Treatment, volume reduction and recycling of large components such as heat exchanges, steam generators and boilers
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1 Treatment, volume reduction and recycling of large components such as heat exchanges, steam generators and boilers INTERNATIONAL NUCLEAR FORUM BULGARIAN NUCLEAR ENERGY NATIONAL, REGIONAL AND WORLD ENERGY SECURITY 5th June 7th June, 2013, Riviera Holiday Club, Varna
2 Drivers and Customer Benefits for conditioning of LLW Minimizing cost by Waste Volume Reduction Improve waste management efficiency Minimizing NPP on-site waste treatment Avoiding interim storage at power plant and free up space Recycling of valuable materials reduces environmental burden Waste volume reduction prolongs repository life time and reduces over all cost Improve public impression of the nuclear industry
3 Thermal treatment in Studsvik Pyrolysis facility Incineration facility - Start up in Feb License 100 tonnes per year - Internationally available - Start up in tonnes per year - Internationally available Licensed capacity 600 ton/year
4 4 Volume reduction by batch pyrolysis process Heat recovery Steam generator Charcoal filter Wet Scrubber Baghouse filter After-burner Batch charger Secondary waste (ash) collection room Pyrolys Vessel
5 5 Volume reduction by incineration 97 % Volume reduction 92% Weight reduction Inert final product Treatment of: Dry radioactive waste Oil Activated Carbon Ion exchange resins U-contaminated waste Incineration Waste ~ 3% Sorting
6 Studsvik - Metal Treatment Facilities in Sweden 6 Metal treatment and melting facility Large components treatment facility Licensed capacity 5000 ton/year Capacity ~2000 ton/year
7 7 Volume reduction by melting - Advantages Simple and proven technique Small volume of secondary waste Free release & Recycling of natural resources Decontamination, homogenisation, volume reduction Low carbon footprint - environmentally friendly process Decontamination - Melting of Uranium contaminated scrap
8 8 Volume reduction by melting - containerized scrap Carbon teel Stainless steel Aluminium Brass Copper Lead Free release > 95 % Logistic Segmentation Decontamination Melting & recycling Recycling rate 97 95%w Segmentation Decontamination Melting Waste conditioning
9 Large Components - treatment concept 9 Blasting box Waste Treatment cell Treatment of: Heat exchangers Steam Generators Turbines Boilers Band saw Sepration of steam dome Remote decontamination Metal for Recycling Melting for Recycling Melting for volume reduction
10 10 Treatment large components, examples 170 t HX, NPP Oskarshamn (S) 800 t Reheaters NPP TVO (Fin) 1600 t Turbine components KKW Forsmark (S) 300 t Turbine components NPP Mühleberg (Ch) 4 x 165 t Steam Generators NPP Stade (D) 6 x 310 t Steam Generatots NPP Ringhals (S) Turbine components NPP Würgassen (D) 700 t Turbine components NPP Ringhals (S) 4x60 t HX, NPP Isar (D)
11 Large components - Transport Phase 11 Steam Generator: Length: 20 m Diameter: 3,5/4,5 m Weight: 310 Mg 0,1-10 TBq/SG ~ 4500 tubes Boiler Transport to harbour Steam Generator- Loading Boiler: Length: 21 m Diameter: 5 m Weight: 310 Mg 40 GBq/boiler Off-loading in Studsvik Arrival treatment facility
12 Steam Generator Treatment Phase 12 Waste categories: Blasting residues tubing decontamination Blasting residues decontamination of SG segments Slag and dust melting activities Tube bundle material - melted or compacted alt. chopped + flattened Pellet of compacted SG inconel tubing Chopped + flattened SG inconel tubing Ingots of melted SG inconel tubing
13 Radiology of treated Steam Generators 13 No decay storage msv/h 10 yeras decay storage msv/h 15 years decay storage msv/h After chemical decontam. msv/h - <0,003 - <0,001-0,035 - <0,001 0,15 0,150 0,1 0,03 0,25 0,08 0,3 0, ,3 0,5 0,04 0,1 0, ,5 1,1 0,1 ~TBq
14 Steam Generator results, mean values 14 Steam Generator Total Treated units Initial volume (m 3 ) Volume, each SG Waste for Final Storage (m 3 net) Waste for Final Storage (% net) Initial weight (Mg) Weight, each SG Recycling (Mg) Recycling (%) Dose / SG Collective dose (man msv) After years of dacay After chemical decontamination No dacy, no chemical deocntamination SG under treatment, no data available Total treatment time of one 310 Mg Steam Generator: 8-12 weeks
15 Boilers results, mean values 15 Boilers Total Treated units Initial volume (m 3 ) Volume, each boiler Waste for Final Storage (m 3 net) Waste for Final Storage (% net) Initial weight (Mg) Weight, each boiler Recycling (Mg) Recycling (%) Dose/boiler Coillective dose (man msv) After 23 years of dacay , Total treatment time of one 310 Mg / 600m 3 boiler: 4-6 weeks
16 16 Treatment large components - Challenges Boilers Steam Generators Logistic: Transport of components with a size of 600 m³ each. Decontamination of finned tubes Steam Generators tubing: Decontamination, segmentation and pulling of ~75 km, 4700 tubes
17 17 Recycling Concept Sampling Samples for beta, gamma and alpha analysis Ingots, conditionally free released, for further re-melting
18 18 Metal recycling concept: Re-melting and free release Metal free release concept based on EC s RP89 (section 3.1) + Swedish Radiation Safety Authority stipulations Melting and metal ingot classification based on radiological data Ownership Change & Free Release <0,1 Bq/g (Co-60) and conditional free release of metal ingots for re-melting Transport and 2 nd re-melt at the conventional foundry - under qualified process for ingots flow control Free released metal as commodity
19 Boilers - results summary 600 m³ / 310 t 285t = 92% Recycling Waste 25t Waste15 m 3 (2,5%vol.) - Slag, dust, blasting residues
20 20 Steam Generator - results summary 430 m³ / 310 t 245 t = 80% Recycling Waste 70t Waste: 36 m 3 (8%vol.) - Slag, dust, blasting residues - Melted/compacted tube bundle material
21 Recycling of Retired Steam Generators - Concept Mass balance Recycling: ~ 80% Final Storage: ~ 20% SEGMENTATION DECONTAMINATION MELTING FOR FREE RELEASE FREE RELEASE MELTING FOR HOMOGNISATION + FREE RELEASE CHEMICAL DECONTAMINATION, SEGMENTATION WASTE FOR FINAL STORAGE
22 22 Borkeley Boilers - transport to Studsvik Berkeley transport
23 Conclusions Large components Challenges: Logistic, decontamination, segmentation and tube treatnemt Feasibility Studies can bring the key to unlocking of the project Collaboration for transports is the key to project success Demonstration to customer & stakeholder, appetite for more The Best Available Technique has to be used Recycling of valuable nature materials resources Minimizing storage volumes and waste legacy Reducing of future unknown costs Recycling of large components is feasible
24 Thank you for your attention 24
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