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Title: Expanding Ring for the DWPF Melter Pour Spout

Abstract

The Materials Technology Section was requested to develop a novel concept, namely that of an expanding ring, to restore the upper knife edge in the DWPF melter pour spout. The expanding ring is a unit that, when deployed in the DPWF pour spout, will self-expand against the inner diameter of the 3-inch section of the pour spout providing a seal against glass leakage and a new knife edge that will mate with a Type 3A insert. This report provides a summary of the final design features of the expanding ring and an overview of its development.

Authors:
Publication Date:
Research Org.:
Savannah River Site (US)
Sponsoring Org.:
US Department of Energy (US)
OSTI Identifier:
802623
Report Number(s):
WSRC-TR-2002-00348
TRN: US0206211
DOE Contract Number:
AC09-96SR18500
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: 23 Sep 2002
Country of Publication:
United States
Language:
English
Subject:
12 MANAGEMENT OF RADIOACTIVE WASTES, AND NON-RADIOACTIVE WASTES FROM NUCLEAR FACILITIES; DESIGN; GLASS; CERAMIC MELTERS; RADIOACTIVE WASTE FACILITIES; OUTLET STRUCTURES; EXPANSION JOINTS; RADIOACTIVE WASTE PROCESSING

Citation Formats

Imrich, K.J. Expanding Ring for the DWPF Melter Pour Spout. United States: N. p., 2002. Web. doi:10.2172/802623.
Imrich, K.J. Expanding Ring for the DWPF Melter Pour Spout. United States. doi:10.2172/802623.
Imrich, K.J. Mon . "Expanding Ring for the DWPF Melter Pour Spout". United States. doi:10.2172/802623. https://www.osti.gov/servlets/purl/802623.
@article{osti_802623,
title = {Expanding Ring for the DWPF Melter Pour Spout},
author = {Imrich, K.J.},
abstractNote = {The Materials Technology Section was requested to develop a novel concept, namely that of an expanding ring, to restore the upper knife edge in the DWPF melter pour spout. The expanding ring is a unit that, when deployed in the DPWF pour spout, will self-expand against the inner diameter of the 3-inch section of the pour spout providing a seal against glass leakage and a new knife edge that will mate with a Type 3A insert. This report provides a summary of the final design features of the expanding ring and an overview of its development.},
doi = {10.2172/802623},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Mon Sep 23 00:00:00 EDT 2002},
month = {Mon Sep 23 00:00:00 EDT 2002}
}

Technical Report:

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  • A study was undertaken to evaluate a variety of materials and coatings for the DWPF pour spout bellows liner. The intent was to identify materials that would minimize or eliminate adherence of glass on the bellows liner wall and help minimize possible pluggage during glass pouring operations in DWPF. Glass has been observed adhering to the current bellow`s liner, which is made of 304L stainless steel. Materials were identified which successfully allowed molten glass to hit these surfaces and not adhere. Results of this study suggest that if these materials are used in the pouring system glass could still fallmore » into the canister without appreciable plugging, even if an unstable glass stream is produced. The materials should next be evaluated under the most realistic DWPF conditions possible. Other findings of this study include the following: (1) increasing coupon thickness produced a favorable increase in the glass sticking temperature; (2) highly polished surfaces, with the exception of the oxygen-free copper coupon coated with Armoloy dense chromium, did not produce a significant improvement in the glass sticking temperature, increasing angle of contact of the coupon to the falling glass did not yield a significant performance improvement; (3) electroplating with gold and silver and various diffusion coatings did not produce a significant increase in the glass sticking temperature. However, they may provide added oxidation and corrosion resistance for copper and bronze liners. Boron nitride coatings delaminated immediately after contact with the molten glass.« less
  • An expanding ring was developed that provided remote repair of the pour spout for a radioactive waste vitrification melter. This passive device used gas pressure to expand a metal ring against the irregularly shaped pour spout wall. Laboratory modeling and testing were performed for proof of concept and optimization before final design and field deployment. The ring expanded radially more than 4.8 mm and successfully repaired the melter pour spout allowing continued glass pouring operation.
  • During the first two years of radioactive operation of the Defense Waste Processing Facility process, several areas for improvement in melter design were identified. Due to the need for a process that allows continuous melter operation, the down time associated with disruption to melter operation and pouring has significant cost impact. A major objective of this task is to address performance limitations and deficiencies identified by the user.
  • The Tanks Focus Area (TFA) identified a major task to address performance limitations and deficiencies of the Defense Waste Processing Facility (DWPF) now in its sixth year of operation. Design, installation, testing, monitoring, operability, and a number of other characteristics were studied by research personnel collaboratively at a number of facilities: Savannah River Technology Center (SRTC), Clemson Environmental Technologies Laboratory (CETL), Pacific Northwest National Laboratory (PNNL), and the Idaho National Engineering and Environmental Laboratory (INEEL). Because the potential limiting feature to the DWPF was identified as the pour spout/riser heater, researches on alternative design concepts originally proposed in the pastmore » were revisited. In the original works, finite element modeling was performed to evaluate temperature distribution and stress of the design currently used at the DWPF. Studies were also made to define the requirements of the design and to consider the approaches for remote removal/replacement. Their heater type/location, their remotely replaceable thermocouples, and their capabilities for remote handling characterized the five alternative designs proposed. Review comments on the alternative designs indicated a relatively wide range of advantages and disadvantages of the designs. The present report provides an overview of the design criteria, modeling results, and alternative designs. Based on a review of the past design optimization activities and an assessment of recent experience, recommendations are proposed for future consideration and improvement.« less
  • A recommendation to eliminate all characterization of pour stream glass samples and the glass fabrication and Product Consistency Test (PCT) of the sludge batch qualification sample was made by a Six-Sigma team chartered to eliminate non-value-added activities for the Defense Waste Processing Facility (DWPF) sludge batch qualification program and is documented in the report SS-PIP-2006-00030. That recommendation was supported through a technical data review by the Savannah River National Laboratory (SRNL) and is documented in the memorandums SRNL-PSE-2007-00079 and SRNL-PSE-2007-00080. At the time of writing those memorandums, the DWPF was processing sludge-only waste but, has since transitioned to a coupledmore » operation (sludge and salt). The SRNL was recently tasked to perform a similar data review relevant to coupled operations and re-evaluate the previous recommendations. This report evaluates the validity of eliminating the characterization of pour stream glass samples and the glass fabrication and Product Consistency Test (PCT) of the sludge batch qualification samples based on sludge-only and coupled operations. The pour stream sample has confirmed the DWPF's ability to produce an acceptable waste form from Slurry Mix Evaporator (SME) blending and product composition/durability predictions for the previous sixteen years but, ultimately the pour stream analysis has added minimal value to the DWPF's waste qualification strategy. Similarly, the information gained from the glass fabrication and PCT of the sludge batch qualification sample was determined to add minimal value to the waste qualification strategy since that sample is routinely not representative of the waste composition ultimately processed at the DWPF due to blending and salt processing considerations. Moreover, the qualification process has repeatedly confirmed minimal differences in glass behavior from actual radioactive waste to glasses fabricated from simulants or batch chemicals. In contrast, the variability study has significantly added value to the DWPF's qualification strategy. The variability study has evolved to become the primary aspect of the DWPF's compliance strategy as it has been shown to be versatile and capable of adapting to the DWPF's various and diverse waste streams and blending strategies. The variability study, which aims to ensure durability requirements and the PCT and chemical composition correlations are valid for the compositional region to be processed at the DWPF, must continue to be performed. Due to the importance of the variability study and its place in the DWPF's qualification strategy, it will also be discussed in this report. An analysis of historical data and Production Records indicated that the recommendation of the Six Sigma team to eliminate all characterization of pour stream glass samples and the glass fabrication and PCT performed with the qualification glass does not compromise the DWPF's current compliance plan. Furthermore, the DWPF should continue to produce an acceptable waste form following the remaining elements of the Glass Product Control Program; regardless of a sludge-only or coupled operations strategy. If the DWPF does decide to eliminate the characterization of pour stream samples, pour stream samples should continue to be collected for archival reasons, which would allow testing to be performed should any issues arise or new repository test methods be developed.« less