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Title: Final Report - Glass Formulation Development and Testing for DWPF High AI2O3 HLW Sludges, VSL-10R1670-1, Rev. 0, dated 12/20/10

The principal objective of the work described in this Final Report is to develop and identify glass frit compositions for a specified DWPF high-aluminum based sludge waste stream that maximizes waste loading while maintaining high production rate for the waste composition provided by ORP/SRS. This was accomplished through a combination of crucible-scale, vertical gradient furnace, and confirmation tests on the DM100 melter system. The DM100-BL unit was selected for these tests. The DM100-BL was used for previous tests on HLW glass compositions that were used to support subsequent tests on the HLW Pilot Melter. It was also used to process compositions with waste loadings limited by aluminum, bismuth, and chromium, to investigate the volatility of cesium and technetium during the vitrification of an HLW AZ-102 composition, to process glass formulations at compositional and property extremes, and to investigate crystal settling on a composition that exhibited one percent crystals at 963{degrees}C (i.e., close to the WTP limit). The same melter was selected for the present tests in order to maintain comparisons between the previously collected data. The tests provide information on melter processing characteristics and off-gas data, including formation of secondary phases and partitioning. Specific objectives for the melter tests aremore » as follows: Determine maximum glass production rates without bubbling for a simulated SRS Sludge Batch 19 (SB19). Demonstrate a feed rate equivalent to 1125 kg/m{sup 2}/day glass production using melt pool bubbling. Process a high waste loading glass composition with the simulated SRS SB19 waste and measure the quality of the glass product. Determine the effect of argon as a bubbling gas on waste processing and the glass product including feed processing rate, glass redox, melter emissions, etc.. Determine differences in feed processing and glass characteristics for SRS SB19 waste simulated by the co-precipitated and direct-hydroxide methods. The above tests were proposed based on previous tests for WTP in which there were few differences in the melter processing characteristics, such as processing rate and melter emissions, between precipitated and direct hydroxide simulants, even though there were differences in rheological properties. To the extent this similarity is found also for simulants for SRS HLW, the direct hydroxide methods may offer the potential for faster, simpler, and cheaper simulant production. There was no plan to match the yield stress and particle size of the direct hydroxide simulant to that of the precipitated simulant because that would have increased the preparation cost and complexity and defeated the purpose of the tests. These objectives were addressed by first developing a series of glass frits and then conducting a crucible scale study to determine the waste loading achievable for the waste composition and to select the preferred frit. Waste loadings were increased until the limits of a glass property were exceeded experimentally. Glass properties for evaluation included: viscosity, electrical conductivity, crystallinity (including liquidus temperature and nepheline formation after canister centerline cooling (CCC) heat-treatment), gross glass phase separation, and the 7- day Product Consistency Test (PCT, ASTM-1285) response. Glass property limits were based upon the constraints used for DWPF process control.« less
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Publication Date:
OSTI Identifier:
Report Number(s):
ORP-56290 Rev 0
VSL-10R1670-1 Rev 0
DOE Contract Number:
Resource Type:
Technical Report
Research Org:
HNF (Hanford Site (HNF), Richland, WA (United States))
Sponsoring Org:
USDOE Office of Environmental Management (EM)
Contributing Orgs:
Department of Energy - Office of River Protection, The Catholic University of America
Country of Publication:
United States