Progress in Nuclear Waste Vitrification by Ceramic Melter Technique
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JP9950237 PROGRESS IN NUCLEAR WASTE VITRIFICATION BY CERAMIC MELTER TECHNIQUE S. WEISENBURGER Forschungszentrum Karlsruhe Institut fur Nukleare Entsorgungstechnik P.O.BOX 3640, 76021 Karlsruhe, Germany ABSTRACT Nuclear waste vitrification by using the liquid-fed ceramic-lined waste glass melter process started in 1973 with the pioneering development at Batelle Pacific Northwest Laboratory. The first radioactive plant applying this technique was the PAMELA plant in Mol/ Belgium which was put into hot operation in 1985. A main part of the technology for this plant including the melter was developed by the Institut fur Nukleare Entsorgungstechnik (INE) of Forschungszentrum Karlsruhe (FZK)! For the time being there is an increasing demand for the availability of small-scale vitrification units for processing of small stocks of high level liquid wastes (HLLW). Limited quantities of HLLW solutions were obtained during the period of development of reprocessing techniques at various international sites. One example is the former WAK (Wiederaufarbeitungs-anlage Karlsruhe) reprocessing plant. It is located at the site of Forschungszentrum Karlsruhe and is now under decommissioning. The overall decommissioning program includes vitrification of 70 m3 of stored HLLW with a total p7y radioactivity of 8.9 x E17 Bq. This paper focuses on progress achieved in the design of small-scale liquid-fed ceramic glass melters for these purposes. Improvements are described regarding extension of power electrode life time by optimized air cooling, glass pouring operation, off-gas pipe cleaning, glass level detection system in the melt tank, and arrangement of a small-scale melter in a hot a cell. Some test results achieved with the new melter are also outlined. INTRODUCTION Ceramic-lined waste glass melters are currently in use in several radioactive vitrification plants like Tokai Vitrification Facility in Japan, Savannah River Defence Waste Processing Facility, and West Valley Demonstration Plant in the US. The PAMELA plant, using this technique as well vitrified 907 m3 of high level waste into 4901 of radioactive waste glass between 1985 and 1991. In Germany the development of the vitrification technology is currently focused on the special aspects of wastes stored at former nuclear reprocessing sites. These include mainly (1) appropriate simplification and scale down of the vitrification system while maintaining or even improving the functional safety, and (2) keeping the overall plant size and thus costs as low as possible particularly in view of the usually limited waste volume to be processed and, hence the short operation time. The VEK-project (Verglasungseinrichtung Karlsruhe) is one example of application of a small-scale vitrification plant for conditioning of small HLLW stocks stored at reprocessing sites under decommissioning [1]. A prototype non-radioactive test facility with such features was designed in 1995 at the Institut fur Nukleare Entsorgungstechnik (INE) of the Forschungszentrum Karlsruhe. After two years of construction the facility has been put into operation in May 1998. The paper outlines the progress which had been achieved referred to the glass melting system. Improvements are described concerning extension of power electrode life time, glass pouring operation, noble metals compatibility, off-gas pipe cleaning, glass level detection in the glass pool, and optimised arrangement of the melter in the hot cell. - 241 - JAERI-Conf 99-004 SMALL-SCALE MELTER TECHNOLOGY The process of converting high-level liquid waste into glass in a liquid-fed ceramic melter is characterized by the fact that individual process steps of vitrification (drying, calcining, and reaction of the waste residue with glass formers) take place simultaneously within the glass melter (Fig. 1). HLLW and glass forming additives - glass frit in the form of beads - are directly fed onto the hot glass melt surface. Vitrification occurs in a limited reaction layer formed on the melt pool surface. The glass melt is current-heated through immersed electrodes according to the Joule principle. The melting tank is thermally insulated and the whole system is encased by a stainless steel containment box. The off-gas leaving the melter through a melter roof nozzle is cleaned in a multistage off-gas treatment system and contains water steam, NOx, particles, volatiles and inleakage air. The melter type developed for use in a small-scale vitrification facility is a conspicuous novelty in melter technology. The design and characteristics of the small-scale glass melter can be seen in Fig. 2. The novel type features cylinder shape, bottom drain (no additional glass overflow system) and reduced size which was primarily achieved by a reduced melt tank content, and substantial simplifications concerning the glass heating system. The compact melter design has considerable impacts on the size of the melter cell, the arrangement of the melter within this cell, and the remote handling technique. The melter has a design throughput of 12 1/h corresponding to a glass production rate of approximately 8.5 kg/h. The glass tank made of high temperature resistant ceramic refractory contains about 150 1 glass melt which corresponds to the volume capacity of one canister with a glass capacity of 400 kg and dimensions 430 mm in dia. and 1335 mm height. The main features of the melt tank are its sloped side walls and the bottom design. The slope forces the noble metals High active ^Gl^frit liquid waste ^ Stainless steel box Alternating el. current -50 Hz <J=" Cooling air pouring channel Canister Fig. 1: Simplified scheme of the liquid-fed ceramic melter process - 242 - lAERI-Conf 99-004 CZZJ Fig. 2: Layout and characteristics of INE's today small-scale melter technology Melter outside dimension: 1500 mm in diameter, 1700 mm height Table 1: Main characteristics of the small-scale glass melter Characteristic Data Nominal throughput 121/h Glass production rate 8.5kg/h Glass pool surface 0.44 m2 Melt tank content 1501 Residence time of glass in the pool 44 h Glass pool heating Direct electric heating Heating power release 40 kW maximum Glass pouring system Bottom drain Quantity of glass per pouring 100 kg, flow rate appr. 100-130 kg/h Frequency of pouring Every 11-12 h Melter size 1.5 m dia., 1.7 m height Weight 8.5 t - 243 - JAERI-Conf 99-004 ruthenium, palladium and rhodium - not soluble in the borosilicate melt and settling to the melter floor - to flow towards the glass discharge area at the melt tank bottom. A special glass channel design in the discharge zone assures the complete outflow of any noble metal sludges arriving in this area. The melt is heated in the melt tank center to !200°C by a single pair of electrodes made of high temperature resistant INCONEL 690. Towards the side walls and the melter bottom, temperature drops between 100-200°C exist. Additional energy can be released, if needed, by a pair of auxiliary electrodes installed in the bottom area of the melt tank. The first melter start-up and also restarts are performed by means of several external SiC-resistance heaters introduced temporarily through openings in the melter roof. At sufficiently high temperatures the electric conductivity of the glass for direct heating is attained. For discharge of the glass the melter is equipped with a draining system at its bottom. The system works on the principle of a thermal valve. For initiation of pouring, the glass solidified in the discharge channel is remelted by external energy supply from two heating systems (direct electric heating and medium frequency induction heating of the pouring pipe). The glass flow rate of approximately 120 kg/h is controlled via energy input of the pipe heating. The flow rate is measured by monitoring the weight increase of the canister vs. time. Some characteristic data of this small- scale melter design are summarised in Table 1. IMPROVEMENTS IN MELTER DESIGN Improvements of the melter design has been made in recent years. They refer to the extension of electrode lifetime by an improved air-cooling, to the glass pouring system and its operation mode, to the cleaning of the melter off-gas pipe, and to a reliable glass level detection system in the melter. Extension of power electrode life time The life time of the power electrodes is an important factor of the overall life time of the melter system. The submerged surface of the INCONEL 690 power electrodes undergoes only negligible corrosion attack by the glass melt as long as the surface is at or below approximately 1000°C. The details of corrosion mechanism and kinetics and the impact of temperature had been investigated and reported in Ref. [2]. The air cooling of the electrodes of the small-scale melter has been optimised in order to keep the submerged electrode surface at or below 1000°C. The cooling air (flow rate around 20 m3/h each electrode) is released into the melter cell after passing the air cooling channels of the electrode. Air cooling lowers the submerged electrode surface temperature by approximately 100°C compared to non-cooling. The results of numerical modelling of the melter system confirms the experimental data. Fig. 3 gives the numerical modelling results of the isotherms in the power electrode area under conditions of air-cooling compared to non-air-cooling conditions. Thus, permanent air-cooling during glass production operation extends the life time of the power electrodes considerably. At INE, a melter is in use since more than 8 years without indications of significant corrosion attack of the air-cooled power electrodes. Glass pouring system Glass pouring into the stainless steel canisters is one of the most important steps in HLLW vitrification. It requires a system with a safe function and a long service life. It must be compatible with the service life of other main components of the melter like the ceramic refractory material of the glass tank/melter plenum, or the power electrodes.