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NASA NTRSDate not supplied

Adapting Waste Processing for Space Applications

It has been estimated that on a 1-year mission, a four-astronaut crew will produce approximately 2,600 kg of waste materials. The current International Space Station practice for waste management is a stow and jettison model in which the trash is simply ejected. The immediate challenge waste poses for long duration space flight is that it represents unproductive mass. Longer term, waste accumulation on planetary surfaces will also pose challenges. A waste management/disposal solution is greatly needed. Simultaneously, significant research and development efforts are being made to enable in-situ resource extraction and recovery for lunar and Mars surface operations. A waste management solution could free up volume, reduce mass and thereby propellant needs, as well as contribute to resource recovery for spacecraft, and eventually, surface operations. The adaptation of many chemical engineering unit operations to the microgravity environment is critical to achieve this goal. An ideal spacecraft waste treatment system would convert waste into useful gases. It should be largely self-sustaining in that it should have the ability to recycle commodities to avoid imposing mass penalties associated with transporting feedstock on the spacecraft at launch. At NASA KSC, a model of what such a system would look like is being developed. In addition, the team has recently completed a suborbital flight campaign with a combustion reactor to demonstrate rudimentary conversion in a microgravity environment and identify challenges for future design. This presentation will discuss what a full waste treatment system could look like, point out challenges relating to various unit operations involved in such a system, and highlight recent progress in space waste management research and development.

Waste Processing↗

NASA NTRS1995

Marshall Space Flight Center solid waste characterization and recycling improvement study

The MSFC Facilities Office, which is responsible for disposing of all waste generated by MSFC, issued a delivery order to the University of Alabama in Huntsville (UAH) to characterize current MSFC waste streams and to evaluate their existing recycling program. The purpose of the study was to define the nature, quantity, and types of waste produced and to generate ideas for improving the present recycling program. Specifically, the following tasks were to be performed: Identify various surplus and waste materials--as identified by the Contracting Officer's Technical Representative (COTR)--by source, location, and type; Analyze MSFC's current methods for handling, storage, transport, and disposition of waste and surplussed materials; Determine the composition of various surplus and waste materials as to type and quantities from various sources and locations; Analyze different methods for the disposition of various surplus and waste materials, including quality, quantity, preparation, transport cost, and value; Study possible alternatives to current methods of handling, storage, transport, and disposition of surplus and waste materials to improve the quality and quantities recycled or sold and to reduce and minimize the quantities of surplus and waste material currently being disposed of or stored; Provide recommendations for source and centralized segregation and aggregation of materials for recycling and/or disposition; and The analysis could include identification and laboratory level evaluation of methods and/or equipment, including capital costs, operating costs, maintenance requirements, life cycle and return on investment for systems to support the waste reduction program mission.

Eley, Michael H.↗

DOE OSTI1961

Laboratory Development of a Pot Calcination Process for Converting Liquid Wastes to Solids

Simulated Darex, Purex, Thorex, and TBP-25 wastes were batch-evaporated and calcined to solids. The weight of residue was decreased to ~ 8% of the original waste for Darex, to ~ 4% for Purex, to ~ 2% for Thorex, and ~ 7% for TBP-25 by calcination to 1200°C. Semicontinuous evaporation and calcination to solids at 900°C of Darex and Purex wastes gave volume reduction factors of ~ 8 and 7 to 10, respectively. The nitrate contents of the residues from batch calcination to 800°C were from ~ 0.07 to 0.5 wt % while the nitrate contents of the residues from semicontinuous calcination to 900°C were from ~ 0.1 to 0.7 wt %. Sodium, calcium, and magnesium additives to Purex waste decreased the percent of sulfate volatilized into the condensate from ~ 30% to <0.5%. Replacement of the atmosphere above the waste with nitric oxide decreased ruthenium volatility from 50 to 60% of that originally present in Purex waste to 0.5 to 3.5%. The thermal conductivities for the calcined wastes, measured in situ, were all >0.1 Btu/hr ft °F at ~ 400°F and increased almost linearly with increasing temperature to >0.3 Btu/hr ft °F at ~ 1600°F in all cases studied.

052001* -- Nuclear Fuels-- Waste Processing↗

NASA NTRSDate not supplied

Integrated Waste Trade Study: Lunar Surface to Deep Space

The Logistics Reduction Project is one of NASA's technology development projects that is preparing humanity for deep space missions. Reducing the mass and volume of logistical supplies that must be carried from Earth to support the missions and their crews is the primary goal of the project. Effective ways to achieve this goal include reducing, reusing, or recycling wastes generated throughout the mission. Due to the goal of the project, waste processing technologies were analyzed for Lunar surface missions at various lengths and an 850-day Mars transit mission to evaluate the potential benefits of waste processing pertaining to each mission. The technologies assessed include trash compaction, trash-to-gas and human metabolic waste processing technologies, integrated with the baseline architectures of each mission’s habitat. The fully integrated systems were analyzed using an equivalent system mass, which is a metric that encompasses the mass, volume, power and cooling of a system, resulting in an estimate of launch mass and serving as a proxy for cost. Each system’s equivalent system mass was compared to that of the baseline waste processing system of the respective habitat, hand compaction with storage for Lunar surface missions and hand compaction with jettisoning for Mars transit, to evaluate whether the traded waste processing technology was beneficial. This analysis identifies a general trend that more sophisticated waste processing can be beneficial depending on the mission duration. For Lunar surface missions, the water recovery from waste processing can pay off over consecutive missions, due to offsetting the losses from the system via extravehicular activities. In contrast for Mars transit, the primary objective is mass removal from the spacecraft, so technologies like trash-to-gas are competitive with the baseline. Furthermore, the technologies which can recover resources from waste, such as water, may present additional advantages to an ever-changing Mars mission architecture.

Waste processing↗

DOE OSTI2024

AI/ML-assisted Design of Phosphate Glass and Ceramic Nuclear Waste Forms

Borosilicate glass is the widely accepted waste form for immobilization of high and medium level nuclear wastes. Advances in nuclear energies and new reactor designs require the development of new waste forms. For example, wastes from molten salt reactors and reprocessing of nuclear fuels lead to salt-based wastes that are difficult to be immobilized by conventional borosilicate glasses due to limited solubility and waste loading. In designing new waste forms, machine learning (ML) and artificial intelligence (AI) based approaches are much needed and can be beneficial in enabling a more efficient design in large parameter spaces as compared to traditional Edisonian trial-and-error approaches. Here, we report in this paper the rationale and latest progress of our ML/AI-based design of phosphate-based waste forms.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Advanced Computational Modeling of High-Level Waste Vitrification at the Hanford Site

The U.S. Department of Energy (DOE) has selected vitrification for stabilizing legacy tank waste at the Hanford site, where radioactive waste from plutonium production was historically stored in underground tanks. This waste will be separated into low-activity waste (LAW) and high-level waste (HLW) fractions and processed at the Waste Treatment and Immobilization Plant (WTP). At WTP, glass melters are used for the vitrification of radioactive tank waste, transforming it into a stable borosilicate glass form for safe long-term storage. The melter vessel is constructed from highly durable and heat-resistant materials, where the vitrification process occurs. The main regions that are modeled are the melt pool, plenum, cold cap, riser/discharge chamber, and surrounding structure with insulation layers. Forced convection induced by air bubblers at the base of the melter ensure uniform temperature distribution and provide heat to the cold cap layer. The cold cap is a region of reacting batch feed that floats on top of the molten glass and is where the batch-to-glass reactions occur. Joule heating provided by electrodes mounted along the vertical walls of the melter and immersed directly in the glass, generates the necessary heat for the net endothermic conversion processes that occur in the cold cap. The high temperatures, radioactivity, and opaque nature of the glass prevent direct observation inside the melters. Therefore, computational models are essential for providing insight into factors that affect melter throughput. Thermocouples in the plenum provide operators with plenum temperature measurements. Operational adjustments include bubbling rate, voltage supplied to the electrodes, feed adjustments, and glass removal rate. Different computational fluid dynamics (CFD) models have been developed, each serving a specific purpose. There are CFD models of different scale melters, as well as models that capture the two-phase flow interfaces of rising bubbles in the molten glass or models with a simplified molten glass region so that the surrounding structure and plenum can be feasibly incorporated. Pilot-scale melter models have been developed to serve as validation of the methods employed in the simulation of the full-scale WTP melters. Models incorporating resolved bubbling are used to develop momentum source terms to implement into a single phase, multi-region, steady-state flow model that is being validated by measured process parameters such as glass production rate, voltage, input power, plenum temperatures, etc. The resolved bubbling model uses the multiphase volume of fluid approach to model the system with a high-resolution interface capturing scheme to maintain sharp interfaces between the molten glass and the air phase. The suite of CFD models is continually being improved to incorporate more realistic physics and achieve faster turnaround time. For example, an incremental controller is implemented to automatically adjust electrode voltage within the simulation to a molten glass set point temperature of 1150°C. Newer models feature improved meshes to ensure conformal meshes between regions and eliminate unnecessary mesh refinement in areas that are not of interest (such as boundary layers in offgas ports). Instead of explicitly modeling the structural, refractory, and insulation layers of the melter, a thermal resistance approach is used with published correlations used for boundary conditions. The development of robust and efficient CFD models will be instrumental in enabling the WTP to successfully fulfill its mission of safely stabilizing legacy nuclear waste.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗

DOE OSTI2024

Performance Testing of Moving Bed Gasifier Using Biomass and Waste Fuels to Generate Low-Cost Clean Hydrogen

Our need for hydrogen is growing as the world transitions toward a low-carbon future. Hydrogen provides long-term energy storage for grid stability in a solar- and wind-dominated power market and can be used to decarbonize other sectors. One promising process for generating low-cost hydrogen that produces net-negative carbon is to gasify biomass with a mixture of legacy coal wastes, waste plastics, and other wastes with carbon capture. Use of waste fuels lowers costs and diverts waste from landfills. EPRI is leading a project, funded by the U.S. Department of Energy, to conduct performance testing of modular, moving-bed gasification for the generation of low-cost, clean hydrogen from biomass mixed with legacy coal waste, waste plastic, and/or refuse derived fuels. The work scope includes preparation of multiple pellet feedstocks using biomass (both woody biomass and corn stover) with a mixture of legacy coal waste, plastic waste (wire insulation), and refuse-derived fuel (RDF). These pelletized feedstocks are being qualified based on performance testing of selected fuel blend compositions in updraft moving-bed gasifier located in Sardinia, Italy. Testing is being conducted to obtain relevant data to advance the modular design of the moving-bed gasification process, and successfully use these feedstocks to produce a high hydrogen content raw syngas that can be shifted to produce clean hydrogen. Testing results will be used to determine the effects of the various fuels on feedstock development, the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics), and impacts on gasifier operations.

08 HYDROGEN↗

DOE OSTI2024

Leverage modern artificial intelligence (AI) enabled systems for waste reduction

Manufacturing industries continue to face challenges in reducing waste, as upstream strategies such as source reduction and product redesign require a deeper understanding of processes compared to conventional recycling methods. Recent advancements in artificial intelligence (AI) and machine learning (ML) have opened new opportunities to integrate modern computational techniques with traditional waste minimization strategies. This paper explores AI-enabled approaches for product redesign, source reduction, and recycling that can significantly reduce waste generation while improving efficiency and sustainability. AI-driven material substitution and lightweighting in product design enable discovery of novel materials with optimized properties, reducing waste without compromising performance. Reinforcement learning models optimize process parameters, raw material specifications, and machine sequencing to minimize production losses, while Industrial Internet of Things (IIoT) systems paired with AI analytics enhance real-time waste tracking, predictive maintenance, and quality inspection. Furthermore, AI-based demand forecasting and production planning reduce overproduction and excess inventory, as demonstrated in industrial applications. In recycling, ML-powered pattern recognition and robotic sorting technologies achieve higher accuracy in waste segregation, directly improving recycling efficiency. Complementary solutions such as smart bins and AI-enabled waste pickup scheduling optimize collection logistics, reducing both costs and emissions. Although implementation requires upfront investment in infrastructure and training, the long-term benefits include higher material efficiency, reduced waste, improved product quality, and stronger sustainability outcomes across the supply chain. By leveraging AI-enabled systems, manufacturers can align waste minimization efforts with circular economy principles, creating scalable solutions for both industry and society.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Analysis of Infrastructures for Processing Plastic Waste using Pyrolysis-Based Chemical Upcycling Pathways

Modern mechanical recycling infrastructure for plastic is capable of processing only a small subset of waste plastics, reinforcing the need for parallel disposal methods such as landfilling and incineration. Emerging pyrolysis-based chemical technologies can "upcycle" plastic waste into high-value polymer and chemical products and process a broader range of waste plastics. In this work, we study the economic and environmental benefits of deploying an upcycling infrastructure in the continental United States for producing low-density polyethylene (LDPE) and polypropylene (PP) from post-consumer mixed plastic waste. Our analysis aims to determine the market size that the infrastructure can create, the degree of circularity that it can achieve, the prices for waste and derived products it can propagate, and the environmental benefits of diverting plastic waste from landfill and incineration facilities it can produce. We apply a computational framework that integrates techno-economic analysis, life cycle assessment, and value chain optimization. Our results demonstrate that the infrastructure generates an economy of nearly 20 billion USD and positive prices for plastic waste, opening opportunities for compensation to residents who provide plastic waste. Our analysis also indicates that the infrastructure can achieve a plastic-to-plastic degree of circularity of 34% and remains viable under various external factors (including technology efficiencies, capital investment budgets, and polymer market values). Finally, we present significant environmental benefits of upcycling over alternative landfill and incineration waste disposal methods, and comment on ongoing work expanding our modeling methodology to other chemical upcycling pathway case studies, including hydroformylation of specific plastics to chemicals.

Interdisciplinary↗

NASA NTRS1987

USBI Booster Production Company's Hazardous Waste Management Program at the Kennedy Space Center, FL

In response to the hazardous-waste generating processes associated with the launch of the Space Shuttle, a hazardous waste management plan has been developed. It includes waste recycling, product substitution, waste treatment, and waste minimization at the source. Waste material resulting from the preparation of the nonmotor segments of the solid rocket boosters include waste paints (primer, topcoats), waste solvents (methylene chloride, freon, acetone, toluene), waste inorganic compounds (aluminum anodizing compound, fixer), and others. Ways in which these materials are contended with at the Kennedy Space Center are discussed.

Venuto, Charles↗

NASA NTRS2005

Influence of Planetary Protection Guidelines on Waste Management Operations

Newly outlined missions in the Space Exploration Initiative include extended human habitation on Mars. During these missions, large amounts of waste materials will be generated in solid, liquid and gaseous form. Returning these wastes to Earth will be extremely costly, and will therefore likely remain on Mars. Untreated, these wastes are a reservoir of live/dead organisms and molecules considered to be "biomarkers" i.e., indicators of life). If released to the planetary surface, these materials can potentially confound exobiology experiments and disrupt Martian ecology indefinitely (if existent). Waste management systems must therefore be specifically designed to control release of problematic materials both during the active phase of the mission, and for any specified post-mission duration. To effectively develop waste management requirements for Mars missions, planetary protection guidelines must first be established. While previous policies for Apollo lunar missions exist, it is anticipated that the increased probability of finding evidence of life on Mars, as well as the lengthy mission durations will initially lead to more conservative planetary protection measures. To facilitate the development of overall requirements for both waste management and planetary protection for future missions, a workshop was conducted to identify how these two areas interface, and to establish a preliminary set of planetary protection guidelines that address waste management operations. This paper provides background regarding past and current planetary protection and waste management issues, and their interactions. A summary of the recommended planetary protection guidelines, anticipated ramifications and research needs for waste management system design for both forward (Mars) and backward (Earth) contamination is also provided.

Hogan, John A.↗

NASA NTRS2011

Microbial Characterization of Solid-Wastes Treated with Heat Melt Compaction Technology

The research purpose of the project was to determine the fate of microorganisms in space-generated solid wastes after processing by a Heat Melt Compactor (HMC), which is a candidate solid waste treatment technology. Five HMC product disks were generated at Ames Research Center (ARC), Waste Management Systems element. The feed for two was simulated space-generated trash and feed for three was Volume F compartment wet waste returned on STS 130. Conventional microbiological methods were used to detect and enumerate microorganisms in HMC disks and in surface swab samples of HMC hardware before and after operation. Also, biological indicator test strips were added to the STS trash prior to compaction to test if HMC processing conditions, 150 C for approx 3 hr and dehydration, were sufficient to eliminate the test bacteria on the strips. During sample acquisition at KSC, the HMC disk surfaces were sanitized with 70% alcohol to prevent contamination of disk interiors. Results from microbiological assays indicated that numbers of microbes were greatly reduced but not eliminated by the 70% alcohol. Ten 1.25 cm diameter cores were aseptically cut from each disk to sample the disk interior. The core material was run through the microbial characterization analyses after dispersal in sterile diluent. Low counts of viable bacteria (5 to 50 per core) were found but total direct counts were 6 to 8 orders of magnitude greater. These results indicate that the HMC operating conditions might not be sufficient for complete waste sterilization, but the vast majority of microbes present in the wastes were dead or non-cultivable after HMC treatment. The results obtained from analyses of the commercial spore test strips that had been added fo the wastes prior to HMC operation further indicated that the HMC was sterilizing the wastes. Nearly all strips were recovered from the HMC disks and all of these were negative for spore growth when run through the manufacturer's protocol. The 10(exp 6) or so spores impregnated into the strips were no longer viable. Control test strips, i.e., not exposed to the HMC conditions, were all strongly positive. All isolates from the cultivable counts were identified, leading to one concern: several were identified as Staphylococcus aureus, a human pathogen. The project reported here provides microbial characterization support to the Waste Management Systems element of the Life Support and Habitation Systems program.

Strayer, Richard F.↗

NASA NTRS2013

Trash-to-Gas: Using Waste Products to Minimize Logistical Mass During Long Duration Space Missions

Just as waste-to-energy processes utilizing municipal landftll and biomass wastes are finding increased terrestrial uses, the Trash-to-Gas (TtG) project seeks to convert waste generated during spaceflight into high value commodities. These include methane for propulsion and water for life support in addition to a variety of other gasses. TtG is part of the Logistic Reduction and Repurposing (LRR) project under the NASA Advanced Exploration Systems Program. The LRR project will enable a largely mission-independent approach to minimize logistics contributions to total mission architecture mass. LRR includes technologies that reduce the amount of consumables that need to be sent to space, repurpose items sent to space, or convert wastes to commodities. Currently, waste generated on the International Space Station is stored inside a logistic module which is de-orbited into Earth's atmosphere for destruction. The waste consists of food packaging, food, clothing and other items. This paper will discuss current results on incineration as a waste processing method. Incineration is part of a two step process to produce methane from waste: first the waste is converted to carbon oxides; second, the carbon oxides are fed to a Sabatier reactor where they are converted to methane. The quantities of carbon dioxide, carbon monoxide, methane and water were measured under the different thermal degradation conditions. The overall carbon conversion efficiency and water recovery are discussed.

Hintze, Paul. E.↗

NASA NTRS2013

Trash-to-Gas: Using Waste Products to Minimize Logistical Mass During Long Duration Space Missions

Hintze, Paul E.↗

DOE OSTI2025

Development of a Robust Reference Electrode in Aggressive Chemical and Radiation Environments in the Hanford Waste Tanks

The Hanford site stores more than 200 million liters of radioactive and chemically hazardous wastes from the production of weapons materials. The wastes are stored in 177 underground carbon-steel storage tanks, separated between 149 single shell tanks (SSTs) and 28 double shell tanks (DSTs). The DSTs provide critical retrieval and interim storage before the waste is vitrified in the Waste Treatment and Isolation Plant (WTP). The tanks will need to remain in-service far beyond the initial 40-year design life, and effective corrosion control practices must remain in force to extend the tanks’ lifespans. This effort includes direct measurements of corrosion rate (e.g., ultrasonic measurements and corrosion coupons) and electrochemical processes (e.g., linear polarization measurements and open circuit potential measurements). The Hanford site began monitoring the corrosion potential in select DSTs in 2008. Of the 45 reference electrodes that have been installed, 29 have failed and 6 others provided unreliable results. DOE-EM is supporting a 3-year program to develop a chemical and radiation resistant reference electrode for application in the Hanford tanks. The first year of the program focused on understanding the failure mechanism for the reference electrodes and identification of candidate construction materials that would mitigate degradation of the electrodes in the waste environment. During the second year of the program, the objectives were to: 1) test candidate materials under simulated waste conditions, 2) design components that will extend the service life of the electrode, 3) fabricate materials for prototype reference electrodes, and 4) assemble prototype reference electrodes for accelerated testing. The reference electrode is constructed of four principal parts: 1) junction, 2) casing, 3) inner chamber backfill materials, and 4) the sensing wire. Principally, improvements of the junction, casing, and inner chamber backfill materials are being pursued. The junction material at the interface between the waste and the inner chamber of the reference electrode was identified as a critical component in the failure of the reference electrodes. Nine candidate replacement junction materials were tested under simulated waste conditions to evaluate permeation rate. These materials included a variety of polymeric and ceramic materials, some of which were 3-D printed. Thus far, porous polyvinylidene fluoride materials have performed satisfactorily and are being considered for prototype development. The commercial electrode casing materials in general have performed well. Additionally, 3-D printing of chemically and mechanically stable materials is being investigated as a means for further improvement in fabrication consistency. SRNL has also investigated altering the reference electrode design to extend the service life. The new design of the interior of the reference electrode casing creates a longer, more tortuous path between the junction material and the electrode sensing wire. A finite element model was used to optimize the design without adversely impacting the circuit resistance of the electrode during the measurements, thus preserving the measurement accuracy while enhancing the service life. The inner chamber back fill materials are also critical to the performance of the reference electrode. Materials that are resistant to intruding tank waste and provide a conductive path to the sensing wire were investigated. Gel and powder materials that are interspersed with a conductive chloride bearing material were tested for their influence on diffusion and electrode resistance. All the investigated materials and components will be assembled, with collaboration from commercial vendors, to fabricate the initial prototypes. Accelerated testing of the prototypes will be initiated in Year 2 of the program and will be completed in Year 3. A recommendation on the materials of construction and the design of the new robust reference electrode will be presented to the Hanford tank farm facility.

Sykes, Kiana [Savannah River National Laboratory (↗

DOE OSTI2025

Strontium Speciation in Relevant Tank Waste Components Examined by Electrospray Ionization Mass Spectrometry

The identification of chemical species formed in complex nuclear waste is crucial for the development and employment of advanced separations technologies to remediate the Hanford site by processing tank waste. The current Tank Side Cesium Removal (TSCR) process deployed at Hanford utilizes crystalline silicotitanate (CST) ion exchange (IX) media to aid in the separation of low-activity waste for proper treatment and disposal. The inorganic IX media is highly selective for Cs but has been shown to also remove Sr from caustic simulants and small-scale IX processing of Hanford tank waste.(Fiskum, Rovira et al. 2019, Fiskum, Campbell et al. 2021, Westesen, Campbell et al. 2022) Quantitative Sr removal has not been observed in all tank waste supernates tested; thus, to better understand Sr removal and effectively predict processing behavior through TSCR, it is necessary to first investigate Sr speciation in tank waste. This work utilized electrospray ionization mass spectrometry (ESI-MS) to identify ionic Sr complexes that form in the presence of NO 3 –, NO 2 –, OH–, and Cl–. Although our results show that NO 3 –, NO 2 –, and OH– are competitive for Sr 2+ binding, previous data from IX studies indicate that [SrOH] + is not the dominant species of concern in tank waste processing schemes.(Fiskum, Campbell and Trang-Le 2020) Our results show that the [Sr(NO3)]+ species and the [Sr(NO2)] + species form in considerable abundances, which may affect the ability to separate Sr using CST in nuclear waste separation processes.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Compositing and Characterization of SE Quadrant Waste Exemplars

This report outlines the experimental investigation and characterization of transport properties in Hanford SE quadrant High-Level Waste (HLW). The goal of the study was to establish baseline behaviors of bulk composite rheology and settling characteristics to facilitate waste treatment process design for the Waste Treatment and Immobilization Plant (WTP) and avoid waste conditions and properties favorable to bubble cascade gas release events. The study focused on two major objectives: 1) identifying, obtaining, and preparing relevant Hanford tank waste samples for evaluation and 2) quantifying the “as-received” rheology and transport properties of the samples. Twenty-three centrifuged core segments originating from tanks AN-101, AN-106, and AW-105 were selected based on compositional relevance to SE quadrant PUREX cladding waste. These materials were composited into five waste composites enriched with target analytes: aluminum (Al), iron (Fe), phosphate (PO 4 ), uranium (U), and zirconium (Zr). Physical property and transport testing examined particle size distributions, bulk densities, settling behaviors, rheological properties, shear strengths, and just-suspended mixing speeds (NJS). Testing revealed two distinct composite classifications based on rheological characteristics: non-Newtonian composites (Fe and PO 4 ) and Newtonian composites (Al, U, and Zr). The Fe and PO 4 composites exhibited slow settling rates and reduced mobilization proclivity, attributable to strong particle-particle interactions and the formation of yield structures within non-Newtonian slurries. In contrast, the Al, U, and Zr composites displayed rapid settling and dense compaction behaviors, indicative of minimal structuring and interactions. Shear strengths for all composites were generally low relative to prior studies of SE quadrant waste, with only the U composite showing elevated strength approaching values reported in previous literature. Repeat shear strength measurements revealed contributions from dense granular material in the U composite and stronger cohesive properties in the Al composite. Settling data highlighted hindered settling behavior, with rates falling more than one order of magnitude below estimates based on Stokes’ law and rate decreasing as composite UDS content increased. NJS testing demonstrated different mobilization behaviors between cohesive and granular composites. The Fe composite required the highest mixing rate for resuspension, while the Al composite was the easiest to resuspend. Comparison of measured NJS against predictions made using the Zwietering correlation suggests non-Newtonian behavior alters resuspension mechanics, rendering non-Newtonian systems more stable against resuspension lift forces relative to their granular counterparts.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

April 2025 Semiannual Composite Salt Waste Processing Facility (SWPF) Decontaminated Salt Solution (DSS) Toxicity Characteristic Leaching Procedure (TCLP) Results

The aqueous waste from the Salt Waste Processing Facility is sampled semiannually for transfers to the Saltstone Production Facility. Salt solution is treated at the Saltstone Production Facility and disposed of in the Saltstone Disposal Facility. Per request of customer, X-TTR-Z-00027, Revision 0, one Saltstone Disposal Facility waste form was prepared at Savannah River National Laboratory using the Salt Waste Processing Facility Decontaminated Salt Solution and Z-area premix material for the April 2025 semiannual Toxicity Characteristic Leaching Procedure sample. The sample contained 60:40 (by weight) of slag and fly ash (referred to as the “Cement-Free grout sample”). Results from the technical report support Task 2: ‘Grout Leaching Analyses’ of the Task Technical Request prepared by Savannah River Mission Completion. At 43 days cured, the Saltstone sample was collected and shipped to a certified laboratory for analysis using the Toxicity Characteristic Leaching Procedure. The April 2025 semiannual Cement-Free grout sample met the South Carolina Code of Regulations for Hazardous Waste Management Regulations 61-79.261.24 and 61-79.268.48 requirements for a non-hazardous waste form with respect to the Resource Conservation and Recovery Act metals and Underlying Hazardous Constituents, and met the Saltstone Production Facility Waste Acceptance Criteria that was in effect at the time of the sample collection at the Salt Waste Processing Facility.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗