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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Road Map for Developing Iron Phosphate Waste Forms for Salt Wastes

In this report, issues that must be addressed to advance the technology readiness level of phosphate glass waste forms being developed to immobilize high-level radioactive salt waste streams are identified, the states of understanding various technical aspects of formulation, processing, and performance are summarized, and approaches supporting further development are recommended. Processing results in dehalogenation of the waste salt, capture of the gaseous halide-bearing species, and immobilization of the residual salt components in a phosphate glass waste form. The approach is suitable for high-level salt waste from electrochemical reprocessing and molten salt reactors. The technology has been demonstrated for chloride-based salts and may also be suitable for the treatment and immobilization of fluoride-based and iodide-bearing waste salts. Aspects of the process requiring further development are identified and approaches recommended.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Synthesis and characterization of super occluded LiCl-KCl in zeolite-4A as a chloride salt waste form intermediate

Here, this paper reports the hygroscopic properties of eutectic LiCl-KCl after absorption into zeolite-4A, up to salt loadings of 75 wt%. Samples of the salt occluded zeolite were hydrated in a humidity chamber at constant temperature and relative humidity for up to 100 h. At up to 45 wt% salt loading, the un-occluded phase of salt consisted primarily of NaCl, which forms when the Na + ions present in the zeolite framework exchange with Li + and K + ions from the eutectic LiCl-KCl. This results in minimal water absorption and corrosion of contacted stainless steel. At greater than 45 wt% salt loading, water absorption and corrosion progressively worsened. The mixture has a significant amount of excess LiCl-KCl, making it highly hygroscopic. This study reveals an option for the intermediate treatment of waste salt from spent nuclear fuel electrorefiners that could facilitate it to be stored in a non-inert atmosphere for extended periods of time before final conversion into a permanent waste form.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Synergy in Materials: Leveraging Phosphosilicate Waste Forms for Electrochemical Salt Waste

Here, waste forms containing glassy and crystalline phosphate and silicate phases were produced to immobilize salt waste simulants from pyroprocessing and characterized by using Raman spectroscopy, Mössbauer spectroscopy, X-ray diffraction, scanning electron microscopy, heat capacity, and chemical durability measurements. In this work, a phosphosilicate waste form is presented to leverage the benefits of both borosilicate glasses and iron phosphate glasses. To improve waste loading, prior to immobilization, salt simulants were successfully dechlorinated using ammonium dihydrogen phosphate, mixed with a borosilicate frit (5–30 wt %) and Fe 2 O 3 , and vitrified. Additions of 2.5–15 wt % borosilicate glass (NBS3) improved normalized release rates for Cs relative to iron-phosphates without NBS3, resulting in chemical durabilities similar to high-level waste borosilicate glass reference materials. The release rates of the alkalis (i.e., Li, Na, K, Cs) were the lowest with the addition of 5 wt % NBS3. Although Sr was not specifically targeted in this study, evidence exists that it preferentially partitioned with Si to form an amorphous droplet phase within the iron phosphate glass matrix.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Perovskite-Derived Cs 2 SnCl 6 –Silica Composites as Advanced Waste Forms for Chloride Salt Wastes

Advanced materials and processes are required to separate halides and fission products from complex salt waste streams associated with the chemical reprocessing of used nuclear fuels and molten salt reactor technologies for immobilization into chemically durable waste forms. Here, in this work, we explore an innovative concept using metal-halide perovskites as advanced host phases to incorporate Cs and Cl with very high waste loadings. Wet chemistry-synthesized Cs 2 SnCl 6 powders from CsCl salt solutions are successfully encapsulated into a silica matrix to form a composite using low-temperature spark plasma sintering with tunable Cs and Cl loadings up to 31 wt.% and 26 wt.%, respectively. Chemical durability testing of the composite waste forms by semi-dynamic leaching experiments demonstrates that incongruent leaching mechanism dominated. The metal-halide perovskite-silica composite waste forms display exceptional chemical durability with the long-term release rates of Cs and Cl comparable to or outperforming the state-of-the-art waste form materials but with significantly higher waste loadings. The scalable synthesis of the metal-halide perovskite from wet-chemistry processes opens up new opportunities in designing perovskite-glass composite waste forms for salt wastes with very high waste loadings and exceptional chemical durability for the sustainable development of advanced fuel cycles and next-generation reactor technologies.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Drying model of a high salt content cementitious waste form: Effect of capillary forces and salt solution

Highlights: • Drying model for a high salt content cementitious waste form is developed. • Water vapor diffusion and capillary liquid flow are distinguished. • Capillary and salt solution effects are considered in vapor-liquid equilibrium. A water transport model coupling capillary liquid flow with vapor diffusion is developed to describe the drying process for a cementitious waste form with high salinity porewater. Vapor-liquid equilibrium is formulated as the driving force for vapor diffusion and the model accounts for pore capillary and high salinity effects on water thermodynamic activity. Pore filling and porewater surface tension as a function of pore size distribution and water saturation have been quantified for the material. Geochemical speciation modeling is used to simulate porewater activity as a function of composition over the range of saturation. The theoretical relationship between relative humidity and water saturation generally agrees with experimental measurement, and the developed model is capable of predicting drying rates under various external relative humidity conditions. The model was developed to be incorporated into reactive transport models considering the effects of drying such as salt redistribution and efflorescence.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Evaluation of Iron‐Phosphate Glass–Ceramic Waste Form for Electrorefiner Salt Waste Simulant Dechlorinated With Phosphoric Acid

The importance of glass and glass–ceramic nuclear waste forms has been reaffirmed in recent years by the growing interest in nuclear power as a reliable energy source. Determination of processing methods for the disposal of halide-containing wastes will be essential for the advancement of nuclear technologies such as non-aqueous fuel reprocessing. Phosphate-based dechlorination and subsequent vitrification of radioactive salt waste into an iron-phosphate waste form have been identified as a potential processing scheme for electrochemical processing waste. The impact of H 3 PO 4 -based dechlorination of complex salt mixtures on the vitrification process and structure of the final iron-phosphate waste form has not yet been investigated. In this work, iron-phosphate glass–ceramics were made from simulant salt waste (48LiCl–33KCl–19NaCl mol%) dechlorinated with the H3PO4-based method. The glass-forming region was compared to that of traditionally prepared Na 2 O–Fe 2 O 3 –P 2 O 5 systems. For a candidate glass-forming composition, the processing scheme presented here was determined to favor Fe 3+ species. The O/P molar ratio was consistent for the candidate composition when dechlorinated at 400°C and 600°C in air and argon environments, indicating glass network connectivity was maintained despite variations in processing parameters. The results presented here validate processing schemes requiring iron-phosphate waste form synthesis following H 3 PO 4 -based dechlorination.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Molten Salt Reactors and Electrochemical Reprocessing: Synthesis and Chemical Durability of Potential Waste Forms for Metal and Salt Waste Streams

The molten salt reactor (MSR) is one of the leading advanced nuclear reactor candidates to replace current nuclear reactor technologies in the U.S. Besides having more economical and reliable designs, MSRs have are amenable to a closed fuel cycle, in which electrochemical reprocessing can be performed to recycle the used nuclear fuel. This review intends to provide information about potential waste forms for metal and salt waste streams from these salt-based nuclear processes. Metal waste streams arise from reactor components and structural materials. Salt waste streams are generated during reactor operations as fission products build up in salt-fueled systems. Waste forms that have the highest waste loading and/or have shown the most commercial promise are discussed with an emphasis on the current state of efforts to understand the synthesis and chemical durability of metal and ceramic waste forms.

molten salt reactors, electrochemical reprocessing↗
DOE OSTI2021

Evaluation of the Generation-2 Dechlorination Apparatus for Treating Salt Wastes

This document satisfies the requirements for two milestones, i.e., M2FT-21PN030103021 and M3FT-21PN030103026, which are described in detail below. Also, details for the work package at the Pacific Northwest National Laboratory (PNNL) are provided below. The goal of this milestone was to demonstrate the generation-2 dechlorination apparatus (G2DA) for removing Cl from chloride-based electrochemical salt simulants. The two salts chosen for this initial study were KCl to simulate a component from the eutectic salt (LiCl is harder to detect with analytical instruments) and CsCl to simulate a fission product chloride that might be present in these types of waste streams. The overall scope of this work included receiving, installing, and testing the G2DA. This new system was designed to address several shortcomings identified with the generation-1 apparatus (G1DA), which are described in detail within this document. The G2DA was designed to address all of these shortcomings. The studies presented in here show that the G2DA worked as intended and will help provide scaled-up batches for additional testing at Argonne National Laboratory.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Dehalogenation of electrochemical processing salt simulants with ammonium phosphates and immobilization of salt cations in an iron phosphate glass waste form

This study demonstrates the conversion of simulated pyroprocessing salt wastes [i.e., ER(SF) and ERV2] into chemically durable iron phosphate glass waste forms through reactions with ammonium hydrogen phosphate precursors [i.e., NH4H2PO4 and (NH4)2HPO4] and added Fe2O3. The reaction of the salt simulants with the phosphate precursors resulted in dehalogenation of the salt through the production of NH4Cl and NH4I (along with water), of which the NH4Cl can be used to produce UCl3 oxidant for use in the electrorefiner during pyroprocessing. These iron phosphate glasses contain a notably higher waste loading than the baseline glass-bonded sodalite ceramic waste form, which requires about 70 vol% sodalite to accommodate Cl from the salt, because they are dehalogenated prior to vitrification. The high waste loadings coupled with higher bulk densities (~3×103 kg/m3) than glass-bonded sodalite (~2.3×103 kg/m3) mean that these glasses have a higher storage volume, i.e., the volume required to immobilize a given mass of waste. The iron phosphate glass waste forms were characterized using a variety of techniques including physical property measurements and chemical durability testing. Following initial testing, a proof-of-concept demonstration was conducted to show that the NH4Cl generated from this process could be used to produce UCl3 using depleted uranium dendrites as a feedstock.

phosphate glass, pyroprocessing, waste forms, salt↗
DOE OSTI2025

Evaluating High-Halide Waste Form Options for Salt-Based Nuclear Waste Simulants

In this study, waste forms were being explored for an electrochemical salt simulant, , referred to as ERV3, which is a high-LiCl/KCl salt containing simulated fission products (i.e., Sr, Cs, Nd) and Na to represent bond sodium from Experimental Breeder Reactor-II metallic fast reactor fuel. The goal was to find glassy systems that could be used to immobilize the salt in a single-step process. The envisionment of this process would be find a frit glass that could be added to the salt waste, heat treated, poured into waste canisters, and then stored for disposal. To perform this study, a literature review was conducted, the most promising seven systems were fabricated without the salt, and then mixed with salt simulant and heat treated under different processes. The criteria that were used to screen potential compositions included demonstrated alkali incorporation, could be melted at reasonably low temperature ( T ≤ 1000°C), and if the compositions had some demonstrated data for waste-form-related properties, that was a benefit. High marks were given for compositions that showed amorphous nature after slow cooling of samples containing ERV3.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
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

Organic Acid-Assisted Thermal Dehalogenation of Halide Salt Nuclear Wastes: From Waste Salts to Borosilicate Glass

Only a handful of high-halide salt waste forms have been demonstrated for vitrification-based immobilization strategies for halide-salt nuclear waste streams (e.g., pyroprocessing wastes, molten salt reactor wastes) and they all have low waste loading potential and most have low chemical durabilities for high-alkali streams. An alternative approach to direct salt immobilization is salt partitioning prior to waste form fabrication and one option for partitioning is halide removal (called dehalogenation). Removing the halogen fraction through dehalogenation can significantly reduce the waste volume required for disposal in the primary waste form. Furthermore, when dehalogenation is performed using organic acids, the dehalogenation reagent can decompose during high-temperature vitrification, reducing waste loading limitations in the waste form. In the current work, different organic acids (i.e., oxalic, formic, acetic, oxamic, and citric) were evaluated for dehalogenation efficiency of a simple chloride salt simulant (7.19% LaCl 3 , 53.77% LiCl, and 39.04% KCl, by mole) and a more complex chloride salt simulant called ERV3 (electrorefiner version 3) at 150 °C–300 °C and using H + /Cl – molar ratios of 1:1, 2:1, and 3:1. Additionally, a borosilicate glass waste form called TARS (or the average of refined specifications) was formulated, produced, and characterized for dehalogenated ERV3.

Amorphous materials↗
DOE OSTI2023

Aluminophosphate Waste Forms for Immobilizing Cations from Electrochemical Salt Wastes

This report provides experimental details and results of evaluating aluminophosphate waste forms for treating and immobilizing the salt cations from salt wastes generated during electrochemical reprocessing of used nuclear fuel. In the waste form process for these materials, chloride salt streams are reacted with NH 4 H 2 PO 4 , the chlorine is removed from the salts and driven off as NH 4 Cl (a solid condensate that can be captured), and then the product can be vitrified in conjunction with glass-forming chemicals (e.g., Fe 2 O 3 , Al 2 O 3 ) to create a high-durability waste form. This study was initiated with some literature review on aluminophosphates containing high alkali oxide content and some of this information is summarized in this report. Following literature review, three new samples were synthesized where two contained Fe 2 O 3 +Al 2 O 3 (i.e., samples G3 and G5 ) and one was only Al 2 O 3 (Fe 2 O 3 -free) (i.e., sample G6 ). In addition to these samples, G1 was also made, which is the baseline reference waste form referred to as DPF5-336 (made without Al 2 O 3 ). Samples G1, G3, G5, and G6 had phases of Li 3 Fe 2 (PO 4 ) 3 (likely), monazite (below XRD detection limits), AlPO 4 , and AlPO 4 , respectively. Characterizations on these materials included optical images, scanning electron microscopy, energy dispersive X-ray spectroscopy, and X-ray diffraction. These samples were shipped to Argonne National Laboratory for chemical durability testing. Depending on how the samples perform in these tests, an additional phase of aluminophosphate formulations could be designed and tested. This report completes the milestone M4FT-23PN030104041 with details provided in Appendix B.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Modeling Interfaces to Support Low-Level Waste Disposal System Performance Assessments - 20366

In low-level waste (LLW) disposal sites, interfaces between cementitious materials, used as waste forms and/or engineered barriers, and the surrounding soil or backfill material are often encountered. Reactions across these interfaces may lead to chemical and structural alteration of the cementitious and backfill materials that may ultimately affect long-term performance. For example, the ingress of carbon dioxide from soil gas into a waste tank concrete shell at the Hanford Site or Savannah River Site (SRS) or a low-level waste disposal vault at SRS leads to carbonation of cement hydration products (e.g. portlandite, calcium-silicate hydrate or C-S-H, and ettringite). The result of carbonation is a decrease in pH in the cement paste portion of the tank wall or vault concrete structure that could ultimately lead to de-passivation of the embedded structural steel and, eventually, to cracking. Cracking can lead to increased ingress of water into the structure, corresponding increased release of constituents of concern, and to subsequent increased transport of these constituents to the surrounding environment. The mobility of trace constituents (e.g., radionuclides of concern) in waste forms may increase in response to changes in pH, pore structure, and mineralogical gradients. Depletion of portlandite results in subsequent decalcification of C-S-H that leads to changes in the cement strength and may lead to structural failure. At the boundary between waste forms and concrete vaults, the migration of sulfate ions from the salt waste form (e.g., the saltstone waste form used for LLW disposal at the Savannah River Site in Saltstone Disposal Units, or SDUs) into the barrier or vault concrete has been predicted to result in expansive mineral phase formation (or 'sulfate attack'). Expansive mineral formation could result in cracking and potential loss of structural integrity in the vault concrete. In the performance assessment (PA) for the SRS SDUs, prediction of both the carbonation and sulfate attack fronts are critical to assessing the long-term performance of these LLW disposal vaults. A general purpose geochemical reactive transport model has been developed in LeachXS/ORCHESTRA to evaluate typical interfaces for LLW disposal environments, including SDUs at SRS. The model may be used to predict the long-term performance of interfaces between cementitious materials and saltstone or backfill materials with respect to primary phases by considering mass transport, cement chemistry, geochemical speciation, and multi-ionic diffusion over interfaces between different materials. The present study compares the performance and interactions between vault concrete and saltstone waste form for a representative SDU scenario. The materials were characterized using pH-dependence leaching test (EPA 1313) and semi-dynamic transport tests (EPA 1315) with test results used to parameterize the interface model. The development of a credible inter model provides an important basis for supporting future PAs where carbonation and sulfate attack are important aging and degradation mechanisms. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Ceramic waste form production from used nuclear fuel

According to one aspect of the invention, a method to create a ceramic waste form from used nuclear fuel. An active metal salt waste, a rare earth metal waste, and raw materials are received. The active metal salt waste is combined with the rare earth metal waste, forming a waste salt. The waste salt is then heated to approximately 500° C. The raw materials are also heated to approximately 500° C. The waste salt and raw materials are then blended to form a homogenous waste mixture. The homogenous waste mixture is heated to a first predetermined temperature for a predetermined amount of time, creating a ceramic waste form. The ceramic waste form is cooled to a second predetermined temperature.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Corrosion Behavior of Developmental Iron Phosphate Waste Forms: FY20 Status Report

Corrosion tests were performed to assess the dissolution behaviors of developmental iron phosphate materials that are being evaluated as an alternative to the glass-bonded sodalite ceramic waste form to immobilize salt wastes from electrochemical separation operations. Production of the iron phosphate waste form results in dehalogenation of the waste salt that increases potential waste loading. Ferric oxide is added to the waste form to increase the chemical durability. Tests conducted to optimize the amount of ferric oxide used to make the waste form are summarized in this report. Specimens prepared from materials made with between 17 and 34 mole % ferric oxide were subjected to two test methods to assess the effects of the iron content on the relative durability and retention of immobilized salt cations including cesium, strontium, and neodymium. Modified ASTM C1308 test results show the intrinsic durability was significantly higher for materials made with 27 mol % ferric oxide. Further additions generated iron-rich inclusion phases and did not improve durability. Modified ASTM C1285 test results show that solution feedback attenuates the dissolution rate similar to what is observed for borosilicate glasses within seven days. Analyses of test specimens after 42 days show no evidence that surface layers formed. Combined with previous studies addressing the salt loading, a composition region of the ammonium (di)hydrogen phosphate-waste salt-ferric oxide ternary has been defined for durable waste form compositions. Materials with that composition can be used to determine optimal processing conditions, assess long-term performance, and parameterize a degradation model.

Stariha, S. A.↗