Hanford Waste Treatment and

Immobilization Plant Project

Hanford Waste Treatment and

Immobilization Plant Project

Presented at the

National Spent Nuclear Fuel ProgramDistrict of Columbia

15 April 2009

Albert A. Kruger

Las VegasLas Vegas

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OutlineOutline

• Background

– Waste Generation at Hanford

– Waste Storage & Feed Delivery

– Waste Treatment and Immobilization Plant (WTP) Project

• Update

• Next Steps

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Tank Farms(1944 -

present)

Generation of Hanford Tank WastesGeneration of Hanford Tank Wastes

9 Reactors; 4 Fuel Reprocessing Flowsheets; 100,000 MT Fuel Processed

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Hanford’s B Reactor, as it stood in 1945Hanford’s B Reactor, as it stood in 1945

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Hanford Tank Waste Cleanup ChallengeHanford Tank Waste Cleanup Challenge

Idaho

1.4 Million (1.6%)

Hanford has:• 63% of DOE tanks; 80% of DOE

single-shell tanks

• 58% of DOE total tank waste

• ~194 million curies of radioactivity

• ~190,000 tons of chemicals

Hanford53 Million

(58%)

Savannah River36.5 Million

(40%)

Oak Ridge 0.4 Million

(0.4%)

Total Number of Gallons in Waste Tanks at DOE Sites:

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The world’s largest radioactive waste treatment plant

Waste Treatment Plant (WTP)Waste Treatment Plant (WTP)

Major Facilities1. Pretreatment (PT) Facility2. Low Activity Waste (LAW)

Vitrification Facility3. High Level Waste (HLW)

Vitrification Facility4. Analytical Laboratory5. Balance of Facilities

HLW Facility CommoditiesConcrete 88,000 CYStructural Steel 9,600 TonPipe 160,000 ftHVAC 571 TonCable Tray 45 milesCable 293 miles

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LAWVitrification

(90+% of waste mass)

HLWVitrification

(90+% ofwaste activity)

Pretreatment(solid/liquid

separation – Cs, Sr, TRU removal)

SLUDGE

SUPERNATANT

MaximizeMass

MaximizeActivity

WTP Flow Sheet – Key Process FlowsWTP Flow Sheet – Key Process Flows

Hanford TankWaste

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How is the Vitrified Waste Dispositioned?How is the Vitrified Waste Dispositioned?

High Level Waste Canisters• 4.5 x 0.61 m (2’ x 14.77’)• 6,600 pounds of glass• 480 canisters to be produced/year• Storage at Hanford until a final disposal

baseline is identified

Low Activity Waste Containers• 4’ x 7.5’• 13,000 pounds of glass• 1,300 containers to be produced/year• Disposed on Hanford Site

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Aerial View of the Waste Treatment PlantAerial View of the Waste Treatment Plant $12.2 B 2019 Completion $12.2 B 2019 Completion

Project 46% complete ~3300 staff

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HLW VitrificationHLW Vitrification

4 Stories (0’, 14’, 37’, 58’)281’ Wide x 448’ Long120’ Tall (Bottom of Basemat @ -21’ to Roof)

HLW Vitrification Facility Feb. 2009Design 77% CompleteConstruction 23% Complete

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IHLW Waste Form Compliance Plan for the IHLW Waste Form Compliance Plan for the Hanford Tank Waste Treatment and Immobilization PlantHanford Tank Waste Treatment and Immobilization Plant

• Denis Koutsandreas, TRG Team Leader, Office of Disposal Operations, EM-12

• Anthony Kluk, Office of Disposal Operations, EM-12

• Mark Senderling, Office of Disposal Operations, EM-12

• Nicholas Machara, Office of Waste Processing, EM-21

• Steven Ross, Office of Waste Processing, EM-21

• Mark Rawlings, Office of Project Management Oversight, EM-53

• Kenneth Picha, Office of Safety Management and Operations, EM-60

• Kriss Grisham, Office of Safety Management, EM-61

• Steven Gomberg, Waste Management Office, RW-9

• Markus Popa, Waste Management Office, RW-9

• Joseph May, Thomas Jefferson Site Office, SC-TJSO

• Jeffrey W. Ray, SRS WSRC

Reviewed by EM-12 / Technical Review Group

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History Sheet

1 Introduction

2 Overview of the WTP Process

2.1 Pretreatment Facility

2.2 HLW Vitrification Facility

2.3 LAW Vitrification Facility

2.4 Analytical Laboratory

3 Overview of the WTP Strategy for Compliance with the WAPS and WASRD

3.1 Waste Form Composition Control and Reporting During Production

3.2 Product Consistency Control for Compliance During Production

3.3 Canister and Canistered Waste Form

3.4 Quality Assurance

Contents of the IHLW Contents of the IHLW Waste Form Compliance PlanWaste Form Compliance Plan

4 Compliance with WAPS and WASRD Requirements

4.1 Specification 1 – Waste Form Specifications

4.2 Specification 2 – Canister Specifications

4.3 Specification 3 – Canistered Waste Form Specs

4.4 Specification 4 – Quality Assurance Specification

4.5 Specification 5 – Documentation and Other Requirements

5 References

5.1 Project Documents

5.2 Codes and Standards

5.3 Other Documents

Appendices

Appendix A Canister Drawings

Appendix B Grapple DrawingsAppendix C Compliance with WTP Contract RequirementsAppendix D WAPS and WASRD Requirements

Contents of the IHLW Contents of the IHLW Waste Form Qualification ReportWaste Form Qualification Report

1. Chemical and Radionuclide Composition Projections for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-01

2. Chemical and Radionuclide Composition During Production for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-02

3. Product Consistency and Phase Stability for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-03

4. Hazardous Waste Specification for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-04

5. Canister Description for Immobilized High-Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-05

6. Canister Fabrication and Closure for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-06

7. Exclusion of Foreign Materials for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-07

8. Canister Fill Height for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-08

9. Canister Decontamination for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-09

10. Canister Drop Testing for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-10

11. Quality Assurance for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-11

12. Documentation for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-12

13. Supplemental Contract Requirements for Immobilized High Level Waste Product Qualification; 24590-HLW-RPT-RT-08-001-13

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Supplemental Contract Requirements for Immobilized Supplemental Contract Requirements for Immobilized High Level Waste Product QualificationHigh Level Waste Product Qualification

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ContentsHistory SheetAcronyms and Other Abbreviations1 Introduction2 IHLW WCP Commitments2.1 Product and Disposal Requirements (Contract Specification 1.2.2.1.1)2.2 Canister System (Contract Specification 1.2.2.1.2)2.3 Fill Height (Contract Specification 1.2.2.1.3.1)2.4 Maximum Heat Generation Rate (Contract Specification 1.2.2.1.3.2)2.5 Surface Contamination Limitations (Contract Specification 1.2.2.1.3.3)2.6 Condition at Delivery (Contract Specification 1.2.2.1.4)2.7 Dangerous and Hazardous Waste Requirements (Contract Specification 1.2.2.1.5)2.8 Product Loading (Contract Specification 1.2.2.1.6)2.9 Product Handling (Contract Specification 1.2.3.1)2.10Quality Assurance (Contract Specification 1.3)2.11Inspection and Acceptance (Contract Specification 1.4)3 References3.1 Essential Documents3.2 Developmental Documents

AppendicesAppendix A WAPS and WASRD Requirements in the IHLW WCP

Contents of the IHLW Waste Form Contents of the IHLW Waste Form Qualification ReportQualification Report

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History Sheet

Introduction

Ch Topic1 Chemical and Radionuclide Composition Projections

WAPS 1.1, 1.1.1, 1.2, 1.2.2, 3.8, 3.8.1, 3.9, 3.9.1

2 Chemical and Radionuclide Composition during Production

WAPS 1.1.2, 1.2.2, 1.6, 3.8.2, 3.9.2, 3.10, 3.143 Product Consistency and Phase Stability

WAPS 1.3, 1.44 Hazardous Waste

WAPS 1.55 Canister Description

WAPS 2.1, 2.3, 2.4, 3.11, 3.136 Canister Fabrication and Closure

WAPS 2.27 Exclusion of Foreign Materials

WAPS 3.1, 3.2, 3.3, 3.4, 3.5

Ch Topic

8 Canister Fill Height

WAPS 3.6

9 Canister Decontamination

WAPS 3.710 Canister Drop Testing

WAPS 3.1211 Quality Assurance

WAPS 412 Documentation

WAPS 5.1 through 5.1413 Supplemental Contract Requirements

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Hanford Tank Waste Treatment and Immobilization Plant (WTP) transmits an IHLW Waste Form Compliance Plan (WCP) to ORP Complete

ORP review of WCP (comment resolution and incorporation) with contract deliverable transmitted to EM-12 Complete

ORP reviews glass formulation algorithm and WTP data management plan for automated collection and use in IHLW development, commissioning, operations, and production records

Complete

June 2008

WTP self assessment of IHLW QA Annually

EM-12 coordinates Radioactive Waste (RW or OCRWM) review (comment resolution and incorporation)Open

Mar 2008

EM-12/Technical Review Group review (comment resolution and incorporation) of WCPComplete

Sept 2008

EM-12 disseminates a revision to the Waste Acceptance Products Specifications (WAPS) UNK

Key ORP staff become certified by RW as auditors and technical specialists Complete 3/08

Upon resolution of mandatory comments from the TRG, WTP issues and delivers the final WCP to HQ Complete 10/08

WTP re-establishes an OCRWM QA program May 2008

ORP WED Assessment of IHLW Technical Activities in compliance with QARD Complete 5/08

WTP issues Waste Acceptance Impacting Items & Activities for IHLW based upon approved WCP April 2009

ORP qualifies WTP OCRWM QA program with RW/EM involvement Phase 2 of EM-60 Plan for QA June 2009

ORP re-establishes an OCRWM QA program (EM approval and RW oversight) June 2009

WTP issues revised Integrated Sampling and Analysis Requirements Document (ISARD) incorporating required accommodations for IHLW activities

Annually or as needed

ORP ESQ Assessments on WTP QA Manual, DOE O 414.1C compliance, configuration management, etc. Complete

END GOAL: WTP issues revised IHLW Waste Form Qualification Report based upon approved WCP April 2009

Road Map to Support Acceptance of Road Map to Support Acceptance of WTP IHLW ProductWTP IHLW Product

Plan for Quality Assurance Surveillances of DOE/ORP and BNI HLW Programs

• Phase 1 (8-11 September 2008)

– Address and support elements of the compliance based audit to take place in Phase 3

• Conclusion: Phase 2 of the qualification process for the BNI program is to be initiated based on the results of Phase 1 surveillances which demonstrated that BNI has established an acceptable HLW QA program. (“The surveillance team determined that there was tremendous progress in developing technical compliance documentation since the assessments conducted in early 2007 by ORP and HQ.”)

• Phase 2– Document review and RW acceptance of the initial QARD Requirements Matrix

and implementing procedures in conjunction with a technical review and RW concurrence of the HLW technical baseline documents.

• Phase 3– Initial compliance-based audit of the ORP and BNI QA programs to evaluate the

adequacy and effectiveness of their QAPs implementation for QARD compliance…

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Backup

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Hanford Cleanup SiteHanford Cleanup Site

2121

Pretreatment FacilityPretreatment Facility

Pretreatment Facility Feb. 2009Design 72% CompleteConstruction 27% Complete

5 Stories (0’, 28’, 56’, 77’, 98’)250’ Wide x 558’ Long + 28’ wide loading bay/dock119’ Tall (Top of Basemat at Grade to Roof)

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LAW VitrificationLAW Vitrification

LAW Vitrification Facility Feb. 2009Design 88% CompleteConstruction 58% Complete

2323

Analytical LaboratoryAnalytical Laboratory

Analytical Laboratory Feb. 2009 Design 74% CompleteConstruction 53% Complete

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Balance of Facilities

Chiller/Compressor PlantChiller/Compressor Plant

Fuel Oil Storage FacilityFuel Oil Storage Facility

Steam PlantSteam Plant

BOF Switchgear BuildingBOF Switchgear BuildingGlass Former

Facility FoundationGlass Former Facility Foundation