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DOE OSTI2013

Waste Management Strategy for Dismantling Waste to Reduce Costs for Power Plant Decommissioning - 13543

Decommissioning of nuclear power plants generates large volumes of radioactive or potentially radioactive waste. The proper management of the dismantling waste plays an important role for the time needed for the dismantling phase and thus is critical to the decommissioning cost. An efficient and thorough process for inventorying, characterization and categorization of the waste provides a sound basis for the planning process. As part of comprehensive decommissioning studies for Nordic NPPs, Westinghouse has developed the decommissioning inventories that have been used for estimations of the duration of specific work packages and the corresponding costs. As part of creating the design basis for a national repository for decommissioning waste, the total production of different categories of waste packages has also been predicted. Studsvik has developed a risk based concept for categorization and handling of the generated waste using six different categories with a span from extremely small risk for radiological contamination to high level waste. The two companies have recently joined their skills in the area of decommissioning on selected market in a consortium named 'ndcon' to further strengthen the proposed process. Depending on the risk for radiological contamination or the radiological properties and other properties of importance for waste management, treatment routes are proposed with well-defined and proven methods for on-site or off-site treatment, activity determination and conditioning. The system is based on a graded approach philosophy aiming for high confidence and sustainability, aiming for re-use and recycling where found applicable. The objective is to establish a process where all dismantled material has a pre-determined treatment route. These routes should through measurements, categorization, treatment, conditioning, intermediate storage and final disposal be designed to provide a steady, un-disturbed flow of material to avoid interruptions. Bottle-necks in the process causes increased space requirements and will have negative impact on the project schedule, which increases not only the cost but also the dose exposure to personnel. For these reasons it is critical to create a process that transfers material into conditioned waste ready for disposal as quickly as possible. To a certain extent the decommissioning program should be led by the waste management process. With the objective to reduce time for handling of dismantled material at site and to efficiently and environmental-friendly use waste management methods (clearance for re-use followed by clearance for recycling), the costs for the plant decommissioning could be reduced as well as time needed for performing the decommissioning project. Also, risks for delays would be reduced with a well-defined handling scheme which limits surprises. Delays are a major cost driver for decommissioning projects. (authors)

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DOE OSTI2013

K-Basins Sludge Treatment and Packaging at the Hanford Site - 13585

Highly radioactive sludge resulting from the storage of degraded spent nuclear fuel has been consolidated in Engineered Containers (ECs) in the 105-K West Storage Basin located on the Hanford site near the Columbia River in Washington State. CH2M Hill Plateau Remediation Company (CHPRC) is proceeding with a project to retrieve the sludge, place it in Sludge Transport and Storage Containers (STSCs) and store those filled containers within the T Plant Canyon facility on the Hanford Site Central Plateau (Phase 1). Retrieval and transfer of the sludge material will enable removal of the 105-K West Basin and allow remediation of the subsurface contamination plumes under the basin. The U.S. Department of Energy (DOE) plans to treat and dispose of this K Basins sludge (Phase 2) as Remote Handled Transuranic Waste (RH TRU) at the Waste Isolation Pilot Plant (WIPP) located in New Mexico. The K Basin sludge currently contains uranium metal which reacts with water present in the stored slurry, generating hydrogen and other byproducts. The established transportation and disposal requirements require the transformation of the K Basins sludge to a chemically stable, liquid-free, packaged waste form. The Treatment and Packaging Project includes removal of the containerised sludge from T Plant, the treatment of the sludge as required, and packaging of all the sludge into a form that is certifiable for transportation to and disposal at WIPP. Completion of this scope will require construction and operation of a Sludge Treatment and Packaging Facility (STPF), which could be either a completely new facility or a modification of an existing Hanford Site facility. A Technology Evaluation and Alternatives Analysis (TEAA) for the STP Phase 2 was completed in 2011. A Request for Technology Information (RFI) had been issued in October 2009 to solicit candidate technologies for use in Phase 2. The RFI also included a preliminary definition of Phase 2 functions and requirements. Potentially applicable technologies were identified through a commercial procurement process, technical workshops, and review of the numerous previous sludge treatment technology studies. The identified technology approaches were screened using the criteria established in the Decision Plan, and focused bench top feasibility testing was conducted. Engineering evaluations of the costs, schedules, and technical maturity were developed and evaluated. Recommendations were developed based on technical evaluations. The criteria used in the evaluation process were as follows: (1) Safety, (2) Regulatory/stakeholder acceptance, (3) Technical maturity, (4) Operability and maintainability, (5) Life cycle cost and schedule, (6) Potential for beneficial integration with ongoing STP-Phase 1 activities, and (7) Integration with Site-wide RH-TRU processing/packaging, planning, schedule, and approach. The TEAA recommended Warm Water Oxidation (WWO) as the baseline treatment technology and two risk reduction enhancement options for further consideration during development of the process - size reduction and chemical oxidation (Fenton's reagent). The enhancement options would potentially allow a useful reduction in the total operating time required to process the K Basins sludge. The U.S. Department of Energy's Richland Field Office (DOE-RL) has approved this recommended technical approach. The baseline process can be broken down into the following main process steps: (1) STSC transfer from T Plant to the Sludge Treatment and Packaging Facility (STPF). (2) Retrieval of sludge from the STSCs and transfer to the Receipt and Reaction Tank (RRT). (3) Preparation for immobilization by oxidation using heated water (i.e., WWO) for those batches that require it and concentration by evaporating water at about atmospheric pressure in the RRT. (4) Immobilization by using additives to eliminate free liquids and packaging of the treated sludge into drums. (5) Inspection and handling of the filled drums prior to transfer to a separate storage and shipping facility. (6) Handling of vapor, condensate, and other waste streams generated by the process. Each of these steps is discussed in the paper, together with the current state of progress in developing the technology and requirements for continued development. A schematic of the recommended baseline WWO treatment process is given below. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Encapsulation of ILW metals by melting technology - 15360

This paper outlines how encapsulation using melting technology can be performed and describe the positive effects in a handling and repository perspective. Based on a feasibility study of a conditioning method for reactor core components and other ILW metals with a high content of long-lived radionuclides, the paper gives an overview of the concept and how the method can be facilitated. The paper covers identification and analysis of alternative techniques that supports the aim from a repository perspective, which is to strengthen the defense in depth for long-lived waste to be disposed. Embedding of radioactive metallic ILW components can isolate the activated component from corrosion and leakage of radionuclides into the repository barrier systems. By implementing a system that delays the mobility of nuclides the leakage to the biosphere can be delayed and by then decreased significantly. Conditioning by embedding has potential to strengthen a repository concept significantly. It may in certain cases also reduce the requirements on the repository barriers. In addition to the above, embedding also serves as an efficient radiation protection, which simplifies post treatment handling of the waste. The concept can be applied on a wide spectrum of metallic components. Positive effects in a handling and repository perspective can be achieved if low level metal not subject to free release is used as embedding material, since conditioning of metallic ILW waste can be carried out at significant lower dose rates and without increasing the total amount to be disposed. The paper discuss why there are embedding alternatives for ILW metals that are considered to be both technically feasible and reasonable in cost both with regards to investment and operational cost. A cost-benefit analysis as well as a risk analysis is discussed in order to support the feasibility assessment of a facility for encapsulation of ILW metals by melting technology. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Remote Retrieval, Disruption and Processing of Legacy Nuclear Waste - 16179

The UK National Nuclear Laboratory (NNL) is currently undertaking, in conjunction with Sellafield Ltd, a series of high profile trials of robotic equipment on a full scale test facility at their Workington Laboratory in England. These trials are designed to underpin and substantiate the processes proposed for the remote retrieval, disruption and processing of legacy Miscellaneous Beta Gamma Waste (MBGW) from a number of different donor plants on the Sellafield site, including some of the older fuel storage ponds and storage silos. These processes will be conducted inside the new Box Encapsulation Plant (BEP) which is due to be commissioned at Sellafield by 2020. These processes will subsequently enable Sellafield Ltd to safely recover legacy Intermediate Level Waste (ILW) from the older storage facilities on site and process it into a safer form which is more suitable for long term storage and then ultimately final disposal in a Geological Disposal Facility. As part of this legacy waste processing within the BEP plant, MBGW waste items will have to be remotely removed from a variety of different types of import skips. This waste will then be transferred, using robots, into the export container, which is a 3 m{sup 3} box liner, where the processed waste will be flood grouted to produce an encapsulated waste package. As part of this processing, any MBGW items consisting of sealed containers will have to be remotely disrupted before being grout encapsulated. This disruption is in order to (a) release any trapped liquors or gases from the containers and (b) ensure full grout infiltration of the container contents, thus minimising the amount of free liquors and voids within the final waste product. The NNL are conducting this technical work to confirm the viability of the proposed concept, processes and equipment. The developed solution consists of a linear layout of processing equipment with a pair of heavy duty, standard industrial, 'commercially off the shelf' (COTS) robots positioned around a Waste Handling Table. These robots have a 500 kg payload capacity and are operated remotely to handle all of the various types of MBGW waste, including the heavy and bulky items. The robots can be operated in manual tele-operation mode as well as pre-programmed automatic mode and have a range of primary and secondary tooling in order to perform the waste processing and disruption tasks as well as undertake general house-keeping and cleaning duties within the cell. The main tools include two types of hydraulic grab for the main waste recovery and handling tasks and a hydraulic shear for the waste disruption activities, but a number of other tools have also been designed and built for ancillary activities, such as a set of general purpose gripper jaws, drilling tool, bolt removal tool, pump tool, spray tool and a number of different housekeeping tools etc. The robot trials were started in November 2014, and have attracted a significant degree of high level stakeholder interest, including the UK Nuclear Decommissioning Authority (NDA), Office for Nuclear Regulation (ONR), Environment Agency (EA) and Radioactive Waste Management Limited (RWML) witnessing a number of the critical demonstration trials. Robots of the type selected are readily available, robust, reliable and easy to use. The trials have been very successful in proving the retrieval, processing and disruption operations, reducing the burden in the legacy waste facilities. Utilising robots to perform these tasks will lower the probability of producing non-compliant waste packages. In addition the robots can increase the consolidation of incoming waste skips into outgoing 3 m{sup 3} box liners, significantly increasing packing efficiencies and reducing the overall number of export containers produced thus lowering the decommissioning and waste storage/disposal costs. The trials have also enabled an assessment of the optimum way to operate the robots, as well as their reliability and maintainability issues. Engineering work associated with recovering failed robots and removing them from a typical Sellafield plant environment and then subsequently replacing them with functioning robots has also been undertaken and further work is now planned. The success of the trials, completed safely to a very challenging timescale, has enabled the use of robots in BEP to be endorsed as a viable option by the key stakeholders. Following a robust decision making process, this was a clear cut decision. The technical development and testing of the robot technology is currently continuing in order to investigate areas such as robot reliability, failure recoveries, human factors, ease of waste identification, optimisation of throughput rates, nuclearisation modifications etc. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Decommissioning Experience at Rokkasho; Standing Type Manipulator: A1000S for Dismantling Tasks - 16434

Decommissioning is a technical process which includes various steps and processes from the clean-up of radioactive materials to the progressive demolition of the plant. One of these steps is the cutting of subassemblies, like tanks, pipes or walls in small pieces suitable for the sorting and disposal. Different solutions are offered for this cutting work and can be grouped as following: - Chip forming - sawing, drilling, milling, turning etc. - Shearing - punching, stamping, scissoring. - Abrading - Grinding, lapping, polishing; water-jet. - Heat - flame cutting, plasma cutting, laser cutting. - Electro-Chemical - Etching, Electrical discharge machining (EDM). Each method has its limitations in accuracy, cost, and effect on the material. In 2013, Waelischmiller Engineering won a contract for two remote handling systems dedicated to the dismantling cell at Rokkasho Nuclear Fuel Reprocessing Facility in Japan. For this project, Inconel and other metals needed to be cut. One of the main cutting methods was decided to use of an angle grinder handled by a robotic arm. Because the use of the overhead systems (bridges and cranes) was difficult for this installation, it was determined, that the best alternative was a power manipulator A1000 installed on the floor with a pre-positioning system. The project proceeded to go forward with the adaptation of the standard A1000 with integration of a control system in a Cartesian coordinate frame; resulting in a heavy duty arm; A1000S with 6 degrees of freedom. The heavy duty power arm A1000S was developed and designed for mechanical cutting with an angle grinder, especially for thick and hard material for example stainless steel and Inconel. Cutting a thick material with an angle grinder requires repeatable precise linear motion, in order not to damage the disc. The angle grinder should be handled with a manipulator which can cut in all directions in a linear motion, since the objects which should be cut are usually very large and fixed in any direction For these requirements, the Cartesian control function was added to our standard power manipulator type A1000. In some cases, the decommissioning work includes repeated access routes or fixed access points that the manipulator arm has to pass repeatedly. For example a fixed point where the waste materials are collected, or repeated transport route that the arm has to go along for each step. For this requirement, the A1000S has been equipped with the 'Go To-Mode'. It is a 'teach and playback mode' which has been developed especially for remote operating manipulators. Quick direct teach, quick play function and an intuitive touch-panel layout are some of the features. With the Go To-Mode high working efficiency was achieved. After rigorous testing at Waelischmiller premises; the manipulator was delivered to JNFL in Rokkasho. It was found that the obtained functionality and precision can be applicable not only for the cutting with a disc grinder, but also the laser cutting method, which requires precise trajectory control. This paper will provide: - A project description, - Presentation of solution process, - Technical description of the A1000S, - Future Applications of the robotic Arm A1000S. (authors)

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DOE OSTI2016

Alternative Canister Processing Operations at an Interim Storage Facility - 16617

The US Department of Energy (DOE) is laying the groundwork for implementing interim storage of spent nuclear fuel (SNF) in response to recommendations by the Blue Ribbon Commission on America's Nuclear Future in their report to the Secretary of Energy published January 2012. These efforts include planning for a Pilot Interim Storage Facility (ISF) and a Larger ISF. In March 2014, the DOE employed the CB and I team to evaluate design alternatives for cask handling operations and storing SNF at an ISF. The report, 'Generic Design Alternatives for Dry Storage of Used Nuclear Fuel', (Alternatives Report) evaluates different aspects of an ISF, including a study on alternative approaches for processing SNF canisters such as different cask handling methods and configurations which might be used to transfer canisters from shipping casks into storage locations at an ISF. The purpose of this paper is to report on the development of alternative cask handling operations that have been evaluated for the receipt and storage of the SNF at an initial Pilot ISF and a Larger ISF. This design study is relevant for host communities considering near-term development of a Pilot ISF. DOE-sponsored system analyses indicate that a processing rate of up to 3,000 MTU/yr (approximately 230 to 300 canisters) would be needed for a single Larger ISF (less if more than one ISF were developed) to remove SNF from commercial nuclear plants in a reasonable amount of time. The study evaluated different canister processing operation methodologies in order to reduce the complexity, cost, and personnel exposure associated with processing operations at an ISF. The conclusions from this design study could help to inform the selection of future canister processing operations for an ISF. (authors)

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DOE OSTI2017

Developing a new criticality methodology to support decommissioning of legacy plutonium facilities

To decommission a legacy plutonium finishing facility, a number of gloveboxes need to be disposed of. These gloveboxes have been in place since the 1960's and were operational until the 1980's. A period of initial clean out and decommissioning took place in the 1990's and the first gloveboxes were removed from the line in the early 2000's. Compliance with downstream waste handling facility requirements meant that the gloveboxes needed to be removed using intensive 'hands-on' methods in order to size reduce them to fit into 200 litre (55 gallon) drums. This is the standard approach for handling waste items known as Plutonium Contaminated Material (PCM) on the Sellafield site and was credited in the criticality safety case for the decommissioning of the gloveboxes as it allowed each waste drum to be individually assayed such that the fissile content of the waste could be known. Not only was this approach time-consuming and laborious but as it involved operators working with cutting tools in a highly contaminated area it was challenged as being overly restrictive to operations and potentially hazardous to the workers. In order to decommission the remaining nine gloveboxes in the facility, a new decommissioning approach and associated criticality methodology has been developed. Instead of intensive size reduction and waste drum assay, the gloveboxes will be removed with little or no size reduction and put into storage crates without assay. The criticality assessor will review the operational history of each glovebox, along with the decommissioning records and relevant plant data, to make an evidence-based judgement that the crated glovebox represents no greater a residual criticality risk than would have been realised from the equivalent number of PCM drums that the standard decommissioning approach would have generated. This method identifies, in conjunction with the plant personnel, a number of review points to ensure that before the glovebox is removed any bulk residue material has been recovered and no more than a safe amount of moderating material (fixative) has been added to fix any remaining fissile contamination. Finally, once these review points have been confirmed to be complete - through a stakeholder meeting with criticality safety, plant operators and project managers - the glovebox will be placed in a crate, and this crate will be declared a Low Criticality Risk crate. No formal assay will be required prior to exporting the crate to the downstream waste handling facility and no fissile mass value will be assigned to the contents of the crate. No further intrusive work will be required on the crate and it can be safely stored without any spacing requirements, pending final disposal. (author)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Updating the Dry Transfer System - 18110

The Dry Transfer System (DTS) was examined for its ability to be redesigned in order to meet needs associated with repackaging used/spent nuclear fuel (UNF/SNF) from existing storage cask systems into alternative systems, while also incorporating design advances based on some lessons learned from Orano's dry UNF handling facility (T0) located at the La Hague recycling plant. In this redesign, the DTS is envisioned to provide some flexibility through the ability to perform repackaging activities from multiple differently designed cask systems, including those with canisters that will require cutting and welding activities, and potentially with waste packages designed for disposal. The redesigned DTS is also intended to provide some operational flexibility by providing lag storage and include a means for examining UNF/SNF during repackaging, using some features implemented at the T0 facility at La Hague. This paper provides a summary of: the original DTS design, which was evaluated by the NRC and portions of which were cold-tested at Idaho National Lab; the lag storage system designed for the DTS, which is able to flexibly handle different fuel assembly designs while providing structural support for design basis events (e.g., seismic); the incorporation of lessons learned from the La Hague T0 facility into the DTS design to facilitate dry handling of UNF/SNF; and identification of other challenges towards designing a complete system. A revised DTS is envisioned to provide an important tool for the future management of UNF/SNF in preparation for transportation, re-storage, re-transportation, and/or disposal and also provides a means for repackaging UNF/SNF in case recovery from a cask/canister system is necessary (e.g., due to extended storage or a transportation event). (authors)

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DOE OSTI2019

Development of Waste Disposal Strategy for RH LLW Stored in the ATR Canal - 19453

The Advanced Test Reactor (ATR), located at Idaho National Laboratory (INL), is 250 megawatt research reactor designed and operated for the United States Department of Energy for irradiation testing of advanced nuclear fuels and material samples. The pressurized light-water moderated and cooled reactor achieved criticality in 1967. It is designed to allow high neutron flux irradiation of structural materials and nuclear fuels to replicate long-term exposure of materials in traditional lower-flux reactor cores. The ATR also produces rare isotopes for the use in the medical and other industries. The ATR is one of only four reactors in the world with this high-flux irradiation capability. Adjacent to the ATR is a water-filled canal which is used to handle casks, prepare experiments, perform irradiation experiments, and store irradiated components generated from reactor operations. The canal is used to store irradiated (activated) metals that are subsequently determined to be waste. In many instances, these items are too radioactive to remove from the canal and remain in temporary storage until a sufficient decay period has elapsed to where they can be safely removed. The more highly-radioactive remote-handled (RH) waste items requiring hundreds of years to decay have been in storage in the canal since the first ATR core internal changeout (CIC) which was conducted in the 1970's. The INL has recently completed construction and startup of a new Remote-Handled Low-Level Waste (RH LLW) Disposal Facility, which will serve as the final disposal capability for legacy RH (greater than 200 mR/hr on contact) metal waste currently stored in the canal. The ATR will need to develop a method for packaging, characterizing, removing, and shipping this material to the new disposal facility. Based on the configuration of the new disposal cells at the RH LLW Disposal Facility, the ATR must produce an entire new process for handing and packaging the legacy RH waste and preparing it for transport and final disposal. The ATR Canal RH LLW Cleanup Project scope is to develop the processes, tools, and equipment for safely sizing, packaging, and removing RH LLW from the canal. This paper presents highlights and challenges the project faces to develop and implement this capability: - Designing new tools, fabricating new equipment, and implementing new processes at an active Hazard Category-I nuclear facility. - Ensuring new equipment and tools are compatible with the existing equipment and processes at both the generator and the disposal facilities. - Sizing legacy waste under water using remote tools and equipment to minimize void space in waste disposal canisters while ensuring as low as reasonably achievable (ALARA) goals are met. - Loading waste containers underwater and preparing them to meet the liquid-free criteria of the disposal facility waste acceptance criteria (WAC). - Providing a new shielded transport container to transfer waste from ATR to the new on-site RH LLW Disposal Facility. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

Optimization of the Shielding of a Canister Loading Machine with the deterministic Code Attila{sup R} - Paper 61

In general shielding components are designed with very conservative assumptions and boundary conditions to cover all possibly occurring situations. This often results in an overestimated shielding design in a lot of different fields of application; the shielding of components will be heavier and more expensive than needed. In most cases an initial shielding calculation in the design process shows an unbalanced shielding effect of the shielded radiation source. Sometimes the dose rate limits are slightly exceeded in several areas. From this arises a need for an optimization of the shielding structure. The goal is to decrease the radiation level in the accessible areas to keep the dose rate limits and to reduce the amount of the used shielding material if possible. Shielding material is moved from areas with higher shielding factors to which with lower ones. The optimization process is shown in an example of a loading machine for vitrified waste in canisters. The design review with an optimization of the shielding geometry was done with the deterministic code Attila{sup R} of the company Transpire, Inc. Attila{sup R} is a powerful tool to calculate and optimize the shielding effect of handling facilities for radioactive materials. It is easy to handle with its CAD integration module and an easy setup of the calculation cases. Areas with a low shielding effect which results in an exceeding of the dose rate limits can be found quickly with the illustration due to an Iso-Dose-Rate-Surface in the 3D Model. In these areas the shielding effect has to be improved. Otherwise there is material, which has no significant influence on the shielding effect and makes the handling facilities heavier and more expensive as needed. The optimization of the shielding design of the canister loading machine in the current case results in lower dose rates outside the facility to keep the dose rate limits. The demand of shielding material could be reduced and resulted in a cost reduction on the facility itself and furthermore in the caring facilities to transport this facility (cranes, etc.). (authors)

42 ENGINEERING↗

DOE OSTI2026

Are the U.S. Biorefineries Over the Hurdle of 2000 Ton Daily Throughput Yet?

The efficient utilization of lignocellulosic biomass for biofuel and biochemical production is hindered by material handling issues such as clogging and segregation among other challenges. Preprocessing methods such as drying, screening, and milling have improved conversion yield but have not sufficiently enhanced flowability, especially herbaceous biomass. The poor flowability of herbaceous biomass is rooted in some particle attributes that remain less altered by those methods, e.g., irregular particle shape, high roughness, and high compressibility, making it hard to scale up throughput to a key benchmark for a biorefinery – 2000 ton per day. Applying additional preprocessing methods like pelletization and torrefaction to drastically change those particle attributes can improve flow and handling but has not been comprehensively verified through test. The flowability of herbaceous biomass feedstock formats generated by three different preprocessing methods was recently assessed at Idaho National Laboratory’s Biomass Feedstock National User Facility: first, loose particles size reduced from as-received materials; second, pellets produced from an efficient densification process; and third, powders milled from torrefied pellets. Benchmarking tests including static angle of repose, basic flow energy measured in a powder rheometer, and discharge flow in an adjustable hopper, were conducted to evaluate those feedstock formats. Beyond the capacity of existing experimental apparatuses, a digital engineering approach involving flow simulations and AI models were used to identity the material attributes and processing parameters that have dominant influences on flow throughput. Techno-economic analysis focusing on hopper flow as a typical material handling operation was conducted for those feedstock formats. Perspectives will be discussed on whether the 2000-ton daily throughput for a biorefinery is achievable at an acceptable cost by using any of the tested preprocessing methods.

09 - BIOMASS FUELS↗

DOE OSTI2017

Improving Decommissioning Success using the Tool of Virtual Reality; Increasing Worker Safety and Project Schedule Stability - 17193

operations, especially underwater, is essential. Equally essential is a precise game plan for disassembly which focuses attention on the skilled remote handling operators who must produce the results. Project success is based on clean, efficient cuts and take-aways, prepared paths for waste placement and containment, programmed return paths; and practice, practice, practice on the part of the operators. Recently, our Partner, WAK Ruackbau- und Entsorgungs- GmbH (Decommissioning and Waste Management Company) was tasked with dismantling and decommissioning the Karlsruhe Reprocessing Plant. The most difficult task in this project is the dismantling of the vitrification plant. Waelischmiller was selected to address this high-consequence project. Together, WAK and Waelischmiller determined that development of a virtual reality suite, where management and operators could create a virtual vitrification layout and subsequently map and rehearse their dismantling plan was essential. This approach, using Virtual Reality (VR) as a tool in streamlining operations and rehearsing difficult moves and cuts, will be a game changer for this and future projects. It will be a first-of-a-kind in Germany. The VR suite is contained in a room at the Karlsruhe facility with a large screen, control cabinet, simulation computer, a Waelischmiller Joyarm and Masterarm. To support the dismantling of the vitrification plant, WAK/HWM will conduct interactive feasibility studies for each dismantling step. All movements; cuts, take-aways and vessel segment insertion into transportation and disposal casks will be established, programed and practiced within virtual test suite. This allows savings in cost-intensive and complex construction of test rigs. Operating personnel can be trained in the VR suite, without taking the risk of damaging expensive remote handling equipment.While the operators are working on the operating element, they stand in front of a wide screen. Instead of a real TELBOT{sup R}, a virtual TELBOT{sup R} is moving on the screen in virtual reality. While practicing, the operators cannot damage the arm and the equipment, which is a big advantage. Moreover an interactive feasibility study can be realized without building a real test rig (mock-up). Consequently significant cost-expenses can be reduced. This paper will describe the virtual suite used by the WAK in Karlsruhe and the advantages of this new and innovative approach, which is unique in decommissioning of nuclear facilities. The viewpoint of each (WAK and HWM), and the decisions and benefits realized along the project path will be detailed in the paper. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Collaborative Robots vs. Master/Slaves - 19522

This paper will discuss the feasibility, application, and economy of applying collaborative robots (co-bots) in lieu of traditional through-the-wall tele-operated manipulator systems, traditionally used within hazardous (radioactive) environments. Both fixed facility and mobile applications will be discussed. Both single- and dual-armed co-bot systems will be employed. The six-axis, plus gripper, single-armed co-bots will provide for machine vision enhanced pick-n-place applications within shielded rooms and also include force-reflecting (haptic) teleoperations controls for non-routine materials-handling operations. The dual-armed system will be mounted to a motorized stand with motorized adjustment both vertically and rotationally (around its base). To complement these co-bots, both two-dimensional and three-dimensional vision technologies will be implemented. The vision technologies, in these applications, are used in lieu of traditional radiation shielding windows. two-dimensional video systems will provide for large area viewing, incorporating pan, tilt, and zoom capabilities. Three-dimensional video systems will be mounted to the dual-armed robot stand and provide viewing, including depth-of-perception, to the operator, performing material handling and other tasks, from an operator workstation located outside the hazardous environment. The unique workstation used with the dual-armed systems will also be described. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Experiences with Mobile Units for Liquid RAW Management in Slovak and Czech Nuclear Power Plants - 20089

In Nuclear Power Plants VVER 440, Russian type of reactor there was designed auxiliary building where according to basic design all operational liquid radioactive waste (RAW) should be stored in large capacity tanks during the whole operational period. That's why there are in the auxiliary building several types of large storage tanks with different internal volume from 110 m{sup 3}, 460 m{sup 3} to 550 m{sup 3}. Storage tanks are usually situated in rooms with limited access and minimal handling space. Operational waste was here transported by the system of pipes from the reactor building. There is possibility to handle with the waste and set the pipeline in to the chosen storage tanks. Nobody takes care about the quality of waste in the storage tanks and waste waits for the period of decommissioning when it should be treated. The storage capacity was designed for the whole lifetime of nuclear power plant. Currently the life time of Nuclear Power Plant's (NPP) is extended and there is necessity to retrieve and treat the RAW in advance. Another reason why the stakeholder, who operates the NPPs, decides to treat the operational RAW during the operational period of NPP, is that there are still new requirements from safety point of view which need to have free available space for example because of potential accident. So treating the operational RAW during the life time of NPP is present issue. Because in basic design nobody cares how the RAW will be retrieved and treated in the future, there is usually no technology for that in existing NPP. Some of the NPPs build an additional building with suitable technologies for treatment or hire the company which offer mobile technology for retrieving the waste from the storage tanks. Wood Nuclear Slovakia PLC provides all activities within liquid RAW management projects by its own staff including management, design, construction and deployment of equipment, engineering support, as well as all RAW retrieval and solidification activities. We offer RAW management as a service without any significant changes in existing NPP's buildings and technology. It is always a technical challenge to conduct successful retrieval, pumping and treatment of RAW. The complex RAW retrieval system can be designed as tailored solution for any RAW storage according to known boundary conditions and specific needs. These systems are based on years of experience with RAW manipulation, processing and treatment and the whole RAW management knowledge by Wood Nuclear Slovakia LTD. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Effect of particle size and moisture on flow performance of loblolly pine anatomical fractions: Experimental findings and model predictions

The rising energy demand has highlighted biomass as a promising next-generation energy source. However, commercializing biomass-derived energy faces challenges, particularly in handling biomass feedstock. Factors like particle size, shape, moisture content, and surface roughness significantly impact biomass flowability. This study addresses a crucial knowledge gap by examining the effects of particle size and moisture content on the flow behavior and shear properties of different anatomical fractions of loblolly pine (Pinus taeda). The bulk shear behavior was examined using a Schulze ring shear tester, while flow performance was tested through gravity-driven flow experiments in a variable wedge-shape hopper. Results were incorporated into empirical and machine learning-based flow prediction models to evaluate their accuracy and limitations. The study found that samples with higher moisture content show higher unconfined yield strength. The critical arching distance increased with particle size, e.g., from approximately 13 and 33 mm for 2- and 6-mm whole chips, respectively at a 32-degree inclination angle. Conversely, the flow rate decreased for a given hopper opening as particle size increased. For instance, at a 60-mm hopper opening and a 32-degree inclination angle, the mass flow rates for 2- and 6-mm whole chips were 7.83 and 6.42 tonne/h, respectively. The empirical model consistently overpredicted the mass flow rate for all anatomical fractions, while the machine learning model more accurately predicted the central tendency of flow rate but was insensitive to varying tissue proportions. These novel findings provide comprehensive characterization of anatomical fractions, reveal significant combined effects of particle size and moisture content on biomass flow behavior, and demonstrate a better predictive accuracy of a machine learning model, all of which are useful for optimizing material handling strategies and biomass utilization technologies in the industry.

09 - BIOMASS FUELS↗

DOE OSTI2025

Active multi-mode data analysis to improve fault diagnosis in AHUs

Faults in heating, ventilation and air conditioning systems can lead to increased energy consumption, occupant comfort issues, and reduced equipment lifetime. Commercial fault detection and diagnosis (FDD) tools has been increasingly deployed in U.S. commercial buildings. While they are helping to achieve energy efficiency and operational reliability, there remain gaps in their fault diagnostic capabilities. The diagnostic results often contain multiple distinct candidate root causes (CRCs) or offer no insight into CRCs. This study developed a novel active rule-based multi-mode data analysis method to enhance diagnostic resolution by applying proven rule sets and additional new rules to data from multiple known operational modes. The proposed method was demonstrated using enhanced air handling unit performance assessment rule sets and validated with the simulated data of two air handling units. New metrics, namely, reduced number of CRCs and improvement ratio, were developed to quantify the improvement of fault diagnostic resolution. The validation results showed that the proposed method effectively reduced the number of CRCs in contrast to analyzing data solely for a single mode of operation. It achieved a median improvement ratio of 80% in 19 test cases.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Challenges of designing, operating, and managing brine extraction at a carbon dioxide storage site

Developing and deploying commercial-scale carbon dioxide (CO 2 ) storage at a site requires operational strategies to manage pressure and CO 2 plume distribution. In the natural gas storage and oil and gas industries, fluid extraction has been successfully implemented as a strategy to manage pressure and control fluid distribution (i.e., hydrocarbon recovery and natural gas storage efficiency, respectively). The technical challenges of integrating brine extraction at CO 2 storage sites are expected to be similar, if not identical, to those in the natural gas storage and petroleum industries. Major technical challenges of using brine extraction to manage storage in a storage unit include (1) designing and completing the brine extraction wells, (2) locating the brine extraction well, (3) assessing the efficacy of brine extraction, and (4) handling the extracted brine. The design and completion of the brine extraction well include the well type (i.e., vertical or horizontal) and perforated interval. The location of the well is influenced by the timing of extraction operations (i.e., prior or after CO 2 injection starts) and project objectives (i.e., desired directional movement of the CO 2 plume and avoid or minimize CO 2 extraction). The efficacy of brine extraction requires a baseline projection of the pressure and CO 2 plume distribution. Options for handling extracted brine include subsurface disposal, surface disposal, and industrial use. Here this paper addresses means of overcoming technical challenges that may likely be encountered before or after CO 2 injection starts.

25 ENERGY STORAGE↗

DOE OSTI2024

Shear rate dependency on flowing granular biomass material

The commercialization of bioenergy has been significantly limited by various material handling issues due to the poor flowability of granular biomass materials. A good understanding of flow physics and robust constitutive models to predict flow behavior across multiple regimes are essential to address these issues. In this study, we investigated the multi-regime flow behavior of loblolly pine chips, a widely used bioenergy feedstock, through comprehensive inclined plane flow experiments and simulations. A quasi-static hypoplastic model and a cross-regime Drucker-Prager-µ(I) model were calibrated and validated against the physical experiments to investigate the quasi-static and dense flow behavior. The results show that for granular biomass, 1) plane flow (iso-thickness along the plane) exists within a smaller range of inclination while heap flow (varying thickness along the plane) exists within a broader range of inclination, as compared with conventional granular materials (e.g., glass beads); 2) the scaling law of granular biomass flowing on an inclined plane (Froude Number versus dimensionless thickness) forms a bi-linear trend with the turning point governed by the quasi-static and dense flow regimes; 3) the multi-regime DP-µ(I) model can capture the flow behavior in both regimes well at the cost of extra calibration. In conclusion, these findings advance the scientific understanding of the multi-regime flow behavior of granular biomass materials and shed light on formulating novel constitutive models to assist granular biomass handling in the bioenergy industry.

09 BIOMASS FUELS↗