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ICEM’ 11– Reims France 26 Septembre 2011

High Waste Loading Glass Formulations for Hanford High-Aluminum HLW Streams wP - 59388. ICEM’ 11– Reims France 26 Septembre 2011. Presented by: Albert A. Kruger Glass Scientist Supervisor, Vitrification Group of the DOE WTP Project Office Engineering Division. July 2011.

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ICEM’ 11– Reims France 26 Septembre 2011

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  1. High Waste Loading Glass Formulations for Hanford High-Aluminum HLW Streams wP - 59388 ICEM’ 11– Reims France 26 Septembre 2011 Presented by: Albert A. Kruger Glass Scientist Supervisor, Vitrification Group of the DOE WTP Project Office Engineering Division

  2. July 2011

  3. Generation of Hanford Tank Wastes 9 Reactors; 4 Fuel Reprocessing Flowsheets; 100,000 MT Fuel Processed

  4. In Fiscal Year 2007, ORP initiated a testing program to develop and characterize HLW & LAW glasses with higher waste loadings, and where possible higher throughput, to meet the processing and product quality requirements. This effort spans the investigation of the melt dynamics and cold cap properties to vitrificationprocesses at the conditions close to those that exist in continuous waste glass melters. Glass Formulation for HLW & LAW Treatment

  5. Background: Current estimates indicate that the number of HLW canisters to be produced in the WTP is 13,500 (equivalent to 40,500 MT glass). The ca. 50,000 MT of sodium to be processed into glass equates to 588,000 tons of ILAW glass. The current glass formulation efforts have been conservative in terms of achievable waste loadings. These formulations have been specified to ensure the glasses are homogenous, preclude secondary phases (sulfate-based salts or crystalline phases), are processable in joule-heated, ceramic-lined melters and meet WTP Contract terms. Glass Formulation for Waste Treatment

  6. SUPERNATANT SLUDGE LAW Vitrification (90+% of waste mass) Maximize Mass Pretreatment (solid/liquid separation – Cs, Sr, TRU removal) HLW Vitrification (90+% of waste activity) Maximize Activity Hanford Tank Waste WTP Flow Sheet - Key Process Flows

  7. It is likely that the capacity of the HLW vitrification plant can be increased significantly by implementation of a variety of low-risk, high-probability changes, either separately or in combination. These changes include: • Operating at the higher processing rates demonstrated at the HLW pilot melter • Increasing the glass waste loading in HLW glasses for wastes that are challenged by Al, Al plus Na, Bi, and Cr. • Operating the melter at a slightly higher temperature

  8. Savannah River DWPF-SRS 2.4 m2 West Valley 2.2 m2 WTP Low Activity Waste RPP-LAW 10 m2 EnergySolutionsM-Area Mixed Waste DM-5000 5m2 WTP High Level Waste 3.75 m2 LAW Pilot DM-3300 3.3 m2 EnergySolutions/VSL Test Melters DM-100 0.11 m2 Hanford HLW Pilot DM-1200 1.2 m2 EnergySolutions/VSL Test Melters DM-10 0.02 m2 Melter Scale Comparison

  9. Oxide Compositions of Limiting Waste Streams (wt%)

  10. These approaches successfully demonstrated increases in glass production rates and significant increases in waste loading at the nominal melter operating temperature of 1150° C. Results of this work have demonstrated the feasibility of increases in waste-loading from about 25 wt% to 33-55 wt% (based on oxide loading) in the glass, depending on the waste stream. Results of this work have resulted in IHLW glasses with waste loadings at 50 wt% (with >25 wt% Al2O3); and Glass throughput rates in excess of 3x commissioning targets.

  11. 70% 62% 48% 59% Reduction in HLW Canister Count Glass Formulation for HLW Treatment

  12. Composition and Properties of Aluminum Limited Waste and Glass Formulation HWI-Al-19 with 45% Waste Loading (wt%)

  13. Composition and Properties of Aluminum Limited Waste and Glass Formulation HWI-Al-19 with 45% Waste Loading (wt%) Cont’d

  14. Composition of LAW Waste Stream and Contributions to Melter Feed and Product Glass

  15. Compositions (wt%) and Properties of Aluminum-Limited Waste and Glass Formulation HWI-Al-19LW with 45% HLW Waste Loading

  16. Compositions (wt%) and Properties of Aluminum-Limited Waste and Glass Formulation HWI-Al-19LW with 45% HLW Waste Loading Cont’d

  17. Composition of LAW Waste Stream and Contributions to Melter Feed and Product Glass

  18. 2500 Glass Production Rate, kg/m2/d 2000 1500 1000 WTP Baseline Requirement 500 Formulation Improvements Most recent tests have reached 3000 kg/m2/d Waste loading increased to 50 wt% (26.6 wt% Al2O3); And Glass production rate further increased

  19. Questions?

  20. Backup Information

  21. How is the Vitrified Waste Dispositioned? • High-Level Waste Canisters • 2’ x 14.75’ (0.61 x 4.5 m) • 6,600 pounds of glass • 600 canisters to be produced/year • Temporarily stored at Hanford until National Repository opened • Low-Activity Waste Containers • 4’ x 7.5’ (1.22 x 2.286 m) • 13,000 pounds of glass • 1,300 containers to be produced/year • Disposed on Hanford Site

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