NDA R&D Needs, Risks and Opportunities

NDA Research & Development Needs, Risks and Opportunities

ISSUED APRIL 2006, VERSION 1. NDA R&D Needs, Risks and Opportunities

 NDA R&D Needs, Risks and Opportunities

NDA Research & Development (R&D) Needs, Risks and Opportunities

Purpose:

This document provides an openly available summary of the R&D requirements presented as part of the Life Cycle Baseline Plans 2005, submitted by the Site Licensee Companies – a requirement identified in the NDA strategy document.

It is designed to provide the R&D community with information regarding areas of best practice and improvement and in particular to highlight the opportunities that exist for developing common and fit for purpose technical solutions to a range of challenging issues.

 NDA R&D Needs, Risks and Opportunities

Executive Summary

The Nuclear Decommissioning Authority (NDA) is a non-departmental public body, set up in April 2005 by the UK Government under the Energy Act 2004 to take strategic responsibility for the UK’s nuclear legacy.

Our mission is clear: ‘To deliver a world class programme of safe, cost-effective, accelerated and environmentally responsible decommissioning of the UK’s civil nuclear legacy in an open and transparent manner and with due regard to the socio-economic impacts on our communities’.

 NDA R&D Needs, Risks and Opportunities

Acceleration of the clean-up The University Research Alliances Experience gained from overseas programme through the application are helping to develop the next decommissioning work feeds directly of innovative technology. generation of nuclear scientists. into our clean-up activities.

The NDA does not carry out clean-up The purpose of including technical baselines 14 work itself but has in place a contract and underpinning R&D requirements within with Site Licensee Companies (SLCs), the LCBL is to establish an auditable trail who are responsible for the day-to-day through the LCBL and a direct link between decommissioning and clean-up activity on the programme components and programme each UK site. Individual sites develop Life delivery. The LCBLs 2005/06 was the first Cycle Baseline Plans (LCLBs) that set out the programme to attempt this process. 7 short, medium and long-term priorities for the Historically, the short-term benefits gained decommissioning and clean-up of each site. from carrying risks associated with the 4 Critical to achieving our main objective technical underpinning of projects led to 17/19 3 and overall mission is to accelerate and significant cost implications and delays to 15 deliver clean-up programmes through the projects and programmes. Today, we believe 18 application of appropriate and innovative the technical baselines and identification 11 12 technology. That’s why our remit as of R&D requirements will help the SLCs to 10 stipulated in the Energy Act is to: ‘promote, focus on overall programme delivery and and where necessary fund, generic research not just short-term activities. In addition, we 9 relevant to nuclear clean-up’. can ensure that investment in technology 2 1 13 8 16 is targeted at priority areas, with common 6 We have therefore considered the investment 5 issues and requirements identified, achieving required in Research & Development (R&D) 20 solutions on a broader scale. both directly and indirectly (i.e. through the SLC clean-up programmes) to ensure Following the production of the LCBLs appropriate delivery of Life Cycle Baseline 2005/06 and in line with the NDA’s mission, Plans and to maximise the return on the we have now completed the first review Reactor sites Research and investment made. of the ‘NDA R&D Needs, Risks and chemical processing sites Opportunities’. We have considered the The sites are required to state within information submitted by the SLCs to the 1. Berkeley 12. Capenhurst each LCBL, at a high level, the proposed NDA in the LCBLs 2005/06, in terms of the 2. Bradwell 13. Culham technical baseline that underpins the LCBL R&D requirements. In doing so, we have 3. Calder Hall 14. Dounreay decommissioning and clean-up activities. compared and contrasted the plans from 4. Chapelcross 15. LLW Repository In addition the sites are required to identify different sites and evaluated commonalities, 5. Dungeness A 16. Harwell technology gaps and opportunities in 6. Hinkley Point A 17. Sellafield differences and potential omissions, with the technical baselines within the R&D 7. Hunterston A 18. Springfields a view to sharing the ‘NDA R&D Needs, requirements section of the LCBL. R&D is 8. Oldbury 19. Windscale Risks and Opportunities’ across the entire categorised in three key areas: 9. Sizewell A 20. Winfrith technical supply chain. 10. Trawsfynydd 1. The ‘needs’ – providing solutions to Based on the output, we are establishing 11. Wylfa known and common issues. a mechanism for ensuring that potential 2. The ‘risks’ – providing options to avoid or solutions identified are communicated fully mitigate the risks. to the NDA. This document is presented at three levels of detail (a) an executive 3. The ‘opportunities’ – delivering innovative summary (b) a detailed analysis of the overall improvements to the LCBL to achieve the ‘NDA R&D Needs, Risks and Opportunities’ NDA’s mission. (c) a tabulated categorisation of the LCBL submissions.

 NDA R&D Needs, Risks and Opportunities

The safe disposal of all waste material The £200m Technology Centre In all of the NDA’s activities is of primary importance. at Sellafield supports the work safety and environment of over 300 technologists. protection are paramount.

Key findings of the LCBLs NDA R&D requirements Good practice 2005/06 review The analysis of the full life cycle of existing The LCBL programmes are compiled liabilities overlaid with the need to deliver individually by each site from a ‘grass-roots’ A top down review of our overall technology the NDA’s mission yields significant R&D assessment of the needs of each project, needs, risks and opportunities has identified challenges. In addition, confidence in the culminating in an overall site plan. This common key issues. technology development activities will grow often leads to unique technology solutions Key issues identified: as the programme of clean-up activities bespoke to the project plan for the site. As a accelerates. The LCBL plans reviewed result, we are encouraging a more integrated Balance of R&D programmes (quite correctly) did not take account approach where sites share proven Owing to the mature nature of the industry, of the proposed acceleration of reactor technology solutions for everyone’s benefit the vast majority of R&D development decommissioning and this may need to be and so avoid the cost of bespoke solutions activities are integrated directly with on- considered in the future. We can expect where possible. We are also fully supportive plant deployment projects and therefore an increase in R&D investment from the of the application of proven technology solution driven in their application. Given the SLCs over the next ten years, if delivery is solutions from non-nuclear fields within the need to accelerate clean-up programmes to be assured. We will be monitoring the nuclear industry. in line with the NDA’s mission, we fully developing R&D programmes to ensure the Additionally, international experience in terms support this approach and recognise the activities are being undertaken in line with of proven technology capability should be importance of maintaining an appropriate the delivery of the NDA strategy. considered further. A number of nations level of underpinning scientific knowledge have had substantial clean-up programmes of the applied processes. In addition we will Underpinning science over the previous two decades, with proven continue to monitor activities to maintain In collaboration with Nexia Solutions, we are delivery capability. As improvements in the the adequate skills to support the clean-up supporting a series of University Research supply chain management take place within projects. Alliances (URAs) to develop and maintain a the competitive clean-up market, more network of basic science capability and skills proven technology options will be proposed, to achieve the short and long-term aims of requiring minimal development activities. our mission.

Delivering accelerated clean-up programmes requires innovative and fit for purpose R&D solutions as well as a strong base of scientific knowledge, capability and skills and an integrated approach where sites share proven technology.

 NDA R&D Needs, Risks and Opportunities

Opportunities exist to share We must maintain a network of Innovative low technology existing solutions for the basic science capability and skills solutions will help us reduce treatment and storage of waste. to achieve our mission. decommissioning costs.

Contingency activities Development of common technology Availability of facilities to meet A further review of the underpinning R&D solutions market needs activities of high priority projects will establish The site LCBLs indicated a range of Whilst the analysis of ‘NDA R&D Needs, whether the level of activities (basic science common problems that would benefit from Risks and Opportunities’ has highlighted and contingency work) are aligned to the combining efforts. Examples include a work to be carried out, no assessment uncertainties and risks associated with the widespread requirement for local and mobile has been made of the ability of the supply projects. Whilst we believe these high priority effluent technology and sludge handling chain to meet these requirements in terms projects are technically underpinned against technology. Clearly, these processes will of facilities. One specific area of concern is current plans, the level of risk associated have commonality in terms of engineering the changing need in terms of measurement with the waste streams involved may require design, waste disposal, IX technology etc. capability and the availability of laboratory more investment to develop contingency facilities and laboratory standards. options in parallel. Development of common waste packaging solutions Technology transfer Safety and environmentally driven Most sites need to package and store Accelerating clean-up programmes means research ILW, whilst awaiting a long-term disposal accelerating the development process and High standards of safety and environmental option. Each waste stream requires process transferring new technology options into the performance are a fundamental requirement development and assessment for suitability market place. A number of interfaces need of the SLCs and we are supporting SLC for eventual disposal. There are opportunities improvement (a) SLC to SLC (b) Nuclear R&D activities that provide improvement to share pre-existing solutions to common research organisations to SLC (c) Non- in these areas. As the R&D drivers are waste materials on different sites. There are nuclear sector to SLC. mainly the same, R&D activities specific to similar opportunities to establish common safety and the environment have not been cement and PFA formulations across the separated out. We will actively encourage waste spectrum, enabling a higher level of the SLCs to work together on specific confidence in waste packages and security technical projects offering improved safety of supply. or environmental performance and therefore mutual benefit.

Maintaining high standards of safety and environmental protection is paramount and we will support the SLCs in working together to apply R&D that makes continual improvements in these areas.

 NDA R&D Needs, Risks and Opportunities

Wylfa power station on Anglesey will cease generation in 2010.

There are a number of issues that present significant R&D opportunities particularly in the areas of material characterisation, waste processing and disposal. We are challenging the R&D community to provide greater cooperation, more forward thinking and proactive approaches to R&D to address these and other issues.

Major technical issues Waste processing Site restoration Major technical needs and opportunities • Development of proven sludge handling • Surveying and characterisation of land were identified and highlighted because of techniques. contamination. their importance or widespread interest: • Remote handling techniques for fuel • Ground remediation technology for active debris and highly activated materials. and non-active contaminated land. Materials characterisation The LCBLs identified issues surrounding the • Methodology and techniques for waste • Development of consistent protocols to characterisation of materials for treatment segregation. underpin site end point considerations for a wide variety of sites. and disposal. • Recycle of materials. The quality of the ‘NDA R&D Needs, Risks • Techniques to assay rapidly low levels of • Graphite management. radiation and contamination in order to and Opportunities’ submissions by the SLCs varied considerably. We will be working sentence materials for low level waste Management of strategic nuclear to ensure that future submissions are of a (LLW) disposal and segregate materials materials consistent and high quality. for release as clean or exempt materials. • Development of immobilisation • Development of techniques to technology for separated plutonium. The NDA intends this document to be characterise contamination of structures. a valuable contribution to informing key • Process development for the conversion stakeholders and potential R&D providers. • Development of techniques to of uranium hexafluoride to a more stable By setting out the current perception of characterise site and contaminated land. form. ‘NDA R&D Needs, Risks and Opportunities’ and by identifying the gaps, weaknesses • Development of techniques to • Long-term options for the UK approach and priorities, we are setting a challenge to characterise waste properties to the management of spent fuel. the SLCs, tier two contractors and the R&D – radiochemical, chemical and physical, community for greater co-ordination, more including facilities for intermediate level Plant termination forward thinking and more imaginative and (ILW) characterisation. • Improved decontamination technology to either enable man access or waste proactive approaches to R&D programmes. re-categorisation. • Improved effluent management to process decontamination reagents. • Development of local and mobile effluent treatment capability. • Technology to carry out size reduction of large items. • Remote dismantling technologies.

 NDA R&D Needs, Risks and Opportunities

Contents

Page 1. Introduction 11 2. NDA’s mission and policy for R&D 14 3. The requirement for R&D 16 .1 Knowledge of the legacy 17 . Reliable technical options to meet the NDA’s goals 17 . Balance within R&D programmes 17 . NDA expectations of R&D programmes 17 4. NDA funding of R&D 18 5. NDA major technical challenges 20 6. Summary of the major clean-up and decommissioning challenges 22 6.1 Goals of clean-up and decommissioning 23 6. Characteristics of the challenges 23 6.3 ‘R&D Needs, Risks and Opportunities’ declared in the Life Cycle Baseline Plans (LCBLs) 6 6. Summary of needs, risks and opportunities 27 6.4.1 Materials and waste characterisation 28 6.4.2 Processing of radioactive wastes 29 6.4.3 Management of strategic nuclear materials 32 6.4.4 Plant termination and decommissioning 33 6.4.5 Asset management 34 6.4.6 Site restoration 34 7. Generic issues identified in the LCBLs 36 8. Strategy for undertaking R&D 38 .1 Basic underpinning research 39 . Applied research 39 . Technology transfer 40 . Collaboration and co-operation 40 .5 Development of the NDA’s R&D portfolio 40 9. Conclusions and summary 42

Appendix 1 – NDA’s R&D policy 44 Appendix 2 – Summary of technical issues identified in the LCBLs 45

 NDA R&D Needs, Risks and Opportunities

Acronyms

NDA Nuclear Decommissioning Authority NTWP Near Term Work Plan LCBL Life Cycle Baseline VLLW Very Low Level Waste SLC Site Licensee Company MCI Miscellaneous Contaminated Items R&D Research & Development MOP Magnox Operating Plan URA University Research Alliance TILWSP Transportable Intermediate Level Waste IX Ion Exchange Solidification Plant PFA Pulverised Fly Ash TRSDU Transportable Radioactive Sludge ILW Intermediate Level Waste Dewatering Unit CoRWM Committee on Radioactive Waste MXD Magnox Dissolution Management PAETP Portable Active Effluent Treatment Plant LLW Low Level Waste C&MP Care & Maintenance Preparations Thorp Thermal Oxide Reprocessing Plant LoC Letter of Compliance SMP Sellafield Mixed Oxide Plant ETP Effluent Treatment Plant AGR Advanced Gas Cooled Reactor NCAW Non-Combustible Active Waste POCO Post Operational Clean Out CAW Combustible Active Waste ALARP As Low As Reasonably Practical MSV Main Sludge Vault HAW Highly Active Waste RSP Resin Solidification Plant MOX Mixed Oxide HEU High Enriched Uranium HLW High Level Waste MTR Materials Test Reactor IPR Intellectual Property Rights HVLA High Volume Low Active BPEO Best Practicable Environmental Option PCM Plutonium Contaminated Material FED Fuel Element Debris LLWR Low Level Waste Repository

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1. Introduction

The NDA’s prime objective is to decommission and clean-up the UK’s civil public sector nuclear legacy safely, securely, cost-effectively and in ways that protect the environment for this and future generations.

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1. Introduction

In short, we are in the business of effective environmental restoration, utilising the best available skills and competition to secure contractor improvements in safety, security, environmental performance and cost effectiveness.

In assuming responsibility for the UK Dealing pragmatically with low level Across the 20 UK sites we own and nuclear legacy including 20 sites, the NDA waste (LLW) is also crucial and will result manage, there is immense opportunity for has inherited huge technical challenges, in significant cost reductions. The policy sharing best practice and knowledge of and expectations of us are justly high. Key review underway by the Government is an technically mature solutions to a range of priorities are projects focused on hazard important first step to a more flexible fit-for- common challenges. In addition we must reduction including legacy facilities at purpose approach. consider and draw on the resource of global Dounreay and Sellafield and reducing the experience. In some areas, nuclear clean-up We will continue to operate the four volume of liquid high level waste (HLW) programmes overseas are more advanced remaining Magnox power stations until in storage tanks. Whilst these long-term than UK clean-up programmes. their declared closure dates. We will run projects are high priority, we also need to operational plant at Sellafield – Thorp and We are looking to the companies operating deliver successes in the short-term. That SMP – until the Government decides that on our sites to find and implement innovative is why we are looking for opportunities to they should close. We will look at the options ways of solving technical challenges, demolish redundant structures and clear for storing AGR fuel in the event that it whilst at all times ensuring safety and sites. We have identified opportunities cannot all be reprocessed. We will continue environmental good practice. By innovation, for ‘spend-to-save’ initiatives e.g. on the to operate the Springfields site for as long we mean the application of ideas to solve approach to decommissioning Magnox and as it has commercial contracts, especially to a specific technical challenge. Given the other reactors – an approach that can only provide AGR fuel for British Energy’s fleet of purposeful ambitious mission of the NDA be pursued if we receive appropriate funding reactors. and the need to accelerate clean-up for our core functions. programmes, we anticipate most innovation We will support the R&D required to deliver Managing intermediate (ILW) and higher (yet not exclusively) will be iterative our mission as an integral part of site level wastes until long-term disposal routes improvements to known processes from plans. Clearly, the ambitious NDA strategy are in place is also a key activity for us. either within or outside the nuclear industry. presented for public consultation in the The Committee on Radioactive Waste summer of 2005 will require the timely This is our first review of the ‘NDA R&D Management (CoRWM) is due to deliver completion of R&D over the next few years Needs, Risks and Opportunities’ and is an its options to Ministers by July 2006. Any to allow the implementation of solutions. essential part of delivering our mission. We delay by the UK Government in making Consideration should be given firstly to have attempted to provide a total NDA- decisions on the long-term disposal routes existing solutions to technical issues wide view of all the technical challenges will carry significant cost implications. before to the development of bespoke and to explain our approach to R&D - why In the meantime, we are proposing a technical options. The application of existing it is needed and where the value lies. The rationalised approach to ILW interim storage technology from the non-nuclear sector will basis of the information presented is taken arrangements. be considered and we will be examining from the Life Cycle Baseline (LCBL) Plans technology transfer methodologies to presented in September 2005 to the NDA. facilitate this area. Analysis is provided of the entire portfolio to highlight where R&D could be undertaken more effectively, where greater emphasis is needed to address longer term issues and where opportunities exist for more innovative approaches.

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Materials structure analysis by X-ray Nuclear sites must be cleaned up tomography at the University of Manchester. safely, security and cost-effectively.

This document is designed to help to Our role is to deliver a world class programme of safe, inform stakeholders and potential R&D cost-effective, accelerated and environmentally responsible providers about our R&D Needs, Risks and Opportunities. The gaps, weaknesses and clean-up and decommissioning of the UK’s nuclear legacy. priorities identified present both a challenge It requires innovative and fit for purpose R&D solutions to and an opportunity to the SLCs, tier two address a number of challenging issues. That may mean contractors and the R&D wider community applying existing solutions from the nuclear industry or for sharing best practice and for developing innovative and forward thinking R&D indeed the non-nuclear industry. solutions. Across the 20 sites we own and manage there are immense opportunities for the entire R&D community to share best practice and knowledge of technically mature solutions to a range of common challenges.

Decommissioning a redundant plant presents both a challenge and opportunity for the Site Licensee Companies.

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2. NDA’s mission and policy for R&D

Our core objective is to ensure that the 20 civil public sector nuclear sites under our ownership are decommissioned and cleaned up safely, securely, cost-effectively and in ways that protect the environment for this and future generations.

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Decommissioning work at WAGR is helping to improve waste packaging techniques for future clean-up projects.

We are seeking a unified and coherent The R&D programmes are required to The second part of the R&D policy involves decommissioning strategy, working in address three key areas: the NDA itself directly contracting a smaller partnership with regulators and Site Licensee portfolio of R&D on issues that are generic 1. The ‘needs’ – providing solutions to Companies to achieve the best value, a to a number of sites. This R&D will include known and common issues. positive contribution to local communities, support for innovative ideas evolving from and the highest environmental standards. 2. The ‘risks’ – providing options to avoid or the supply chain, the technical underpinning mitigate the risks. of strategic and policy issues and the The NDA R&D policy calls on the SLCs maintenance of long-term strategic options to carry out the majority of the R&D. (see 3. The ‘opportunities’ – delivering innovative and key skills. We will actively encourage the Appendix 1). Therefore each SLC must improvements to the LCBL to achieve the generation of ideas from the supply chain. evaluate the R&D programmes necessary NDA’s mission. When NDA – supported projects mature to support the LCBL for each individual site, into site specific applications, affected including the programme required beyond The NDA will also consider how an SLC sites will be invited to consider the work for the Near Term Work Plan. might act as a single point lead on a multiple site programme that meets the requirements incorporation into LCBL activities. across a number of sites, especially where the issue is of national importance.

Our R&D policy requires the Site Licensee Companies to identify R&D programmes in line with the LCBLs and to carry out the majority of the work. One SLC may take the lead on a multiple site programme, particularly when it addresses an issue of national importance. Where we contract a smaller portfolio of R&D direct on issues generic to a number of sites, we will actively encourage the generation of innovative ideas from the supply chain.

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3. The requirement for R&D

In order to achieve our mission, we recognise that there are many opportunities to improve the knowledge base. Realising these opportunities will include R&D activities.

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Balance within R&D programmes. NDA expectations of R&D programmes.

Solve problems once for an individual site Knowledge Reliable gaps technical Generic R&D options Solve problems once for all sites (addressing long-term as well as short-term issues)

3.1 Knowledge of the legacy 3.2 Reliable technical options The preferred and more cost-effective approach is to continue to develop the The knowledge gaps generically fit into to meet the NDA’s goals knowledge base but in the context of two categories: Establishing reliable and appropriate accelerating clean-up programmes in technical options reduces the risk of • Uncertainties about the properties line with the NDA’s mission. This will be unsuccessful implementation. Therefore (physical, chemical and radiochemical) achieved by finding innovative workable carrying out fit for purpose R&D will lower the and behaviour of wastes. solutions to challenges which are not solely risk of abortive work, hazards and decrease dependent on the precise characteristics of • Uncertainties about the condition the environmental impact. It is also important the material to be treated or the facility to be and content of facilities awaiting that the reliable technical option does not in decommissioned etc. decommissioning. itself generate additional significant liabilities. Reliable solutions need to address three 3.4 NDA expectations of Many of the facilities and associated critical criteria: wastes have been studied for many years R&D programmes 1. The ‘needs’ – providing solutions to and the challenges and uncertainties It is imperative that our investment in R&D known and common issues. are well understood. However where is channelled efficiently and effectively. In the uncertainties associated with other 2. The ‘risks’ – providing options to avoid or simple terms, we will consider generic R&D issues are less well understood and pose mitigate the risks. programmes that: a potential risk to clean-up programme 3. The ‘opportunities’ – delivering innovative 1. Develop innovative solutions to generic delivery, R&D skills, knowledge and issues. innovation must be developed and applied improvements to the LCBL to achieve the to ensure that the liability is discharged NDA’s mission. 2. Solve problems once that have relevance successfully and efficiently. to all sites (addressing long-term as well 3.3 Balance within R&D as short-term issues). programmes 3. Develop strategic options. As with most industrial R&D, there is Wherever possible, the NDA expects R&D a balance to be struck between filling programmes to take advantage of previous knowledge-gaps and finding robust, fit research and expertise that currently exists for purpose solutions that achieve the in the UK and overseas. operational objectives. Spending time filling all the knowledge gaps associated with the unique nature of some of the NDA’s liabilities will be a slow process and may not necessarily lead to a successful outcome.

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4. NDA funding of R&D

We have estimated the funding levels to support our R&D requirements. As the NDA requires mainly applied R&D work, it is often difficult to establish the precise point at which development work is completed on any given project. Therefore the following table represents our best estimate of the R&D activities and associated funding based on input from the SLCs and other organisations.

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R&D increases the understanding of the technical R&D activities have helped the UKAEA Innovative techniques have resulted challenges associated with the programme of accelerate the decommissioning of in a 90% reduction in discharges of decommissioning and clean-up activities Dounrey from 2063 to 2036. technetium-99 from the Sellafield site.

Proposed spend 2006/07

Research organisations contracted Funding Organisation Scope to lead the work programme levels (£)

British Nuclear Group Technical support for site delivery activities Numerous ~50M Sellafield

UKAEA Technical support for site delivery activities Numerous ~12M

British Nuclear Group Technical support for site delivery activities Numerous ~30M Magnox

NDA Generic R&D and university support activities Nexia Solutions 8M

NDA Waste disposal concept development Nirex 12M

NDA Epidemiological studies Westlakes 1M

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5. NDA major technical challenges

The NDA’s mission presents many and varied technical challenges. At the highest level, the mission is underpinned by two clear operational challenges:

1. To clean-up legacy waste and decommission radioactive plant and facilities. 2. To continue to operate reactors, reprocessing and storage facilities, safely, environmentally sound and economically.

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Waste Management Vitrification Test Facility Determine best approaches for interim management (Courtesy British Nuclear Group, Sellafield) of HLW and ILW: and disposal of LLW.

• Ensure targets for reducing liquid high level waste (HLW) are met and material put into passive safety. • Review options for interim storage of intermediate level waste (ILW). • Press for an early decision by the Government on the long-term management arrangements for HLW and ILW. • Reduce volumes of LLW produced: seek new approaches to low level waste (LLW) disposal.

This sets the context for identifying the NDA’s Categorisation table R&D requirements, recognising that a balance must be struck between achieving both. Needs, Risks and Opportunities Quintessa Categories

In addition, we have reviewed the LCBLs 1. Radioactive materials characterisation 5.1 Radioactive materials characterisation and compiled a number of categories, as outlined in the table opposite, against which 1.1 Characterisation of hazards 5.1.1 Materials characterisation 5.1.2 Materials inventory we have identified the NDA’s R&D needs. We believe this additional breakdown of 2. Management of radioactive waste 5.1 Management of radioactive waste clean-up and decommissioning activity into 2.1 Waste retrieval and transfer 5.2.11 Waste retrieval and transfer a number of stages is helpful, particularly if it 2.2 Processing, conditioning and packaging 5.2.1 Waste processing, conditioning and reflects the chronological order in which the packaging 5.2. Optimisation strategy technical challenges need to be addressed. 5.2.1 Waste minimisation at source It also provides us with a basis to compare 5.2.6 Solid waste volume reduction and contrast technical challenges and 5.2. Process optimisation assess their significance in relation to the 5.2. Waste segregation NDA’s overall mission. 2.3 Waste recycling and reuse 5.2. Clearance, recycling and reuse The categorisation provides a logical ‘cradle 2.4 Waste transport (internal and international) 5.2.13 Package transport to stores to grave’ approach that aims to take account 5.1.4 Waste ageing effects of all of the important technical challenges. 2.6 Waste disposal It also provides a series of headings against 3. Management of other nuclear materials 5.2 Management of other nuclear materials which the various challenges in clean-up and decommissioning may be considered: 3.1 Plutonium 3.2 Uranium • Radioactive materials inventory, characterisation and behaviour. 3.3 Fuel 4. Plant termination and decommissioning 5.3 Plant termination and decommissioning • Management of radioactive waste and other nuclear materials. 4.1 Removal of plant contamination 5.1.3 Plant characterisation 5.3.1 Strategy • Plant termination and decommissioning. 5.3.2 POCO 4.2 Management of effluents 5.2.4 Liquid discharges • Asset management. 5.3.5 Gas discharges • Site restoration management. 4.3 Plant dismantling 5.3.4 Plant dismantling 5.3.3 Care & Maintenance A final category, not included in the above categorisation, completes the picture: 5. Asset management 5. Asset management 5.1 Reactors 5.5.1 Life extension of operational facilities • Waste disposal. 5.2 Chemical plant 5.5.2 Facility operational strategies 5.3 Low Level Waste Repository 5.5.3 Management of the LLWR facility 6. Site restoration management 5.4 Site restoration management 6.1 Characterisation and restoration 5.4.1 Site characterisation 5.4.2 Site restoration methods 6.2 Site end point 5.4.4 Site end point definition 5.5.3 Site control issues and restoration planning

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6. Summary of the major clean-up and decommissioning challenges

The clean-up and decommissioning challenges across our 20 UK sites are many and varied. We are looking for R&D that accelerates clean-up programmes and provides cost-effective once-for-all solutions, whilst ensuring stringent levels safety and environmental protection.

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R&D activities must support the final disposal of radioactive wastes.

An important contribution from R&D will be to provide ways of accelerating the clean- up programmes whilst supporting the final disposal of radioactive wastes.

6.1 Goals of clean-up and Value for money Wastes that may be destined for geological decommissioning Obtaining value for money is an important disposal pose challenges in terms of whether driver as financial resources are not key parameters, which have an important Final disposal of radioactive materials unlimited. It is essential that R&D activity effect on the safety case for the repository, In general terms, the overall goal of clean-up delivers fit for purpose solutions without are sufficiently well known. The need to and decommissioning is to process and creating further challenges down the line. re-sample or characterise wastes once they transfer all radioactive wastes into forms The R&D programme has the opportunity have been immobilised by encapsulation is and to locations that present minimal hazard to deliver value for money by simplifying a risk that needs to be minimised on safety indefinitely. However, until CoRWM reports challenges, accelerating clean-up activity and cost grounds. back to the UK Government in July 2006, and providing once-for-all solutions. options for the final disposal of radioactive Management of radioactive waste and other nuclear materials wastes remain undecided. Even by then 6.2 Characteristics of the there is likely to be a significant period The management of radioactive waste of public debate and consultation before challenges presents a series of challenges associated agreement on the final disposal routes for As previously stated, the challenges with a number of key activity phases: radioactive wastes is reached. associated with the clean-up and • Retrieving the waste. decommissioning of the NDA’s 20 UK sites Therefore most of the R&D challenges are many and varied. Some sites have small • Processing the waste. identified are focused around achieving an volumes of well-characterised and stable interim point of safe long-term storage, from wastes, whilst others, notably Sellafield, have • Packaging the waste. which a number of options for the final state large volumes of poorly characterised wastes • Storing the waste. may be pursued. An important contribution with significant hazards. from R&D will be to provide ways to expedite • Disposing of the waste. clean-up and yet support the final disposal of Summaries of the challenges, under the radioactive wastes. categories outlined earlier are as follows: Given the variety of wastes, the technical challenges associated with each of these phases varies from minor to major with the Safety and environmental criteria Radioactive materials inventory, major challenges demanding much more In all of the NDA’s activities, safety, security characterisation and behaviour sophisticated technical solutions. and environmental protection are paramount. There is a wide range of radioactive materials The need to maintain exacting standards that need characterisation if the correct In terms of retrieval, the more difficult of safety and environmental protection treatment, packaging, storage and disposal challenges are where loose waste has been means that attaining our clean-up and solutions are to be adopted. The challenge tipped into vaults or silos. Often the waste decommissioning goals and mission is minor for homogenous wastes with is inhomogeneous as a result of historic presents further challenge. Therefore from low radioactivity content but a few highly operations. Where significant degradation a safety perspective, there is a need to radioactive, non-homogeneous wastes or corrosion of the accumulated waste has balance the risk of clean-up activity with present considerable challenges. Increasing occurred, often over decades, there may the benefits of reducing hazards associated the knowledge of the radioactive material be uncertainty about the physical form and with untreated waste. Maintaining good usually yields considerable benefits in terms behaviour of the waste during retrieval. environmental performance requires a similar of selecting the appropriate treatment The characterisation of retrieved waste balance. R&D has a fundamental part to play options. is essential to ensure it is suitable for in alleviating risks, expediting clean-up and packaging and that the final waste packages minimising environmental impact. meet appropriate standards for eventual disposal.

23 NDA R&D Needs, Risks and Opportunities

6. Summary of the major clean-up and decommissioning challenges (continued)

Waste is processed in which ever way Whilst immobilisation in glass or ceramics Management of strategic nuclear enables it to be packaged safely. This may requires high temperature processes, materials include dewatering or drying (for sludges) the waste products produced retain high There are other strategic nuclear materials and segregation into different size fractions concentrations of radionuclides and are that require separate consideration with or waste types and even, treatments to therefore suitable for the waste management regard to their management. reduce the volume. Approaches to date have of high fissile content material. There is a favoured low temperature and low energy challenge to achieve the advantages of high Strategic materials are those that have processes. However, high temperature temperature processes using the simplest potential use in future nuclear power or other high energy processing may possible equipment, having high availability scenarios and therefore may not be regarded offer advantages of increased versatility, and throughput as well as low secondary solely as waste. The three main categories of throughput, volume reduction and more waste generation. material are: stable waste forms. 1. Plutonium (Pu) Waste storage Packaging of wastes can range from simply 2. Uranium (U) packing waste into a drum or box through to The current approach to waste storage is to encapsulation to create a monolithic waste. treat and package wastes in such a way that 3. Fuel. In some cases, waste can be compacted stores can be managed in the same way as a conventional warehouse. In principle, Given that decisions have yet to be made into pucks without encapsulation before on the use of strategic materials, there is a being loaded into storage containers. the stores will not be exposed to loose radioactive material and therefore will remain challenge to amass the necessary technical Encapsulation in cement-based matrices uncontaminated. data to evaluate the options fully. Reuse of is widely used because it produces wastes any or all of the material in various future with good long-term properties and in a form The major technical challenge arises from the scenarios will present significant technical as that is compatible with the Nirex repository prospect that some stores will hold material well as economic challenges and these need concept for intermediate level waste. The for many decades, possibly over 100 years. to be understood sufficiently to inform the technical challenges associated with cement It is therefore important to understand the decision-making. Equally the consequences encapsulation are to increase the ratio of long-term behaviour of stored wastes. of treating the strategic nuclear materials waste to cement, to improve the percolation At the end of storage, it is essential that as wastes also have to be understood of grout into loose solid wastes within a packages can be retrieved from the stores. fully. Whatever becomes the final route for container and to reduce the difficulties It is also necessary therefore to minimise radioactive wastes disposal, consigning posed by metals that corrode in the alkaline the potential for package degradation in strategic materials to that same end point cement matrix. Encapsulation in materials addition to being able to monitor the risk is likely to have significant technical, safety other than cement-based matrices is a valid associated with packages losing their ability and environmental issues that need to be option for wastes that are difficult to cement. to contain radioactive material or their ability addressed. to be retrieved. For large stores, containing Processes similar to cementation, which Whichever way the strategic materials are can be operated at temperatures close to thousands of packages, reliable inspection and monitoring is essential. treated and disposed of longer-term, there is ambient temperature, may provide attractive a need to operate to international standards alternatives. of safeguards.

Waste storage Waste stores may hold material for many decades, possible over 100 years. A key challenge for the R&D community is to fully understand the long-term behaviours of stored wastes. Minimising the potential for package degradation and being able to monitor waste package containment performance and retrieval ability are key R&D challenges and requirements.

24 NDA R&D Needs, Risks and Opportunities

Plant termination and decommissioning Waste disposal Much of Nirex’s earlier work has been Plant termination and decommissioning The Committee on Radioactive Waste focused on intermediate level and low level involves the treatment and removal of Management (CoRWM) is currently waste but more recently, consideration has radioactive facilities (including the removal developing the strategy for the long-term been given to highly active waste, irradiated of contaminated equipment, vessels and disposal of radioactive waste and a report is fuel and strategic nuclear materials. These pipework etc.) once the bulk wastes have expected in July 2006. The report will include present significant challenges because of been removed. One important challenge options for highly active waste, intermediate the potential increased inventory of fissile is to remove the final small quantities of level waste and irradiated fuel. It is likely that materials and long-lived fission products. waste. The removal of even small quantities progress from CoRWM’s recommendations Disposal of low level radioactive waste at the of radioactive liquids, sludges and dusts to a fully agreed and supported strategy UK’s national Low Level Waste Repository significantly reduces the challenge of will take several years, given the anticipated (LLWR) is an established capability that subsequent dismantling or demolition of the extent of public and political debate and is scheduled to continue until the middle facility. There is a law of diminishing returns, consultation. of the 21st century. Given the importance but an important challenge is to remove Nirex is currently undertaking research in of the low level waste disposal in every residual wastes from convoluted geometries the area of deep geological disposal and aspect of the NDA’s mission, there are and ‘hard-to-access’ facilities. the NDA is assisting Nirex in establishing the incentives to use remaining LLWR capacity A major challenge in dismantling radioactive availability of a disposal route for radioactive as efficiently as possible. The environmental facilities is where high radiation levels wastes. performance of the LLWR is a high profile prevent, or severely limit, human entry. issue, particularly in the long-term (typically Nirex has a science programme, supported As a consequence, dismantling has to be 10,000 years) and increasing the quality of by the NDA, which is continuing to underpin done remotely, which is usually slow and the underpinning science is a key challenge. their concept of phased geological disposal. cumbersome. Therefore, the challenge The work is aimed at increasing confidence The disposal of large volumes of very can be approached in two ways. Firstly in the approach and is providing guidance low level waste is expected to arise by decontaminating plant and equipment to waste producers on the packaging of from the dismantling and demolition of surfaces to reduce radiation levels or radioactive wastes. The R&D includes decommissioned facilities but it is evident secondly by developing more adaptable a range of experimental research and that such material is inappropriate for remote handling technology or innovations computer model studies on the safety of disposal at the LLWR. Disposal in shallow such as underwater working. radioactive waste forms, waste packages burial at the site of origin is a prime option and the repository system. A key output is and finding the right combination of disposal the ability to calculate the long-term safety or reuse for such materials is an important of the repository system following repository technical challenge. closure, through a process known as ‘performance assessment’.

Waste management • Ensure nuclear materials are stored safely, securely and without danger to the environment; • Discuss with Government what proportions of civil-owned uranic materials and plutonium should be regarded as strategic stock; and what proportions as waste; • Discuss and agree with Government whether to sell plutonium to an overseas manufacturer of MOX fuel; HIP Process – Pu waste treatment • Commission R&D to address Pu disposition options. (Courtesy Nexia Solutions)

25 NDA R&D Needs, Risks and Opportunities

6. Summary of the major clean-up and decommissioning challenges (continued)

Asset management Site restoration management 6.3 R&D needs, risks and Whilst the primary goal of NDA’s mission is The final part of the NDA’s mission is opportunities declared in the clean-up and decommissioning for the next to manage the sites (i.e. the land) once Life Cycle Baseline Plans 5-10 years, we also need to continue to radioactive wastes and facilities have been (LCBLs) operate plant at a number of sites effectively removed. The principal challenge relates to and efficiently. sites where below ground contamination is The current assessment of the ‘NDA R&D present. Needs, Risks and Opportunities’ has been The technical challenges associated with largely determined by the Site Licensee ongoing operational plants relate principally We need to demonstrate sufficient Companies as outlined in their individual to making incremental improvements in understanding of the long-term effect of LCBLs. Each site LCBL has been scrutinised throughput, costs, safety and environmental the contamination to determine whether, if for R&D needs and they have been performance. The successful and timely any, remedial treatment is necessary. Where summarised in appropriate categorises in the completion of reprocessing of the majority remediation is not carried out, or where table above. of the Magnox fuel is an important part of it does not remove all the radioactivity, the NDA’s mission as it will avoid the need a significant challenge will be to develop Tables for individual sites are presented in to deal with large quantities of irradiated sufficient confidence in the understanding Appendix 2. Magnox fuel. Therefore, the key technical of the effect of contaminated land to ensure In addition to the technical needs declared and operational challenge relating to a variety that the residual risks are regarded by all in the LCBLs, the NDA has set up a smaller of facilities is to ensure that the entire plant stakeholders as acceptable. A desirable goal programme of R&D, focused on site-wide, and processes operate at high throughput will be to release as many sites, or parts of longer term issues. and without the need for large-scale capital sites, from nuclear site licence control. investment. Asset management means maintaining radioactive facilities in a safe state until Summary of LCBL technical issues clean-up and decommissioning can begin. In some cases this is because of the hazards associated with the radioactive Need/Risk/ Issue Timescale Opportunity Characteristics of a Solution wastes they contain and in other cases, it is because of the age of the facility. At a 1. Radioactive materials characterisation minimum, asset management involves the 1.1 Characterisation of hazards surveillance of a facility and its contents. 2. Management of radioactive waste Appropriate measures are needed to provide 2.1 Waste retrieval and transfer assurance that degradation or other hazards are not occurring. In a few cases, asset 2.2 management will require positive intervention to remedy degradation.

Materials

3.1 Plutonium

7.2 Chemical plant

7.3 Low Level Waste Repository

8. Site restoration management

8.2 Characterisation and restoration

8.2 Site end point

26 NDA R&D Needs, Risks and Opportunities

Our programme for NDA supported work Therefore, in the LCBL summaries 6.4 Summary of needs, risks is based upon seven key strategic areas, and in the section that follows, we and opportunities each containing a number of key themes. have given priority consideration to the As outlined in the previous section and The figure below illustrates the focus of safety and environmental aspects of the accompanying appendices, there is a wealth each programme relative to the timescale technical issues identified. There are two of information on the R&D needs of the of the NDA’s mission. Two overarching complementary themes: individual sites. However what is missing is programmes; environment and skills and 1. Facilitate the reduction of potential a collective overview that will enable us to capability, span the entire timeframe of the hazard by expediting clean-up and effectively guide and direct the NDA’s R&D NDA’s mission. decommissioning. programme in the medium to long-term. Safety and environmental research We have therefore reviewed and analysed 2. Undertake clean-up and the R&D needs declared in the individual A key focus for the NDA and, indeed the decommissioning with technologies that LCBLs summaries shown in Appendix 2 regulators, is to ensure that sufficient reduce risks, improve safety and minimise and produced a UK-wide view across each research is undertaken into safety and environmental impact. environmental issues. NDA is fostering category of R&D issues and challenges. the approach of making safety and Furthermore, we have compared and environmental research an integral part of contrasted the declared needs for all the the entire R&D performed across clean-up sites in order to answer the following four and decommissioning activity. questions: 1. What are common issues? (e.g. Can a higher level issue be addressed and identified to encompass several site-specific ones?)

NDA strategic key programmes over the timescale 2. Where and what are the inconsistencies? (e.g. Issues identified at some site but not Environment at similar ones.) 3. Where and what are the missing issues? (e.g. Risks overlooked or underestimated, Contaminated Nuclear land and site inadequate end points etc.) LLW ILW materials Decommissioning end point management 4. Where are the additional opportunities? management (e.g. Use a different approach to solve more than one issue, do things quicker Skills and capability and cheaper without compromising safety, or achieve a more robust end point.)

The skills pyramid

Nuclear Institute & National Laboratory PhD Partnership with Masters key universities

Degree National Nuclear Skills Academy

Modern Apprenticeship, HND, Foundation Degrees, NVQs

Science, Engineering, Energy foresight Technology & Maths 14-16 years

27 NDA R&D Needs, Risks and Opportunities

6. Summary of the major clean-up and decommissioning challenges (continued)

This section summarises the analysis for 2. Techniques to characterise the degree The wastes and materials currently each of the R&D categories: of contamination in structures identified are: Again this is likely to be of benefit • Sludges 6.4.1 Material and waste across all the sites. Decommissioning characterisation will involve dismantling large steel and • Effluents concrete structures. The measurement • Hydrogen Common issues of contamination will expedite decisions Every site identified characterisation issues about decontamination requirements and • Graphite sentencing waste arising as ILW, LLW or but different sites placed greater emphasis • Steels on different topics. The NDA supported R&D clean and exempt. Advances in R&D that can measure contamination in porous activities also identified characterisation as Inconsistencies surfaces or in convoluted geometries are important to several sites. Four common No inconsistencies have been identified desirable end points. issues have been identified together with other than common issues not being a recommendation of where they are most 3. Techniques and methods to identified at all sites. likely to be appropriate: characterise sites or contaminated land 1. Techniques to assay low levels of There are relatively few sites where Missing issues radiation and contamination in order to: contaminated land has been identified as The one issue missing from all the LCBL • sentence to LLW disposal an issue. The ability to provide reassurance summaries is the need for environmental of the absence of contamination is likely to sampling. This is probably driven by the • segregate clean and exempt materials. be a key step in determining the long-term current perception that there is little need to These are common challenges and it is use of sites. Therefore increased speed improve current practice. This in fact may expected that improved techniques would of characterisation to greater depths and not hold true in the future when significant benefit all the NDA sites. Rapid assay of to lower concentrations of radioactive clean-up has taken place and there may be a wide variety of materials is important contamination is an important requirement. a need for greater reassurance before the and increased capability to survey management and surveillance of sites is 4. Techniques to characterise specific reduced. convoluted geometries would be a desirable wastes and materials advancement. These techniques are more site-specific Opportunities (or rather facility-specific). Unlike the above No specific characterisation opportunities techniques where the goal is measurement were identified apart from a generic one of radioactivity, they are focused on the to ensure that the necessary experimental chemical and physical properties of the bulk facilities are available. materials.

Key issues – Contaminated land

Clean-up Stakeholder Climate change technology engagement

Activity Environmental Contaminated retention impact land mechanisms

Leaching: Model of a radioactive plume of End point • Mechanism contaminated ground water. • Modelling (Courtesy Nexia Solutions).

28 NDA R&D Needs, Risks and Opportunities

6.4.2 Processing of radioactive • chemicals Techniques for waste minimisation wastes • organic and combustible materials There is no unified approach to waste We identified four major themes common to minimisation because different drivers are • uranium hexafluoride cylinders most sites for waste management. These seen to be important at different sites. are: • lead Certainly, better characterisation of wastes and redundant facilities will focus effort more 1. Retrieval of historic wastes especially • oils effectively on waste minimisation. Given sludges. that the waste already exists, the emphasis • sand filters 2. Processes to assist waste minimisation. needs to be placed on minimising additional • resins waste produced during the processing 3. Re-categorisation of wastes as LLW or of wastes and the decommissioning of • IONSIV cartridges clean and exempt. redundant facilities. It will be important to • desiccants use the correct parameters in measuring 4. Packaging wastes for disposal or interim waste minimisation, since volume alone is storage. • mercury too coarse for the complexity of issues to be addressed. Common issues • asbestos Techniques for sludge handling Reactor sites have waste desiccant from One aspect of waste minimisation is The difficulties associated with retrieving, re- gas drier circuits that is currently stored in cutting, shredding and compaction. For mobilising and pumping wet heterogeneous sealed drums until a method for passive many sites, both ILW and LLW wastes are sludges and also some resins from a range immobilised storage is identified. Generic processed using a range of technologies that of storage facilities are identified by many solutions may involve collection for treatment reduce the size and volume of waste. One sites. Improved techniques that would apply at a common facility or in some cases specific issue is the removal and handling to a variety of sludges without the obvious decontamination for reuse or recycling. of irradiated and hence brittle graphite sleeves which has the potential to generate disadvantages of effluent generation or There is little incentive for individual sites to undue mechanical complexity are clearly large quantities of small particles which are invest in new technology for small arisings of hazardous and difficult to package. desirable. wastes. This is a case where a co-ordinated Miscellaneous wastes requiring treatment UK-wide approach is more likely to lead to Techniques for treating fuel element effective solutions to the benefit of all. debris and radioactive sources Sites have a wide range of miscellaneous wastes, usually secondary process wastes or Many sites have fuel element debris and small volume wastes that may be radioactive radioactive sources in storage and will need or simply hazardous. A number of these remote-handling technology to remove these are unsuitable for treatment in available items from storage holes and vaults as well facilities. Techniques commensurate with the as treatment facilities for packaging, storage waste hazards will be needed for retrieving, and disposal. handling, sorting and processing or reusing wastes. Wastes and materials that have been identified include:

Key areas – Plant washout

Characterisation: Process Contaminated Physical flowsheet mechanisms Radiochemical

Residual solids POCO/ Oxide dissolution e.g. HASTs Decontamination

Environmental 3T ingress steels Waste disposal impact HAST solids formation (Courtesy Nexia Solutions)

29 NDA R&D Needs, Risks and Opportunities

6. Summary of the major clean-up and decommissioning challenges (continued)

Treatment of historic wastes drums Technical issues associated with transport Techniques for the care and maintenance Development of a processing and disposal relate mainly to achieving a satisfactory of waste stores route for waste drums produced at Harwell safety case, which means having a sufficient It is assumed that a repository will be (originally destined for sea disposal) understanding of the waste behaviour available for disposal of ILW in 2040. In could take account of wastes with similar during transport. A more radical approach the meantime, stores will require care composition and inventories elsewhere. may be needed for the transport of large and maintenance particularly of handling items arising from decommissioning. Size systems for package retrieval, systems for Improved techniques for managing gases reduction to fit existing containers and environmental control and building cladding. Flammable and hazardous gases are transport may not be efficient and options Control systems will eventually become generated from the corrosion of reactive for non-standard or even unconventional obsolete and may need to be replaced. metals and waste degradation and ageing. approaches could be investigated. National policy may change leading to Gases have the potential to impact on all Storage strategy accelerated or delayed disposal, or to stages of waste management and in order to continued surface storage, in which case Many sites have constructed, or plan to manage this safely, plant operations typically consideration would have to be given to construct, stores for the interim storage make pessimistic assumptions, which often extending store lifetimes. necessitate over-engineered solutions. of a range of wastes, while other sites are Improved methods for the measurement, planning to transport waste off site for Techniques for waste package monitoring assessment and control of gases would storage. Rationalisation of the numbers, and inspection support more realistic plant design and designs and locations of stores would make Successful storage of highly active and greater waste loads in packages. efficient use of resources and optimise intermediate level wastes for many decades security arrangements. depends upon the ability to provide Process route for asbestos Storage strategy requires consideration of reassurance that the waste and the store are Asbestos is a ubiquitous material used in the the range of waste products to be stored, not deteriorating in any significant way. This construction of older facilities. It increases the development of lower specification will require regular inspection of both the the hazards of demolition particularly stores for some waste categories e.g. waste and the store, which given the high involving manual operations. This material is lower bound ILW and LLW unsuitable for radiation environment within many of the no longer acceptable in landfill sites and an the Low Level Waste Repository, and the stores, requires remote techniques. There alternative route for disposal or packaging storage of waste generated during Care & is scope for more robust and also more solution for storage is needed. Techniques Maintenance, decommissioning and site sophisticated monitoring technologies to will also be needed for separating and restoration phases. Extended storage due provide reassurance and an early warning of collecting asbestos from building rubble. to delay in the development of a repository unexpected deterioration, therefore reducing Transport of waste to another site for long-term disposal, may lead to a need the need for the premature retrieval of waste or the refurbishment of stores. The effective use of the available waste to replace stores, reworking or overpacking processing and storage facilities across the of failed waste packages and the option to Waste disposal develop a central store for all nuclear sites. UK depends upon the ability to transport There are technical challenges associated waste within and between sites. with the packaging of some potentially reactive wastes in forms suitable for long- term storage and disposal. Examples include aluminium, tritiated wastes and thorium wastes.

Metabolism and energy yields

Organic Matter CO2

Sediment/water interface

O2 reduction NO - / Mn4+ reduction 3 Zones of dominant Fe3+ reduction terminal electron accepting processes 2- SO4 reduction

CO2 reduction

30 NDA R&D Needs, Risks and Opportunities

Inconsistencies • A more searching examination is needed • The stability of graphite from reactor Inconsistencies mainly arise from a common where a two-stage strategy is being cores needs detailed study. For example, issue not being identified at all sites. Four proposed for treating some wastes. it is not known whether there would be inconsistencies are judged to be worth Usually, this is because the short-term significant diffusion of C-14 from the noting since they impact on the scope of the need to condition waste for safe interim graphite during interim storage. storage cannot be achieved consistent R&D needs: • A technical case for the disposition of with producing a waste suitable for vitrified HLW has been identified as part 1. Few sites declare the need to understand disposal. The consequences of this two- of the work funded directly by NDA. waste behaviour in order to support the stage strategy are greater expenditure justification of disposal routes for wastes, in the long-term. Therefore options for • Options for graphite treatment are including Nirex letters of compliance. different conditioning technology and required. 2. There is little recognition of a requirement options to remove the difficulties in for waste sorting and segregation disposal deserve study. Opportunities although most sites have heterogeneous • Technology is needed to process the There are clearly many opportunities that will wastes. Segregation may enable simpler residue of ‘higher contamination’ oils and result from having common approaches and waste treatment, waste re-categorisation solvents that are considered unsuitable solutions. For the waste category: or even the recycling of clean and exempt for incineration by existing routes. • Recycling and reusing uncontaminated materials. • There is a need for a consistent approach or lightly contaminated materials is a 3. Several sites identify a need to package to remedial action, i.e. what to do if waste major opportunity to reduce the liabilities tritiated wastes and thorium wastes containers fail during storage and what of waste for storage and disposal. We and a generic treatment facility for each to do if wastes prove unacceptable for should exploit and promote current good waste would promote efficient use of site disposal or indefinite storage. Attention practice in terms of clean and exempt resources. needs to be given to the re-working of materials. For more difficult wastes, such as lead or mercury, an NDA-wide 4. Few sites identify a need to manage lead, failed waste product mixes and/or to approach may lead to a ‘value-for-money’ asbestos and organic wastes although overpacking waste containers that have solution. these materials are expected to occur at failed due to ageing and degradation all sites. during storage. • Using common waste processing plants, • The behaviour of stored wastes for for example grouting, promotes efficient Missing issues periods of time significantly beyond the use of resources and facilitates best The missing issues have emerged from current expected storage regimes of a practice. taking a longer term perspective, in few decades needs to be studied. • Currently, small volume wastes may contrast to the SLCs. A number of technical take as much effort to develop individual challenges have been identified: • Waste processing and/or packaging solutions are required for a number justifications for letters of compliance • Common approaches are required for of wastes that are not in a passive as for major wastes. The development packaging heterogeneous wastes. state such as aluminium, carbide fuels of a standard approach would be more and neutron sources in older reactors effective both for waste producers and containing Am/Be. regulators.

H H 0 0 H H

H EXAFS fitting parameters H 0 0 H Proposed coordination environment H of Np on FeS surface. Np

S S Fe S S Fe Fe Fe Fe S Fe Fe Fe Fe Fe Fe Fe Fe Fe Fe Fe Fe

(Courtesy University of Manchester)

31 NDA R&D Needs, Risks and Opportunities

6. Summary of the major clean-up and decommissioning challenges (continued)

• Adopting standardised grout recipes 6.4.3 Management of strategic Uranium and powder specifications would enable nuclear materials A broader view is needed of the common issues such as changes in materials, Our review of the LCBL summaries focused issues. R&D programmes should include bulk buying and security of supply to on three nuclear materials – uranium, uranium from reprocessing as well as stocks be addressed in a consistent way and plutonium and irradiated fuel as they have of depleted and natural uranium. Uranium produce common package design strategic value and also present significant is stored in various locations and in many specifications. technical challenges with regard to their forms as oxides, hexafluoride, nitrates, • There is scope to improve existing grouts, longer term management. carbides and metal, which raises questions for example through the use of improved about the suitability for long-term storage superplasticisers and the options to use Common issues and options for eventual reuse or disposal. A specific issue involves: alternative cements/polymers should be Generally the LCBL summaries do not examined. identify issues associated with strategic • The need for a process to convert • There is scope for in situ disposal of materials, but these are well covered by NDA uranium hexafluoride to a more stable waste at nuclear sites as a way of supported work. The analysis identified a form, probably as an oxide. range of common issues as follows: managing liabilities more efficiently. Irradiated fuel • NDA supported work has identified that Plutonium The situation regarding irradiated fuel is better rationalisation of strategies to Most of the Sellafield issues are expected to incomplete. There are stocks of various manage LLW has the potential to deliver apply to Dounreay as well as Sellafield. types of fuels at Harwell, Winfrith, Dounreay large savings at Sellafield and Calder Hall. and Sellafield which all need to be included • There is a need to understand the long- Similar opportunities are likely exist at the in studies of continued storage, disposition term behaviour of separated plutonium other sites. or recycling. dioxide. • Development of synergies between • There is a need to be able to immobilise Inconsistencies British Energy and Magnox dual sites. Pu residues (i.e. materials which are As the total picture is incomplete, it was not unsuitable for recycling into fuel). possible to identify inconsistencies. • There is a need to ensure effective MOX fuel manufacture to expedite the return of Missing issues Pu oxide to overseas customers. One key missing issue was the need for a suitable decision-making framework that could balance the value of the strategic nuclear materials in the long-term with the requirements of long-term storage and, Calcite-water interaction possibly, disposal.

Photodetector

Laser beam

Cantilever Tip

Line scan

Surface AFM (Atomic Force Microscopy):

Tip atoms • surface topography 3-D • z-direction in Ångströms Force • area up to 40 µm • takes images in UHV, in air and in solution. Surface atoms

32 NDA R&D Needs, Risks and Opportunities

Plutonium Common issues The perceived disadvantages of current A study is needed of the options for the Removal of plant contamination decontamination techniques are the need to manage the effluent arisings and the disposition of separated civil plutonium from • Improvement in techniques to survey for incompatibility of the decontaminants with the UK’s reactors to include the: radiation and contamination. existing effluent and waste processes. • feasibility of recycling Pu within UK This is the same issue described in the Effluent management reactors characterisation category and, whilst not identified by every site, it is judged to be The common issues associated with effluent • options for immobilisation in forms universally beneficial. management are linked to decontamination suitable for disposal or long-term storage. operations: Uranium • Improvement in decontamination techniques. • Improved techniques to process chemical Options for the disposition of stocks of decontaminating reagents. highly enriched uranium are needed, along Two key objectives were identified that with options for treating stocks of depleted underpin improvement in this area: Development of processes and systems uranium metal. to treat chemical decontamination agents – The reduction of radiation dose rates would enable most sites to achieve higher Irradiated fuel to enable man-access to facilitate plant degrees of decontamination. dismantling. The missing issue is that of a holistic UK • Mobile effluent treatment plant. approach as outlined earlier. – The reduction of contamination to enable wastes to be re-categorised For sites without an operational effluent Opportunities as LLW or even clean and exempt system, the provision of mobile effluent No opportunities were identified but this materials. treatment plant would enable the use of needs to be revisited as the complete UK aqueous decontamination agents. The In some cases, the contamination is mobile picture emerges. challenge is to provide technology that (liquid, dusts and powders), demanding does not create additional liabilities or techniques to access convoluted geometries unacceptable safety issues. 6.4.4 Plant termination and and to remove residual traces of material. decommissioning The technological focus is to loosen and • More efficient ion exchange materials to collect material, often in areas of restricted treat aqueous effluents. There are three sub-headings in this access. One example is the removal of the category: Efficient ion exchange materials that can final traces of radioactive sludges from the be used in a replaceable cartridge have the 1. Removal of plant contamination. base and walls of empty reactor ponds. capability to improve the functionality of 2. Management of effluents. In other instances, the contamination is fixed a mobile effluent treatment plant. For the onto surfaces, often steel or concrete. This sites with a centralised effluent treatment 3. Plant dismantling. requires technology that disrupts or dissolves system, ion exchange materials with There is a spread of issues across all three the surface to release the radioactivity. High higher capacities for radionuclides are also categories with Reactor sites generally energy technologies using inert agents may desirable. having fewer issues than the chemical plant be appropriate, while the more conventional sites, notably Sellafield and Dounreay. approach is to use aggressive chemical reagents. One application for improved decontamination techniques could be the reactor defuelling machines.

Plant termination and decommissioning There are a number of issues in the area of plant termination and decommissioning that we need to address through innovative and fit for purpose R&D. The challenges relate mainly to the chemical plant sites and are associated with plant contamination, the management of effluents and plant dismantling.

33 NDA R&D Needs, Risks and Opportunities

6. Summary of the major clean-up and decommissioning challenges (continued)

Plant dismantling Inconsistencies Common issues There were a great variety of issues identified No inconsistencies were apparent The LCBL summaries do not reveal any by the sites regarding plant dismantling. We from the LCBL summaries. However, significant common issues, which given the extrapolated issues identified at a few sites decommissioning of the tritium plant at remaining operational life of the reactors and with similar liabilities and found the following Chapelcross does present some issues not the diversity of the chemical plants, is not common issues: found at the other reactor sites. surprising. However, one issue pointed to the need for better technical underpinning of • Size reduction of large items. Missing issues subsequent asset decommissioning. Dismantling contaminated items is necessary As most of the issues were included in Historic information to enable packing into suitable containers for a least one site LCBL, there is only one There is a need to harness and share storage and disposal. Even items that do not missing issue. the pool of operational experience and need to be packaged will need to be size- Removal of plant contamination knowledge relating to all assets to accelerate reduced for storage or transport. Improved decommissioning. In addition, a common technologies are needed to: Applied decontamination technology and techniques for large structures (steel and approach for creating and archiving asset – increase the rate of cutting. concrete) such as heat exchangers, reactor records is needed. – reduce dust, fines and fumes pressure vessels and biological shields Inconsistencies generation. creates the opportunity to re-categorise large volumes of waste to less demanding No inconsistencies were identified. – contain the contaminated dust, fines and less expensive categories. and fumes. Missing issues – support items while cutting is Opportunities The LCBL summaries do identify all undertaken. One opportunity was identified for plant the assets at all sites. Consistent and dismantling: complete strategies for the surveillance and • Fixing mobile radioactivity to surfaces. maintenance of assets are needed. • Temporary containment around large Several sites will have ventilation systems, structures. Monitored storage is a significant issue for or similar plant, where slightly contaminated both wastes and strategic materials and The erection of temporary containment dust has collected over decades of applies to the containers and changes to around large structures might permit operation. Preventing the dispersion of this contents. More effort is needed to address faster dismantling as less restrictive dust dust during dismantling would simplify the these R&D needs. operation and reduce the hazard. control measures would be needed. The containment needs to be light yet robust and Opportunities • Remote dismantling technologies. cleanable for reuse. No opportunities were identified. Early dismantling of reactor cores accelerates the challenges of remote 6.4.5 Asset management operations. There will be common issues 6.4.6 Site restoration Care and maintenance of ageing facilities with the dismantling of high radioactive and operating systems is vital. The The timescales for site restoration vary chemical plant at Sellafield and Dounreay. requirement for techniques to support greatly across the LCBLs and consequently There is a clear incentive to develop a the effective inspection and condition the detail at which technical issues have common approach for the reactors, even monitoring of assets is common to all been identified also varies. though they differ in detail. Tools to explore asset management activities including and rehearse dismantling techniques for those supporting electricity generation. Common issues example by virtual reality and full scale mock- In certain facilities, the implementation of Common issues for site restoration fall up will be important to minimise ‘re-inventing revised operating practices and process broadly into two areas, site investigation and the wheel’ for each reactor. performance improvements will shorten technology requirements. This is an area • Asbestos programme timescales and mitigate risk, where the NDA – funded work has identified for example in the operation of highly active a number of common issues as follows. Asbestos will be an issue at most sites and liquor evaporation at Sellafield. this has been discussed earlier.

34 NDA R&D Needs, Risks and Opportunities

Surveying and characterisation of Ground remediation Consistent site end point strategy contaminated land Ground remediation is often assumed The site end point will influence the Site surveying and characterisation to involve excavation followed by simple strategy for clean-up and land remediation investigation are important prerequisite packaging and transport to a disposal site. throughout the various programme stages activities for the restoration at all sites. However, where this is not practicable or leading to site restoration. It is therefore A range of site and waste specific appropriate, alternative solutions will be necessary that consistent standards characterisation technologies will be needed, required. and approaches are agreed early with depending on the extent of contamination. stakeholders and propagated across the Building slabs For example at the Low Level Waste NDA sites. Repository, there are a number of significant A number of sites have identified advantages Climate change and coastal erosion issues, namely, near and far field studies, in retaining building slabs to then landscape geochemistry and risk models, contaminant over. A common approach is needed to Whilst this is missing from the LCBL transport, coastal erosion, saline interfaces promote best practice. summaries, the NDA directly funded work has identified the need to update the current and colloidal transport. Providing public reassurance understanding and assess the scale of the Monitoring and care of contaminated land Monitoring regimes to reassure the public are technical challenge associated with climate A number of sites are assuming that most likely to be needed for many, if not all change and coastal erosion. much of the existing radioactive ground sites. Consistent standards and approaches contamination will be retained in situ during are needed, taking into account the extent of Opportunities Care & Maintenance with and without potential hazard. No opportunities were identified. engineered enhanced containment. A wide range of activities will be needed to support Inconsistencies this including the monitoring of boreholes No inconsistencies were identified. and drain outlets to confirm contamination is within the bounds of the safety case, and Missing issues maintenance and replacement of monitoring Chemo-toxic hazards installations and engineered containment. The management and remediation of chemo-toxic materials will be an important aspect of site remediation.

Research & Development Plutonium co-ordination • NDA will establish direct (Courtesy University of Manchester) contracts with organisations to {PuO } 2++[BiW O ]9- Key Co-ordinated Unco-ordinated support R&D activities when 2 9 33 generic to a number of our sites.

• Output of all R&D activities Absorbance will be made available to other organisations that are delivering work scope on NDA sites. 800 825 850 875 900 925 950 975 1,000 1,025 Wave length (nm) • NDA will annually produce an overview of R&D activities supported by the NDA.

35 NDA R&D Needs, Risks and Opportunities

7. Generic issues identified in LCBLs

Our analysis of the LCBL summaries has highlighted several generic issues that apply to all the R&D categories and are key to the successful implementation of the NDA’s R&D programmes.

36 NDA R&D Needs, Risks and Opportunities

Deconversion operations using the Sharing best practice will help overseas Vitrification immobilises high level Integrated Dry Route (IDR) process. sites to develop effective and safe waste for long-term storage. decommissioning strategies.

The four top-level issues: 1. There is a need to share good practice between sites. 2. The requirements for experimental facilities need thorough evaluation. 3. There is a need for technology to support contingency plans (should the principal options prove unworkable). 4. There is a need for consistency in the criteria for selecting technology options. This is apparent in four challenges where decisions at site-level need to be evaluated in terms of the impact upon the whole of the NDA’s liabilities: − How to maximise the use of existing assets in the treatment all wastes. − How to have consistent methodologies to support safety and environmental performance. − How to ensure consistent economic modelling is input into decision-making. − How to evaluate the benefits of transferring liabilities between sites.

Technical baseline – Deconversion operations

1 Process – Conversion

of UF6 to uranium oxide using the Integrated Dry

External Route (IDR) process. storage racks

2 3 4 5 6

Deconvert Inspection

Receipt Storage in former Storage in former diffusion plant diffusion plant

37 NDA R&D Needs, Risks and Opportunities

8. Strategy for undertaking R&D

The previous analysis illustrates the breadth of the technical challenges that need to be tackled. Our strategy is to adopt a multi-stranded approach to addressing the technical issues. We appreciate that much R&D has already been undertaken, spanning more than two decades, by the previous owners of the nuclear liabilities.

38 NDA R&D Needs, Risks and Opportunities

Development of techniques to characterise waste materials for treatment and disposal.

Our strategy, therefore, is to build on the Whilst the NDA aims to accelerate clean-up In view of the consequences of developing base of experience that already addresses and make substantial progress early, we also the wrong or inadequate solutions, the NDA many of the same goals that still exist recognise the need to establish sufficient will expect programmes of applied R&D to today. In terms of new goals and issues, basic R&D to underpin later aspects of our undergo rigorous challenge at each stage. we are seeking new R&D programmes to mission. Where this underpinning R&D is Whilst external peer review will take place, complement the existing capability. specific to a site, then the site in question will programmes must contain mechanisms to lead the programme of work. challenge assumptions, goals and methods The strategy for undertaking R&D has three etc. It is essential that the R&D programmes key elements: The NDA is keen to take advantage of the have robust mechanisms in place to select intellectual capital that exists within the UK’s 1. Basic underpinning research. the most credible and robust options for universities. Our basic research programmes development into deployed solutions. 2. Applied research. should be a fruitful area for university collaboration. We anticipate that some of Given the specific focus of applied research, 3. Technology transfer. the research will be conducted within a the NDA is looking for value for money, university’s own facilities. However, where which means delivering R&D solutions to 8.1 Basic underpinning studies involve radioactive material, it will more than one problem. We expect the research be necessary to use the NDA’s specialised development of more robust solutions, e.g. facilities. In the absence of suitable NDA less sensitive to waste composition and Where the options for managing the facilities we will access international facilities. more tolerant to product specifications etc, liabilities are not robust, basic research We plan to give university researchers flexible will generally yield more workable solutions. will be required to increase the detailed use and access to our facilities so that they understanding of the technical challenges The opportunity to deliver aspects of can fully contribute to meeting the NDA’s and their related issues. Basic research the applied research is open to a wide research needs, possibly beyond what they would be of key benefit in a number of variety of research organisations. At the could achieve in their own facilities. areas. For example, a greater understanding problem definition stage there is scope of waste is required to ensure the effective for ‘desk-based’ analysis and modelling implementation of its safe retrieval, treatment 8.2 Applied research work. This will extend into the early stages and storage at low technical risk. Applied research focuses on delivering a of option development and beyond that, experimental studies. We anticipate that the With regard to managing materials such solution to a specific problem and we expect R&D programmes will involve initial non- as uranium, plutonium or irradiated fuel, most of the R&D carried out for the NDA will active studies using stimulants, progressing basic research would also help to identify fall into this category. We define success through to work using radioactive material. innovative approaches to determine how in this area as a thorough definition of the best to treat and manage such materials problem and a clear understanding of the Clearly, work with radioactive material will longer term. constraints within which the solution must require specialised facilities, fumehoods, operate. Usually, applied research will be gloveboxes, and in some cases highly active Finally, basic research will help us to carried out in stages, moving from problem cells. As with the basic research outlined understand more fully the issues associated definition through to option development and previously, we are looking for a flexible with long-term storage and eventual disposal industrial demonstration. approach to gain maximum value from the (if that becomes an option) – a fundamental limited specialised facilities. requirement of the NDA’s mission.

39 NDA R&D Needs, Risks and Opportunities

8. Strategy for undertaking R&D (continued)

8.3 Technology transfer 8.5 Development of the • The final disposal of radioactive wastes. Technology transfer involves adapting and NDA’s R&D portfolio The final disposal of radioactive wastes will deploying solutions developed elsewhere, From our analysis detailed earlier, the not be resolved quickly or simply. It is evident both in the global nuclear industry and in the breadth and scope of the technical issues that a consistent and robust site-wide non-nuclear industry. The advantages are still to be addressed are evident. In order to strategy is needed. Uncertainties will remain obvious in terms of time and cost savings develop an R&D portfolio in a logical manner for a considerable time and the technical to deploy a solution developed elsewhere. and to minimise the potential confusion and programme needs to offer solutions that However, correct assessment is needed of conflict between individual programmes, we minimise the impact of such uncertainty. the applicability to the NDA’s challenges to intend to develop the portfolio under three The technical approach will be focused in ensure that the transferred technology is as priority themes: three areas: robust as it needs to be. – Understanding the challenges and 1. Addressing common issues We will encourage the use of technology implications of long-term storage. transfer as a way of meeting our R&D needs. There are significant gains to be made We will expect R&D providers to be fully by solving common issues with common – Development of remedial options. solutions. Whilst this may result in some aware of technology that exists around the – Continued search for improved short-term delays at some sites the overall world and through adaptation offers cheaper solutions. and faster solutions compared to developing benefits in terms of value for money and technology from scratch. earlier resolution of issues across the • The final disposal of strategic materials whole spectrum of the NDA’s sites are Given the quantity and variety of strategic considerable. 8.4 Collaboration and materials (including irradiated fuel and co-operation The forward programme will involve: separated Pu) there remain large unresolved technical issue for the NDA. It is clearly • Understanding the common issues more We anticipate that collaboration and necessary to develop a consistent approach thoroughly. co-operation between R&D providers will taking account of the current uncertainties yield substantial benefits. The long-term • Targeting the issues where common and scope for change in the UK’s priorities nature of our vision requires access to a solutions provide the greatest benefit. over this material. It is intended to develop a secure technology base that will help us technical approach focused in six areas: to accelerate clean-up and provide value • Inviting R&D providers to offer more for money. The NDA will encourage R&D robust and effective solutions. – Stabilising strategic materials for long- providers to explore how they can meet term storage. Addressing long-term issues these needs through collaboration and co- – Understanding the challenges of long- operation. There is a clear need for a consistent term storage. and far-sighted approach to longer term A key area is the efficient use of specialised issues. Short-term hazard reduction and – Developing options for better long-term facilities, already described previously. demonstration of progress in clean-up storage. In addition, each R&D provider needs to must not detract from the need to resolve recognise skills and experience that exist challenging issues in two key areas: – Understanding the ‘value’ of the elsewhere that can contribute to the delivery strategic material. of robust, cost-effective and time saving – Understanding the options for and technology solutions. impact of disposal. – Developing options for reuse and recycle.

40 NDA R&D Needs, Risks and Opportunities

Addressing site end points Scope for innovation Publishing this document is our way of The end points of individual sites clearly have A core theme that we encourage is inviting the R&D community to become a large impact on the scope of the clean-up innovation. By innovation we mean more proactive by identifying potentially and decommissioning programmes. There technology that offers different approaches advantageous technical solutions to the is considerable variation between the LCBLs to deliver our mission cheaper, faster and challenges outlined. on the definition of the end points and it is safer. Our analysis in terms of common Communication of R&D programmes not clear that there is a consistent approach issues, inconsistencies, gaps and We will continue to share the results of across all sites. We believe the technical opportunities is a basis for R&D providers to the NDA’s R&D programmes amongst the challenges of clean-up and decommissioning take a different perspective on the technical SLCs and R&D providers. In addition we need a more consistent approach to site challenges by injecting their own innovative will continue to publish information about end points. It is to be expected that for thinking into solutions they offer, either the R&D programmes to encourage greater certain sites there will be considerable input directly to the NDA or to the SLCs. cooperation and to stimulate more innovative from regulators and the public as to the Means of delivering R&D thinking towards solving technical issues. future safety and evolution of sites. The R&D programme needed to underpin the delivery We intend to adopt the existing policy of of our clean-up and decommissioning goals undertaking the bulk of our R&D programme will focus on five key areas: through the SLCs. At the same time, we will have a small direct R&D portfolio for issues – Standards for characterisation of sites. that do not readily sit with the SLCs. The – Technical options for long-term care SLCs will define the detailed scope of the and maintenance. R&D and will seek delivery through a number of R&D providers. We will re-examine the – Technical options for environmental precise split between the SLC programmes monitoring. and the direct portfolio. – Technical options to minimise the impact of buried radioactivity. – Technical options to remediate buried radioactivity.

Research & Development • Site Licensee Companies (SLCs) are accountable for conducting R&D programmes to deliver the LCBL – innovative improvements. • The majority of NDA R&D will be conducted by the SLC as an integral part of LCBL activities. • Requirements for the identification of these R&D plans are described in the NDA procedure – Life Cycle Baseline requirements.

U-Tc complex formed using the Purex process. (Courtesy University of Manchester)

41 NDA R&D Needs, Risks and Opportunities

9. Conclusions and summary

This document represents our first site-wide review of R&D needs. It has reviewed individual site perspectives of R&D technical challenges to give a broader context and generic perspective.

42 NDA R&D Needs, Risks and Opportunities

All processes and site activities are The acceleration of clean-up programmes Computer generation of the final regularly monitored. must be carefully balanced with their end point of the Sellafield site. environmental impact.

The document provides a summary of the technical issues, taken from the LCBLs, in a format, which is easy to digest and understand. We believe our objective of providing a comprehensive view has been achieved. Refinement of the way we describe the issues will probably evolve and emerge in later versions of this document. One of the most significant outcomes of the site-wide analysis is the scope that exists for R&D to tackle common issues across sites with the potential to deliver more effective solutions. The site-wide view has also given us a better perspective on most of the long-term issues, even where these have not received specific attention in the individual site LCBLs. The importance of consistent approaches that are robust to changes in political policy or public perception has been emphasised. Throughout this document, we have set out our view of the approach we wish to take in addressing the major technical issues. The messages contained in this document are intended to provide a stimulus both to the SLCs and to current and potential R&D providers.

Technical baseline – Decommissioning through to site end state

Land investigation

Decontamination and demolition

Ground water sample analysis

43 NDA R&D Needs, Risks and Opportunities

Appendix 1

NDA R&D policy

Our policy is that the Site Licensee Our policy will be to establish direct Our policy will be to work with the Companies (SLCs) are accountable for contracts with organisations to support SLCs, regulators, universities and other conducting Research & Development Research & Development activities where interested organisations to ensure that UK programmes to deliver the LCBL, including they are generic to a number of our nuclear Research & Development activities are progression of innovative improvements sites. Our direct Research & Development communicated and co-ordinated against to these plans and supporting longer term work areas will include support for innovative the NDA mission. Furthermore, we will look programmes which are site specific. The ideas evolving from the supply chain, to consider technology options available majority of NDA Research & Development technical underpinning of strategic and worldwide to ensure the most appropriate will be conducted by the SLC as an integral policy issues, maintenance of long-term technologies and thinking are applied part of LCBL activities. The requirements strategic options and underpinning key skill against the NDA mission. The NDA has for identification of these Research & requirements. We will actively encourage established the ’NDA Research Board Development plans are described in the idea generation from the supply chain. When on Nuclear Decommissioning and Waste NDA Procedure – Life Cycle Baseline Research & Development projects mature Clean-up’ where Research & Development Requirements (NDA PCP 02). We will assess into site specific applications, then affected programmes from the NDA and other the LCBL for each site to evaluate the sites will be invited to consider the work for organisations will be shared and evaluated, appropriateness of Research & Development incorporation into LCBL activities. with the intent of communicating and looking activities in terms of (a) delivering LCBL for collaboration of R&D activities. Our policy is that the output of Research Research & Development ‘needs’ (b) & Development activities funded by systematic identification of technology the NDA either directly or through SLC needs, risks and opportunities in delivering activities, should be made available to the LCBL and carrying out of Research & other organisations that are delivering work Development activities that reflect the value scope on NDA sites to support the clean- of these to delivering the LCBL effectively up mission, taking into account relevant and to reduce and eliminate these risks(c) IPR issues. We will annually produce an delivering innovative improvements to overview of Research & Development LCBL by identification and technical activities supported by the NDA in a underpinning of ’opportunities’. (d) that publication ‘Technology Needs, Risks and the tier 1 contractors are investing in a Opportunities’, which will be made available balanced portfolio of R&D that meets the via the NDA web site. This document will be short, medium and long-term requirements coordinated with the production of LCBL of the LCBL. (e) that tier 1 contractors are documentation. systematically applying the R&D where appropriate to ensure the delivery of the LCBL. Where there is benefit for multiple site programmes that meet the requirements across a number of sites, the NDA will consider approaches that will enable single point leads on key national issues.

44 NDA R&D Needs, Risks and Opportunities

Appendix 2

Summaries of technical issues identified in the Life Cycle Baselines (LCBLs). Each LCBL has been scrutinised for technical issues and these have been placed in the appropriate research categories, as discussed in the main text. A table of issues for each of the NDA sites are presented in this appendix. The tables are grouped in the following order:

Reactor sites Research and chemical processing sites

1. Berkeley 7. Hunterston A 12. Capenhurst 17. Sellafield 2. Bradwell 8. Oldbury 13. Culham 18. Springfields 3. Calder Hall 9. Sizewell A 14. Dounreay 19. Windscale 4. Chapelcross 10. Trawsfynydd 15. Low Level Waste 20. Winfrith 5. Dungeness A 1 1. Wylfa Repository 6. Hinkley Point A 16. Harwell 14

7

4 Opportunities exist to share Decommissioning a redundant plant 3 existing solutions for the presents both a challenge and opportunity 17/19 storage of waste. for the Site License Companies. 15

18 11 12

10

9 2 1 13 8 16 6 5

20

45 Reactor Site

1. Berkeley

Berkeley houses two Magnox reactors, the Magnox power station headquarters, and their centre for engineering and technical support. Innovative clean-up technology should enable it to become the first nuclear site to enter care and maintenance in 2009.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation of hazards 2. Management of radioactive waste 2.1 Waste retrieval and transfer Complete retrieval of legacy waste from active waste 2005-2009 N Design and development of the retrieval equipment for vaults. installation within existing building. Residue wastes (sludge, fines and gravels) at the base of R Retrieval rates are underpinned by operational research the Active Waste Vault are uncharacterised and difficult to modelling. Further activities will establish a robust spares recover delaying the C&M phase. strategy and robust performance in plant specifications. Retrieval of resin, sludge and other aqueous wastes from 2005-2009 N the caesium removal plant. Waste transport and disposal regulations change. R Monitor and influence the development of waste transport and disposal regulations and requirements. Waste volume and activity estimates change. R Regularly review and update the predicted waste arisings. 2.2 Processing, conditioning and packaging Processing and packaging of legacy waste from the 2005-2009 N Package for interim storage and disposal. active waste vaults, PIE store and resin, sludge and other aqueous wastes from the caesium removal plant. Non- hazardous waste will be collected for off site disposal and scrap metal will be recycled. 2.3 Waste recycling and reuse 2.4 Waste transport 2.5 Waste storage strategy On site storage of packaged legacy and decommissioning 2009-2049 N waste until disposal. Unable to gain approval of the safety case for the R The generic store design and generic store safety case does operation of the ILW store. not preclude partially underground stores. Early engagement with the Regulator to mitigate this risk. National waste repository is delayed. R Unplanned refurbishing of store may be needed. 2.6 Waste disposal Dispose of decommissioning LLW, including waste from N Littlebrook, at the LLW Repository. Process organic liquid LLW and sentence for off site disposal or incineration. Waste disposals at the LLW Repository are restricted by R Ensure adequate short-term on site storage capability. regulators. 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel

46 NDA R&D Needs, Risks and Opportunities

Berkeley

Need/risk/ Issue Timescale opportunity Characteristics of a solution 4. Plant termination and decommissioning 4.1 Removal of plant contamination 4.2 Management of effluents 4.3 Plant dismantling Decontamination and demolition of shielded area, waste 2005-2009 N Clean-up remaining site hazards, decontaminate and compound, active effluent treatment plant for caesium dismantle laboratory cells and incinerator. Placing the reactor removal and other redundant buildings. Transfer ILW from building and plant in quiescent storage requires stabilisation the waste compound to the shielded area to enable the of the primary circuit components, asbestos management waste compound to be deplanted and demolished in and plant and building modifications. 2006. O Decommissioning of part of the site is to be accelerated and delicensed first to provide an opportunity for redevelopment. Contaminated land remediation and survey to support 2006-2010 N Monitor radioactivity levels to demonstrate adequate production of the site’s safety case for entry into the care contamination control and compliance with authorised and maintenance phase. discharge limits. Survey will help to define remediation required and show that previous hazards will not impact on possible future development. Additional maintenance to building structure required e.g. R Regular building surveys and site inspections particularly more rapid degradation of cladding than predicted during after severe weather events for early detection of C&M. degradation. Replacement of cladding is planned after 30 years and the design will be reviewed and upgraded if early degradation occurs. 5. Asset management 5.1 Reactors 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Monitoring and maintenance of reactor buildings 2009-2074 N Obtain radiological information through reactor building especially external cladding during C&M period. internal inspection visits, sampling and surveys. Limited off site monitoring will include sampling and assay of green vegetation to measure ambient levels of radioactivity in the local environment. The C&M period will allow benefits of radioactive decay to be realised. Internal radiation of reactor decays as predicted during R Radiation levels will be surveyed before final site closure. Care & Maintenance. Higher than expected radiation will require additional robotic handling. 6.2 Site end point

47 Reactor Site

2. Bradwell

Bradwell power station ceased generation in March 2002. Removal of spent fuel will be completed in 2006, and this will be followed by the start of dismantling and demolition, and radioactive waste treatment and storage.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation Feasibility study on remote monitoring of reactor. 2015-2017 N Liaison with Safestore and waste store projects for The assessment phase of this project involves: monitoring requirements. • Identification of remote monitoring requirements. Review of monitoring requirements for environmental, • Confirmation of standards and design criteria i.e. minimum safety and security required during the C&M period. 10 year life span for individual pieces of equipment. To identify and agree the scope and prepare tenders for • Essential for easy access and replacement. the design, construction and commission phases. • Minimum maintenance. Preparation of tender for both remote monitoring. • Provision of uninterrupted power. Determine the rate and quantity of hydrogen generation during 2008 R The active ventilation systems will be capable of the Magnox FED encapsulation process. ensuring the hydrogen in air level does not exceed the design criteria of 1% v/v. The project design is based on the presence of Magnox sludge 2008 R at the bottom of the FED storage vaults, estimated as 13% of the volume of the FED consigned to the vaults. Radiological assay systems for crates and drums in the LLW 2014-2015 N facility. LLW undertake bulk shielding assessment. 2005-2008 N 2. Management of radioactive waste 2.1 Waste retrieval and transfer Characterisation of ILW. 2005-2008 N Estimation of total number of waste containers needed (wet and solid). Physical segregation of the retrieved wet and solid ILW. N The FED vaults sludge that will be recovered and separated 2005-2008 N from the solid waste. Disposal route for asbestos is not available i.e. use of landfills is 2009-2011 R Investigate alternative disposal strategies. no longer possible. 2.2 Processing, conditioning and packaging Assess implications of hydrogen generation rates. Assess 2005-2008 N implications of uranium in solid wastes. Solid ILW concept design. 2005-2008 N Carry out indicative corrosion assessment of the solid waste packages. Develop waste sort concept design including wet and solid separation. Produce a Best Practicable Environmental Option (BPEO) study. The issue, with respect to Nirex compatibility, of corrosion issues 2008 R with mixing graphite and Magnox FED is not resolved. 2.3 Waste recycling and reuse 2.4 Waste transport (internal and international) 2.5 Waste storage strategy 18m3 of desiccant from the gas drier circuits has no agreed 2008 passive immobilised storage that will satisfy the NII and EA. Current strategy is unencapsulated storage.

48 NDA R&D Needs, Risks and Opportunities

Bradwell

Need/risk/ Issue Timescale opportunity Characteristics of a solution 2.5 Waste storage strategy (continued) ILW storage concept design including: 2005-2008 • Assess requirements for natural ventilation. • Determine dose at store and station boundaries. • Preliminary store and bounding consequence calculations. • Determine preliminary shielding requirements for store and packages. • Develop requirements for solid ILW facility. • Develop requirements for wet ILW facility. 2.6 Waste disposal 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel 4. Plant termination and decommissioning 4.1 Removal of plant contamination At present, it is anticipated that there could be internal 2008-2009 contamination in pumps and motors in the boiler house (LLW). This scope assumes a decontamination process will be developed during the NTWP period to minimise the contaminated materials. Removal and decontamination of pond plant and furniture, A trial will be required to establish the amount of pondwater treatment plant, cooling ponds and ventilation plant. contamination on the skips and the most appropriate Cleaning and draining of ponds and transfer tunnels. way of removing it. Complete decontamination of pond building structures Minimise the generation of ILW. – including demolition of fuel transfer tunnels. 4.2 Management of effluents 4.3 Plant dismantling Complete decontamination of waste vaults. Minimise ILW and effluents generated. Feasibility study for design of containment tent. Construction of 2014-2015 negative pressure containment tenting over the ponds complex. Vault demolition. 2014-2016 Minimise ILW and LLW. Exploit opportunities for recycling and reuse. 5. Asset management 5.1 Reactors 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Site characterisation. 2017 onwards 6.2 Site end point

49 Reactor Site

3. Calder Hall

Calder Hall was the world’s first commercial scale nuclear power station. Electricity generation ceased in 2003, and removal of spent fuel from the four Magnox reactors will start in 2006. Clean-up operations are proceeding in parallel.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation Survey of inventory of control rod legacy silo stores. From 2005 N Water sampling and underwater probes may show inventory O is incomplete. Potential for waste re-categorisation leading to faster retrieval and a lower specification store. Improved waste characterisation techniques in the new 2005-2010 O Rapid and reliable sentencing. waste management facility. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Construction of ILW retrieval facility and mortuary store for 2005-2008 N control rods. Retrieval of miscellaneous activated components from the 2005-2019 N bioshield mortuary holes. Retrieval process for mortuary holes is not robust. R Alternative method. Removal of AGR partition rod, which is jammed in a N storage hole. 2.2 Processing, conditioning and packaging Provision of a waste management facility for ILW, LLW, 2005-2010 N Potential for use of Sellafield waste management facilities hazardous and non-hazardous waste from interim O to process Calder Hall decommissioning wastes. decommissioning including assay, monitoring, sorting, Acceleration of programme through innovation and decontamination, compaction and packaging. experience gained at other nuclear sites. Optimisation of requirement to process legacy LLW 2015-2020 O Use of dedicated LLW facility. miscellaneous activated components. Treatment of contaminated metal plant items including 2005-2011 N Experiences of international initiatives. large vessels and boilers. 2.3 Waste recycling and reuse Techniques for waste monitoring and sentencing including 2005-2019 N An industry-wide approach. re-categorisation for recycling. Reuse of non-radioactive waste scrap. O 2.4 Waste transport (internal and international) No provision for movement of nuclear waste and material 2005-2019 R to Sellafield. 2.5 Waste storage strategy Export of packaged ILW from defuelling and preparations 2007-2009 N Specialist waste facilities offer potential for improved waste for C&M to storage on the Sellafield site. management at lower cost. ILW to be exported to Sellafield. O No requirement for on site storage of packaged ILW. 2.6 Waste disposal Optimise disposal of wastes including reactor core 2005-2014 N graphite and asbestos from heat exchangers and turbine halls. Lacks potential for on site disposal of VLLW. 2005-2014 R Reuse of VLLW as infill for future infrastructure. O

50 NDA R&D Needs, Risks and Opportunities

Calder Hall

Need/risk/ Issue Timescale opportunity Characteristics of a solution 3. Management of other nuclear materials 3.1 Reactors 3.2 Chemical Plant 3.3 Low Level Waste Repository 4. Plant termination and decommissioning 4.1 Removal of plant contamination Removal of non-radioactive asbestos lagging, waste oil 2005-2019 N and solvents and scrap metals. 4.2 Management of effluents 4.3 Plant dismantling Demolition in parallel with defuelling to accelerate From 2005 O Facilitated by early retreat from non-reactor areas combined Safestore programme. Regulators would like shorter with passive safety case. timescale.

Weatherproofing of four reactor buildings and conversion 2004-2019 to Safestore. Ageing reactor A frame support structure may weaken From 2020 R Passive moisture control, inspection and C&M. through corrosion. Deplanting and demolition of redundant buildings 2005-2019 N including cooling towers. Inspection, C&M phase of heat exchanger and primary From 2020 N circuit, reactor building and reactor block assembly. 5. Asset management 5.1 Reactors 5.2 Chemical plants 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Radiological clearance monitoring, land surveys and 2005-2019 N Check to determine there are no significant amounts of landscaping for interim decommissioning. contaminated land on site and remediation if required. Early land release for reuse, storage or new build. O 6.2 Site end point

51 Reactor Site

4. Chapelcross

Chapelcross was the first commercial nuclear power station in Scotland. Generation ceased in 2004, and completion of removal of spent fuel from the four reactors in 2009, will be followed by preparations for care and maintenance.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation Condition of plants. 2005 onwards Need to make area safe and suitable for construction activities. Early assessments to assist the development of appropriate hazard reduction methodologies. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Improvements to handling of graphite sleeves associated 2005-2009 N with defuelling operations. The cooling ponds will have the remaining skips of resin Complete resin retrieval and processing by January 2017. removed and packaged for disposal, following which the ponds will be drained of water, any residual contamination removed then demolished. Collection, storage and disposal of hazardous waste Completed by Complete sludge retrieval and processing by 16-07-2008. including asbestos, chemicals (including chlorine), August 2019 sludges, clinical wastes and turbine oil. Fuel discharge route needs improving to overcome a March 2008 Direct shipment to Sellafield. number of historical operational difficulties with the original defuelling equipment. 2.2 Processing, conditioning and packaging Resizing, compaction and packaging of solid LLW for 2005 onwards disposal off site or stored on site if no disposal route is agreed. Treatment of liquid effluents. 2005 to March Not to constrain decommissioning. 2008 Meet the expectations of the stakeholders. There is a need to treat and condition the wet LLW (mainly 2005 to March Disposal options will be supported by a Best Practicable contaminated waste oil) to render them passively safe and 2008 Environmental Option (BPEO) study. hence suitable for interim storage and eventual disposal. Three types of wet ILW need processing: Complete sludge retrieval and processing by 2008. Ion exchange resins AW500 (Zeolite). Treatment from 2011 to 2021. Sludge Rotary pump lubricant absorbed into vermiculite. Solid ILW treatment of two ILW types: Retrieval Stable waste form suitable for prolonged storage. Miscellaneous contaminated items (MCI) mainly steel and by 2015, desiccants from the reactor circulating gas drier units. treatment by 2021 Treatment of waste disposal drums from Harwell. 2011 onwards Proposed to be treated in a solid ILW processing building and drum processing facility.

52 NDA R&D Needs, Risks and Opportunities

Chapelcross

Need/risk/ Issue Timescale opportunity Characteristics of a solution 2.3 Waste recycling and reuse Site to maximise the amount of material that can be 2005 onwards recycled and free released from the site as opposed to being sent as LLW. 2.4 Waste transport (internal and international) Spent fuel flask deliveries to Sellafield will meet the Ongoing N numbers defined in the MOP and no external factors will prevent despatches from the site. 2.5 Waste storage strategy Need to store conditioned waste on site until a repository 2040 N becomes available. Need to agree an approach to tritiated waste assay with 2005 onwards N the Regulator and develop a technique to deliver this.

No off site store available for the transfer of ILW. 2015 R Safety of continued storage in present location or compatibility with an existing store elsewhere. 2.6 Waste disposal Some waste streams may have no identified available 2005 onwards R waste routes as identified in the integrated waste strategy. No secure route for the disposal of low level tritiated 2005 onwards R Tritiated waste strategy is being formulated for site and is waste. due for completion by September 2005. The feasibility study is ongoing for on site disposal. Treatment, storage and disposal options for LLW graphite 2005 onwards resulting from reactor dismantling need to be determined. Removal and treatment of largely uncontaminated 2005 to asbestos. November 2014 Means to manage the large volumes of water from the Completed by N Feasibility study and subsequent design package ongoing. cooling towers and the fuel storage pond. March 2006 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium The storage and transfer of Magnox depleted uranium 2005 to It is programmed to retrieve and despatch the drums at a

(UO3) to Capenhurst. November rate of approximately 1,800 per year. 2014 3.3 Fuel

53 Reactor Site

4. Chapelcross (continued)

Need/risk/ Issue Timescale opportunity Characteristics of a solution

4. Plant termination and decommissioning 4.1 Removal of plant contamination

Methods to deal with areas of contamination of the heat N exchangers.

Demolition of dry fuel handling facilities. Decontamination 2010 N and disposal of the site fuel flasks. (Will need characterisation and decontamination of the site fuel flasks and the handling facility building). 4.2 Management of effluents

Effluent line upgrade. N To prevent discharge of activity from the site’s drains

Retrieve, condition, process and package liquid ILW Facilities required include a Solidification Plant and waste streams from the pond. Radioactive Sludge Dewatering Unit required to treat and package sludge and resin arisings from various decommissioning activities. 4.3 Plant dismantling

Dismantling of tritium extraction and purification plant. Complete by Packaging and exporting ILW to Sellafield from the • Minimising the release of residual tritium held up in the 2018 Chapelcross processing plant. lines and tanks during deplanting of the process line to ensure the site tritium discharge authorisation is not breached. • Disposal of the tritiated waste (LLW and ILW) produced during decommissioning.

Effluent discharge lines: removal or in-fill with grout.

54 NDA R&D Needs, Risks and Opportunities

Need/risk/ Issue Timescale opportunity Characteristics of a solution

5. Asset management 5.1 Reactors

Archiving data for long-term record keeping needs 2005-2021 N Document services identified in the LCBL. 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration

C&M contaminated land monitoring. N Provide reassurance to stakeholders and determine options No plans to remediate the land during C&M. for long-term management. A programme of environmental monitoring is needed. Periodic review of the contaminated land safety case.

Contaminated land remediation. N Treat contaminated land as LLW. Need to determine if remediation of contaminated land Alternatives to excavation and sentencing to LLW disposal down at low levels, such as 0.4 Bq/g total radionuclides are desirable. will be necessary. Confirmatory investigation works to check that the contamination levels are broadly as expected. 6.2 Site end point

55 Reactor Site

5. Dungeness A

Dungeness site has two Magnox reactors and electricity generation will cease in 2006. Removal of spent fuel will finish in 2009, and dismantling, demolition and waste management operations will proceed in parallel, prior to care and maintenance.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation Non intrusive contaminated land survey to provide 2008-2019 N Rapid techniques. a preliminary address of both radioactive and non- Must have stakeholder confidence. radioactive contaminants. Higher levels of contamination found during R Mitigation activity: Establish detailed HP monitoring protocol decommissioning that could lead to delays in early in project to establish extent of contamination. decommissioning. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Fuel Element Debris (FED) and Miscellaneous N Contaminated Items (MCI) safely removed, dissolved and/ or encapsulated from the lug vaults and MXD plant. 2.2 Processing, conditioning and packaging Retrieve and process into a passively safe state all mobile 2008-2015 N (sludges and flowable solids) liquid and solid ILW that has been stockpiled during the operational life of the power station. Retrieve and process into a passively safe state all solid 2010-2016 N ILW that has been stockpiled during the operational life of the power station. 2.3 Waste recycling and reuse 2.4 Waste transport (internal and international) 2.5 Waste storage strategy Design and build an ILW store to provide a temporary 2008-2014 N storage for all ILW processed into a passively safe state during the C&M Preps phase. 2.6 Waste disposal Disposal route not available for contaminated asbestos April 2009 R Mitigation activity: Assign project personnel early, maintain leading to delays to decommissioning. close contacts with likely disposal routes LLW Repository/ Winfrith and with similar projects at other decommissioning stations in British Nuclear Group.

56 NDA R&D Needs, Risks and Opportunities

Dungeness A

Need/risk/ Issue Timescale opportunity Characteristics of a solution

3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel 4. Plant termination and decommissioning 4.1 Removal of plant contamination

R1 and R2 FED/MCI splitter vaults, retrieval building, 2013 N voids retrieval building, lug vaults and MXD plant decontamination. 4.2 Management of effluents

Install a Portable Active Effluent Treatment Plant (PAETP) 2014-2018 N facility during the C&M Preps phase.

Provide a post generation alternative discharge route for 2008-2011 N effluents that require prompt offshore disposal. 4.3 Plant dismantling 5. Asset management 5.1 Reactors 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration 6.2 Site end point

57 Reactor Site

6. Hinkley Point A

The twin Magnox reactors at Hinkley Point A ceased generation in 1999. Removal of spent fuel was completed in 2004 and current operations are focused on waste treatment and storage, and dismantling and demolition.

Need/risk/ Issue Timescale opportunity Characteristics of a solution

1. Radioactive materials characterisation 1.1 Characterisation Reports to define characteristics of the waste to be 2005-2009 N encapsulated and three key trials to underpin the aspects of concept design, including the encapsulation of the organic resin in cement. No more than 20 samples will be taken as part of Reactor 1 pond sludge waste characterisation. Obtain Letter of Comfort (LoC) from Nirex for the waste streams to be encapsulated. Contaminated land survey. 2005-2014 N Fuel element found in pond skip during transfer operations 2005-2009 R Possible impact: Completion of transfer work will be causes delays to progress. delayed pending retrieval solution by others. Mitigation activity: Put fuel element to one side and continue working with another skip while others recover and dispose of fuel. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Wet and dry Fuel Element Debris (FED) from vaults that contain 2007 N Installation of ILW retrieval arms in each of the vaults FED and activated nimonic springs. along with all the necessary equipment required to facilitate the export of loaded packages to the new ILW store, including the provision of a cross site transporter. Retrieve and process the wet ILW. Ongoing N Design, construction and commissioning of all plant and equipment required to retrieve and process the wet ILW. Treatment of orphan ILW that is currently stored in the Reactor 1 2005-2009 Design, procurement, installation and commissioning of and 2 cooling ponds in the Effluent Treatment Plant (ETP) lower equipment for the recovery and treatment of ILW. vault and in the non-combustible Active Waste (NCAW) store e.g. IONSIV cartridges. 2.2 Processing, conditioning and packaging Encapsulation of ILW waste. The plant will need to receive solid Constructed N Design, construct and commission the ILW encapsulation ILW that has previously been placed in interim containerisation 2026-2028 plant. in the ILW store in order to grout it and return it to the store. LLW processing. 2005-2009 N Collect, package and grout into half height ISO containers. Despatch to the Low Level Waste Repository.

ILW store – for the wastes processed on site ‘problem’ N Design complete by March 2006. packages will be overpacked in secondary containment vessels Construction complete by November 2007. Commissioning complete by June 2008. The current cement formulation for solidification of organic Ongoing R A series of trials are ongoing in order to underpin this resins in cement will comply with Nirex criteria. assumption. Treatment of the active IONSIV cartridges, 2005-2009 N An alternative grout capable of penetrating the resin bed. 2.3 Waste recycling and reuse 2.4 Waste transport (internal and international)

58 NDA R&D Needs, Risks and Opportunities

Hinkley Point A

Need/risk/ Issue Timescale opportunity Characteristics of a solution 2.5 Waste storage strategy The regulators will not accept the proposal to store R Possible impact: Significant redesign and new build will result. ungrouted waste on site. Mitigation activity: Early engagement of stakeholder on proposed plans. 2.6 Waste disposal 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel 4. Plant termination and decommissioning 4.1 Removal of plant contamination Decontaminate pond skips and size reduce to allow 2005-2009 N Design, development, manufacture, installation and disposal as LLW. commissioning of equipment for decontamination and size reduction. AETP plant, station final effluent monitoring and delay tanks 2012 N to be decommissioned, decontaminated and dismantled. Storm drain decontamination. 2005 N 4.2 Management of effluents Mobile effluent treatment plant. 2012 N This will replace the installed Active Effluent Treatment Plant (AETP) facility after its demolition. 4.3 Plant dismantling For a number of specialised operations (e.g. control rod 2094 N removal and segmentation) it may be cost-effective or necessary to develop dedicated equipment. Pond water treatment plant, active laundry, decontamination 2005-2014 N building, vaults and ponds decontamination and decommissioning. Asbestos removal: This material cannot be disposed of at 2005-2014 N the usual licensed waste sites and must be disposed of as LLW at the Low Level Waste Repository. Prior to disposal as LLW, asbestos waste must be super-compacted to reduce the volume and to remove excess moisture. 5. Asset management 5.1 Reactors Detailed design difficult due to poor legacy information. Ongoing R Possible impact: Rework of design or delay to on site installation. Mitigation activity: Surveys planned at start of detailed design and programme of design reviews held prior to start of manufacturing or construction. 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration 6.2 Site end point

59 Reactor Site

7. Hunterston A

Hunterston A has two Magnox reactors which ceased generation in 1990. The site is midway through waste management, dismantling and demolition activities, in preparation for care and maintenance which is planned to start in 2016.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation of hazards Characterise porous concrete layer at base of bunker. From 2005 N Determine whether waste requires treatment as ILW. 2. Management of radioactive waste 2.1 Waste retrieval and transfer 2.2 Processing, conditioning and packaging Demonstration of retrieval processes for solid ILW from 2005-2015 N Potential for improved packaging process. cartridge cooling pond and solid active waste bunkers. O Technology for packaging of solid operational ILW, 2005-2015 N Suitable for long-term storage, acceptable for disposal or Magnox fuel casings, graphite, filters, desiccant and re-treatment. miscellaneous items and decommissioning ILW. Technology for recovery, stabilisation and packaging of 2006-2010 N Suitable for long-term storage, acceptable for disposal or operational wet ILW; cartridge cooling pond sludges, R re-treatment. resins and filter sand. Retrieval inefficient and difficult. No fuel elements/parts or uranium hydride present in solid 2005-2015 R active waste bunkers. Construct sand reception facility to treat sand filters in 2005-2016 active effluent and pond water treatment plants. Technology to enable re-categorisation of waste as LLW 2005-2015 O Decontamination, characterisation and radiation monitoring. or for free release. 2.3 Waste recycling and reuse 2.4 Waste transport (internal and international) Transport of LLW packages to an approved disposal From 2005 N facility. 2.5 Waste storage strategy Construction and commissioning of new modular store for 2005-2007 N Suitable for long-term storage and monitoring and inspection operational ILW. of waste packages. Interim on site storage of ILW packages until disposal. 2016-2040 N Passive operation with appropriate package monitoring, inspection and store maintenance. Volume of ILW exceeds estimates. R There is a requirement to store oversize packages. R Alternative solution or minimise number of oversize packages. 2.6 Waste disposal Disposal of cartridge cooling pond skip and miscellaneous 2005-2010 N Low Level Waste Repository or other licensed facility. LLW at an approved facility.

60 NDA R&D Needs, Risks and Opportunities

Hunterston A

Need/risk/ Issue Timescale opportunity Characteristics of a solution 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel 4. Plant termination and decommissioning 4.1 Removal of plant contamination Technology for the decontamination of equipment used N for waste retrieval and plant. 4.2 Management of effluents Development and construction of mobile effluent 2005-2008 N treatment plant. 4.3 Plant dismantling Deplanting and dismantling of precipitator tower and other 2005-2016 N Continued safety improvements and innovation to accelerate buildings excluding the reactor. programme. Deplant pile cap and reclad reactor with weather envelope 2005-2050 N Weather cap constructed for long-term durability. for quiescent phase. Emptying, cleaning and demolition of cartridge cooling 2006-2015 N Reduce, reuse and recycle strategy and utilise mobile active pond and containment building, fuel tunnels and effluent treatment plant. blockhouses, pond water treatment plant and chemical dosing facility. Non-radiological degradation leads to delays. R Lack of a repository will delay decommissioning. R 5. Asset management 5.1 Reactors 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Site survey and radiation monitoring of contaminated From 2015 N areas. Technology for building C&M during quiescent phase 2017-2081 Maintenance commensurate with risk presented and including building surveys, radiation surveys, replacement demonstration of no increases of ambient radiation levels in of cladding at regular intervals and off site monitoring. the surrounding environment. 6.2 Site end point

61 Reactor Site

8. Oldbury

Operation of the two Magnox reactors at Oldbury is planned to end in 2008. The removal of spent fuel will follow, for completion in 2010, and preparations for decommissioning will begin in parallel.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation of hazards 2. Management of radioactive waste 2.1 Waste retrieval and transfer Demonstration of retrieval processes for solid ILW in active 2006-2009 N Use of grab and petal grab for solids and robotic vacuum waste vaults. cleaner for debris. Demonstration of retrieval processes for removal of mobile 2006-2011 N Hydraulic technology. ILW (sand, sludges, IX resins). Degradation of solid waste makes grabbing inefficient. R Removal of asbestos waste from turbine hall. 2008-2013 N Safety improvements for hazard management. 2.2 Processing, conditioning and packaging Install Sludge Dewatering Unit and ILW Solidification Plant for 2009-2010 N Generic mobile equipment for use at a number of the removal and treatment of mobile ILW (sand, sludges and O Magnox stations. IX resins).

Availability of mobile waste treatment plants at power station R sites constrained by delays due to slippage in timescales for waste retrieval, decontamination and maintenance. Technology for packaging of solid operational ILW, 2011-2020 N Suitable for long-term storage, acceptable for disposal or graphite, filters, desiccant, miscellaneous items and re-treatment. decommissioning ILW. Technology for stabilisation and packaging of operational 2011-2020 N Suitable for long-term storage, acceptable for disposal or wet ILW; cartridge cooling pond sludges and resins and filter re-treatment. sand. R Retrieval inefficient and difficult. Technology to enable the re-categorisation of waste as LLW Decontamination, characterisation and radiation or for free release. monitoring. 2.3 Waste recycling and reuse Technology for sorting and separation non- radioactive waste. From 2009 Free release & recycling. 2.4 Waste transport (internal and international) Transport of LLW packages to an approved disposal facility. 2006-2020 N O Consider local disposal to minimise transport. 2.5 Waste storage strategy Construction and commissioning of new store for operational 2006-2012 N Suitable for long-term storage and monitoring and & decommissioning ILW. inspection of waste packages. Interim on site storage of ILW packages until store emptying 2011-2046 N Passive operation with appropriate package monitoring, and disposal. inspection and store maintenance. Storage of miscellaneous activated ILW components in 2006-2110 N Decay storage for hazard reduction. vaults and holes within the reactor block until dismantling. 2.6 Waste disposal Disposal of LLW at an approved facility. N LLW Repository or other licensed facility. O Develop local or on site disposal facility. Insufficient capacity at licensed sites for disposal of R Review total power station asbestos arisings and hazardous waste especially asbestos. compare with expected capacity of licensed sites.

62 NDA R&D Needs, Risks and Opportunities

Oldbury

Need/risk/ Issue Timescale opportunity Characteristics of a solution

3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel 4. Plant termination and decommissioning 4.1 Removal of plant contamination

Technology for clean-up of fuel storage ponds. 2009-2018 N

Technology for the decontamination of equipment used 2011-2020 N Build on shared knowledge and experience at stations. for waste retrieval and plant.

Technology for the decontamination and dismantling of the 2110-2115 N Early consideration of deplanting and care and reactor block. O maintenance operations to assist future dismantling. 4.2 Management of effluents

Development and construction of mobile effluent treatment 2006-2011 N Local treatment at site of generation when bulk of liquid plant. effluents have been treated. 4.3 Plant dismantling

Deplanting and dismantling of ISO container, turbine hall, N Continued safety improvements and innovation to effluent treatment plant and other buildings for dismantling. accelerate the programme.

Deplant pile cap and reclad the reactor with weather Weather cap constructed for long-term durability. envelope for quiescent phase.

Non-radiological degradation leads to delays. R

Lack of a repository will delay decommissioning. R 5. Asset management 5.1 Reactors

Maintain power generation. 2008 N Maximise value of generation while maintaining nuclear, industrial and public safety and environmental protection. 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration

Technology for building care and maintenance during 2020-2109 N Maintenance commensurate with risk presented and quiescent phase including building surveys, radiation demonstration of no increases of ambient radiation levels surveys and the replacement of cladding at regular intervals. in the surrounding environment.

Assessment of geological, hydro-geological and chemical 2109-2118 N Establish requirements for remediation, landscaping and characteristics, surface gamma measurements and drainage. boreholes at varying depths. 6.2 Site end point

63 Reactor Site

9. Sizewell A

The two Magnox reactors at Sizewell A will continue generation until December 2006. Removal of spent fuel is planned for completion in 2009 and clean out operations will start in parallel, prior to initial dismantling and demolition.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation Activity assessments for ILW disposals to the approved 2005-2008 N storage facilities and collation of record sheets into the site ILW inventory. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Processing desiccant and catalyst from the active ash 2005-2015 N store into approved Nirex containers, then transfer into the approved storage location and finally to the ILW store. Fuel Element Debris (FED) retrieval and processing from 2005-2015 N FED and the springs will be removed using a petal type splitter vane store cells. grab and placed in approved containers then placed in store. The nimonic springs will be segregated. The sludge will be removed hydraulically using standard vault emptying methods into the Active Effluent Treatment Plant (AETP). Miscellaneous Contaminated Items (MCI) retrieval and 2005-2015 N Drummed (MCI) retrieved from the (CAW) and (NCAW) voids processing From the Combustible Active Waste (CAW) packaged and categorised as LLW. and Non-Combustible Active Waste (NCAW) voids. Retrieval and processing of sludge with placement of 2005-2015 N Encapsulation in lost paddle drums. the waste in HHISOs ready for disposal to the Low Level Waste Repository. Design and commence plant construction to retrieve, 2005-2009 containerise and store the FED. Retrieval of ILW desiccant and catalyst from the reactor 2005-2015 N gas conditioning plants and gas driers, followed later by encapsulation ready for transfer into the ILW store. 2.2 Processing, conditioning and packaging Characterise the needs of a waste management facility. 2008-2009 N Solid LLW processing. 2005-2008 N LLW sand retrieval and processing. 2010-2014 N Collection, treatment, minimisation and processing of 2005-2018 N radioactive LLW oil. Retrieval and processing in a cementitious matrix of SVS 2010-2014 N cell 1 contents and Ionsiv resin cartridges from ponds.

64 NDA R&D Needs, Risks and Opportunities

Sizewell A

Need/risk/ Issue Timescale opportunity Characteristics of a solution 2.3 Waste recycling and reuse 2.4 Waste transport (internal and international) 2.5 Waste storage strategy Build an ILW store. 2.6 Waste disposal 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel 4. Plant termination and decommissioning 4.1 Removal of plant contamination Decontamination of ponds building, active laundry and 2010-2014 N effluent treatment plant. Decommission and dismantle radioactive waste handling building, contaminated waste incinerator and oil filtration building, final monitoring and delay tanks, active drains and effluent discharge line. 4.2 Management of effluents 4.3 Plant dismantling 5. Asset management 5.1 Reactors 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration The completion of all contaminated land surveys Completed by O and the compilation and the issue of all appropriate 2018 documentation. 6.2 Site end point

65 Reactor Site

10. Trawsfynydd

The two Magnox reactors at Trawsfynydd ceased generation in 1993. Removal of spent fuel was completed in 1995, and the site location in the Snowdonia National Park, has strongly influenced the dismantling and demolition work in progress.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation Assess south FED waste form to allow a new LoC 2007 R Determine if current waste forms are acceptable. submission to be drawn up if required. Unexpected waste items, including items with higher than 2007 R Surveys to be performed wherever possible e.g. ground expected dose or fissile inventory. penetrating radar prior to excavation. Pond building cores will be investigated for radiological 2008-2011 N contamination and asbestos. Surveying of pond structures pre and post 2008-2011 N decontamination. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Main Sludge Vault (MSV) sludge retrieval. N Resin vault retrieval. N 2.2 Processing, conditioning and packaging Box grouting: hydrogen evolution or grout formulation 2007 R does not match predicted model. Decontamination and deplanting of the ion exchange 2008-2009 N Resin Solidification Plant (RSP). 2.3 Waste recycling and reuse 2.4 Waste transport (internal and international) 2.5 Waste storage strategy 2.6 Waste disposal 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel

66 NDA R&D Needs, Risks and Opportunities

Trawsfynydd

Need/risk/ Issue Timescale opportunity Characteristics of a solution 4. Clean out and decommissioning 4.1 Removal of plant contamination Pond structure scabbling. 2005-2008 N The laundry, north and south Magnox vault concrete 2007-2011 N structures will be decontaminated utilising remotely operated equipment. 4.2 Management of effluents 4.3 Plant dismantling 5. Asset management 5.1 Reactors 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Contaminated land survey – radiological and hydrocarbon 2006-2012 N contamination. Decide if review safety case for contaminated land. Contaminated land survey during C&M. Confirm that the effective containment of the contamination. Monitor boreholes and drain outlets etc. Maintenance and possible replacement of any engineered containment. 6.2 Site end point

67 Reactor Site

11. Wylfa

Wylfa has two operating Magnox reactors which are the largest of their type. Electricity generation is planned to cease in 2010, and will be followed by removal of spent fuel for 2012, and initial dismantling and demolition.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation of hazards Characterisation of active effluent sludge to identify 2005-2010 N treatment and packaging requirements. Waste characteristics are different from those assumed R impacting on processing, packaging and throughput. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Develop waste retrieval and processing facilities for waste 2005-2012 N from C&M Preps and effluent sludge for disposal or separate for free release. Retrieval of reactor gas drier desiccant for packaging and 2005-2015 N Suitable for long-term storage, acceptable for disposal or transfer to Safestore. re-treatment. 2.2 Processing, conditioning and packaging Processing and packaging of beta contaminated items. N Grouting of desiccant required when there is no facility to 2005-2015 R do that. Waste sorting assaying equipment inadequate. 2005-2015 R Upgrade facility or new build. 2.3 Waste recycling and reuse 2.4 Waste transport (internal and international) 2.5 Waste storage strategy Alumina desiccant for decay storage in reactor Safestore. N Store for 50 years to enable re-categorisation as LLW. 2.6 Waste disposal Disposal of LLW and asbestos to licensed sites. 2010-2015 N 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel 4. Plant termination and decommissioning 4.1 Removal of plant contamination Identification of redundant plant for interim 2005-2025 N Accelerate interim decommissioning. decommissioning (decontamination and dismantling) O including turbine hall, flask and nuclear flask handling equipment, waste treatment plant, active drain systems miscellaneous contaminated plant and removal of non- nuclear facilities. Development of facility for the decontamination of nuclear 2012-2025 N fuelling machinery.

68 NDA R&D Needs, Risks and Opportunities

Wylfa

Need/risk/ Issue Timescale opportunity Characteristics of a solution 4.2 Management of effluents Provision of a mobile effluent treatment plant to treat 2010-2015 N Detailed assessment of requirements to define the margin of stored active effluent for discharge to drains. Filters to be spare capacity. stored on site pending disposal. Effluent activity may exceed design capability of mobile R plant. 4.3 Plant dismantling Removal of asbestos, VLLW oil and redundant active 2005-2010 N plant. Interim decommissioning of turbine hall and generators, 2010-2016 N workshops and ancillary buildings, flask handling and despatch plant. Higher than expected dose rates may delay work or R contaminate personnel. Conversion of reactor building to a sealed Safestore 2012-2025 N including ILW storage. 5. Asset management 5.1 Reactors Maintain electricity generation. 2005-2010 N Maximise generation whilst maintaining safety and environmental protection. Modify fuel handling equipment to facilitate safe rapid and 2010-2012 N Plant enhancement and innovation. reliable defuelling of the reactor at the end of operation and irradiated fuel in storage cells. 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Reactors, primary dry store cells and ILW storage vaults N Maintain in a safe and secure state. put into passive Safestore. C&M Preps including a survey to establish required From 2012 N landscape works outside controlled area and a survey of buildings outside the controlled area. 6.2 Site end point

69 Research and chemical processing site

12. Capenhurst

Capenhurst housed the only diffusion enrichment plant in the UK, and has developed innovative processes for decommissioning, which is planned for completion in 2010. The site will be maintained for storage of uranium materials.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation of hazards 2. Management of radioactive waste 2.1 Waste retrieval and transfer 2.2 Processing, conditioning and packaging Completion of techniques for the retrieval, treatment, From 2005 N Mobile processing equipment such as AEAT super- recycling and packaging of waste including uranium compactor. contaminated material, asbestos, lead and IX material. Use of ISO freights as fissile packages for enriched wastes. Recovery of uranium from residues. 2005-2008 O Design and development of uranium deconversion UHD 2005-2020 N Facility to incorporate updated technology and design

facility with facilities to wash and size reduce the UF6 O for waste recycling and minimisation and ease of cylinders. decommissioning.

Conversion of UF6 tails to uranium oxide and treatment of 2020-2028 N Stable form suitable for reuse or long-term storage. process wastes. Incineration of oily material and solvents and packaging of 2005-2008 N incinerator ash. Tritiated material available for release. 2005-2010 O 2.3 Waste recycling and reuse 2.4 Waste transport (internal and international) Completion of waste transport and disposal. 2005-2009 N 2.5 Waste storage strategy Quiescent storage of deconverted uranium oxide and 2010-2015 N Mild steel drums overpacked with stainless steel. slightly enriched uranium in mild steel drums in uranium 0 Demand for uranium increasing, alternative commercial uses. store and also depleted uranium from Sellafield and Chapelcross. Regular inspection of uranium drums. From 2005 R Visual inspection based on sample accessed by camera. 2.6 Waste disposal 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel Storage of uranium until an alternative solution is available. N Stored uranium oxide may be subsequently declared as R Packaging in a form suitable for disposal and transport to waste. repository.

70 NDA R&D Needs, Risks and Opportunities

Capenhusrt

Need/risk/ Issue Timescale opportunity Characteristics of a solution 4. Plant termination and decommissioning 4.1 Removal of plant contamination 4.2 Management of effluents 4.3 Plant dismantling Completion of decommissioning and demolition of the 2005-2010 N Disposal of waste as LLW or VLLW. diffusion plant and uranium deconversion plant, including O Accelerate decommissioning for completion 2008 size reduction, cutting and asbestos stripping. through optimising techniques such as characterisation of contamination, residue recovery, size reduction and efficient packaging. 5. Asset management 5.1 Reactors 5.2 Chemical plant Refurbishment of uranium store. 2005-2010 N 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Maintain site licence for uranium oxide storage. N Land investigation 2005-2008 N 6.2 Site end point BPEO assessment for retention of site building slabs. 2005-2010 N Landscape over building slabs. Maintain site in quiescent storage until it can be From 2032 N Requires sustainable and low cost regime involving safety delicensed. management, monitoring and maintenance of Urenco site interface to 2015. O Experience could be applied to other sites as Capenhurst will be the first site to achieve a quiescent state.

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13. Culham

Culham houses JET, a tokomak to investigate the physics of fusion, which will continue operation until 2008. Preparations for the removal of tritium, and the start of plant dismantling in 2009, are proceeding in parallel.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation Techniques for radiological survey, assay and 2005 - 2011 N characterisation of waste including metals, concrete, carbon tiles, glass, plastic before decommissioning of equipment, plant and buildings. 2. Management of radioactive waste 2.1 Waste retrieval and transfer 2.2 Processing, conditioning and packaging De-tritiation and passivation of uranium beds. 2006 N To meet waste acceptance criteria. Develop and optimise techniques for the de-tritiation of 2006 R Reduce contamination levels and meet LLW acceptance compactable waste and metals. criteria. Development of boxes for the packaging of tritiated ILW. 2006 N To meet waste acceptance criteria. Define ILW and LLW waste packaging requirements and 2005-2009 N To meet waste acceptance criteria for storage and/or specifications. disposal. Development and commissioning of assaying and 2005-2011 N Replace hard and soft LLW facilities. Modular facilities characterisation laboratory and facility for grouting of ILW within existing buildings, designed to minimise building decommissioning wastes. contamination and ease of decommissioning. Size reduction and grouting for interim storage and disposal. 2.3 Waste recycling and reuse Ship bulk tritium and tritiated water from the active gas 2011-2018 N handling system to Ontario for tritium recycling. Recycle concrete and steel clean and exempt wastes. 2010-2019 O Routes exist for these materials. 2.4 Waste transport (internal and international) Transport decommissioning waste off site for storage and 2018-2019 N disposal. 2.5 Waste storage strategy All waste to be sent off site for interim storage and R disposal. 2.6 Waste disposal Develop methods for simplifying the disposal of tritiated 2005-2010 N wastes. No disposal route for uranium beds preventing planned R Investigate alternative routes. site end state. No disposal facility for ILW delaying decommissioning 2015 R

72 NDA R&D Needs, Risks and Opportunities

Culham

Need/risk/ Issue Timescale opportunity Characteristics of a solution 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel 4. Plant termination and decommissioning 4.1 Removal of plant contamination Removal of equipment and accumulations of tritiated dust 2009-2011 N A range of techniques will be used including pulsing in and flakes in the Torus. deuterium, glow discharge cleaning and air purging. 4.2 Management of effluents 4.3 Plant dismantling Design, manufacture and commissioning of remote 2009 N All equipment removal activities can be undertaken remotely. handling equipment for removal of in-vessel equipment. Design size reduction plant for decommissioning wastes. 2009 N Decommission remaining facilities under site clearance 2010-2018 N including active gas handling system. Experimental neutron production is lower than expected, O reducing the decommissioning liabilities. 5. Asset management 5.1 Reactors 5.2 Chemical plant Maintain JET research facilities and experiments. 2005-2008 N Notice (at least 1 year) will be given at the end of experiments for transition to closure. Operational life of Culham extended delaying R decommissioning. 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Establish environmental assessment and monitoring 2005-2008 N procedures to identify land and groundwater that may need remediation and technologies for remediation and landscaping. 6.2 Site end point Site delicensing. 2020 N

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14. Dounreay

At Dounreay, radioactive waste treatment and storage, and building clean up and dismantling, for several facilities including two fast reactors and fuel reprocessing plants, will continue until 2025. Site decommissioning and remediation will follow.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation of hazards 1.2 Characterisation Improved graphite characterisation. 2010 N Problems with Wigner energy may be alleviated. Characterisation and packing of depleted uranium. N Development of DFR breeder in cement matrix. 2006 N Security and safeguards concerns met. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Develop technology for robotic handling and cutting. 2012 N Improved access. Greater understanding of chemical issues surrounding NaK 2012 N Greater control of pressure excursions. residue removal. Computer modelling to demonstrate Na reactions. 2005 N Better control of sodium reactions and pressure excursions. Technology for waste retrieval grab systems. 2011 N To enable retrieval of solids and sludge from the shaft and silo. Technology for waste retrieval manipulations. 2011 N Will allow remote use. Technology to deliver sludge pumping systems. 2011 N Will allow remote use. Shielding for short-term retrieval operations. 2011 N Will allow easier decontamination and decommissioning. Technology to enable the remote placement of rock anchors. 2011 N Will allow remote use. Technology to deliver waste retrieval platform and 2011 N Will allow remote use. manipulations. Technology to deliver conveyors for waste. 2011 N Will allow remote use. In-cell solids handling equipment. 2006 N Will minimise development work. 2.2 Processing, conditioning and packaging Technology to carry out size reduction with shears. 2011 N Will allow remote use. Technology to carry out size reduction at depth. 2011 N Will allow remote use. Development of cost-effective waste packages. 2006 O Reduce cost. Technology to deliver size reduction with shears. 2011 N Will allow remote use. Technology to deliver waste wash systems. 2011 N Will allow remote use. Technology to deliver shredder design and operation. 2011 N Will allow remote use. Develop sacrificial lidded bins for separator products. 2011 N Will allow remote use. Develop assay systems. 2011 N Will allow remote use. Assessment of super-compaction approaches. 2011 O Maximisation of waste loading. Cementation trials to support decommissioning work. 2006 N Meet Nirex requirements. Active cementation trials. 2006 N Prove specific wastes can be cemented. Inactive product development for DFR raffinate. 2006 R Will allow waste to be immobilised.

74 NDA R&D Needs, Risks and Opportunities

Dounreay

Need/risk/ Issue Timescale opportunity Characteristics of a solution 2.2 Processing, conditioning and packaging (continued) Inactive product development for solid remote handled ILW. 2006 R Cementation technology will be proven. Inactive neutralisation product development for DFR 2005 N Will prove technology works. raffinate. Full-scale cementation trials for PFR raffinate. 2006 N Will prove technology works. Container development. 2006 O Improvement of waste loading. Non-destructive analysis development. 2006 N Minimise development work. Evaporation. 2007 O Potential to concentrate ADU floc. Development of over-packing method for fuels and 2012 N Will be compatible for storage in flasks. powders from oxidation. LLW bulk size reduction facility. 2008 O Reduction of labour costs and voidage. Development of encapsulation method for sentencing fuel 2008 N Allow the disposal of thorium. stream. Grout trials to confirm cementation criteria. 2006 N Process approved by stakeholders. Un-irradiated thorium cementation trials. 2010 N Avoid requirement of an oxidation facility. Assessment of HEU waste. 2007 N Disposition route confirmed. Mixed carbide oxidation trials. 2007 N Stabilised product. Irradiated fuel oxidation trials. 2007 N Stabilised product. 2.3 Waste recycling and reuse Continue programme of DFDX trials. 2005 Reduction of waste from ILW to LLW or exempt. Development of technology for the abatement of caesium 2005 DFR decommissioning can continue. from high salt solutions. Ion exchange technology for the abatement of caesium 2008 Assist access problems. and cobalt from liquid solutions. Chemical conversion of Na to a passively safe form. 2005 Better control of sodium reactions and pressure excursions. Technology to deliver magnetic separators. 2005-2019 O No other methodology is currently utilised. 2.4 Waste transport (internal and international) Transport PCM to Sellafield for compaction and disposal. 2008-2011 N Return of cemented MTR raffinate to overseas customers. 2010-2025 N 2.5 Waste storage strategy Interim storage of nuclear material in casks and 2020-2036 N conditioned ILW until disposal. 2.6 Waste disposal Packages for on site disposal of LLW & HVLA wastes. 2011 O Potential cost savings.

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14. Dounreay (continued)

Need/risk/ Issue Timescale opportunity Characteristics of a solution

3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium Develop ion exchange equipment to remove fission 2007 N Fission products removed. products. 3.3 Fuel Technology for welding of irradiated fuel containers. 2012 O Will allow remote working. 4. Plant termination and decommissioning 4.1 Removal of plant contamination Development of washout techniques for decommissioning Unknown N Generic requirement across the FCA. within the FCA. Development of techniques to carry out in situ cleaning of 2005/06 N Generic requirement across the FCA. gaseous sample transfer line internals. Technology for the chemical removal of residual 2018 N Reduce potential blockages. radioactive contamination within pipe-work. Technology for the remote handling of mortuary 2016 R Improved handling of unexpected items. components. Development of a cleaning process for Na contaminated 2005 N Reduce the potential for hazardous gases. absorbers. Design of shielding for short-term retrieval operations. 2011 N Easier decontamination and decommissioning. Trials on thorium removal. 2009 N Increased percentage of thorium removal. Thorium tank decommissioning. 2010 N Waste can then be designated. 4.2 Management of effluents Development of fluidic pump systems for Floc and solvent Immediate O Reduces potential dilutions and volumes. tank emptying. 4.3 Plant dismantling Development of robotics technology for decommissioning Unknown N Generic requirement across the FCA. within the FCA. Development of techniques to coat internals of ventilation 2005/06 N Generic requirement across the FCA. ducts. Development of dry diamond wire cutting technology. 2015-2020 N A remote application. Development of robotic handling and cutting technology 2010 N Improved access. for reactor components. Robotic dismantling of the irradiated fuel cave. 2017 N Will allow dismantling. Technology for remote concrete cutting of silo cell roof. 2011 N Will allow remote use. Technology for the remote removal of pipe-work. 2011 N Will allow remote use.

76 NDA R&D Needs, Risks and Opportunities

Need/risk/ Issue Timescale opportunity Characteristics of a solution

5. Asset management 5.1 Reactors 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Statistical treatment of censored spatial characterisation 2008 O Improved estimate of contaminated land volumes. data. Develop characterisation and remediation methodologies 2008 O Potential cost savings and stakeholder support. for contaminated land. Develop analytical techniques for characterisation of 2007 N Improved understanding of particle lifetimes. Dounreay particles interiors. Demonstrate the use of best practicable technology 2006 N Improved stakeholder support. for monitoring of public beaches and the detection and removal of Dounreay particles. Technique for assessment of particle populations in the 2008 N Improved stakeholder support. marine environment. 6.2 Site end point Requirement for a grout curtain to reduce hydraulic 2008 R Allow retrieval of waste from the shaft. continuity.

77 Research and chemical processing site

15. Low Level Waste Repository

The national low level radioactive waste disposal site is planned to operate until 2050. After transfer of Plutonium Contaminated Material to storage at Sellafield is completed in 2006 redundant buildings will be dismantled.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation of hazards 2. Management of radioactive waste 2.1 Waste retrieval and transfer Retrieval of items requiring size reduction including 2005-2007 oversize items, 200 litre drums of retrieved and secondary waste. Retrieval of Hex cylinders and Hex drums from magazines. Retrieval methods of Hex cylinders and drums from PCM Risk to PCM R Mitigation actions: assessment of Hex cylinder safety case magazines could be incompatible with PCM retrieval retrieval requirements. Assay of all Hex cylinders. project requirement. beyond 2006 Assay and crate monitor failure. Risk to PCM R retrieval beyond 2006 Retrieval and despatch of PCM drums from the LLW By 2007 N Repository drum store to the engineered drum store at Sellafield. PCM may not be retrieved from the LLW Repository by From 2006 R 2006. Potential re-definition of PCM could increase the number From 2006 R Mitigation actions: Liaison with Sellafield site to ensure of items requiring retrieval. flexibility in storage and acceptance of PCM packages. Waste tracking and record keeping for magazine N retrievals, PCM consignment and returns paperwork required for the movement of PCM, waste management and the disposal of LLW accumulated during PCM retrieval operations. 2.2 Processing, conditioning and packaging Size reduction of large PCM items may impact on PCM From 2006 R Mitigation actions: Modification to safety case, source and retrieval. purchase suitable kit and re-schedule for current year.

78 NDA R&D Needs, Risks and Opportunities

Low Level Waste Repository

Need/risk/ Issue Timescale opportunity Characteristics of a solution

2.3 Waste recycling and reuse 2.4 Waste transport 2.5 Waste storage strategy 2.6 Waste disposal

Disposal of liquid effluent arisings from magazine and N drum store change rooms, hand washing facility and 90 gallon drums from PCM re-drumming operations. 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel 4. Plant termination and decommissioning 4.1 Removal of plant contamination

Produce safety cases for the removal of all Hex cylinders 2005-2006 N Hazard and Operability study (HAZOP), Hazard Analysis and Hex drums from the magazines, – size reduction (HAZAN), and safety memo to supplement current safety activities to take place within the magazines. case.

Removal of part of the external wall of magazine 4. By 2007 N Post Operations Clean Out (POCO) operations when magazines are empty.

Repacking operations create more drums than expected 2006 R Mitigation actions: licence to allow increase in inventory to delaying 2006 end date. 230g fissile material and drum and uranium assay re-evaluation for drums.

Identification of further high assay items. 2006 R Establish a high assay item storage and security arrangements.

Decontaminate and decommission facilities to prepare 2010 N De-classify facilities. Disconnection and removal of internal for demolition. Strip out services within the building. Strip services. Preparation and removal of reusable equipment. out and remove reusable equipment, such as monitoring Demolition and removal of the magazines 3, 4, 5, 9 and 10 equipment and transport containers. Demolish and and their magazine retrieval facilities. remove the LLWR PCM magazines, magazine retrievals facilities and crate process building.

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15. Low Level Waste Repository (continued)

Need/risk/ Issue Timescale opportunity Characteristics of a solution

4.2 Management of effluents 4.3 Plant dismantling Feasibility and design studies to identify options and 2010 N constraints for the demolition of all facilities associated with LLW Repository PCM retrievals project. Detailed design of preferred option resulting in a decommissioning and removal plan. Investigate the reuse or resale of specialist assay and O transport equipment. Demolition and removal of drum processing building and 2010 N Decommission and remove assay equipment comprising drum store. drum and packet monitors and crate monitor in the magazine retrievals facilities, drum monitors at the drum process building, drum store link corridor, drum monitor and crate monitor at the assay building. Transport to new location. Landscape and enhance in line with the LLW Repository landscape and wildlife management strategy. 5. Asset management 5.1 Reactors 5.2 Chemical plant 5.3 Low Level Waste Repository Improvements to the trench cap performance monitoring 2005-2050 N systems for the interim cap over the closed disposal trenches 1-7 inclusive. Maximise and increase the storage capacity of the existing vault 8 and provide a temporary storage area. Refurbishment of the Grout Facility including storage 2005-2050 N vessels, pipework, mixer vessel and delivery systems.

80 NDA R&D Needs, Risks and Opportunities

Need/risk/ Issue Timescale opportunity Characteristics of a solution

6. Site restoration management 6.1 Characterisation and restoration Remediation of compound and visitor centre slabs. Site 2010 N investigation to include: • Concrete core sampling for contamination. • Sub-slab window sampling. • Analysis of samples for radionuclides and chemical analysis. • Interpretative report for site investigation and sample analysis to enable preparation of a detailed remediation and waste management strategy. Refining of engineering brief to include: • Option selection for slab remediation at compound and visitor centre. • Hazardous operations (HAZOP 2). • PSR. • Initial design for the disposal of waste from slab areas. Finalisation of the engineering brief as follows: 2010 N • Detailed design of the compound and visitor centre slabs remediation project. • HAZOP 2. • Post Closure Safety Report (PCSR). 6.2 Site end point

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16. Harwell

Harwell houses experimental nuclear reactors and research facilities. Operations are focused on radioactive waste treatment and packaging, and will progress to demolition of the redundant facilities, leading to site closure in 2025.

Need/risk/ Issue Timescale opportunity Characteristics of a solution

1. Radioactive materials characterisation 1.1 Characterisation Survey of solid residues in liquor tanks in LETP buildings. 2008 N Compatible with tank and building decommissioning activities. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Development of retrieval machine RM2 for use in 2007-2008 N Reliable and efficient in order to meet decommissioning underground storage holes and retrieval of long cans. timescales. 2.2 Processing, conditioning and packaging Grouting techniques for remote handled ILW such as 2005-2010 N Suitable for long-term storage, acceptable for disposal or Fingal wastes and strontium 90 contaminated equipment. re-treatment. Techniques for size reduction of long cans. 2007 N Grouting and packaging techniques for BEPO and MTR 2009-2012 N Common approach across UKAEA and other sites for graphite and other decommissioning ILW. O packaging graphite and decommissioning wastes. 2.3 Waste recycling and reuse Decontamination techniques for segregation of exempt From 2009 Ensure liability of decontamination less than savings in non- and non-exempt decommissioning waste. exempt waste. 2.4 Waste transport 2.5 Waste storage strategy 2.6 Waste disposal 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel

82 NDA R&D Needs, Risks and Opportunities

Harwell

Need/risk/ Issue Timescale opportunity Characteristics of a solution 4. Plant termination and decommissioning 4.1 Removal of plant contamination Remotely operated equipment and robots for the 2006-2011 N Common strategies across UKAEA and other sites for decontamination of cells. O decontamination. Contamination and radiation surveys for decommissioning 2009-2011 N of MTRs. 4.2 Management of effluents Replacement of effluent treatment techniques after 2007 N Utilise off-the-shelf equipment. closure of LETP. O 4.3 Plant dismantling 5. Asset management 5.1 Reactors 5.2 Chemical plant Determination of ventilation parameters for waste 2005 N Demonstrate acceptable management of hydrogen gas. encapsulation plant and vault store. 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Methods for monitoring and verifying the condition of the 2010 N Utilise technologies used in other industries e.g. water site discharge pipeline after cleaning. O supply. Waste assay techniques for high volume low activity None at N An industry-wide need. waste for exemption (primarily soil) and clearance. present O 6.2 Site end point

83 Research and chemical processing site

17. Sellafield

Commercial fuel reprocessing operations and mixed oxide fuel manufacturing at Sellafield are planned to continue until 2012. In parallel, waste treatment and storage, and clean- up and decommissioning of a number of redundant facilities is underway.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation Characterisation and quantification of expected clean From 2005 N Early characterisation and quantification of clean out wastes out wastes including plant locations where activity may will provide information for the development of technologies build up. for clean out, decontamination and decommissioning. Inventory determination of heterogeneous LP&S wastes. From 2005 N Provision of data for nuclear accountancy, packaging and disposal. Development of monitoring and sentencing techniques for 2005 N Opportunity for free release or waste recycling. waste fingerprinting of LLW and waste segregation. O Destructive and non-destructive measurement techniques From 2005 O for matrices and contaminants to enable re-categorisation of materials. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Technology, including umbilicals for ROVs and retrieval 2005-2018 N heads in ponds, for retrieval of sludges and solids from LP&S. Retrieval delayed or stopped: sludge behaviour is outside R process design envelope, activity transfer exceeds design assumptions challenging effluent treatment, increases in ground contamination. Extensive waste sorting and segregation for inventory determination and disposal requirements. Techniques for hydrogen and other flammable gas From 2005 N management. Safety cases for the management of hydrogen without R inerting are not acceptable. Contingency measures for use if leakage during retrieval. 2007-2011 2.2 Processing, conditioning and packaging Waste packaging technologies for interim storage 2010-2019 N and/or disposal of legacy ILW wastes, reactive metals, IX O Acceleration of waste package development and/or materials and secondary wastes. adoption of modular encapsulation technology for early sludge treatment. Availability of powders for ILW encapsulation is dependent R on the cement, steel and power generation industries. Single source providers for special grade cement powders, drums and stillages and sourcing alternative powders is difficult. Negotiations for new LoC delay implementation of technologies.

84 NDA R&D Needs, Risks and Opportunities

Sellafield

Need/risk/ Issue Timescale opportunity Characteristics of a solution

2.2 Processing, conditioning and packaging (continued)

New encapsulants and waste packaging concepts From 2005 to prevent corrosion of reactive metals and product deterioration during storage and avoid the need for reworking.

Processes for the conversion of PCM wastes into disposal 2005-2030 R products.

Processes for the management of residual fuel when 2008 reprocessing stops.

Processes for minimising waste re-categorisation and for From 2005 N overcoming non-technical constraints on free release.

Waste reduction techniques for organic wastes. From 2005 N

Decontamination of bulk metals, plant steelwork and From 2005 N MEBs pond furniture for free release or the development of disposal options.

Predicted lifetimes of Magnox waste packages are From 2005 N pessimistic and data is needed to make more realistic predictions about water availability in the grout.

Treatment and disposal methodologies for orphan waste From 2005 N Early identification of treatment for key orphans, e.g. mercury streams including asbestos, oils, mercury and lead. O and oils, would help the development of an optimised national strategy.

Deferral of treatment results in missed windows of R opportunity for treatment in process plants.

Development of size reduction techniques and efficient 2005 N space packaging for LLW.

Reworking strategies and processes for packaged wastes R unsuitable for disposal required to meet LoC.

Containment process for failed AGR fuel (over can). 2011 N 2.3 Waste recycling and reuse

Decontamination techniques for a range of matrices and From 2005 N Agreement with stakeholders on implementation instructions decontaminants for recycling and reuse. for free release would promote maximum use.

A better understanding of waste analysis, From 2005 O decontamination and sentencing to increase the scope for reuse and recycling.

Practical opportunities for the reuse of materials do not R exist to a sufficient degree.

85 Research and chemical processing site

17. Sellafield (continued)

Need/risk/ Issue Timescale opportunity Characteristics of a solution 2.4 Waste transport (internal and international) A new generation of flasks for spent fuel transport. 2005-2008 Improved Excellox 8 design. On site transport packages for THORP, Magnox, residues N Improved decontamination techniques to accelerate flask and conditioned Pu products. turn around. Novel approaches to on site transport to improve efficiency and reduce cost. Utilise technology and expertise to support group need e.g. use Chapelcross packages for decommissioning activities. O Utilise transport technology and expertise to support transport to Yucca Mountain or PFS with benefits of increased UK skills, enhanced international reputation and alternative funding to reduce NDA costs in 2006-2007. New flasking capability for fuel elements to support 2010 N Flask design should be compatible with B13. accelerated site decommissioning. Development of mechanical systems for efficient flask 2010 O handling in fuel element examination facility. Development studies to support the shipment of HAW From 2007 N Development of transport infrastructure (including ship and returns to Europe and HAW and MOX returns to Japan. rail) to support the transport of European vitrified waste. 2005-2009. Preferred VPS flask for European returns may be R unsuitable for handling by REF and the Sellafield to Barrow rail link. 2.5 Waste storage strategy Technology for remote condition monitoring and 2005-2070 N Increase knowledge base with better condition monitoring inspection of interim and final products. capabilities in existing stores. Lack of data on the condition of stored waste packages R may lead to destructive examination and re-working. Simple techniques for real time determination of the extent 2005-2070 N to which store environmental conditions can promote degradation of waste package and store. New or alternative storage facilities will not be available R Utilise vault space in MBGW for the storage of materials from when existing stores are full. O site remediation and to support the UK redundant sealed source project. Emptying of waste boxes and extensive sorting and R conditioning to reduce voidage, immobilise activity etc. is required for disposal. Mild steel waste boxes may be unsuitable for extended surface storage and disposal. Solutions for surface storage of raw and conditioned PCM. 2020 N May need to limit and prevent interaction between PVC and stainless steel waste boxes. Techniques for integrity assessment of pond structures 2008 N for storage. Assessment and monitoring of high burn up AGR fuel 2008 N Modified techniques may be needed for the management cladding in wet storage. of high burn up AGR fuel. Alternative interim storage solutions for AGR, other 2011 N residual fuels and Magnox fuel end crops.

86 NDA R&D Needs, Risks and Opportunities

Need/risk/ Issue Timescale opportunity Characteristics of a solution

2.6 Waste disposal Data for some radionuclides are not available or not 2005-2070 R Use existing knowledge to influence disposal requirements. determined with sufficient precision to demonstrate suitability for disposal. The miscellaneous and wide ranging nature of waste makes it more difficult to demonstrate its acceptability for disposal. Overpacking and re-working of reactive waste metals (Magnox and uranium) might be needed for disposal. Disposal of silts from drainage trenches. 2005 urgent 3. Management of other nuclear materials 3.1 Plutonium Develop an understanding of longer term product storage 2005-2010 N chemistry. Develop understanding of MOX batch blending and 2005-2016 pooling technology to support the management of separated Pu stockpile to meet customer requirements. Development of technology for long-term storage and From 2022 N recycling of residues. Process route for Pu residues unsuitable for use in 2022-2050 N An economic process for the separation of suitable quality MOX fuel. O Pu from Pu residues would enable their use in MOX fuel. 3.2 Uranium Half height ISO freight container capable of meeting IP2 From 2007 N Construction materials for operation at temperatures to package requirements. -40°C. 3.3 Fuel Off line facilities (U only and Pu active) to support the 2005-2009 N Off line development and testing to supplement current modification of MOX fuel fabrication plant and SMP facilities. process throughput, maximise recycle incorporation and minimise residues. Technical improvements to MOX may enable the ramp up 2005-2009 O programme to be exceeded. Final conditioning and disposal routes for un-reprocessed From 2005 N AGR, other residual fuels and Magnox fuel end crops. Criticality and safety assessments could allow SMP to 2008-2012 O utilise Magnox derived PuO2. Technical solutions to allow legacy and other fuels outside 2005-2012 O the plant process envelope to be processed.

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17. Sellafield (continued)

Need/risk/ Issue Timescale opportunity Characteristics of a solution 4. Plant termination and decommissioning 4.1 Removal of plant contamination Proven technologies for decontamination of all areas of From 2005 N Use of common technologies for clean out in different plants site to obtain man access. with shared learning to enable process optimisation and improved efficiency. Improved clean-up operations to enable reductions in the scope of decommissioning and dismantling operations. Characterisation of technical challenges cannot be R completed until the start of decontamination and dismantling. Uncertainty on decontamination process delays new plant development. Difficulty of deploying technologies within different plant Additional containment for demolition. configurations, geometries and local constraints. After clean out contamination remains at hazardous levels making plants unacceptable for handover to decommissioning and demolition. It is assumed that clean out and dismantling will not generate HLW. HAST emptying and retirement strategy to inform and 2005-2015 N assist early POCO and decommissioning. Definition of a VPS process envelope for the treatment 2015 N of site clean out and decommissioning liquors. Systems for the removal of residual radioactive liquor in 2010-2027 N heels in non-drainable vessels and pipework lutes. Aggressive decontamination techniques for vessels and From 2005 N cells, robotics technologies for remote cutting, dismantling and waste removal. Processes for the removal and fixing of contamination on From 2020 N internal building structures and furniture. Systems for the mobilisation and removal of sludge, solid From 2007 N deposits and dust from inaccessible parts of plants. Utilise existing encapsulation plants beyond anticipated From 2010 O lifetimes to support remediation work. Timescales planned for deployment of clean out R technologies may be insufficient. Technologies to facilitate in situ management of 2005-2010 N contaminated ground and groundwater during plant decommissioning and excavation. Recycling and disposal options for steelwork including 2006 N flasks, skips, MEBs, containers and pond furniture.

88 NDA R&D Needs, Risks and Opportunities

Need/risk/ Issue Timescale opportunity Characteristics of a solution 4.2 Management of effluents Local effluent treatment processes for decontamination 2010-2020 N and clean out effluents. Improved clino ion exchange performance understanding From 2005 N to support process improvement and regulator confidence. An improved understanding of the effluent challenge may O lead to lower volumes and inventories for lifetime arisings and plant challenge. Decontamination liquors are within flowsheets of existing infrastructure. Modification and use of existing effluent infrastructure for processing a wider range of decommissioning effluents. Low cost and low impact water treatment plants for local plant usage. Novel decontamination techniques to reduce the treatment challenge and simplify plant design. Use of SIXEP to store some sludges. Uncertainty on the active and inactive inventory of N decontamination liquors delays new plant development. Decontamination liquors not treatable within the constraints of discharge authorisations. Management and abatement of strontium 90 and alpha 2007-2010 N in effluents from sludge packaging plant enable treatment by SIXEP within discharge limits. Identification of decontamination technology to enable the 2008 N development of effluent treatment strategies. Tertiary effluent treatment to supplement SIXEP treatment N during LP&S retrieval. IX systems with minimum discharges to ease constraints 2005-2040 N on MOP and LP&S operations whilst remaining OSPAR compliant and IX systems to enable pond operation post-OSPAR. Antimony-125 clean-up technology. 2010 N 4.3 Plant dismantling Development of suitable technologies for the demolition From 2005 N of facilities. Treatment and disposal options for the management N of bulk decommissioning concretes.

89 Research and chemical processing site

17. Sellafield (continued)

Need/risk/ Issue Timescale opportunity Characteristics of a solution

5. Asset management 5.1 Reactors 5.2 Chemical plant

HAL chemistry rheology and glass technology to support 2005-2024 N plant operations and clean out.

Engineering, thermal stress and fluidics modelling, slurry 2005-2024 N handling support for condition monitoring, re-evaluation of the process envelope of transport and agitation equipment in HALES and WVP.

Higher waste incorporation to reduce immobilised waste O inventory and programme timescale. Implementation of revised operating practices and process performance improvements through agreement with COGEMA to mitigate risk and reduce programme timescale.

HAST emptying and retirement strategy to 2005-2024 O OR modelling to support HAL strategy, HAST emptying, accelerate clean out and inform the development of retirement and POCO strategy, VPS container storage & decommissioning technologies. returns.

Design and implementation of simplified systems and 2015 N support for long-term operation of WVP line 3.

Maintain ageing plant without compromising plant 2005-2024 N throughput during HALES operation.

Solutions for long-term asset care and updating From 2005 N obsolescent equipment and control systems. O Passivation and sealant techniques for process coolant systems in Thorp.

Changes to downstream plant require radical R flowsheet and conditioning changes for MOX process streams.

Assessment of the effects of high irradiation on materials, 2005-2010 N corrosion and welding and techniques for monitoring and inspection.

Technology to inspect asset integrity of structures under N irradiation including pond water bars. 5.3 Low Level Waste Repository

Effluent treatment technology to manage discharges from 2020 N the LLW Repository.

90 NDA R&D Needs, Risks and Opportunities

Need/risk/ Issue Timescale opportunity Characteristics of a solution

6. Site restoration management 6.1 Characterisation and restoration

Technology to determine trace levels of analytes in the From 2005 N fields of environmental and radiation analysis.

Development of environmental assessment models may O help to demonstrate that the site could be delicensed without removal of all contamination.

Land and groundwater off site requires remediation. R Vaults for ground management at Sellafield site are not acceptable. 6.2 Site end point

91 Research and chemical processing site

18. Springfields

Springfields is the sole manufacturer of Magnox and AGR fuels and makes fuel products to customer specifications. Preparations for closure of Magnox fuel production are underway although oxide fuel production is expected to continue until 2023.

Need/risk/ Issue Timescale opportunity Characteristics of a solution 1. Radioactive materials characterisation 1.1 Characterisation Characterisation of historic and problematic uranium 2005-2009 N Assess uranium content and impurities. residue stocks to confirm suitability for process routes. 2. Management of radioactive waste 2.1 Waste retrieval and transfer 2.2 Processing, conditioning and packaging Send residual soft wastes from recovery of natural and 2005-2009 N Incineration enables final processing or consolidation for storage. enriched uranium to Capenhurst for incineration and O Early processing of residues with high uranium levels will non-combustibles to Ranstad in Sweden for processing. recover valuable material and enable early hazard reduction.

Use existing potential for other national users of enriched UO2 recovery facility. Availability of Capenhurst incinerator is extended to 2008. R Alternative route. Rework of ex-dissolver feed material containing uranium above disposal limits may not remove all uranium from the residues. Higher than expected impurity levels in residues for Disposal to landfill or alternative process routes. processing. Start operation of a new enriched uranium residues 2006-2008 N Internal washing, processing and size reduction.

process facility for processing obsolete UF6 cylinders.

Management and delivery of UF6 tails to Capenhurst. 2005-2016 Investigate routes including external options for graphite 2005-2009 N Use more complex treatments to recover uranium. Waste processing, contaminated metals and depleted uranium. O graphite may be processed in a uranium mine. Use commercial service to recycle depleted uranium. Develop alternative residue process routes for higher 2009 N Recover for utilisation as off-specification by customers or impurity residues which the site does not have the store until an alternative route is available. capability to process. 2.3 Waste recycling Decontamination of plant, equipment and scrap. 2005-2023 N Recycle and free release. 2.4 Waste transport (internal and international) Maintain shipments of fuel and intermediate products to N customers. Loss of transport routes. R 2.5 Waste storage strategy 2.6 Waste disposal Disposal of non-radioactive operational waste and VLLW 2016-2023 N to Clifton Marsh and LLW to the LLW Repository. Key disposal routes remain open. R Removal of uranium materials. 2023 N 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium Completion of the recovery of natural and enriched 2005-2008 N uranium residue liabilities.

92 NDA R&D Needs, Risks and Opportunities

Springfields

Need/risk/ Issue Timescale opportunity Characteristics of a solution 3.3 Fuel No routes identified to recover, process, store or dispose From 2008 N of surplus Magnox fuel. 4. Plant termination and decommissioning 4.1 Removal of plant contamination 4.2 Management of effluents 4.3 Plant dismantling Clean out, decommission and demolish plants including, 2005-2009 N Clean out at the end of production will avoid the need for

UF4 kiln (export), oxide production, residue storage rafts C&M Irradiated materials are not handled hence delay will and the magnesium store. not benefit from radioactive decay. Clean out, decommission and demolish plants including 2009-2016 N the fuel assembly plant, chemical plants, Magnox and AGR production plants and enriched uranium residues recovery plant, enriched uranium decontamination plant and storage tanks. Clean out decommission and demolish plants including 2016-2023 N

UF6 production plants and storage rafts, UF4 kiln (home boards), UOC drum store, UO3 production and decontamination centre. Clean out, decommission and demolish plants including 2023-2028 N the oxide fuels complex, powder and pellet export and hex cylinder wash facility. Loss of external waste disposal and residue processing R Alternative routes required. routes. Decommissioning is based on site knowledge and may uncover additional site activities. 5. Asset management 5.1 Reactors 5.2 Chemical plant Maintain fuel manufacturing for Magnox production. 2009

Maintain manufacturing of oxide fuel and UO2 products. 2005-2023 N Subject to AGR lifetime extensions. Commercial operations are reliant on the supply of feed R materials from power stations. 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Opening of new analytical services, ground contamination 2028-2031 N monitoring and investigation. 6.2 Site end point Demolition of buildings, new analytical services, site 2028-2031 N effluent facilities, ground remediation, excavation of east site burial pits leading to greenfield site. No alternative options addressed. R

93 Research and chemical processing site

19. Windscale

Windscale is adjacent to the Sellafield site. Decommissioning of the Advanced Gas Reactor is serving as a demonstration project for UK reactors. During the period to 2015, fuel will be removed from the piles and the reactor demolished.

Need/risk/ Issue Timescale opportunity Characteristics of a solution

1. Radioactive materials characterisation 1.1 Characterisation Intrusive and non-intrusive surveys of pile 1 core for 2005-2010 N development of waste retrieval and decommissioning strategies. Techniques to complete characterisation of WAGR 2005-2010 N structures. 2. Management of radioactive waste 2.1 Waste retrieval and transfer Develop and implement an integrated waste strategy for 2005-2015 N Dispose of LLW at the Low Level Waste Repository or solid LLW. other site. Removal of remaining active materials in WAGR. 2005-2008 N Inventories taken from WAGR archives. Remove ILW currently stored in containers and package 2005-2015 N Size reduce waste and containers and encapsulate in for disposal. WAGR boxes. Soft ILW to be encapsulated with containers of irradiated graphite. Development of equipment and trials for the retrieval of 2005-2010 N Fuel and isotope areas and areas external to the core can fuel and interim decommissioning. be accessed without dismantling the core. Utilise Sellafield facilities for ILW disposal route. Large volumes of decommissioning wastes may have R Undertake disposal and recovery route studies or delay no disposal routes and UK capacity to handle bulk free decommissioning. release material is limited. 2.2 Processing, conditioning and packaging Process and package retrieved isotopes and waste from 2005-2015 N Isotopes and special wastes to be characterised WAGR, piles, B52 caves, tenanted buildings and send to and treated for storage. Assay and packaging and existing ILW store. encapsulation of waste as appropriate. 2.3 Waste recycling and reuse 2.4 Waste transport 2.5 Waste storage strategy C&M of ILW store for WAGR decommissioning waste. 2015-2025 N Existing storage capacity is sufficient for ILW radioactive sources and special nuclear materials. 2.6 Waste disposal 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel

94 NDA R&D Needs, Risks and Opportunities

Windscale

Need/risk/ Issue Timescale opportunity Characteristics of a solution 4. Plant termination and decommissioning 4.1 Removal of plant contamination Technology for the demolition of the outer building of 2005-2015 N pile 1, WAGR bioshield and outer sphere and redundant buildings. 4.2 Management of effluents 4.3 Plant dismantling Removal of in cave equipment, decontamination of 2005-2026 N surfaces and demolition of the building. Technology for the demolition of the outer building of 2005-2015 N pile 1, WAGR bioshield and outer sphere and redundant buildings. Lead decontamination techniques. O Utilise international experience. Radiological and asbestos conditions in buildings make R access and maintenance difficult. No disposal route for tritiated concrete from WAGR N Characterisation of bioshield and disposal studies. bioshield. Preparation of piles 1 & 2, for long-term C&M, including 2005-2025 N Unannealed graphite to be left in cores. sealing the bioshield and building a surrounding weatherproof structure. Placing pile 1 in long-term C&M requires regulatory R approval. 5. Asset management 5.1 Reactors 5.2 Chemical plant Maintain commercial operations and support for tenant 2005-2020 N clean out. Failure due to ageing facilities and inadequate historic data. R Life care of structures and condition assessments. 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Contaminated land and water remediation and control for 2005-2026 N interim end state. Environmental remediation of areas after plant is 2005-2026 N demolished. Incomplete information on land quality. R Staged characterisation work. 6.2 Site end point

95 Research and chemical processing site

20. Winfrith

Winfrith operated nine prototype reactors and three remain to be decommissioned. Until 2015, site clean up, demolition of redundant buildings and waste packaging and storage, will be the main activities, leading to site closure in 2020.

Need/risk/ Issue Timescale opportunity Characteristics of a solution

1. Radioactive materials characterisation 1.1 Characterisation Characterisation of tritium content in VLLW. 2005-2010 N Rapid, reliable and representative sampling. May need to treat as LLW rather than free release. R Minimise the volume and avoid tritium release applicable to varied materials. 2. Management of radioactive waste 2.1 Waste retrieval and transfer 2.2 Processing, conditioning and packaging Grouting of ion exchange resins. 2005-2006 N Stable, long-life waste form. Grouting of thorium metal. 2005-2006 N Suitable for long-term storage, acceptable for disposal or re-treatment. Insufficient long-term stability of thorium product. R Packaging of contaminated sodium. 2005-2007 N 2.3 Waste recycling and reuse 2.4 Waste transport (internal and international) Objections to the transfer of sodium to Dounreay. R Demonstrate acceptable risks in transport and storage. 2.5 Waste storage strategy No off site store available for the transfer of ILW. 2015 R Safety of continued storage in present location or compatibility with an existing store elsewhere. 2.6 Waste disposal 3. Management of other nuclear materials 3.1 Plutonium 3.2 Uranium 3.3 Fuel

96 NDA R&D Needs, Risks and Opportunities

Winfrith

Need/risk/ Issue Timescale opportunity Characteristics of a solution

4. Plant termination and decommissioning 4.1 Removal of plant contamination 4.2 Management of effluents 4.3 Plant dismantling Understand location and the extent of contamination in 2005/06 N Reliable and representative measurement to enable SGHWR and Dragon reactor cores. decisions to be taken. Tools and techniques to plan and rehearse dismantling. 2007-2017 N Must be able to translate non-active simulation into action for the real situation. Tools and techniques to achieve faster decommissioning 2007-2017 O Large fractions saved from original plan; not generate and increase the amount of waste for free release. additional liability elsewhere, not increase downtime due to maintenance etc. Decontaminate surfaces to reduce arisings of LLW. 2007-2017 O Ensure liability of decontamination less than savings in LLW. 5. Asset management 5.1 Reactors 5.2 Chemical plant 5.3 Low Level Waste Repository 6. Site restoration management 6.1 Characterisation and restoration Manage solvent contaminated land. 2005-2020 N Demonstrate acceptable safety. Establish a safety case for delicensing. 2005-2020 R EA does not accept the case for no remediation. 6.2 Site end point

97 NUCLEAR DECOMMISSIONING AUTHORITY HERDUS HOUSE, WESTLAKES SCIENCE AND TECHNOLOGY PARK, MOOR ROW, CUMBRIA, CA24 3HU TEL: 01925 802073 / FAX: 01925 802078 / WWW.NDA.GOV.UK