Presented by: Robert M. Szozda

1. Speaking on behalf of the Project Team, the U-233 project is the most interesting, challenging and rewarding project we have ever been involved in I would like to provide you an overview of the U233 Disposition Project Reasons for Project Scope Issues A specific benefit � medical isotopesSpeaking on behalf of the Project Team, the U-233 project is the most interesting, challenging and rewarding project we have ever been involved in I would like to provide you an overview of the U233 Disposition Project Reasons for Project Scope Issues A specific benefit � medical isotopes

2. Isotek Systems, LLC Includes: Because of the complex scope of work one company could not do the whole scope - LLC was put together to provide expertise to DOE in: In addition DOE required commercialization of the medical isotopes which resulted in a Priv Sector Beneficial Use program Isotek � management of production, marketing and distribution PNNL � R&D for isotope generators, tech support to isotope producers Commercial production partners � turn isotope commodity into an FDA approvable pharmaceuticalBecause of the complex scope of work one company could not do the whole scope - LLC was put together to provide expertise to DOE in: In addition DOE required commercialization of the medical isotopes which resulted in a Priv Sector Beneficial Use program Isotek � management of production, marketing and distribution PNNL � R&D for isotope generators, tech support to isotope producers Commercial production partners � turn isotope commodity into an FDA approvable pharmaceutical

3. Problem Situation: an excess inventory of U-233 exists Building 3019 is the oldest continuous operating Hazard Cat 2 nuclear facility in the DOE complex and contains 1.5 tons of U including U233 Some of the inventory has been in place since the 1960s Problem: The inventory is a liability Inventory was the subject of DNFSB Recommendation 97-1, Safe Storage of U-233 DOE issued an Implementation Plan in 1997 which committed to perform a study of alternatives to the continued storage of 233U The material may have to be repackaged to address safety concerns if storage continued indefinitely Cost of security is increasing in response to potential threats --------------------------------------------------------------------------------------------------------------- ID Mtl: 350 kg U-233 dioxide mixed with 14 tons of thorium and other oxides within unirradiated fresh fuel Other inventories at LANL and LLNL are proposed by DOE to be consolidated with the Oak Ridge inventorySituation: an excess inventory of U-233 exists Building 3019 is the oldest continuous operating Hazard Cat 2 nuclear facility in the DOE complex and contains 1.5 tons of U including U233 Some of the inventory has been in place since the 1960s Problem: The inventory is a liability Inventory was the subject of DNFSB Recommendation 97-1, Safe Storage of U-233 DOE issued an Implementation Plan in 1997 which committed to perform a study of alternatives to the continued storage of 233U The material may have to be repackaged to address safety concerns if storage continued indefinitely Cost of security is increasing in response to potential threats --------------------------------------------------------------------------------------------------------------- ID Mtl: 350 kg U-233 dioxide mixed with 14 tons of thorium and other oxides within unirradiated fresh fuel Other inventories at LANL and LLNL are proposed by DOE to be consolidated with the Oak Ridge inventory

4. Solution: Department of Energy Initiated the U-233 Project to: 2001 DOE issued Excess Material Disposition Decision Memorandum No. 2 that discussed potential use of the material Alternatives: Source of Bi-213 for possible cancer treatment Tag for HEU to allow ID of the source of uranium Fissile mtl for developing an advanced Th fuel cycle Determined there was no programmatic use other than as a source of medical isotopes Solution: DOE ONE conducted a competitive procurement and awarded a contract in October 2003 There are 3 principal objectives of the work downblend the inventory to eliminate security and nuclear safety cost Package and move the downblended oxide to a less expensive storage facility provide medical isotopes that are in short supply2001 DOE issued Excess Material Disposition Decision Memorandum No. 2 that discussed potential use of the material Alternatives: Source of Bi-213 for possible cancer treatment Tag for HEU to allow ID of the source of uranium Fissile mtl for developing an advanced Th fuel cycle Determined there was no programmatic use other than as a source of medical isotopes Solution: DOE ONE conducted a competitive procurement and awarded a contract in October 2003 There are 3 principal objectives of the work downblend the inventory to eliminate security and nuclear safety cost Package and move the downblended oxide to a less expensive storage facility provide medical isotopes that are in short supply

5. U-233 Project Work Phases DOE planned the work around 3 distinct phases: Phase I - Oct 03 to July 05 Process design Development of the auth basis Design of security � we are conducting a new VA using new threat guidance to design security measures NEPA assessment � DOE completed an EA and FONSI Phase II � if awarded will be after review of the design and congressional approval of the business case (6.5 years and 2.5 of that is operations) Turn-over of facility operations from the incumbent contractor to Isotek Construction of processing equipment Commissioning Readiness Assessment Processing operations Phase III 0.5 years of process cleanout and equipment stabilizationDOE planned the work around 3 distinct phases: Phase I - Oct 03 to July 05 Process design Development of the auth basis Design of security � we are conducting a new VA using new threat guidance to design security measures NEPA assessment � DOE completed an EA and FONSI Phase II � if awarded will be after review of the design and congressional approval of the business case (6.5 years and 2.5 of that is operations) Turn-over of facility operations from the incumbent contractor to Isotek Construction of processing equipment Commissioning Readiness Assessment Processing operations Phase III 0.5 years of process cleanout and equipment stabilization

6. A Short History of the Building 3019 Complex May 1943 Nov 1943 A little history: Complex was constructed in 1943 as the chemical separations plant for the graphite rector � these pictures show construction in progress Between 1943 and 1976, Building 3019A functioned as a pilot plant for radiochemical reprocessing technology including Purex and Thorex Became a national repository for U-233 1962 The core of the complex is the original building structure, which consists of seven shielded processing cells. Complicated facility to conduct construction due to: equipment that shut down but remains in place contamination from a 1950s incident that spread Pu contamination Massive walls several feet thick concrete ------------------------------------------------------------------------------------------------------------------ Design of processes and equip must fit the footprint � used LASER mapping to get exact dimensions for the processing foot print May 1943 Nov 1943 A little history: Complex was constructed in 1943 as the chemical separations plant for the graphite rector � these pictures show construction in progress Between 1943 and 1976, Building 3019A functioned as a pilot plant for radiochemical reprocessing technology including Purex and Thorex Became a national repository for U-233 1962 The core of the complex is the original building structure, which consists of seven shielded processing cells. Complicated facility to conduct construction due to: equipment that shut down but remains in place contamination from a 1950s incident that spread Pu contamination Massive walls several feet thick concrete ------------------------------------------------------------------------------------------------------------------ Design of processes and equip must fit the footprint � used LASER mapping to get exact dimensions for the processing foot print

7. A Short History of 233U A little history of the material: Made by irradiating natural thorium (Th-232) with neutrons in a reactor Natural Th is readily available in monazite sands in the US and Brazil Was believed to be easier to chemically separate 233U from Th than to use separate 235U from 238U viewed as a strategic alternative to enrichment Over 2000 kg produced between OR, HAN and SRS Use of 233U in fuel cycle was ultimately abandoned in favor of lower cost low-enriched uranium A little history of the material: Made by irradiating natural thorium (Th-232) with neutrons in a reactor Natural Th is readily available in monazite sands in the US and Brazil Was believed to be easier to chemically separate 233U from Th than to use separate 235U from 238U viewed as a strategic alternative to enrichment Over 2000 kg produced between OR, HAN and SRS Use of 233U in fuel cycle was ultimately abandoned in favor of lower cost low-enriched uranium

8. The material presents special design challenges Storage and handling requirements for fissile materials must take into consideration containment, criticality control, safeguards, and shielding 233U has some similar properties to highly enriched uranium and weapons grade plutonium Specific activity is 3 orders of magnitude > U235 Critical mass is 1/3 to � of that of U-235 From a security perspective it is in the same category as Pu-239 The inventory is not uniform in isotopic composition and depends on the source and how it was used Uranium-232 is present along with U-233 at concentrations ranging from 1�to about 220�parts per million (ppm) that results in a daughter Tl-208. Lab samples are 2-4 R/hr requiring special handling Canisters can be up to 300 R/hr resulting in design of multi-layer several foot thick shielding in hot cellsThe material presents special design challenges Storage and handling requirements for fissile materials must take into consideration containment, criticality control, safeguards, and shielding 233U has some similar properties to highly enriched uranium and weapons grade plutonium Specific activity is 3 orders of magnitude > U235 Critical mass is 1/3 to � of that of U-235 From a security perspective it is in the same category as Pu-239 The inventory is not uniform in isotopic composition and depends on the source and how it was used Uranium-232 is present along with U-233 at concentrations ranging from 1�to about 220�parts per million (ppm) that results in a daughter Tl-208. Lab samples are 2-4 R/hr requiring special handling Canisters can be up to 300 R/hr resulting in design of multi-layer several foot thick shielding in hot cells

10. Some Representative Canister Types  These are representative pictures of the canisters Typically 3 3/4 inch outside diameter and varying lengths The top set of containers are those used for the U oxide monolith 24-inch long 3 � inch diameter welded steel inner container contained in an outer jacket for contamination control The majority of the containers are can inside can inside a can as shown in the lower 2 examples Retrieved from the tube vaults by magnetic or vacuum lifting deviceThese are representative pictures of the canisters Typically 3 3/4 inch outside diameter and varying lengths The top set of containers are those used for the U oxide monolith 24-inch long 3 � inch diameter welded steel inner container contained in an outer jacket for contamination control The majority of the containers are can inside can inside a can as shown in the lower 2 examples Retrieved from the tube vaults by magnetic or vacuum lifting device

11. Summary of 233U Downblending & Dispositioning This is representation of the process Chemically simple - U dissolves in nitric acid The process is more lab scale than production plant scale with a thru-put of approximately 18 kg per week on the average � 7 batches of oxide monolith The challenge is to handle the range of containers and forms of U, and provide >95% recovery of the 40g of Th-229 The process will start with sorting ��. ------------------------------------------------------------------------------------------------- The Down Blend tank will initially be filled to a specified level with DUN DUN will be re-circulated through an eductor, where it will be mixed with a small stream of HEUN coming from a predetermined volume held in the HEU Head Columns The eductor is utilized so that a HEUN addition to an empty Blend Tank cannot occur CEUSP 120:1 High Purity 200:1 => increase a factor of 300 (approx 450T)This is representation of the process Chemically simple - U dissolves in nitric acid The process is more lab scale than production plant scale with a thru-put of approximately 18 kg per week on the average � 7 batches of oxide monolith The challenge is to handle the range of containers and forms of U, and provide >95% recovery of the 40g of Th-229 The process will start with sorting ��. ------------------------------------------------------------------------------------------------- The Down Blend tank will initially be filled to a specified level with DUN DUN will be re-circulated through an eductor, where it will be mixed with a small stream of HEUN coming from a predetermined volume held in the HEU Head Columns The eductor is utilized so that a HEUN addition to an empty Blend Tank cannot occur CEUSP 120:1 High Purity 200:1 => increase a factor of 300 (approx 450T)

12. Controls are Part of theDesign Basis Radiological control, nuclear criticality safety and contam control are essential components of design � guidance to designers developed early on Dose mapping established shielding requirements to ensure doses are less than 0.5 mR/hr Geometry (size, shape, volume) and interaction (spacing, separation, isolation) control design up to where downblending occurs Pipes and tanks are limited to 4 inch diameter. The dissolvers exceed 4 inches to allow the U monolith canisters to be placed inside and are mass controlled Tanks and sumps are limited to 1 inch depth Radiological control, nuclear criticality safety and contam control are essential components of design � guidance to designers developed early on Dose mapping established shielding requirements to ensure doses are less than 0.5 mR/hr Geometry (size, shape, volume) and interaction (spacing, separation, isolation) control design up to where downblending occurs Pipes and tanks are limited to 4 inch diameter. The dissolvers exceed 4 inches to allow the U monolith canisters to be placed inside and are mass controlled Tanks and sumps are limited to 1 inch depth

13. Major Capabilities Added toBuilding 3019A Include Adding major capabilities to the facility because there is no current processing infrastructure for this material New hot cell for inspection, canister opening, pretreatment, dissolution and waste packaging with 4 manipulator stations Modifying an original cell for safe tank storage, NMC&A measurement and downblending activities. New hot cell for thorium extraction, purification, packaging and storage with 5 manipulator stations ------------------------------------------------------------------------------------------------ Chloride elution � and use of IX to separate Pu and U Adding major capabilities to the facility because there is no current processing infrastructure for this material New hot cell for inspection, canister opening, pretreatment, dissolution and waste packaging with 4 manipulator stations Modifying an original cell for safe tank storage, NMC&A measurement and downblending activities. New hot cell for thorium extraction, purification, packaging and storage with 5 manipulator stations ------------------------------------------------------------------------------------------------ Chloride elution � and use of IX to separate Pu and U

14. Major Capabilities Added toBuilding 3019A (cont.) After downblending adding an area for Uranyl nitrate concentration by an evaporator (1000gU/l) Denitration with 3 rotary trough denitrators to convert UN to UO3 Oxide conversion furnace to convert the UO3 to a more stable U3O8 Product packaging and container sealing Also adding equipment to existing labs for analysis glove boxes for resin handling a NOx scrubber waste tanks NDA equipment for measuring waste containers After downblending adding an area for Uranyl nitrate concentration by an evaporator (1000gU/l) Denitration with 3 rotary trough denitrators to convert UN to UO3 Oxide conversion furnace to convert the UO3 to a more stable U3O8 Product packaging and container sealing Also adding equipment to existing labs for analysis glove boxes for resin handling a NOx scrubber waste tanks NDA equipment for measuring waste containers

15. Key Technical Issues Addressedin Design Phase Key Technical issues Dissolution rate � process development to optimize dissolution parameters (molarity, temperature, pH, circulation rate) to dissolve quickly without foaming and overflow Th separation/purification � ORNL developed the process and Isotek did PD to ensure >95% recovery of 40g Th in the variety� Denitration � did PD for in-situ and rotary trough in parallel Insitu � no powder handling, simpler � spattering, peak NOx emissions RT � proven at Y-12 and Hanford, lower peak NOx emissions, more moving parts, powder handling Isotope partitioning � looked at separation of daughters an daughter ingrowth and modeled shielding Rn Holdup � how much will be generated; how many HL delay necessary to meet discharge limit; how much hold up exists in vent system; method of providing additional hold up. Product packaging � type of container for Th inventory [100mCi batches for isotope producers] Security � most effective methods to address the new DBTKey Technical issues Dissolution rate � process development to optimize dissolution parameters (molarity, temperature, pH, circulation rate) to dissolve quickly without foaming and overflow Th separation/purification � ORNL developed the process and Isotek did PD to ensure >95% recovery of 40g Th in the variety� Denitration � did PD for in-situ and rotary trough in parallel Insitu � no powder handling, simpler � spattering, peak NOx emissions RT � proven at Y-12 and Hanford, lower peak NOx emissions, more moving parts, powder handling Isotope partitioning � looked at separation of daughters an daughter ingrowth and modeled shielding Rn Holdup � how much will be generated; how many HL delay necessary to meet discharge limit; how much hold up exists in vent system; method of providing additional hold up. Product packaging � type of container for Th inventory [100mCi batches for isotope producers] Security � most effective methods to address the new DBT

20. Integrated Safety Design Implemented the 10 CFR 830 requirements for integration of safety basis with the design and operation of the modifications to the existing facility following ISMS: First integrated design meeting in December 2003 Major integrated design meetings about every 60 days UT-Battelle personnel for facility knowledge and experience NFS personnel for process design and operations experience BREI personnel for nuclear facility upgrade experience Merrick personnel for hot cell design experience Designated Operations Manager with nuclear facility upgrade experience Supporting safety staff with DOE facility safety and operations experience Design concepts reviewed for technical feasibility of meeting both defined DOE safety requirements and safety requirements resulting from safety analysis of the modifications following ISMS Core Functions.

21.  Defined Design Requirements ESH Design Expectations provided to all personnel from December 2003 to about August 2004 Early definition of hazardous chemical design expectations including Waste Acceptance Criteria Established a Work Smart Standards Set 10 CFR 830 requirements DOE O 420.1A design for nuclear safety, fire protection, nuclear criticality prevention, and natural phenomena resistance DOE G 420.1-1 for nuclear safety defined design requirements Early definition of fire protection requirements from DOE-STD-1066 Early independent review of DOE O 420.1A nuclear criticality design requirements with DOE criticality safety branch Integrated defined design requirements from DOE G 420.1-2 for natural phenomena hazard mitigation, using DOE-STD-1020

22. Operations Design Input Essential that Operations is Integrated Early in Design System Owner and Operator Ensures appropriate integration between various support organizations Safety Analysis Nuclear Criticality Safety Environmental Safety & Health Radiation Protection

23. Operations Design Input Essential For Design Team to Understand the Hazards and Required Controls High Rad Levels � Dose Mapping needs to be Completed at the Conceptual Stage Involve Operations and Maintenance Staff in the Design Hot Cell Technicians Manipulator Repair Personnel Single Point Failure Remote Work � Mock Up as Much as Possible even the Simple Activities

24. Operations Design Input Experience Pays High Dividends Site Specific Experience � ORNL, Y-12, LANL,�. DOE Department Experience � EM, NE, NNSA, .. Isotope Specific Experience � U-233 Chemical Processing Experience � Uranium Processing � NFS Remote Operations The more Unique the System, The Higher the Return on Experience Complete Job Hazard Analysis as early as possible

25. Lessons Learned Communication, Communication, Communication Site visits ~ 1 day of pay Integrate Design at the Conceptual Stage Denitration Strong ES&H is necessary for Complex Systems Establish Design Basis Early Evolves with Design Establish Operations interface for all disciplines and systems System Engineers Operations Supervisors Technical Support Personnel

26. Lessons Learned Multiple Design Firms � Establish a Single Design Process Work Closely with Your Customer Early Design � Be Conservative Involve All Disciplines (Rad Protection, Crit. Safety, Env., ES&H, �) Reveal All � All Things Are Discovered � Just a Matter of When Make Progress on Big Issues Early Stay Informed � Rules, Expectation, Approach, Regulation Changes Daily