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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Technology Advancement and Insertion into Operating Nuclear Facilities

Key challenges in the NNSA modernization effort are centered around the selection of new processing / production technologies to deploy in existing, operating, and oftentimes, aging nuclear facilities. New uranium processing technologies may offer significant improvements in worker and environmental safety, material control and accountability, and production efficiencies, but adaptation of these technologies into existing facilities presents unique (and usually, difficult) engineering solutions for each new technology. This presentation discusses approaches utilized at Y-12 to mature and demonstrate new processing and production technologies for deployment into aging nuclear facilities. The technology advancement lifecycle (from concept to deployment) of uranium electrorefining technologies will be reviewed, as a prototypical example, to describe steps and approaches utilized at Y-12 (and NNSA Sites) to (i) mature technologies and manufacturing strategies, (ii) establish testbed capabilities for full-scale process demonstrations, and (iii) reduce risks associated with operational disruptions when commissioning new uranium processing technologies.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2013

Dismantling of the 904 Cell at the HAO/Sud Facility - 13466

La Hague facility, in France, is the spent fuel recycling plant wherein a part of the fuel coming from some of the French, German, Belgian, Swiss, Dutch and Japanese nuclear reactors is reprocessed before being recycled in order to separate certain radioactive elements. The facility has been successively handled by the CEA (1962-1978), Cogema (1978-2006), and AREVA NC (since 2006). La Hague facility is composed of 3 production units: The UP2-400 production unit started to be operated in 1966 for the reprocessing of UNGG metal fuel. In 1976, following the dropout of the graphite-gas technology by EDF, an HAO workshop to reprocess the fuel from the light water reactors is affiliated and then stopped in 2003. - UP2-400 is partially stopped in 2002 and then definitely the 1 January 2004 and is being dismantled - UP2-800, with the same capacity than UP3, started to be operated in 1994 and is still in operation. And UP3 - UP3 was implemented in 1990 with an annual reprocessing capacity of 800 tons of fuel and is still in operation The combined licensed capacity of UP2-800 and UP3 is 1,700 tons of used fuel. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Radioactive Waste Management at the New Conversion Facility of 'TVEL'{sup R} Fuel Company - 13474

The project on the new conversion facility construction is being implemented by Joint Stock Company (JSC) 'Siberian Group of Chemical Enterprises' (SGChE) within TVEL{sup R} Fuel Company. The objective is to construct the up-to-date facility ensuring the industrial and environmental safety with the reduced impact on the community and environment in compliance with the Russian new regulatory framework on radioactive waste (RW) management. The history of the SGChE development, as well as the concepts and approaches to RW management implemented by now are shown. The SGChE future image is outlined, together with its objectives and concept on RW management in compliance with the new act 'On radioactive waste management' adopted in Russia in 2011. Possible areas of cooperation with international companies are discussed in the field of RW management with the purpose of deploying the best Russian and world practices on RW management at the new conversion facility. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

EnergySolution's Clive Disposal Facility Operational Research Model - 13475

EnergySolutions owns and operates a licensed, commercial low-level radioactive waste disposal facility located in Clive, Utah. The Clive site receives low-level radioactive waste from various locations within the United States via bulk truck, containerised truck, enclosed truck, bulk rail-cars, rail boxcars, and rail inter-modals. Waste packages are unloaded, characterized, processed, and disposed of at the Clive site. Examples of low-level radioactive waste arriving at Clive include, but are not limited to, contaminated soil/debris, spent nuclear power plant components, and medical waste. Generators of low-level radioactive waste typically include nuclear power plants, hospitals, national laboratories, and various United States government operated waste sites. Over the past few years, poor economic conditions have significantly reduced the number of shipments to Clive. With less revenue coming in from processing shipments, Clive needed to keep its expenses down if it was going to maintain past levels of profitability. The Operational Research group of EnergySolutions were asked to develop a simulation model to help identify any improvement opportunities that would increase overall operating efficiency and reduce costs at the Clive Facility. The Clive operations research model simulates the receipt, movement, and processing requirements of shipments arriving at the facility. The model includes shipment schedules, processing times of various waste types, labor requirements, shift schedules, and site equipment availability. The Clive operations research model has been developed using the WITNESS{sup TM} process simulation software, which is developed by the Lanner Group. The major goals of this project were to: - identify processing bottlenecks that could reduce the turnaround time from shipment arrival to disposal; - evaluate the use (or idle time) of labor and equipment; - project future operational requirements under different forecasted scenarios. By identifying processing bottlenecks and unused equipment and/or labor, improvements to operating efficiency could be determined and appropriate cost saving measures implemented. Model runs forecasting various scenarios helped illustrate potential impacts of certain conditions (e.g. 20% decrease in shipments arrived), variables (e.g. 20% decrease in labor), or other possible situations. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Protecting Lake Ontario - Treating Wastewater from the Remediated Low-Level Radioactive Waste Management Facility - 13227

The Port Granby Project is part of the larger Port Hope Area Initiative, a community-based program for the development and implementation of a safe, local, long-term management solution for historic low level radioactive waste (LLRW) and marginally contaminated soils (MCS). The Port Granby Project involves the relocation and remediation of up to 0.45 million cubic metres of such waste from the current Port Granby Waste Management Facility located in the Municipality of Clarington, Ontario, adjacent to the shoreline of Lake Ontario. The waste material will be transferred to a new suitably engineered Long-Term Waste Management Facility (LTWMF) to be located inland approximately 700 m from the existing site. The development of the LTWMF will include construction and commissioning of a new Wastewater Treatment Plant (WWTP) designed to treat wastewater consisting of contaminated surface run off and leachate generated during the site remediation process at the Port Granby Waste Management Facility as well as long-term leachate generated at the new LTWMF. Numerous factors will influence the variable wastewater flow rates and influent loads to the new WWTP during remediation. The treatment processes will be comprised of equalization to minimize impacts from hydraulic peaks, fine screening, membrane bioreactor technology, and reverse osmosis. The residuals treatment will comprise of lime precipitation, thickening, dewatering, evaporation and drying. The distribution of the concentration of uranium and radium - 226 over the various process streams in the WWTP was estimated. This information was used to assess potential worker exposure to radioactivity in the various process areas. A mass balance approach was used to assess the distribution of uranium and radium - 226, by applying individual contaminant removal rates for each process element of the WTP, based on pilot scale results and experience-based assumptions. The mass balance calculations were repeated for various flow and load scenarios. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Westinghouse Cementation Facility of Solid Waste Treatment System - 13503

During NPP operation, several waste streams are generated, caused by different technical and physical processes. Besides others, liquid waste represents one of the major types of waste. Depending on national regulation for storage and disposal of radioactive waste, solidification can be one specific requirement. To accommodate the global request for waste treatment systems Westinghouse developed several specific treatment processes for the different types of waste. In the period of 2006 to 2008 Westinghouse awarded several contracts for the design and delivery of waste treatment systems related to the latest CPR-1000 nuclear power plants. One of these contracts contains the delivery of four Cementation Facilities for waste treatment, s.c. 'Follow on Cementations' dedicated to three locations, HongYanHe, NingDe and YangJiang, of new CPR-1000 nuclear power stations in the People's Republic of China. Previously, Westinghouse delivered a similar cementation facility to the CPR-1000 plant LingAo II, in Daya Bay, PR China. This plant already passed the hot functioning tests successfully in June 2012 and is now ready and released for regular operation. The 'Follow on plants' are designed to package three 'typical' kind of radioactive waste: evaporator concentrates, spent resins and filter cartridges. The purpose of this paper is to provide an overview on the Westinghouse experience to design and execution of cementation facilities. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

HiRadMat at CERN SPS - A test facility with high intensity beam pulses to material samples

HiRadMat (High Irradiation to Materials) is a facility at CERN designed to provide high-intensity pulsed beams to an irradiation area where material samples as well as accelerator component assemblies (e.g. vacuum windows, shock tests on high power targets, collimators) can be tested. The beam parameters (SPS 440 GeV protons with a pulse energy of up to 3.4 MJ, or alternatively lead/argon ions at the proton equivalent energy) can be tuned to match the needs of each experiment. It is a test area designed to perform single pulse experiments to evaluate the effect of high-intensity pulsed beams on materials in a dedicated environment, excluding long-time irradiation studies. The facility is designed for a 10{sup 16} maximum number of protons per year, in order to limit the activation to acceptable levels for human intervention. This paper will demonstrate the possibilities for research using this facility and showing examples of upcoming experiments scheduled in the beam period 2014/2015. (authors)

43 PARTICLE ACCELERATORS↗
DOE OSTI2017

Low Activity Waste Pretreatment System Bench-Scale Testing: Supporting Integrated Testing and Facility Safety Analyses - 17171

The Low Activity Waste Pretreatment System (LAWPS) is being designed to enable the direct feed of waste to the Hanford Tank Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) facility to be immobilized. Prior to construction of the LAWPS, pilot-scale integrated testing of the key unit operations (crossflow filtration, ion exchange using spherical resorcinol-formaldehyde (sRF) resin) will be conducted by a team led by Washington River Protection Solutions (WRPS) to increase the technology maturation level of the facility's critical technology elements. As a part of this effort, Pacific Northwest National Laboratory (PNNL) has conducted a series of tests to perform two major objectives: (1) support pilot-scale integrated testing of the LAWPS by supplying information or performance data in advance of operating the pilot-scale facility (1/9. scale); and (2) collect data needed to establish or confirm assumptions/approaches planned for implementation in the LAWPS safety basis. The first objective was focused in two technical areas: developing simulants that are representative of expected waste feed and can be produced at larger scales, and using these simulants in a bench-scale crossflow filter to establish expected solid-liquid separation performance. The crossflow filter was also used to observe the efficacy (with respect to filter production rate) of selected operational strategies. The second objective also included two technical areas: measuring the effect of sRF resin on hydrogen generation rate under irradiation, and demonstrating that the planned hydrogen management approach is effective and robust. The hydrogen management strategy involves fluidization of the sRF resin bed in the ion exchange columns and recirculating the liquid, a scenario that is planned for testing at full column height. The full height tests at PNNL also supported full-scale IX column testing conducted as part of the technology maturation plan. The experimental approaches used at PNNL in these four technical areas are summarized and selected key preliminary results are provided. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Experiences from Implementing Waste Led Decommissioning in Practice at a Research Facility - 17216

The decommissioning of MAX-lab (a national accelerator laboratory hosted by Lund University) has been performed using a risk-based concept for dismantling of the equipment and clearance measurement of the facility. To support the concept, a radiological characterisation was performed containing scintillation and dose rate measurements as well as nuclide vector determination based on nuclide specific analysis of the activity content in material samples. This paper describes the decommissioning at MAX-lab, performed during 2015 and 2016. Dismantled waste was sent to the Studsvik site for treatment. Clearance measurements of material were performed at MAX-lab and at the Studsvik site. The levels of activity have been compared with the threshold values in the Swedish clearance regulations (material or buildings for free use) and the detected levels are below the limits for clearance of material with some exceptions. Activity above the clearance levels were found in a few locations in the facility. After removal of installations and small amounts of building structures at these locations clearance of the facility is possible. Keywords: Risk based approach, fast decommissioning, on- and offsite material clearance. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Safety Assessment of El Cabril, the Spanish Surface Disposal facility for LILW and VLLW - 17233

El Cabril project was launched in 1986, for Low and Intermediate Level Waste (LILW) disposal, based on concrete barriers and concrete disposal units. The operation of a Very Low Leve Waste (VLLW) complementary facility based on clay and High Density Polyethylene (HDPE) barriers and different types of disposal units started in 2008. Two main objectives are considered in the design: Immediate and post-closure protection and no radiological restrictions, after institutional control period. To fulfil these objectives several design criteria like waste isolation through a multi-barrier system, surveillance period no longer than 300 years and limitation of activity are applied. The Safety Assessment process follows a methodology which, taking into account important facts like safety and design criteria, time frame, radiological protection criteria, waste characteristics, environment, FEPs (features, events and processes), etc., develops different scenarios, models and calculations to define the safety approach. This safety approach follows the current guides and recommendations of international organizations, it covers the potential impact of the facility for the operational and long-term periods and it includes normal evolution and less likely accidental and inadvertent human intrusion events. All the studies and considerations done for the Safety Assessment have to be included in a safety Report, required for getting the Operation License for Nuclear Installations in Spain. The content of this Report is defined by the Spanish regulation and it has to be revised if there is a change in the facility that may affect the safety. It is also mandatory making a Safety Periodic Review (every 10 years in the case of El Cabril) that has to be presented to the Regulatory Council. This paper outlines the principles, objectives and criteria of El Cabril's disposal installation and it explains the safety assessment performed, for both LILW and VLLW disposal, as part of the documentation produced to obtain the authorization to operate. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Integrity Assessment of Hanford 242-A Evaporator Facility E-A-1 Re-boiler Vessel via Fluorescein Liquid Tracer Test Methods - 17357

The 242-A Evaporator Facility is critical to the United States Department of Energy's (DOE) Hanford Site clean-up mission due to limited space within the existing Double-Shell Tanks (DSTs) used to store nuclear and chemical waste until future processing. The 242-A Evaporator Facility is currently the sole waste volume reduction process used at Hanford, and the E-A-1 Re-boiler is essential to the Evaporator process. Due to the potential for cross-contamination between the Re-boiler tubes through which waste passes and the tube sheets of uncontaminated steam, an assessment of the Re-boiler vessel's integrity is required for continuing operations of the facility. In order to meet these requirements, an independent integrity assessment was designed to use fluorescein liquid tracer (LT) to verify the leak-tightness of the Re-boiler vessel in accordance with Washington River Protection Solutions, LLC (WRPS) tightness test standards, as well as, the ASME Boiler and Pressure Vessel (B and PV) Code, Section III, Division 1, NB-6300. LT test methodologies were evaluated and determined to be appropriate for a vessel with restricted access, such as the E-A-1 Re-boiler, as it provided the needed sensitivity, reliability, and cost; as well as, exceeded the leak-tightness specifications required by both WRPS and ASME B and PV Code standards. The integrity test requires water laced with fluorescein be circulated through the waste processing loop of the 242-A Evaporator and samples of steam condensate be collected and analyzed for traces of fluorescein to determine leak-tightness. Liquid condensate sampling was conducted prior to and during testing and the samples were analyzed for fluorescein tracer to determine the amount of fluorescein that flowed out of the tubes of the Re-boiler into the steam side of the vessel. Given the established criteria for 'leak-tight,' test results determined that the Re-boiler passed the integrity assessment. After further scrutiny of the 2014 test and data results, it was determined that although the Re-boiler was 'leak-tight,' as established by the test criteria, there was concern of future leakage. The DOE and the DOE Office of River Protection (ORP) requested that WRPS repeat the integrity assessment in two and a half years to determine if the potential leak was growing, which could threaten continuing operations of the 242-A Evaporator. The 2017 test has been redesigned using lessons learned from the 2014 test and was modified to account for ergonomic and safety considerations, ease of repeatability, and accuracy of results. The liquid tracer methodology and test plan developed for the Re-boiler will continue to be implemented in 5 year increments to monitor current and future integrity. The method may also prove useful for other aging components across the Hanford Site, where appropriate. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Radiological mapping of facilities under dismantling process by digital autoradiography - 15230

because safety standards have changed. In that context, radioactive waste management is a challenging task faced by existing nuclear power countries. Therefore, characterization is essential to classify wastes and to reduce costs. In many facilities, after the removal of glove boxes, fume cupboards and so on, the remaining materials on the floor, walls, and ceiling must be characterized. Gamma emitters can be detected remotely by commercial devices. However, analytical techniques to detect alpha and beta emitters in situ are generally not well suited for large area investigations. The Digital Autoradiography (DA) technique, initially dedicated to research in biology, was re-routed for final state characterization before facility demolition. It is based on the exposure of radio-sensitive phosphor screens on the materials to characterize. Phosphor screens, after a scanning process, provide a picture of the radioactivity, and are reusable several tens of times. This analytical technique is sensitive to all types of radioactivity, requires neither operators nor electricity during acquisition process, and produces only very few wastes. DA has already been tested in different facilities to obtain semi-quantitative values of C-14 and H-3 activities. Large amount of data gathered to cover the whole surface to be characterized. A Geographic Information System (GIS) associated with geostatistical method has been used to provide Radiological Mapping. This method to interpret Digital Autoradiography results has been proved very efficient to prepare remediation project. (authors)

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2015

SORTIE DB - Source term integrated environmental management disposal facility database - 15249

The Environmental Management Disposal Facility (EMDF) in Oak Ridge, Tennessee, is a proposed U.S. Department of Energy low-level Comprehensive Environmental Response Compensation and Liability Act (CERCLA) waste disposal facility with an operational start in the early 2020's. As a DOE low-level waste disposal facility, it is subject to DOE Order 435.1, requiring a composite analysis and possibly a performance assessment. The Source Term Integrated EMDF Data Base - SORTIE DB - provides source term estimates used in these assessments. An Oak Ridge Office of Environmental Management (OREM) Federal and Contractor team developed this state-of-the-art descriptive analytics and visualization schema. DOE OREM senior management has recognized complementary beneficial uses of SORTIE DB in decisions for accelerating clean-up progress, dealing with conflicting sequencing and budget priorities, and enhancing stakeholder and regulatory interfaces. SORTIE DB is designated as an OREM planning tool. SORTIE DB contains estimated forecast waste volumes and masses for over 800 Decontamination and Decommissioning (D and D) and Remedial Action (RA) sequenced baseline packages over the next 25+ years. Available characterization data, radionuclide identification and concentrations, and data from safety basis and emergency management documents are incorporated into SORTIE DB. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Planning large-scale excavation and construction activities within an aerially constrained site for construction of a repository for low and short-lived intermediate level radioactive waste at the Bulgarian national disposal facility - 15372

The Bulgarian State Enterprise for Radioactive Waste Management (SERAW) is planning the construction of a near-surface repository for low and short-lived intermediate level radioactive waste, the National Disposal Facility (NDF), at the Radiana Site adjacent to the Kozloduy Nuclear Power Plant (KNPP). The Site, a rectangular area approximately 1.2 km east-west by 0.4 north-south, is located on a slopping area between the second and sixth loess terraces above the River Danube with elevations ranging from approximately +40 m to elevation +95 m. Construction of the NDF will be divided into three phases separated by approximately 20 years each. The first phase will see the construction of the primary support facilities, referred to as the Auxiliary Buildings and including the Waste Reception and Buffer Storage (WRBS) Building, and the first set of 22 reinforced concrete disposal cells and supporting infrastructure, including a network of subsurface observation galleries, the Infiltration Network Control (ICN) Galleries. Each disposal cell will be 20.15 m long by 17.05 m wide by 9.45 m in height. The disposal cells will be arranged in two parallel rows. Disposal activities will be conducted using overhead cranes installed inside of track mounted mobile roofs. Each row of disposal cells will be serviced by one mobile roof. The mobile roofs will be supported by massive concrete foundations. Construction at the site will present several logistical challenges that will need to be overcome to fully realize the NDF. First in order to begin construction of these facilities nearly 1 million 3 of soil will require excavation and handling. Consistent with requirements to minimize potential environmental impacts identified in the site Environmental Safety Assessment (EIA) excavated soil will, to the extent possible, remain onsite. Approximately three quarters of the soil can be accommodated within the site boundaries. Another challenge results from requirements imposed by the ground conditions. The sub-grade at the site, which consists primarily of loess, will require considerable improvement. To this end a 5 m thick loess-cement cushion will be constructed across much of the site. Specifically, the cushion will be required beneath the disposal cells and the WRBS Building. Construction of the loess-cement cushion in the disposal area will require detailed planning and coordination, particularly as the cushion beneath the disposal cells also contains embedded structures, including the ICN Galleries as well as massive concrete foundation beams required for the two mobile roofs. Construction of these structures will require planned interruptions in the construction of the loess-cement cushion. Specific cement types and strict quality requirements will be required for completion of the loess-cement cushion as well as for completion of the ICN Galleries. The construction planning will need to account for the large volumes of soil to be excavated as well as ensuring sufficient material supplies in terms of both quality as well as quantity. Large quantities of materials including both dry cement for mixing with the loess, and wet concrete for pouring of the mobile roof foundations are accounted for by the plan. However, even after completion of these activities additional challenges are addressed by the plan related to the contemporaneous construction management of the auxiliary buildings and the disposal cells. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Salt Waste Processing Facility project lessons learned: Acquisition through construction - 15518

The Salt Waste Processing Facility (SWPF), located at the Savannah River Site (SRS) in Aiken, South Carolina, is a multi-billion dollar Liquid Radioactive Waste (LRW) processing facility that represents the keystone for the U.S. Department of Energy (DOE)-EM clean-up mission at SRS. The SWPF facilitates DOE-EM clean-up at SRS by decontaminating the salt waste, which is the dominant volumetric component in the LRW tanks, thereby allowing the cleaned salt waste to be removed from the tanks and stabilized into an approved grout-based final waste form. The small volume of removed radionuclides is sent to the Defense Waste Processing Facility (DWPF) for vitrification. Emptied LRW storage tanks are then grouted into an approved configuration for final closure. The SWPF project is currently 100% complete with design, 80% complete with construction, and 10% complete with commissioning. To date there have been numerous lessons learned with regard to project acquisition, design, procurement, construction, and quality assurance (QA) approaches (both good practices and mistakes) that are considered to be of significant value in improving the state of major project execution within the DOE-EM clean-up program as well as to the wider DOE enterprise. An overview of the current SWPF project status is provided and key lessons learned in the aforementioned areas are presented relative to improving future DOE major project execution performance. Specific areas to be addressed include strategies to optimize integration of design and nuclear safety, constructability tools for design and construction synchronization, commercial grade dedication (CGD) approaches to mitigate atrophy in the nuclear supply chain, and QA perspectives to facilitate effective and efficient project execution. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Development and Expansion of Research Facilities to Address the Challenges of the Nuclear Industry - 16055

With the wide variety of challenges that surround nuclear decommissioning, bespoke facilities are required to undertake experiments which can inform decision making. Here we describe research carried out at The University of Manchester's Dalton Cumbrian Facility, a custom built research environment which incorporates a 5 MV ion accelerator as well as a self-shielded {sup 60}Co irradiator. The ion accelerator allows the investigation in to the radiolytic consequences of various charged particles, including protons, alpha particles and a variety of heavier (metal and nonmetal) ions, while the {sup 60}Co irradiator allows the effects of gamma radiation to be studied. We provide specific research examples that demonstrate how this equipment can improve our mechanistic understanding of various aspects of the deleterious effects of radiation in the nuclear industry. These examples include applications in waste encapsulation as well as geological disposal and novel surveying techniques. The outlook for future research and expansion of the facility is also presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Facility Improvements and Modifications to Extend the Operational Life of the Modular Caustic-Side Solvent Extraction Process - 16082

Savannah River Remediation, LLC (SRR) is working to remove, stabilize, and dispose of approximately 36.7 million gallons (138.9 million liters) of liquid radioactive waste currently stored in 43 underground waste tanks, and ultimately close waste tanks. In 2008, as an interim salt treatment system to remove cesium from high level waste salt solutions prior to the Salt Waste Processing Facility start up, the Modular Caustic-Side Solvent Extraction Unit (MCU) initiated the removal of cesium from liquid radioactive salt waste prior to disposal. The MCU was designed and built for an expected three-year operational life and five-year design life. The first MCU cold runs began in June 2007 and hot startup was completed in April 2008. MCU remains in hot operation to this day, aiding in multiple, high-level tank closures. In an effort to continue liquid waste disposition at the Savannah River Site (SRS), equipment upgrades and operational improvements have been made to extend the life of the MCU beyond the original three years. Several pieces of fixed equipment have been converted into removable equipment which reduces the downtime associated with equipment change-outs and thereby reduces the dose to workers and processing impacts. Multiple pumps and filters have been upgraded to more robust designs. Process monitoring and controls have been upgraded to improve process performance. Redundant centrifugal contactor vibration equipment has been installed on each contactor in order to better assess the reliability, processing performance, and lifetime of the contactors. A new Solvent Hold Tank (SHT) Sampler has been installed to minimize the organic cross-contamination within the sampler, dose to workers, and sample analysis time. To increase processing availability and aid in visually obtained data, camera port has been added to the Salt Solution Feed Tank (SSFT). In order to decrease the overall background dose to the workers, the Process Vessel Ventilation (PVV) duct work now has the capability to be flushed to remove contamination. The caustic wash addition system has been modified to be a once-through system to improve equipment reliability, decrease downtime, and decrease dose to workers. In addition, the solvent that MCU utilizes to extract Cesium out of salt waste has been upgraded to Next Generation Solvent (NGS) which is based on MaxCalix extractant instead of a BobCalix extractant. Further, these upgrades and improvements have allowed MCU to be able to process at higher flow rates (up to 8.5 GPM) and with increased throughput (as high as 1.3 million gallons in FY13 and 5.3 million gallons since hot operations initiated) that have allowed SRR to continue the disposition of nuclear salt waste. The continued operation of MCU ensures more curies are stabilized into a glass matrix at SRS's Defense Waste Processing Facility (DWPF) and less curies are retained within South Carolina at SRS's Saltstone Disposal Facility (SDF). Unique challenges associated with modifying and improving a demonstration plant that is in hot operations and was designed to be temporary with a limited plant footprint have been successfully overcome. Further, creative strategies for removing old equipment have been utilized given the limited decontamination agents available for use that will not interfere with the organic solvent. This paper presents and discusses the deployment of these upgrades and operational improvements to MCU in order to allow continued, increased salt waste processing beyond the initial design life. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Life Extension of Nuclear Plant Facilities through Monitoring and Detailed Analysis - 16175

The UK has accumulated a substantial legacy of radioactive waste from various civil nuclear and defence programmes. Presently, however most of the UK radioactive waste is generated from nine power stations which generate approximately one sixth of the of the country's electricity. Irradiated fuel is removed from these reactors and safe management of the radioactive solid and liquid effluents is required. The safe management of these effluents is essential. Sellafield, in West Cumbria UK, contains two reprocessing plants, one designed to process nuclear fuel from Magnox reactors (CO{sub 2} cooled with Uranium bar fuel) and the other to process nuclear fuel from Advanced Gas cooled Reactors and Pressurized Water Reactors. The reprocessing stage enables extraction of fissile material for recycling. This leaves a volume of dilute but high-level waste. The high-level radioactive liquid waste is concentrated to reduce its volume and then incorporated into borosilicate glass, using a process called vitrification. The glass is then poured into stainless steel containers and placed in long term storage. This required concentration of HLW liquor is achieved using a suite of aging evaporators. All evaporators are of similar design constructed from corrosion resistant stainless steel having dimensions height ∼11 m, internal diameter 3.05 m and capable of holding 13.7 m{sup 3} of liquor. The basic principle of operation is to heat the dilute liquor under partial vacuum, at constant volume, until the target concentration is achieved. Heating of the liquor is achieved using steam heated coils within the evaporator, and steam in the jacket which surrounds the lower half of the evaporator vessel. The evaporator is then brought to atmospheric pressure and the concentrated liquor is ejected whilst hot. The evaporator is then cooled with water cooled coils and a water filled jacket. New dilute liquor is then added for a new batch. The process is then repeated. As the evaporators reach the end of their original design life accurate prediction of the current condition of nuclear plant facilities is essential to safely justify continued plant operation by ensuring structural integrity. This poses a significant challenge as many aging UK nuclear facilities were not inherently built with inspection in mind. The potential life limiting components of the HA evaporators at Sellafield are the surfaces that contact the product liquor at elevated temperatures i.e. the steam heated surfaces of the coils within the evaporator vessel and the vessel base and wall surrounded by the steam jacket. Each heating component is critical to the operational life of the evaporator - the removal from service of a coil heating component significantly reduces the operational flexibility and remnant life of this plant. Over the last decade a variety of cutting-edge expertise and methodologies have been utilised to accurately measure and then predict the current condition of the plant and also to predict its remnant life. This paper provides an overview of the development of several techniques deployed, namely non-destructive testing/inspection, in-house software development and finite element modelling. These methods have been validated by lab-scale or full-scale experiments along with historical plant data. These techniques have been evolved and refined for over a decade, providing vital insights into the physical behaviour of this complex reprocessing system. This enables not only accurate assessment of the current condition of the plant equipment but also allows scientifically underpinned predictions to be made of how it will behave into the future. This is critical for Sellafield as this knowledge feeds into their safety case to the Office of Nuclear Regulation to justify continued operation. It is concluded that this integrated approach provides a robust analysis tool which has driven change and optimisation of plant procedures ensuring continued safe operation whilst extending the life of the facility. (authors)

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