Thermochemical processing using powder metal fuels of radioactive and hazardous waste M I Ojovan 1, W E Lee 1 , I A Sobolev 2 , S A Dmitriev 2 , O K Karlina 2 , V L Klimov 2 , G A Petrov 2 and C N Semenov 2 1 Immobilization Science Laboratory, Department of Engineering Materials, University of Sheffield, Sheffield, UK 2 Moscow SIA ‘Radon’, Moscow, Russia Abstract: An overview of thermochemical treatment technologies (TTTs) for radioactive and toxic wastes is given. TTTs have been developed for pretreatment (e.g. decontamination), treatment and conditioning of specific wastes such as mixed, organic or chlorine-containing radioactive waste and contaminated soils. TTTs use powder metal fuels (PMFs) specifically formulated for the waste composition, which react with some of the waste components. Thermochemical processing can be carried out in a self-sustaining regime and enables ecologically safe processing of wastes without complex and expensive equipment. It leads to almost total confinement of contaminants in a mineral or glass composite end-product with minimal release of hazardous components and radionuclides in the off-gas. Keywords: thermochemical processes, waste processing, radioactive waste, toxic waste NOTATION IER ion-exchange resin PMF powder metal fuel PVC polyvinyl chloride SHS self-sustaining high-temperature synthesis SIA Scientific and Industrial Association TTT thermochemical treatment technology VRC volume reduction factor 1 INTRODUCTION Thermochemical processing has been developed predomi- nantly in Russia to immobilize toxic and radioactive wastes and utilizes selective combustion of powder metal fuel (PMF) constituents with the most hazardous waste components in a heterogeneous system ensuring complete decomposition of organics and retention of toxic and radio- active elements in the condensed combustion products. These are in the form of mineral-like or glass composite materials suitable for subsequent safe storage, transpor- tation and eventual reuse of non-radioactive materials or disposal of radioactive waste. Thermochemical treatment technologies (TTTs) are intended for pretreatment (e.g. decontamination), treatment and conditioning of specific types of radioactive and toxic waste such as spent ion-exchange resins, inorganic absor- bents, wastes from research nuclear reactors, irradiated graphite, mixed, organic or chlorine-containing radioactive waste, contaminated soils and unburnable heavily surface- contaminated materials. Table 1 compares TTTs with other thermal methods for processing of wastes. Thermochemical processing uses the energy of exothermic reactions in a mixture of radioactive or hazardous waste with PMF. The PMF composition is designed to minimize the release of hazardous substances and radionuclides in the off-gas and to confine the contaminants in the solid products. Generally, the PMF consists of combustible powder metals, oxygen-containing components and some additives (pore-forming materials, stabilizers, surface-active substances and others), with a predominance of metal powders. Thermo- dynamic simulation is applied widely during designing of the PMF, followed by experimental performance and operational safety assessment tests of TTTs. 2 TTT DEVELOPMENT AND APPLICATIONS A number of applications of thermochemical processing methods have been demonstrated, including: (a) pretreatment: surface decontamination of metals, asphalt and concrete; The MS was received on 18 November 2003 and was accepted after revision for publication on 14 June 2004. Corresponding author: Department of Engineering Materials, University of Sheffield, Sir Robert Hadfield Building, Mappin Street, Sheffield S1 3JD, UK. 1 E04503 # IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part E: J. Process Mechanical Engineering
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Thermochemical processing using powder metalfuels of radioactive and hazardous waste
M I Ojovan1�, W E Lee1, I A Sobolev2, S A Dmitriev2, O K Karlina2, V L Klimov2, G A Petrov2
and C N Semenov2
1Immobilization Science Laboratory, Department of Engineering Materials, University of Sheffield, Sheffield, UK2Moscow SIA ‘Radon’, Moscow, Russia
Abstract: An overview of thermochemical treatment technologies (TTTs) for radioactive and toxic wastes
is given. TTTs have been developed for pretreatment (e.g. decontamination), treatment and conditioning of
specific wastes such as mixed, organic or chlorine-containing radioactive waste and contaminated soils.
TTTs use powder metal fuels (PMFs) specifically formulated for the waste composition, which react with
some of the waste components. Thermochemical processing can be carried out in a self-sustaining
regime and enables ecologically safe processing of wastes without complex and expensive equipment. It
leads to almost total confinement of contaminants in a mineral or glass composite end-product with minimal
release of hazardous components and radionuclides in the off-gas.
and others), with a predominance of metal powders. Thermo-
dynamic simulation is applied widely during designing of the
PMF, followed by experimental performance and operational
safety assessment tests of TTTs.
2 TTT DEVELOPMENT AND APPLICATIONS
A number of applications of thermochemical processing
methods have been demonstrated, including:
(a) pretreatment: surface decontamination of metals,
asphalt and concrete;
The MS was received on 18 November 2003 and was accepted after revisionfor publication on 14 June 2004.�Corresponding author: Department of Engineering Materials, Universityof Sheffield, Sir Robert Hadfield Building, Mappin Street, SheffieldS1 3JD, UK.
1
E04503 # IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part E: J. Process Mechanical Engineering
(b) treatment: processing of organic wastes, namely spent
ion-exchange resins, plastics, polymers and medical
and biological waste;
(c) treatment and immobilization: processing irradiated
Characteristics Thermal processing withdecomposition of chemicalcompounds on heating
Chemical process that occurs withrelease of heat in autowave regimeof combustion and resulting information of solid products
Thermochemical process that useswaste specific fuels and utilizesconstituents in both synthesis anddecomposition chemical reactions.May involve liquid phase
Area of application Toxic, low- and intermediate-levelradioactive wastes, mixed wastes
Toxic, low-, intermediate- and high-level radioactive wastes, mixedwastes
Toxic, low-, intermediate- and high-level radioactive wastes, mixedwastes
Main targets Decomposition of organics, volumereduction
Synthesis of waste forms Decomposition of organics, volumereduction; synthesis of wasteforms; immobilization throughmelting; decontamination;selective recovery
Stage of implementation Industrial application Laboratory experiments Pilot industrial application
Advantages Universal High efficiency High efficiency and selectivity
Table 2 Thermochemical treatment methods for toxic and radio-
active wastes
Method Reference
Calcination of wastes [1]Sintering of ceramics [2]Decontamination of asphalt [3]Decontamination of concrete [4]Decontamination of metals [5]Deep decontamination of metals [6]Treatment of mixed wastes [7]Incineration of biological wastes [8]Vitrification of ash residues [9]Incineration of ion exchangers [10]Processing of reactor graphite [11]Synthesis of Synroc-type ceramics [12]Synthesis of mineral-like matrices [13]Immobilisation of U- and Pu-containing wastes [14]Remelting of metals [15]
2 M I OJOVAN, W E LEE, I A SOBOLEV, S A DMITRIEV, et al.
Proc. Instn Mech. Engrs Vol. 218 Part E: J. Process Mechanical Engineering E04503 # IMechE 2004
3 THERMOCHEMICAL DECONTAMINATION
The thermochemical decontamination technique can be
used to decontaminate surfaces of materials including
asphalt, concrete and metals. This technology is particularly
suitable when the radioactive contamination is strongly
bonded in the near-surface layers where conventional
decontamination methods cannot efficiently remove the
radionuclides [16]. Thermochemical decontamination is
based on thermal treatment of a superficial layer of contami-
nated material by the heat generated from combustion of a
layer of PMF covering the surface (Fig. 1) [3–6].
The PMF layer on the surface is burning flameless and
continuously within a few minutes. The heat volatilizes
most of the radionuclides, which are then trapped by
the resulting slag layer, which is formed as a result of
PMF combustion. Thermochemical interaction between
the slag layer and decontaminated material may also result
in removal of a near-surface layer along with the
contaminants.
Thermochemical decontamination technology is rather
simple and comprises few operations [3–6]. The first oper-
ation is to determine the extent of and then to cover the con-
taminated region of the surface with a thin (0.8–1 cm) layer
of PMF. This layer is then ignited, combustion lasting
for several to a few tens of minutes, depending on the
PMF type. The last stage following the extinction of the
PMF involves collecting the resulting slag from the surface.
Decontamination efficiency is calculated by the formula
K ¼A0 � Af
A0
100% (1)
where A0 is the radioactivity of the material surface before
decontamination and Af is the radioactivity of the material
surface after decontamination. The decontamination effi-
ciency depends mainly on temperature and duration of sur-
face heating. These variables are determined by the PMF
composition and its consumption per unit of treated area.
Process optimization for various materials includes select-
ing the mixture composition and ensuring the necessary
combustion temperature.
Decontamination of metal surfaces is achieved as a result
of radionuclide volatilization and their fixation in a slag
layer that forms as a result of PMF combustion. To
remove well-bonded radioactive contamination typically
requires removal of a thin layer (�1 mm) of the metal sur-
face. Relatively deep penetration of radioactive contami-
nants into metals may occur owing to corrosive and
mechanical destruction of the near-surface metal structure.
A special thermochemical technique has been developed
for deep (�100 m) decontamination, which combines both
thermal volatilization and chemical surface oxidation of
the metal [6, 15–17].
Thermochemical decontamination of concrete (Fig. 2) is
achieved via thermal shock spallation caused by PMF. The
PMF is coated on the contaminated concrete plate and
ignited. After PMF combustion, the concrete upper layers
crack and spall. These spalled concrete fragments are
embedded in the slag and both are removed after cooling.
Decontamination efficiency for concrete is as high as
90–95 per cent for each decontamination procedure.
The depth of radioactive contamination removed is up to
5–8 mm, and these procedures can be repeated if necessary
to remove several layers of contaminated concrete.
Fig. 1 Schematic of a thermochemical decontamination
technique
Fig. 2 Thermochemical decontamination of a concrete slab: PMF layer covers the contaminated region (left)
and spalled fragments ready for collection (right)
THERMOCHEMICAL PROCESSING USING POWDER METAL FUELS OF RADIOACTIVE AND HAZARDOUS WASTE 3
E04503 # IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part E: J. Process Mechanical Engineering
For asphalt decontamination transfer, of the contaminated
layer to the softened state of asphalt is achieved at
130–180 8C. The glass fibre backed PMF filling is applied
to the contaminated asphalt surface. After PMF combustion,
the softened asphalt is removed mechanically to the neces-
sary depth. The deeper the radionuclide contamination of
asphalt, the longer is the PMF combustion and consequently
the thicker the PMF layer needed.
The main characteristics of the thermochemical deconta-
mination method are given in Table 3. Thermochemical
decontamination was successfully used in many cases
when conventional methods were inefficient [3–6, 16, 17].
4 PROCESSING OF ORGANIC WASTES
Some organic radioactive wastes require special treatment
technologies. These include spent ion-exchange resins
(IERs), mixed, polymer and chlorine-containing (for
example PVC) wastes and biological objects. The thermo-
chemical processing of radioactive organic waste is based
on application of a specifically formulated PMF. The com-
position of this PMF is designed using thermodynamic cal-
culations and takes into account the chemical composition
of waste and the need to decompose certain organics but
retain the toxic and radioactive elements. The goal of the
thermodynamic simulation is to achieve simultaneous
decomposition of organic matter in the waste and retention
of hazardous radionuclides and chemical species in the final
ash–slag product.
IERs most generally used in water purification systems at
nuclear power stations and nuclear research centres are
copolymers of styrene and divinylbenzene. The thermo-
chemical technology for spent IERs was developed to
treat resins in a wet state [18, 19]. Spent IERs usually con-
tain a large amount of water, often more than 50 wt %. The
major radioactive contaminants of spent IERs are 137Cs,90Sr, 60Co, 106Ru and 54Mn. In addition, spent IERs are fre-
quently contaminated with heavy and toxic metals. The
metal powders in the PMF (including Al, Mg, Ca and Si)
react with water from the IERs, producing enough heat to
sustain its thermal destruction and interaction with the
PMF-generated slag. As a result, the waste volume is
decreased significantly and contaminants combine with
the PMF slag to form chemically stable compounds. A
number of PMFs have been developed for this purpose
(Table 4).
The process of incineration of IERs mixed with PMFs is
illustrated schematically in Fig. 3. A wet IER and PMF,
previously mixed in the appropriate ratio, are fed into the
furnace where reaction is initiated and combustion occurs,
resulting in the release of a great quantity of heat, evapor-
ation and gasification of the IER. Air is supplied to the
combustion chamber to burn out the products of IER gasifi-
cation and hydrogen resulting from the reaction of the metal
with water.
The process in the furnace is controlled so that radio-
nuclides contained in the wet resin are converted into low-
volatile compounds of ash residue. Figure 4 shows an
actual thermochemical facility (capacity up to 20 kg/h).
Table 3 Main features of thermochemical decontamination process
NO and NO2 20/50 300–500SO2 and SO3 220/430 100–2000CO ,1.25 50–200
Fig. 5 Schematic of PMF field incineration of biological
waste: 1, cadaver of animal; 2, trench; 3, fire grate;
4, air supply; 5, vertical supports; 6, metal hood; 7,
layer of PMF with coke
Fig. 6 PMF field incineration of biological waste: left, before; centre, process under way; right, final ash–slag
residue
THERMOCHEMICAL PROCESSING USING POWDER METAL FUELS OF RADIOACTIVE AND HAZARDOUS WASTE 5
E04503 # IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part E: J. Process Mechanical Engineering
5 PROCESSING OF IRRADIATED REACTORGRAPHITE
Graphite waste containing fragments of fuel and activation
and fission products mainly arise during operation of
uranium–graphite reactors. The 14C content in reactor
graphite may be as much as 1 wt %. For safe disposal and
long-term storage, such waste must be properly processed
into chemically stable materials. Other carbon-containing
(including 14C radionuclide) wastes are also the subject of
special attention. Incineration of irradiated carbon is not
permitted because of discharge into the atmosphere of bio-
logically significant 14C in 14CO2 and14CO. To treat 14C-
containing waste, a thermochemical treatment technology
has been developed based on self-sustaining exothermic
reactions in a mixture of carbon (graphite), aluminium and
titanium dioxide [11, 21]
3C (graphite)þ 4Alþ 3TiO2 ! 3TiCþ 2Al2O3
As a result, 14C and other radionuclides become immobi-
lized in a stable carbide–corundum ceramic matrix.
Figure 7 demonstrates the SHS process of formation of
carbide–corundum waste from a mixture of graphite
with PMF.
Thermochemical processing of graphite is carried out in
an inert atmosphere, e.g. in an argon atmosphere. A mixture
of PMF with powdered graphite is placed into a crucible
container where the self-sustaining synthesis reaction
is ignited (Fig. 7, left photo). The self-sustaining process
occurs with substantial release of heat; temperatures
higher than 1700 8C are achieved. Nevertheless, the relative
carryover of carbon is minimized to values of 1024/1027 for
CO and CO2 respectively. The self-sustaining reactions
result in a chemically stable titanium carbide–corundum
matrix acceptable for long-term storage and disposal.
Special additions such as zircon, barium and calcium
metatitanites have also been used to improve radionuclide
retention [22–24].
6 SELF-SUSTAINING IMMOBILIZATION
While vitrification is the best current solution for immobi-
lizing hazardous waste, its use is limited to large-volume
waste streams such as high- and intermediate-level nuclear
waste. This is due to the relative complexity of the vitrifica-
tion technology and the high initial cost of equipment. How-
ever, in addition, a range of accumulated wastes of different
composition and properties from the bulk streams have been
generated during various activities of both industrial facili-
ties and research institutions, usually in relatively small
amounts. Examples include spent ion exchangers, wastes
from research centres, contaminated soils and incinerator
ashes. Owing to the relatively small volumes of such
wastes, the use of conventional vitrification technologies
cannot be justified. A viable alternative is the application
of a self-sustaining immobilization process that utilizes
the energy released during exothermic chemical reactions
Table 6 Results of the analysis of ash–slag residue
Parameter
From the results ofLABTECH Brno,Czech Republic(mg/l)
From the resultsof SIA ‘Radon’(wt %)
Sum of polycyclicaromatichydrocarbons
,0.0006 Not measured
Al 195 4Sb ,0.001 Not measuredPb ,0.05 Not measuredCd ,0.005 Not measuredHg ,0.0008 Not measuredFe ,0.1 Not measuredAmmonia ions 175 Not measuredNitrides 0.22 Not measuredPhosphates 0.6 Not measuredSulphates ,0.6 Not measuredK2O Not measured 3MgO Not measured 49Al2O3 Not measured 20MgAl2O3 Not measured 24
Fig. 7 Thermochemical processing of graphite: left, ignition: centre, downward motion of reactive zone;
right, final product
6 M I OJOVAN, W E LEE, I A SOBOLEV, S A DMITRIEV, et al.
Proc. Instn Mech. Engrs Vol. 218 Part E: J. Process Mechanical Engineering E04503 # IMechE 2004
in a mixture of radioactive waste with specially designed
PMFs [9, 25–28]. PMFs are used to melt the waste and
form a glass-like material without requiring an external
power supply. This process is controlled by the composition
of the initial mixture of waste and PMF. The composition of
the PMF is designed to release sufficient heat to sustain
waste melting and to produce a mineral or glass-like end-
product. Suitable PMF compositions and PMF/waste
ratios are determined through computer simulation, mini-
mizing carryover of hazardous components and ensuring
retention of contaminants in the final waste form. Self-
sustaining immobilization does not require expensive
equipment and is economically justified, particularly for
small-volume hazardous wastes. The possibility of such
processes has been demonstrated for a number of waste
streams including calcined radioactive waste, contaminated
clay soils, ashes and spent inorganic ion exchangers, zirco-
nium alloys and irradiated graphite. New schemes are
designed to be applied in situ, ensuring waste immobiliz-
ation in the final disposal environment [28].
Thermodynamic simulation has been applied to the design
of appropriate PMF formulations [29, 30]. Ash residues
from radioactive waste incineration as well as contaminated
clay soil were used. The b,g-emitting radionuclides of cae-
sium, strontium and cobalt and the a-emitting radionuclides
of heavy metals (actinides, radium, and polonium) were the
main carriers of radioactivity in the ash residue. The radio-
nuclide content in the soil was represented mainly by137Cs. For U- and Pu-containing wastes, natural zircon was
added to the PMF to aid radionuclide retention [31].Table 7 illustrates the properties of the glass composites
obtained through a thermochemical solidification process
such as self-sustaining immobilization. The retention of
radionuclides by glass composite materials is due to high
leaching rates similar to those obtained by conventional
vitrification.
A significant advantage of the thermochemical immobil-
ization process is its autonomy: self-sustaining immobiliz-
ation can be carried out remotely without the need for a
processing area. This method has been proposed recently
for in situ immobilization of waste in borehole-type reposi-
tories [14, 27]. Figure 8 demonstrates the process occurring
in a double-walled container in field tests of in situ
immobilization.
Self-sustaining immobilization has been proven as a
feasible scheme to vitrify ashes produced as a result of
Table 7 Characteristics of self-sustaining immobilization processes and the glass composites obtained
23 Karlina, O. K., Dmitriev, S. A., Klimov, V. L., Ojovan, M. I.,
Pavlova, G. Yu. and Yurchenko, A. Yu. Retention investi-
gation of the carbon-14 being contaminated in the irradiated
reactor graphite. In Proceedings of International Conference
ICEM’03, Oxford, 21–25 September 2003, CD-ROM, 4567.pdf.
24 Karlina, O. K., Varlakova, G. A., Ojovan, M. I.,
Tivansky, V. M. and Dmitriev, S. A. Conditioning of radio-
active ash residue in a wave of solid phase exothermal reac-
tions. Atomic Energy, 2001, 90(1), 43–48.
25 Karlina, O. K., Klimov, V. L., Pavlova, G. Yu.,
Penionzhkevich, N. P., Yurchenko, A. Yu., Ozhovan, M. I.
and Dmitriev, S. A. Thermodynamic analysis and experimen-
tal investigation of phase equilibria in the thermochemical pro-
cessing of irradiated graphite in the C–Al–TiO2 system.
Atomic Energy, 2003, 94, 405–410.
26 Karlina, O. K., Varlakova, G. A., Dmitriev, S. A. and
Ojovan, M. I. Thermochemical conditioning of radioactive
waste: structure and properties of final processed product. In
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27 Ojovan, M. I., Karlina, O. K., Petrov, G. A., Sobolev, I. A.,
Dmitriev, S. A. and Lee, W. E. Self-sustaining immobilisation
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28 Ojovan, M. I. and Lee, W. E. Self-sustaining vitrification for
immobilization of radioactive and toxic waste. Glass Technol.,
2003, 44, 218–224.
29 Ojovan, M. I., Klimov, V. L. and Karlina, O. K. Math-
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31 Kulyako, Yu. M., Perevalov, S. A., Vinokurov, S. E.,
Myasoedov, B. F., Petrov, G. A., Ozhovan, M. I.,
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THERMOCHEMICAL PROCESSING USING POWDER METAL FUELS OF RADIOACTIVE AND HAZARDOUS WASTE 9
E04503 # IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part E: J. Process Mechanical Engineering
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