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Title: RECENT PROCESS IMPROVEMENTS TO INCREASE HLW THROUGHPUT AT THE DWPF

Abstract

The Savannah River Site's (SRS) Defense Waste Processing Facility (DWPF), the world's largest operating high level waste (HLW) vitrification plant, began stabilizing about 35 million gallons of SRS liquid radioactive waste by-product in 1996. The DWPF has since filled over 2000 canisters with about 4000 pounds of radioactive glass in each canister. In the past few years there have been several process and equipment improvements at the DWPF to increase the rate at which the waste can be stabilized. These improvements have either directly increased waste processing rates or have desensitized the process and therefore minimized process upsets and thus downtime. These improvements, which include glass former optimization, increased waste loading of the glass, the melter heated bellows liner, and glass surge protection software, will be discussed in this paper.

Authors:
Publication Date:
Research Org.:
SRS
Sponsoring Org.:
USDOE
OSTI Identifier:
909351
Report Number(s):
WSRC-STI-2007-00084
TRN: US0703882
DOE Contract Number:
DE-AC09-96SR18500
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
12 MANAGEMENT OF RADIOACTIVE WASTES, AND NON-RADIOACTIVE WASTES FROM NUCLEAR FACILITIES; BY-PRODUCTS; CONTAINERS; GLASS; OPTIMIZATION; RADIOACTIVE WASTES; SAVANNAH RIVER PLANT; SURGES; VITRIFICATION; WASTE PROCESSING; WASTES

Citation Formats

Herman, C. RECENT PROCESS IMPROVEMENTS TO INCREASE HLW THROUGHPUT AT THE DWPF. United States: N. p., 2007. Web. doi:10.2172/909351.
Herman, C. RECENT PROCESS IMPROVEMENTS TO INCREASE HLW THROUGHPUT AT THE DWPF. United States. doi:10.2172/909351.
Herman, C. Wed . "RECENT PROCESS IMPROVEMENTS TO INCREASE HLW THROUGHPUT AT THE DWPF". United States. doi:10.2172/909351. https://www.osti.gov/servlets/purl/909351.
@article{osti_909351,
title = {RECENT PROCESS IMPROVEMENTS TO INCREASE HLW THROUGHPUT AT THE DWPF},
author = {Herman, C},
abstractNote = {The Savannah River Site's (SRS) Defense Waste Processing Facility (DWPF), the world's largest operating high level waste (HLW) vitrification plant, began stabilizing about 35 million gallons of SRS liquid radioactive waste by-product in 1996. The DWPF has since filled over 2000 canisters with about 4000 pounds of radioactive glass in each canister. In the past few years there have been several process and equipment improvements at the DWPF to increase the rate at which the waste can be stabilized. These improvements have either directly increased waste processing rates or have desensitized the process and therefore minimized process upsets and thus downtime. These improvements, which include glass former optimization, increased waste loading of the glass, the melter heated bellows liner, and glass surge protection software, will be discussed in this paper.},
doi = {10.2172/909351},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Wed Feb 14 00:00:00 EST 2007},
month = {Wed Feb 14 00:00:00 EST 2007}
}

Technical Report:

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  • The Savannah River Site's (SRS) Defense Waste Processing Facility (DWPF) began stabilizing high level waste (HLW) in a glass matrix in 1996. Over the past few years, there have been several process and equipment improvements at the DWPF to increase the rate at which the high level waste can be stabilized. These improvements have either directly increased waste processing rates or have desensitized the process to upsets, thereby minimizing downtime and increasing production. Improvements due to optimization of waste throughput with increased HLW loading of the glass resulted in an 8 % waste throughput increase over the standard 28 %more » waste loading based upon operational efficiencies. Improvements in canister production include the pour spout heated bellows liner (7 %), glass surge (siphon) protection software (2 %), melter feed pump software logic change to prevent spurious interlocks of the feed pump with subsequent dilution of feed stock (2 %) and optimization of the steam atomized scrubber (SAS) operation to minimize downtime (3 %) for a total increase in canister production of 14 %. A number of process recovery efforts have allowed continued operation. These include the off gas system pluggage and restoration, slurry mix evaporator (SME) tank repair and replacement, remote cleaning of melter top head center nozzle, remote melter internal inspection, SAS pump J-Tube recovery, inadvertent pour scenario resolutions, dome heater transformer bus bar cooling water leak repair and new Infra-red camera for determination of glass height in the canister are discussed. (authors)« less
  • The Savannah River Site's (SRS) Defense Waste Processing Facility (DWPF) began stabilizing high level waste (HLW) in a glass matrix in 1996. Over the past few years, there have been several process and equipment improvements at the DWPF to increase the rate at which the high level waste can be stabilized. These improvements have either directly increased waste processing rates or have desensitized the process to upsets, thereby minimizing downtime and increasing production. Improvements due to optimization of waste throughput with increased HLW loading of the glass resulted in a 6% waste throughput increase based upon operational efficiencies. Improvements inmore » canister production include the pour spout heated bellows liner (5%), glass surge (siphon) protection software (2%), melter feed pump software logic change to prevent spurious interlocks of the feed pump with subsequent dilution of feed stock (2%) and optimization of the steam atomized scrubber (SAS) operation to minimize downtime (3%) for a total increase in canister production of 12%. A number of process recovery efforts have allowed continued operation. These include the off gas system pluggage and restoration, slurry mix evaporator (SME) tank repair and replacement, remote cleaning of melter top head center nozzle, remote melter internal inspection, SAS pump J-Tube recovery, inadvertent pour scenario resolutions, dome heater transformer bus bar cooling water leak repair and new Infra-red camera for determination of glass height in the canister are discussed.« less
  • The primary purpose of this business case is to provide Operations and Maintenance with a detailed transfer process review for the first High Level Waste (HLW) feed delivery to the Privatization Contractor (PC), AZ-101 batch transfer to PC. The Team was chartered to identify improvements that could be implemented in the field. A significant penalty can be invoked for not providing the quality, quantity, or timely delivery of HLW feed to the PC.
  • The Defense Waste Processing Facility (DWPF) has been vitrifying High Level Waste sludge since 1996. Sludge batch 1a, 1b, 2, and 3 have been successfully stabilized. In the last several years, the Savannah River National Laboratory (SRNL) has worked with DWPF to implement process and compositional changes to improve throughput. These changes allowed significant increases in waste throughput for processing of sludge batch 3 and will be necessary to maintain reasonable throughput for Sludge Batch 4 (SB4). SB4 processing was initiated in June 2007 and will be the first significantly HM-type sludge batch processed. This sludge is high in aluminummore » and other components troublesome to DWPF processing. In addition, coupled processing is scheduled to start in the next fiscal year, which will also impact throughput. Coupled processing will begin with the incorporation of waste streams from the Actinide Removal Process and the Modular Caustic Side Solvent Extraction Unit and will eventually transition to the feed from the larger scale Salt Waste Processing Facility. A discussion of the programs to improve throughput and implement salt processing will be provided.« less
  • This document presents the details of the Savannah River Plant Flowsheet for the Rad Operation with Tank Sludge and ITP Cycle 1 Precipitate. Topics discussed include: material balance; radiolysis chemistry of tank precipitates; algorithm for ESP washing; chemistry of hydrogen and ammonia generation in CPC; batch sizes for processing feed; and total throughput of a streams during one cycle of operation.