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At least 775 records · Page 43

Supplemental Immobilization of Hanford Low-Activity Waste: Cast Stone Augmented Formulation Matrix Tests

More than 56 million gallons of radioactive and hazardous waste are stored in 177 underground storage tanks at the U.S. Department of Energy’s (DOE’s) Hanford Site in Washington State. The HLW will be vitrified in the HLW facility for ultimate disposal at an offsite federal repository. A portion (~35%) of the LAW will be vitrified in the LAW vitrification facility for disposal onsite at the Integrated Disposal Facility (IDF). The pretreatment and HLW vitrification facilities will have the capacity to treat and immobilize all of the wastes destined for those facilities. However, a second facility will be needed for the expected volume of LAW requiring immobilization. Cast Stone, a cementitious waste form, is being considered to provide the required additional LAW immobilization capacity. The Cast Stone waste form must be acceptable for disposal in the IDF. The Cast Stone waste form and immobilization process must be tested to demonstrate that the final Cast Stone waste form can comply with the waste acceptance criteria for the disposal facility and that the immobilization processes can be controlled to consistently provide an acceptable waste form product. A testing program was developed in fiscal year (FY) 2012 describing in detail the work needed to develop and qualify Cast Stone as a waste form for the solidification of Hanford LAW. A statistically designed test matrix was used to evaluate the effects of key parameters on the properties of the Cast Stone as it is initially prepared and after curing. For the processing properties, the water-to-dry-blend mix ratio was the most significant parameter in affecting the range of values observed for each property. The single shell tank (SST) Blend simulant also showed differences in measured properties compared to the other three simulants tested. A review of the testing matrix and results indicated that an additional set of tests would be beneficial to improve the understanding of the impacts noted in the Screening Matrix tests. A set of Cast Stone formulations were devised to augment the original screening test matrix and focus on the range of the test conditions. Fly ash and blast furnace slag were limited to either northwest or southeast and the salt solutions were narrowed to the Average and the SST Blend at the 7.8M Na concentration. To fill in the matrix, a mix ratio of 0.5 was added. In addition, two admixtures, Xypex Admix C-500 and Rheomac SF100 (silica fume), were added as an additional dry material binder in select compositions. As in the Screening Matrix, both fresh and cured properties were evaluated for the formulations. In this study, properties that were influenced by the W/DM ratio in the Screening Matrix; flow diameter, plastic viscosity, density, and compressive strength, showed consistent behavior with respect to W/DM. The leach index for highly soluble components, sodium and nitrate, were not influenced by changes in formulation or the admixtures. The leach index for both iodine and Tc-99 show an influence from the addition of the admixture, Xypex Admix C-500. Additional testing should be performed to further evaluate the influence of Xypex Admix C-500 on the leach index over a range of admixture concentrations, Cast Stone formulations, and curing and storage conditions.

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Evaluation of Technetium Getters to Improve the Performance of Cast Stone

Cast Stone has been selected as the preferred waste form for solidification of aqueous secondary liquid effluents from the Hanford Tank Waste Treatment and Immobilization Plant (WTP) process condensates and low-activity waste (LAW) melter off-gas caustic scrubber effluents. Cast Stone is also being evaluated as a supplemental immobilization technology to provide the necessary LAW treatment capacity to complete the Hanford tank waste cleanup mission in a timely and cost effective manner. One of the major radionuclides that Cast Stone has the potential to immobilize is technetium (Tc). The mechanism for immobilization is through the reduction of the highly mobile Tc(VII) species to the less mobile Tc(IV) species by the blast furnace slag (BFS) used in the Cast Stone formulation. Technetium immobilization through this method would be beneficial because Tc is one of the most difficult contaminants to address at the U.S. Department of Energy (DOE) Hanford Site due to its complex chemical behavior in tank waste, limited incorporation in mid- to high-temperature immobilization processes (vitrification, steam reformation, etc.), and high mobility in subsurface environments. In fact, the Tank Closure and Waste Management Environmental Impact Statement for the Hanford Site, Richland, Washington (TC&WM EIS) identifies technetium-99 ( 99 Tc) as one of the radioactive tank waste components contributing the most to the environmental impact associated with the cleanup of the Hanford Site. The TC&WM EIS, along with an earlier supplemental waste-form risk assessment, used a diffusion-limited release model to estimate the release of different contaminants from the WTP process waste forms. In both of these predictive modeling exercises, where effective diffusivities based on grout performance data available at the time, groundwater at the 100-m down-gradient well exceeded the allowable maximum permissible concentrations for 99 Tc. (900 pCi/L). Recent relatively short-term (63 day) leach tests conducted on both LAW and secondary waste Cast Stone monoliths indicated that 99 Tc diffusivities were at or near diffusivities where the groundwater at the 100-m down-gradient well would exceed the allowable maximum permissible 99 Tc concentrations. There is, therefore, a need and an opportunity to improve the retention of Tc in the Cast Stone waste form. One method to improve the performance of the Cast Stone waste form is through the addition of “getters” that selectively sequester Tc inside Cast Stone.

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Liquid secondary waste. Waste form formulation and qualification

The Hanford Site Effluent Treatment Facility (ETF) currently treats aqueous waste streams generated during Site cleanup activities. When the Hanford Tank Waste Treatment and Immobilization Plant (WTP) begins operations, a liquid secondary waste (LSW) stream from the WTP will need to be treated. The volume of effluent for treatment at the ETF will increase significantly. Washington River Protection Solutions is implementing a Secondary Liquid Waste Immobilization Technology Development Plan to address the technology needs for a waste form and solidification process to treat the increased volume of waste planned for disposal at the Integrated Disposal Facility IDF). Waste form testing to support this plan is composed of work in the near term to demonstrate the waste form will provide data as input to a performance assessment (PA) for Hanford’s IDF.

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Prioritized List of Research Needs to support MRWFD Case Study Flowsheet Advancement

In FY-13, a case study evaluation was performed of full recycle technologies for both the processing of light-water reactor (LWR) used nuclear fuels as well as fast reactor (FR) fuel in the full recycle option. This effort focused on the identification of the case study processes and the initial preparation of material balance flowsheets for the identified technologies. In identifying the case study flowsheets, it was decided that two cases would be developed: one which identifies the flowsheet as currently developed and another near-term target flowsheet which identifies the flowsheet as envisioned within two years, pending the results of ongoing research. The case study focus is on homogeneous aqueous recycle of the U/TRU resulting from the processing of LWR fuel as feed for metal fuel fabrication. The metal fuel is utilized in a sodium-cooled fast reactor, and the used fast reactor fuel is processed using electrochemical separations. The recovered U/TRU from electrochemical separations is recycled to fuel fabrication and the fast reactor. Waste streams from the aqueous and electrochemical processing are treated and prepared for disposition. Off-gas from the separations and waste processing are also treated. As part of the FY-13 effort, preliminary process unknowns and research needs to advance the near-term target flowsheets were identified. In FY-14, these research needs were updated, expanded and prioritized. This report again updates the prioritized list of research needs based upon results to date in FY-15. The research needs are listed for each of the main portions of the flowsheet: 1) Aqueous headend, 2) Headend tritium pretreatment off-gas, 3) Aqueous U/Pu/Np recovery, 4) Aqueous TRU product solidification, 5) Aqueous actinide/lanthanide separation, 6) Aqueous off-gas treatment, 7) Aqueous HLW management, 8) Treatment of aqueous process wastes, 9) E-chem actinide separations, 10) E-chem off-gas, 11) E-chem HLW management. The identified research needs were prioritized within each of these areas. No effort was made to perform an overall prioritization. This information will be used by the MRWFD Campaign leadership in research planning for FY-16. Additionally, this information will be incorporated into the next version of the Case Study Report scheduled to be issued September 2015.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

From Alloy Processing to Performance: An In Situ Experimental and Modeling Effort

Solidification is present in almost all materials. It is influenced by grain size and shape, chemical homogeneity, defect type and density, and mechanical properties. During micro-mechanical testing, the following occur: 1) Micro-CT (as processed) - Map Initial 3D Microstructure 2) Nano-Radiography (In situ under Tension) - Observe of Damage Initiation/Propagation 3) Micro-CT (Post Mortem) - Global Fracture Study 4) Nano-CT (Post Mortem) - High-Resolution Fracture Study.

36 MATERIALS SCIENCE↗

Laser Weld Geometry and Microstructure of Cast Uranium-6 wt% Niobium Alloy

Laser welding was performed on a U6 wt% Nb uranium alloy using a 400W solid state laser with welding speeds from 20 to 2,500 mm/s. This speed range spanned melt pool sizes from traditional welding to surface modification and additive manufacturing. With increasing scan speed, the ratio of weld length relative to depth and width increased, with melt pool lengths being more than 5x greater than the width and 10x greater than the depth at the highest speeds. Keyhole mode welds were shown to occur at low speeds, while conduction mode welds occurred at 700 mm/s or higher as the weld depth dropped off more rapidly than width at higher speeds. Microstructures that form at the boundary between the fusion zone and base metal were observed to have a nonconventional appearance consisting of interpenetrating dark and light contrast phases before cells or dendrites appear. Dendrites with secondary arms form from this boundary in keyhole welds and refine to no visible secondary arms near the weld center. Primary and secondary dendrite arms, where present, were shown to refine in size inversely with cooling rate raised to the 0.465 and 0.376 powers respectively. Dendrites were largely absent from the conduction mode welds at higher speeds, and were replaced by a banded microstructure, that appears to form by an oscillatory solidification front mechanism.

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SRPPF Aqueous Recovery System Sorbent Testing

This study details preliminary testing of 7 inorganic sorbents for the solidification of the surrogate SRPPF aqueous recovery system liquid excess material of 4M sodium nitrate. Sorbents were subject to various mixing methods to incorporate sodium nitrate solution including static, rotating, and in situ paddle mixing. Paddle mixing was found to be the most effective mixing technique, while simple static tests were also successful, though only for some of the sorbents. Setting tests were performed to ensure that the sorbent sequestered the liquid without release through a conical paint filter. Recommended set times ranged from near immediate to 7 days. The set mixtures were investigated further using ultra-centrifugal liquid release testing, thermogravimetric analysis, and visual microscopy to understand the mechanism by which the sorbent sequestered the liquid. Most sorbents seem to incorporate liquid by sorbing it onto and into the sorbent particles, while Drierite ® , anhydrous calcium sulfate, created a crystal structure that bound the surrogate liquid. Overall, four sorbents are recommended for continued testing: Aquaset II, Aquaset IIG, Drierite ® , and Spill-X-A.

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Manufacture of Wear-Resistant Cast-Iron Grinding Balls without Shrinkage Defects

A manufacturing technology has been developed for wear-resistant cast-iron grinding balls without shrinkage defects. In this method, the balls are cast in single-use sand–clay molds. A new approach to designing the casting system is developed. By numerical modeling, the time dependence of solidification is derived. As a trial, grinding balls are produced by the proposed technology.

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Mechanical Behavior of Al–Al2Cu–Si and Al–Al2Cu Eutectic Alloys

In this study, laser rapid solidification technique was used to refine the microstructure of ternary Al–Cu–Si and binary Al–Cu eutectic alloys to nanoscales. Micropillar compression testing was performed to measure the stress–strain response of the samples with characteristic microstructure in the melt pool regions. The laser-remelted Al–Al2Cu–Si ternary alloy was observed to reach the compressive strength of 1.59 GPa before failure at a strain of 28.5%, which is significantly better than the as-cast alloy with a maximum strength of 0.48 GPa at a failure strain of 4.8%. The laser-remelted Al–Cu binary alloy was observed to reach the compressive strength of 2.07 GPa before failure at a strain of 26.5%, which is significantly better than the as-cast alloy with maximum strength of 0.74 GPa at a failure strain of 3.3%. The enhanced compressive strength and improved compressive plasticity were interpreted in terms of microstructural refinement and hierarchical eutectic morphology.

36 MATERIALS SCIENCE↗

A Common Origin of Magnetism from Planets to White Dwarfs

Isolated magnetic white dwarfs have field strengths ranging from kilogauss to gigagauss. However, the origin of the magnetic field has not been hitherto elucidated. Whether these fields are fossil, hence the remnants of original weak magnetic fields amplified during the course of the evolution of their progenitor stars, or are the result of binary interactions, or, finally, they are produced by other internal physical mechanisms during the cooling of the white dwarf itself, remains a mystery. At sufficiently low temperatures, white dwarfs crystallize. Upon solidification, phase separation of its main constituents, {sup 12}C and {sup 16}O, and of the impurities left by previous evolution occurs. This process leads to the formation of a Rayleigh–Taylor unstable liquid mantle on top of a solid core. This convective region, as it occurs in solar system planets like the Earth and Jupiter, can produce a dynamo able to yield magnetic fields of strengths of up to 0.1 MG, thus providing a mechanism that could explain magnetism in single white dwarfs.

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Characterization techniques for TRU waste from the Analytical Laboratory Hot Cells at Idaho National Laboratory

Characterization techniques for TRU waste from the Analytical Laboratory Hot Cells at Idaho National Laboratory Since the first reactor went hot in 1942, there has been a never ending desire to improve the nuclear reactor and the fuel that it burns. The Idaho National Laboratory has been a key player in reactor and fuel development. As more research projects begin, the spectrum of waste parameters grows. Over the years, the Analytical Laboratory (AL) at the Materials and Fuels Complex (MFC) at Idaho National Laboratory (INL) has supported a large range of various research projects. Each project brings its own challenge and analytical technique that, in turn, yields its own unique waste parameters. The AL Hot Cells at INL consist of 6 small cells that can support around 12 different fuel research projects at a time along with infrastructure and environmental samples. Each different project yields different levels of transuranic (TRU) material, RCRA constituents, dose, and contamination levels. The waste parameters from each project dictate a path forward for the waste Low-Level Waste (LLW), Contact Handled TRU (CH-TRU), Mixed Contact Handled TRU (M-CH-TRU), Remote Handled TRU (RH-TRU), or Mixed Remote Handled TRU (M-RH-TRU). With visual examination techniques and process knowledge as an aid, there have been waste handling methods developed that allow debris and sample material to be segregated. Unique characterization mechanisms have been applied for each debris and sample material that are generally more accurate than smear and surface contamination data. For debris found in the Hot Cells, analytical data is gathered and conservatively summarized for each fuel type and research method. This consists of data from Quadrupole Inductively Coupled Plasma Mass Spectrometry (Q-ICP-MS), Gamma Spectroscopy, and some data verification through Thermal Ionization Mass Spectrometry (TIMS) and Multi-Collector Inductively Coupled Plasma Mass Spectrometry (MC-ICP-MS). This data gives a range of TRU isotope concentrations. Fuel age is taken into account to determine the dominant TRU activity isotopes. Cesium concentrations are also gathered. Each parameter/fuel type then ties a measured Cesium number to TRU content based on historical analytical data. Debris in the hot cells is segregated by project and packaged in individual 2 gallon metal paint cans. Each can is counted by gamma spectroscopy in a calculated and measured geometry. Using process knowledge to determine the fuel or project type, newly counted cesium numbers can be applied to the historic analytical data and TRU content can be estimated. The TRU content allows waste debris to be segregated between CH-TRU and RH-TRU. Packaging techniques can allow for the minimization if RH-TRU waste. Sample material received into the AL must be dissolved into a liquid matrix in order to be analyzed in most cases. When analysis is complete, these liquids go through a consolidation, complexation, neutralization, and solidification process where real time analytical data can be used to calculate TRU content and RCRA constitutes. These calculations allow for no further analytical data to be gathered. The waste matrix is considered stable and acceptable by all AK [define AK] documents. The unique techniques used in characterizing and handling the Analytical Laboratories Hot Cell waste can be applied to various situations and various laboratories. They allow for more accurate data for waste constituents and also for the minimization of RH-TRU waste.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Improvement of Radwaste Management System at Bilibinskaya NPP in the Far North Conditions - 13456

Since 2009 Bilibinskaya NPP is getting started to prepare to the decommissioning in the Far North conditions. Bilibinskaya NPP is located in the Far North of Russian Federation in Chukotka region. Since 1974 it operates 4 units EGP-6 with the capacity of 48 MW each. According to the contract, SIA Radon has performed the following works: - LLRW disposal safety analysis, - The technology of spent ion-exchanger and salt residue solidification is proposed, - Expected radwaste (till 2027) management economical analysis, - Technical proposals for LLRW and IRW management. (authors)

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Westinghouse Modular Grinding Process - Enhancement of Volume Reduction for Hot Resin Supercompaction - 13491

In nuclear power plants (NPP) ion exchange (IX) resins are used in several systems for water treatment. Spent resins can contain a significant amount of contaminates which makes treatment for disposal of spent resins mandatory. Several treatment processes are available such as direct immobilization with technologies like cementation, bitumisation, polymer solidification or usage of a high integrity container (HIC). These technologies usually come with a significant increase in final waste volume. The Hot Resin Supercompaction (HRSC) is a thermal treatment process which reduces the resin waste volume significantly. For a mixture of powdered and bead resins the HRSC process has demonstrated a volume reduction of up to 75 % [1]. For bead resins only the HRSC process is challenging because the bead resins compaction properties are unfavorable. The bead resin material does not form a solid block after compaction and shows a high spring back effect. The volume reduction of bead resins is not as good as for the mixture described in [1]. The compaction properties of bead resin waste can be significantly improved by grinding the beads to powder. The grinding also eliminates the need for a powder additive.Westinghouse has developed a modular grinding process to grind the bead resin to powder. The developed process requires no circulation of resins and enables a selective adjustment of particle size and distribution to achieve optimal results in the HRSC or in any other following process. A special grinding tool setup is use to minimize maintenance and radiation exposure to personnel. (authors)

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Multi-discipline Waste Acceptance Process at the Nevada National Security Site - 13573

The Nevada National Security Site low-level radioactive waste disposal facility acceptance process requires multiple disciplines to ensure the protection of workers, the public, and the environment. These disciplines, which include waste acceptance, nuclear criticality, safety, permitting, operations, and performance assessment, combine into the overall waste acceptance process to assess low-level radioactive waste streams for disposal at the Area 5 Radioactive Waste Management Site. Four waste streams recently highlighted the integration of these disciplines: the Oak Ridge Radioisotope Thermoelectric Generators and Consolidated Edison Uranium Solidification Project material, West Valley Melter, and classified waste. (authors)

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Reuse of Ion Exchange Resins for Reduction of Spent Radioactive Resins - 17125

A process is proposed to reuse ion exchange resins. The process consists of ion exchange beds for the ion exchange and regeneration, regeneration solution (regenerant) make-up tanks, an evaporator for concentration of spent regenerant, a dryer for the drying of concentrate, a pulverizer for grinding dried salt and a mixer for polymer solidification of the salt. A spent resins storage tank and a spent regenerant storage tank are also involved in the process. The role of each component in the process for reuse of the resins is explained. In addition, the effect of the reuse of ion exchange resins by regeneration was estimated in view of the reduction of spent resins. As the number of regenerations increases, the volume of spent resins is obviously inversely proportional to the number of regenerations. Although a polymer waste form is generated instead of spent resins when the ion exchange resins are reused, its volume is only about one-fifth of that of spent resins. (authors)

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Savannah River Remediation Liquid Waste Operations Making the Workplace Safer - Lean and Human Performance Improvement Initiatives - 17244

The Savannah River Site, a U.S. Department of Energy facility, contracted Savannah River Remediation (SRR) to manage its liquid waste project, which is a unique, high hazard nuclear waste treatment and disposal facility consisting of 51, one million gallon underground waste tanks, a solvent extraction processing unit, a vitrification facility for the highest radioactive waste, and a grout solidification and disposal facility for a decontaminated salt solution. Our Project mission is to treat the nuclear waste and close the associated storage and treatment facilities, of which, 8 of the 51 tanks have been closed to date. Over the past three years, SRR implemented a Lean Business Management System to address site inefficiencies, aging infrastructure concerns and budget constraints. The Lean philosophy started with the work of W. Edwards Deming and his contemporaries. In more recent years the process has matured in the Toyota Production System and migrated into fields as diverse as services industries, health-care, and now the DOE complex. Like safety, continuous improvement is a fundamental core business value that starts at the top. The Lean Business System, led by our executive management team, drives quality, production and waste elimination by focusing on People using a structured Process that allows the workforce to identify and fix problems in their workplace. Many inefficiencies and quality related issues start with the desire to make systems fail-safe without defining the core requirements for which that process or program was created. This leads to added complexity and latent or inherent human performance issues embedded within our processes. While Lean can't fix all problems, a combination of strong nuclear safety culture, robust conduct of operations, active human performance improvement process, and a business practice of continuously looking for improvements leads to excellence across our industry and creates a culture that is worthy of promoting. Without strong management, our systems fail because no one sponsors or encourages those attributes we covet. Leadership starts at the top with our customer defining what provides 'value' to them, and filters down through to the organization and ultimately the workforce in day to day conduct of operations. It is imperative that our customer drives these desirable ideals through recognition and contractual requirements to encourage and support those behavioral traits that are critical to our ongoing success.This paper focuses on how the Lean Business Management System supports those attributes that we value: a strong nuclear safety culture; disciplined conduct of operations; and a culture of robust human performance and continuous improvement. These attributes in our daily work environment propel a safer, more consistent, more efficient workplace. (authors)

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SRR's 'Next Step' in the Lean Journey -Taking Lean to the Workforce - 17247

The Savannah River Site, a U.S. Department of Energy (DOE) facility, contracted Savannah River Remediation (SRR) to manage its liquid waste project, which is a unique, high hazard nuclear waste treatment and disposal facility consisting of 51, one million-gallon underground waste tanks, a solvent extraction processing unit, a vitrification facility for the highest radioactive waste, and a grout solidification and disposal facility for a decontaminated salt solution. Our Project mission is to treat the nuclear waste and close the associated storage and treatment facilities, of which, 8 tanks have been closed to date. At SRR, the Lean business management system has been adopted to address site inefficiencies, aging infrastructure concerns and budget constraints. The Lean philosophy took root decades ago in the manufacturing sector and started with the work of W. Edwards Deming and his contemporaries. In more recent years the process has matured in the Toyota Production System and migrated into fields as diverse as services industries, health-care, and now the DOE complex. The first step of the SRR Lean Journey was to formally identify areas of improvement and initiate Value Stream Analysis (VSAs) and Rapid Improvement Events (RIEs). SRR has achieved improvements in procedure implementation, work planning and control, project schedule compression, and engineering requirements. SRR is now phasing in the next phase of Lean through Managing for Daily Improvement (MDI), Visual Management and 5S (sort, set in order, shine, standardize, and sustain). MDI is a fundamental Lean principle in that we use our most valuable asset, our employees, to drive continuous improvement versus a smaller population through formal events. Part of MDI includes visual management where the workforce can go to a 'dashboard' to see and understand the company mission and status. 5S is a process where a work group improves performance in an area by addressing physical organization, efficiency, uniformity, standardization, and mechanisms to sustain improvements. 5S stands for: Sort, Set in Order, Shine, Standardize, and Sustain. This paper will focus on the 'Next Step' in SRR's Lean journey by address how SRR is implementing MDI and 5S to improve CONOPs, Project efficiencies, and worker engagement in day to day operations. (authors)

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EPRI Research Results: The EPRI Implementation Guide for the NRC BTP on Concentration Averaging and Encapsulation - 17488

The Nuclear Regulatory Commission published Revision 1 of the Branch Technical Position (BTP) on 'Concentration Averaging and Encapsulation' (BTP 2015.) PRI developed an Implementation Guide for applying BTP 2015 to nuclear power plant specific waste streams. This Implementation Guide has been vetted and supported by an EPRI organized working group consisting of industry participants (including utilities subject matter experts, disposal sites, NRC and Agreement State representatives and industry experts) will ensure compliant and consistent application during waste generation, packaging, processing and disposal activities. The Implementation Guide provides for a comparison to previous BTP guidance and provides clarification and common understanding of the key concepts contained within the revised BTP. These include averaging constraints, hot spots, waste streams, waste types, discrete items, blending, solidification, encapsulation and alternative approaches. EPRI published the Implementation Guidance for the Nuclear Regulatory Commission Branch Technical Position on 'Concentration Averaging and Encapsulation, Revision 1' (EPRI Report 3002008189) in the September 2016 and it was made available to the public. (authors)

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