program. In-vessel composting has lower manpower requirements, lower water and volume requirements, and greater potential for sanitization of human waste compared to alternative bioreactor designs such as continuously stirred tank reactors (CSTR). Residual solids from the process (i.e. compost) could be used a biological air filter, a plant nutrient source, and a carbon sink. Potential in-vessel composting designs for both near- and long-term space missions are presented and discussed with respect to the unique aspects of space-based systems.

NASA Discipline Life Support Systems↗

Uranyl oxalate species in high ionic strength environments: stability constants for aqueous and solid uranyl oxalate complexes

Uranyl ion, UO 2 2+ , and its aqueous complexes with organic and inorganic ligands can be the dominant species for uranium transport on the Earth surface or in a nuclear waste disposal system if an oxidizing condition is present. As an important biodegradation product, oxalate, C 2 O 4 2– , is ubiquitous in natural environments and is known for its ability to complex with the uranyl ion. Oxalate can also form solid phases with uranyl ion in certain environments thus limiting uranium migration. Therefore, the determination of stability constants for aqueous and solid uranyl oxalate complexes is important not only to the understanding of uranium mobility in natural environments, but also to the performance assessment of nuclear waste disposal. In this work, we developed a thermodynamic model for the UO 2 2+ –Na + –H + –Cl – –ClO 4 – –C 2 O 4 2– –NO 3 – –H 2 O system to ionic strength up to ~11 mol•kg –1 . We constrained the stability constants for UO 2 C 2 O 4 (aq) and UO 2 (C 2 O 4 ) 2 2– at infinite dilution based on our evaluation of the literature data over a wide range of ionic strengths up to ~11 mol•kg –1 . We also obtained the solubility constants at infinite dilution for solid uranyl oxalates, UO 2 C 2 O 4 •3H 2 O, based on the solubility data over a wide range of ionic strengths. The developed model will enable for the accurate stability assessment of oxalate complexes affecting uranium mobility under a wide range of conditions including those in deep geological repositories.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Laboratory-Scale Melter Systems for Simulated and Real AP-107 Tank Waste - 20483

The Hanford Waste Treatment and Immobilization Plant (WTP) will process and stabilize waste that is stored in underground tanks on the Hanford Site. At the WTP, the tank waste will be combined with glass-forming and modifying additives to form an aqueous and solid mixture called melter feed, which will then be vitrified in joule-heated melters. A small-scale melter system, the continuous laboratory-scale melter (CLSM), is designed to operate with a continuous feeding process while periodically pouring glass product and collecting off-gas. Two CLSMs were constructed: one in a non-radioactive environment for processing waste simulants and another in a fume hood capable of handling radioactive material for processing actual Hanford tank waste. The waste sample received for vitrification in the CLSM was from Hanford tank 241-AP-107. Approximately 12 liters of melter-feed slurry was vitrified into 7 kilograms of glass product over the course of 10 hours of charging to the CLSM. The partitioning of technetium-99 in the product streams was used to calculate the technetium-99 recovery and help determine when the vitrification process had reached a steady state. The average single-pass retention of technetium-99 in the glass product was then calculated for the processing of AP-107 waste in the CLSM system. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Filmless Radiography

Technology initially prototyped under a Small Business Innovation Research contract between Quantex Corporation and Langley Research Center was licensed to Liberty Technology and incorporated into RADView, a new filmless radiography technology. The NASA-sponsored work involved the investigation of Electron Trapping, which led to a solid-state film that uses a special class of photoluminescent materials to capture radiographic images. RadView is a total imaging solution for the conversion of radiographic film records to digital format and digital acquisitions of radiographs. With the RADView technology, there is a reduction of exposure times and errors; film waste is eliminated; and the efficiency of data management and precise image analysis is boosted. The solid-state film can be exposed, read, erased, and re- exposed indefinitely until mechanical replacement is required. Digital images can be stored to optical media for up to 100 years and beyond without information loss.

Source record↗

Vitrification of inorganic ion exchange media

The primary objective of these tests outlined in the Test Plan for this work [15] and described herein was to demonstrate the vitrification of ion exchange media for cesium removal, either alone or in combination with a representative Hanford HLW stream. This included one formulation with chabazite as the only waste component and two formulations containing direct-feed fully washed AY-102 HLW solids combined with either CST or chabazite. Feed processing characteristics, glass production rate, melter emissions, and feed carryover were determined for each of the three feed compositions. This was accomplished through VGF and DM100 melter system testing.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

A Step toward Process Electrification: Microwave-Assisted Co-Gasification of Waste Plastics and Biomass to Produce Clean Energy

Barely 9% of the 353 million metric tons of plastic waste produced worldwide over the last two decades has been recycled, with the majority of it being either landfilled or incinerated. Recycling and upcycling plastic waste is thus essential in mitigating environmental pollution. Gasification is the thermochemical conversion of solid carbon feedstock at high temperatures using a gasifying agent to produce hydrogen-rich syngas. Existing gasification technologies are energy-intensive and require high operating temperatures (>1000 °C), leaving them uncommercial. Microwave heating has sparked attention in a variety of chemical processes due to its specific advantages over traditional heating technologies, such as rapid and selective heating to improve process efficiency. NETL’s research team recently investigated the synergistic advantages of corn stover and mixed plastics in producing hydrogen-rich syngas via microwave heating. As a continuation of the research, this study provides an outlook over the non-catalytic versus catalytic effects of plastic-corn stover gasification via process electrification to enhance H2 production, minimize undesired tar, and improve process efficiency. Our aim is to provide complete electrification of the existing gasification process by using waste plastics as a starting block to produce valuable fuel and support the nation’s net zero goals.

Abedin, Ashraf↗

Using Radioiodine Speciation to Address Environmental Remediation and Waste Stream Sequestration Problems at the Fukushima Daiichi Nuclear Power Plant and a DOE Site

Iodine-129 ( 129 I), with a half-life of half-life of 16 million years, is commonly considered the single greatest risk driver in high-level and low-level nuclear repositories. This risk stems from several basic properties of 129 I, and under many geochemical conditions, it can move as an anion at nearly the rate of water through the subsurface environment. 129 I is also extremely radiologically toxic because over 90% of body burden accumulates in the thyroid, which weighs only about 14g in an adult. There is also a large worldwide inventory of radioiodine as a result of its high fission yield and this inventory is rapidly increasing as a result of nuclear energy production. Radioiodine is produced at a rate of 40 GBq (1 Ci) per gigawatt of electricity produced by nuclear power. To illustrate how the properties of 129 I magnify its risk, 129 I accounts for only 0.00002% of the radiation released from the Savannah River Site in Aiken, South Carolina, but contributes 13% of the population dose, a six orders of magnitude magnification of risk with respect to its radioactivity. The currently favored solid phase for LLW immobilization is cement, while HLW immobilization is the incorporation of waste into glass (vitrification). However, so far, the incorporation into cement and subsequent leaching of only iodide has been seriously investigated. The major problem with this approach is that it ignores the complex speciation of iodine, i.e., it ignores iodate and organo-iodine which have different chemistries. Most of the past research was devoted to the mechanism of iodide uptake in cement hydrate phases that is sorption and/or incorporation. Very few data exist on iodate and organo-iodine incorporation in cement, even though large quantities of liquid waste containing also radioiodine have already been solidified in cement Iodine-129 from low-level waste is commonly disposed of in cementitious materials. Grout, a dense cementitious fluid, mixed with a reducing slag, is often used to immobilize radionuclides. However, the reducing environment might not be conducive to immobilize iodine. For example, the silver based immobilization technologies (e.g., AgCl, Ag-impregnated granular activated carbon, Ag-mordenite) remove iodine from the aqueous phase by promoting the formation of Ag-iodide precipitates. The solubility of AgI is eight orders of magnitude lower than it is for AgIO 3 . Similarly, coprecipitation of iodine into calcium carbonate phases occurs only with IO 3 - and not with I - and org-I. If one would want to immobilize iodine more effectively, different engineering approaches would need to be used to promote binding of I - , IO 3 - , or organo-I. Using laboratory experiments with grout, slag, and silver-based adsorbents, and GC-MS and I K-edge XANES and EXAFS and C K-edge XANES spectroscopy for identifying iodine speciation, the major problems with these methods have been identified as focused too much on just one of the iodine species for immobilization, while others, especially organo-I, remained mobile. Finally, we established that most of the adsorbents that are used contain sufficient amounts of organic matter to create organo-I . It is anticipated that increased attention directed at understanding and quantifying the speciation of radioiodine, as opposed to simply total radioiodine, will lead to improved remediation results to be used for long-term radioiodine disposal in cementitious waste forms.

129-Iodine↗

Filtration Performance of Simulated 200 West Area Waste Feeds

This report describes the scaled experimental system and approach used to examine dead-end filtration performance of representative 200W waste feeds. The scaled system, which was originally designed and assembled to test Tank Side Cesium Removal (TSCR) system performance with higher-than-expected solid loadings in 2021 (Schonewill et al. 2021), was repurposed to conduct the current experiments at ~1/145 of full scale (based on throughput). Six experimental runs were conducted with five different 200W waste feed simulants: three using a DEF module scaled for TSCR and three using a DEF module scaled for the 200W process modules (based on the current design for the Advanced Modular Pretreatment System). Each experiment was run continuously for multiple days with an operating approach prototypic of the full-scale system. Staff performing the experimental runs monitored performance, obtained data from calibrated process instruments, and collected samples for observation and analysis. The measured data are presented with a focus on assessing DEF performance – specifically, the filters’ differential pressure response to the five waste simulants, frequency and efficacy of backwashing, and baseline recovery between experimental runs; data related to ion exchange column performance are also discussed in cases where the opportunity arose. The experimental campaign demonstrated that the DEFs satisfied their primary function of protecting the ion exchange column from solid intrusion for all the representative simulants used. The filters readily handled solids loadings of =500 ppm (and even greater), especially the modules scaled to the 200W process modules. Adjustments to the processing flow rate and reductions in feed temperature were observed to affect the rate of differential pressure increase on the filters, but neither adversely affected the ability of the DEFs to perform their primary function. Backflushing reliably recovered filter performance in all runs, although it did not prevent irreversible fouling for one simulant. The run that exhibited irreversible fouling established that both the quantity and the nature of the solids being filtered need to be considered when projecting filter performance.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Tank 27 Solids Disturbance Testing Using M-Star for the Impact of CSMP Usage on Blend Tank Mixing Effectiveness

Savannah River Mission Completion (SRMC) plans to operate Tank 27as a blend tank for future waste disposal operations. It is desirable to avoid additional worker exposure by using the planned commercial submersible mixing pump (CSMP) installations in Risers B2 and B4 to function as the blend pumps for prolonged blend tank operations. The purpose of this task is to evaluate the impacts to mixing across a range of pump installation heights from 1 to 201 inches above the tank floor. The CSMPs shall maintain adequate blending within a 24 hour maximum timeframe and an adequate nozzle discharge velocity as outlined in U-ESR-G-00030, using the specifications of the planned CSMPs listed in PO SRRA149971 and M-DS-G-00081. Specifications include: maximum pump diameter of D=22.5 in., dual nozzles placed tangentially opposed with nominal inside diameter of 2 in., total flow range (both nozzles combined) of 500 to 1950 GPM and maximum RPM of 1800. Tank 27 is expected to have a fill height maximum of 360". This analysis began by using results from the 2010 testing and applying them to the Tank 27 design to calculate a mixing time as a function of pump flow rate. These results were modified to account for the higher liquid level in Tank 27. Once the liquid level was increased to 360 inches, the results were modified to account for a higher viscosity in Tank 27 than in the testing. Once the viscosity was increased, the effect of changing pump elevation was applied to calculations of the mixing time in Tank 27. Finally, the uncertainty from the testing was included in the analysis to recommend a blend time as a function of pump flow rate and elevation. The conclusion from this study is that the particles in tank 27 will be suspended at both the 600 and 900 gpm flow rates. Only particles above 90 micron will not be suspended in significant amounts when the flow rate is 600 gpm. At 900 gpm even 100 micron particles were thoroughly suspended in the tank. From the series of simulations it has been concluded that it will not be possible to mix tank 27 at the proposed fluid flow rates and not suspend the solid particles at the bottom of the tank.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Numerical Simulation of Container Breach and Airborne Release of Solids Due to Mechanical Insults

Throughout U.S. Department of Energy (DOE) complexes, safety engineers employ the five-factor formula to calculate the source term (ST) that includes parameters of airborne release fraction (ARF), respirable fraction (RF) and damage ratio (DR). Limited experimental data on fragmentation of solids, such as ceramic pellets (i.e., PuO2), and container breach due to mechanical insults (i.e., drop and forklift impact), can be supplemented by modeling and simulation using high fidelity computational tools to estimate these parameters. This paper presents the use of Sandia National Laboratories' SIERRA solid mechanics (SM) finite element code to investigate the behavior of the widely utilized waste container (such as 7A Drum) subject to a range of free fall impact and puncture scenarios. The resulting behavior of the container is assessed, and the estimates are presented for bounding DRs from calculated breach areas for the various accident conditions considered. This paper also describes a novel multiscale constitutive model recently implemented in SIERRA/SM that simulates the fracture of brittle materials such as PuO 2 and determines ARF during the fracture process. Furthermore, comparisons are made between model predictions and simple bench-top experiments.

61 RADIATION PROTECTION AND DOSIMETRY↗

Reduced Neutralization Feasibility Study for H-Canyon Accelerated Basin De- Inventory (ABD) Program

An alternative approach to Spent Nuclear Fuel (SNF) and Nuclear Material Processing was developed for future H-Canyon (HCAN) and L-Area operations that involves a paradigm shift from current HCAN, Concentrate, Storage, and Transfer Facility (CSTF), and Defense Waste Processing Facility (DWPF) operations. The alternative, referred to as Accelerated Basin De-inventory (ABD), requires that all Domestic and Foreign Research Reactor SNF currently at the Savannah River Site (SRS) will be dissolved, stored, and then transferred to CSTF without recovery of Highly Enriched Uranium (HEU). Concentrated nitric acid is utilized to dissolve aluminum spent nuclear fuel (ASNF) in HCAN. The vessels and piping in HCAN are fabricated from 304L stainless steel and are ideally suited to handle the acidic waste stream. However, as the waste is transferred to the CSTF and DWPF, it will contact the carbon steel waste tanks in CSTF. In order to prevent corrosion of the carbon steel, the acidic waste is neutralized (i.e., pH adjusted over 11) by the addition of sodium hydroxide (NaOH). The NaOH is added until the final solution contains 1.2 M excess -OH. Additionally, if the waste is not neutralized to a pH greater than 11, then aluminum hydroxide (Al(OH) 3 ) would form, and solids may form in the piping as it is transferred to CSTF. This document presents an analysis of the influence of reducing the excess caustic that is added to the neutralization tanks on the corrosion protection scheme primarily for the CSTF waste tanks. The implications to HCAN and DWPF were also assessed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Hanford Double Shell Waste Tank Corrosion Studies- Final Report FY2024

For fiscal year (FY) 2024, the Savannah River National Laboratory (SRNL) focused on two experimental tasks related to Hanford Double Shell Tank (DST) chemistry and integrity. The first task focused on understanding risk of corrosion due to formation of either continuous layers or discrete patches of solids on the tanks’ inner sidewalls and bottoms. The objective of this task was to determine the effect of solid deposits on the corrosion risk to the tank bottom, and whether a combination of scale, saltcake and loose solids lead to under deposit corrosion. Electrochemical testing in a single cell arrangement was employed to determine a threshold inhibitor level for the interstitial liquid in the solids, above which carbon steel was not susceptible to corrosion beneath the solids. The inhibitor levels tested were based on the previously determined probability of failure for carbon steel in a simulated waste (i.e., Pitting Factor).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing

Decarbonizing industrial manufacturing is a significant challenge in the effort to limit the impacts of global climate change. Additive manufacturing (AM) is one pathway for reducing the impacts of manufacturing as it creates parts layer-by-layer rather than by removing (i.e., subtracting) material from solid stock as with conventional techniques. This reduces material inputs and generates less waste, which can substantially lower life cycle energy consumption and greenhouse gas emissions. However, AM adoption in the manufacturing sector has been slow, partly due to challenges in making a strong business case compared with more traditional and widely available techniques. This paper highlights the need for the development of simple screening analysis tools to speed the adoption of AM in the manufacturing sector by providing decision-makers easy access to important production life cycle emissions, and cost information. Details on the development of two Microsoft Excel software tools are provided: upgrades to an existing tool on the energy and carbon impacts of AM and a new tool for analyzing the major cost components of AM. A case study applies these two tools to the production of a lightweight aerospace bracket, showing how the tools can be used to estimate the environmental benefits and production costs of AM.

GHG emissions↗

Solid state SPS microwave generation and transmission study. Volume 2, phase 2: Appendices

The solid state sandwich concept for SPS was further defined. The design effort concentrated on the spacetenna, but did include some system analysis for parametric comparison reasons. Basic solid state microwave devices were defined and modeled. An initial conceptual subsystems and system design was performed as well as sidelobe control and system selection. The selected system concept and parametric solid state microwave power transmission system data were assessed relevant to the SPS concept. Although device efficiency was not a goal, the sensitivities to design of this efficiency were parametrically treated. Sidelobe control consisted of various single step tapers, multistep tapers and Gaussian tapers. A hybrid concept using tubes and solid state was evaluated. Thermal analyses are included with emphasis on sensitivities to waste heat radiator form factor, emissivity, absorptivity, amplifier efficiency, material and junction temperature.

Maynard, O. E.↗

Development of Lead Free Energy Absorber for Space Shuttle Blast Container

The Space Shuttle is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the Space Shuttle and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the blast container for two specific reasons: (1) To eliminate lead for environmental concerns, and (2) To reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hang-ups. This upgrade will replace the lead liner with a unique open cell aluminum foam material, that has commercial and military uses. The aluminum foam used as an energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: (A) Lead handling/exposure and possible contamination, along with hazardous waste disposal, will be eliminated; (B) Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam instead of lead; (C) The new aluminum liner is designed to catch all shrapnel from frangible nuts, thus virtually eliminating chance of debris exiting the HDP and causing potential damage to the vehicle; and (D) Using the lighter aluminum liner instead of lead, allows for easier assembly and disassembly of blast container elements, which also improves safety, operator handling, and the efficiency of operations.

Balles, Donald↗