Joel M. Tingey

Estimate of Hanford Waste Rheology and Settling Behavior

The U.S. Department of Energy (DOE) Office of River Protection’s Waste Treatment and Immobilization Plant (WTP) will process and treat radioactive waste that is stored in tanks at the Hanford Site. Piping, pumps, and mixing vessels have been selected to transport, store, and mix the high-level waste slurries in the WTP. This report addresses the analyses performed by the Rheology Working Group (RWG) and Risk Assessment Working Group composed of Pacific Northwest National Laboratory (PNNL), Bechtel National Inc. (BNI), CH2M HILL, DOE Office of River Protection (ORP) and Yasuo Onishi Consulting, LLC staff on data obtained from documented Hanford waste analyses to determine a best-estimate of the rheology of the Hanford tank wastes and their settling behavior. The actual testing activities were performed and reported separately in referenced documentation. Because of this, many of the required topics below do not apply and are so noted.

Deposition Velocities of Newtonian and Non-Newtonian Slurries in Pipelines

The WTP pipe plugging issue, as stated by the External Flowsheet Review Team (EFRT) Executive Summary, is as follows: “Piping that transports slurries will plug unless it is properly designed to minimize this risk. This design approach has not been followed consistently, which will lead to frequent shutdowns due to line plugging.” A strategy was employed to perform critical-velocity tests on several physical simulants. Critical velocity is defined as the point where a stationary bed of particles deposits on the bottom of a straight horizontal pipe during slurry transport operations. Results from the critical velocity testing provide an indication of slurry stability as a function of fluid rheological properties and transport conditions. The experimental results are compared to the WTP design guide on slurry transport velocity in an effort to confirm minimum waste velocity and flushing velocity requirements as established by calculations and critical line velocity correlations in the design guide. The major findings of this testing is discussed below. Experimental results indicate that the use of the Oroskar and Turian (1980) correlation in the design guide is conservative—Slurry viscosity has a greater affect on particles with a large surface area to mass ratio. The increased viscous forces on these particles result in a decrease in predicted critical velocities from this traditional industry derived equations that focus on particles large than 100 m in size. Since the Hanford slurry particles generally have large surface area to mass ratios, the reliance on such equations in the Hall (2006) design guide is conservative. Additionally, the use of the 95% percentile particle size as an input to this equation is conservative. However, test results indicate that the use of an average particle density as an input to the equation is not conservative. Particle density has a large influence on the overall result returned by the correlation. Lastly, the viscosity correlation used in the WTP design guide has been shown to be inaccurate for Hanford waste feed materials. The use of the Thomas (1979) correlation in the design guide is not conservative—In cases where 100% of the particles are smaller than 74 m or particles are considered to be homogeneous due to yield stress forces suspending the particles the homogeneous fraction of the slurry can be set to 100%. In such cases, the predicted critical velocity based on the conservative Oroskar and Turian (1980) correlation is reduced to zero and the design guide returns a value from the Thomas (1979) correlation. The measured data in this report show that the Thomas (1979) correlation predictions often fall below that measured experimental values. A non-Newtonian deposition velocity design guide should be developed for the WTP— Since the WTP design guide is limited to Newtonian fluids and the WTP expects to process large quantities of such materials, the existing design guide should be modified address such systems. A central experimental finding of this testing is that the flow velocity required to reach turbulent flow increases with slurry rheological properties due to viscous forces dampening the formation of turbulent eddies. The flow becomes dominated by viscous forces rather than turbulent eddies. Since the turbulent eddies necessary for particle transport are not present, the particles will settle when crossing this boundary called the transitional deposition boundary. This deposition mechanism should be expected and designed for in the WTP.

Retrieval and Pipeline Transfer Assessment of Hanford Tank 241-AN-105 Waste

This study assesses five steps for Tank 241-AN-105 waste retrieval and subsequent pipeline transfer: 1. Remove supernatant liquid waste from AN-105 and transfer it through a pipeline with inline dilution with water (1st liquid waste transfer). 2. Add water (as a diluent) to Tank AN-105. 3. Mix the saltcake waste and water with mixer pumps to dissolve soluble solids. 4. Let undissolved solids settle to the tank bottom. 5. Remove the resulting supernatant liquid waste from Tank AN-105 (2nd liquid waste transfer). To assess these five steps for waste retrieval and pipeline transfer, AN-105 waste rheology was measured and solids identified with bright field image, select area diffraction, and energy dispersive x-ray spectroscopy. By combining available in situ and laboratory data, an AN-105 specific viscosity model was developed that can change from several centiPoise of viscosity to tens of millions of centiPoise as a function of strain rate and solid concentration. This viscosity mo del was implemented into the AN-105 computer model to simulate pump jet mixing. The report also evaluates AN-105 slurry waste transfer to AP-102 and AP-104 through a 3-inch (0.07-m) pipeline.

Dangerous Waste Characteristics of Waste from Hanford Tank 241-S-109

Existing analytical data from samples taken from Hanford Tank 241-S-109, along with process knowledge of the wastes transferred to this tank, are reviewed to determine whether dangerous waste characteristics currently assigned to all waste in Hanford underground storage tanks are applicable to this tank waste. Supplemental technologies are examined to accelerate the Hanford tank waste cleanup mission and to accomplish the waste treatment in a safer and more efficient manner. The goals of supplemental technologies are to reduce costs, conserve double-shell tank space, and meet the scheduled tank waste processing completion date of 2028.

Compilation and Integration of K Basin Sludge Particle Size Analysis Data

This report consolidates and integrates all of the particle size analysis data generated during the Hanford K Basin sludge characterization campaigns. The provides the most representative particle size distribution curves for the various K Basin sludge types. Understanding the particle size distribution of the sludge is necessary to design sludge retrieval and processing systems and to address sludge transportation and storage safety issues due to the potential reactivity of sludge.

Design of the Laboratory-Scale Plutonium Oxide Processing Unit in the Radiochemical Processing Laboratory

This report describes a design for a laboratory-scale capability to produce plutonium oxide (PuO2) for use in identifying and validating nuclear forensics signatures associated with plutonium production, as well as for use as exercise and reference materials. This capability will be located in the Radiochemical Processing Laboratory at the Pacific Northwest National Laboratory. The key unit operations are described, including PuO2 dissolution, purification of the Pu by ion exchange, precipitation, and re-conversion to PuO2 by calcination.

Conceptual Design for the Pilot-Scale Plutonium Oxide Processing Unit in the Radiochemical Processing Laboratory

This report describes a conceptual design for a pilot-scale capability to produce plutonium oxide for use as exercise and reference materials, and for use in identifying and validating nuclear forensics signatures associated with plutonium production. This capability is referred to as the Pilot-scale Plutonium oxide Processing Unit (P3U), and it will be located in the Radiochemical Processing Laboratory at the Pacific Northwest National Laboratory. The key unit operations are described, including plutonium dioxide (PuO2) dissolution, purification of the Pu by ion exchange, precipitation, and conversion to oxide by calcination.