AdrnnistrtiyReviGw,I>DLL.Q.II---3CVName:DFinalEffluentPonds1and2DelistingPetitionBWXTechnologies,IncNavalNuclearFuelDivisionMarch6,2002InPartnershipwiththeEnvironment1.0 Background 1.1 Purpose 1.2 Overview

of BWXT Activities 1.3 Description

of Waste Streams 1.4 Delisting

of Non-Radioactive

“F006 Listed” Sludge 1.5 Non-Radioactive

“F006 Listed” Sludge Accumulations

in the FEP 1.6 Regulatory Concerns

with “F006 Listed” Sludge 1.7 NNFD’s

Need

to Delist

the FEPs 1.8

FEP Delisting Petition Methodology 2.0 Wastewater Treatment Systems 2.1 General 2.2
FEPs History 2.3 Historical

LLR

and PA Wastewater Treatment Systems 2.4 Replacement

of Clarification

Systems

with Microfiltration

Systems 2.5

LLR Waste Treatment
System 2.6

PA Waste Treatment
System 2.7

Grit Blast Waste Treatment
System 2.8 Water Production

Waste Treatment
System 2.9 Sanitary
Waste Treatment
System 2.10 Once-Through Non-Contact

Cooling Water 3.0 Manufacturing
Operation Process Descriptions 3.1 Overview 3.2 Production Processes Generating Non-Radioactive
Wastewater 3.2.1 Metal Processing

and Pickling 3.2.2 Metal Anodizing 3.2.3 Copper Dissolution 3.2.4 Hafnium

and Inconel Processing

and Pickling 3.2.5 Aluminum Pickling

and Anodizing 3.2.6 X-Ray Processing 3.2.7

Grit Blasting

and Water

Jet Cutting Operations 3.2.8 Water Treatment 3.2.9 Sanitary (Domestic)

Waste Generation 3.2.10
Once Through Non-Contact

Cooling Water3.3 Production Processes Generating Radioactive Wastewater 3.3.1 Uranium Recovery Operations 3.3.2 Downblending
Operations 3.3.3

CRF Development

Process 3.3.4 Chemistry Laboratory
Facility 3.3.5 Research

Test Reactor

and Targets (RTRT) 3.3.6 Atomic Energy

of Canada Limited (AECL) Target Fabrication 3.3.7

Fuel Assembly

Area 3.3.8 Metallographic
Laboratory 3.3.9 Laundry 3.4 Lynchburg Technology

CenterBWXT

FEP Delisting Petition

03/22/02 1.0 BACKGROUND 1.1 Purpose This petition

seeks

to exclude

from regulation

under Subpart

D of 40 Code

of Federal Regulation Part
261
the Final Effluent
Ponds (FEPs)

and the sludge cunently deposited
therein

for the wastewater treatment facilities

at the BWX Technologies,

Inc Naval Nuclear

Fuel Division’s (NNFD)

Mt. Athos

Site

in Lynchburg,
Virginia.

In addition

to NNFD,

the Mt. Athos

Site

is also home

to the Lynchburg Technology

Center (LTC). 1.2 Overview

of BWXT Activities Since

its formation

some

45 years

ago

to present, NNFD

has been involved

in the production

and as cmbly

of components primarily

for the United States Government.

This work requires

the p0:-session

and use

of Special Nuclear Material (SNM), primarily unirradiated
enriched uranium. Ovr

the years, BWXT

has expanded

its workscope

to include

the recovery

and purification

of scr

p uranium

and uranium downblending.

These operations

are currently

being performed

and regulated

under Nuclear Regulatory Commission

(NRC) License SNM-42. NNFD

is primarily

a metal fabricator

(SIC 3443), which involves

the fabrication

of metal components

from stock metals through various machining processes, welding, grinding, pickling, cleaning,

and final assembly. Secondary

to this

is the recovery

of uranium

fuel,

the research

and development

of uranium

fuel manufacturing techniques,

and downblending operations.
Support facilities

for the Mt. Athos

site include

a steam plant, water treatment facilities,

and wastewater treatment facilities. The LTC consists

of McDermott Technologies,

Inc. Research

& Development

Division

(MTI) and BWXT Services Division (BWXS).

MTI focuses

on non-destructive

analyses, ceramics,

fuel cell energy systems. BWXS operates hotcells

and
the Nuclear Environmental Laboratory. Operations

at the LTC

are widely diversified, changing frequently

to meet research

and laboratory

testing needs. Solid waste

and wastewater generated

at the LTC

are delivered

or piped to NNFD

for processing, treatment, recycling,

and/or disposal. 1.3 Description

of Waste Streams The liquid waste streams treated

at the NNFD Wastewater Treatment Facilities

are categorized as wastewater generated

from industrial processing operations

and wastewater generated

from non-industrial processing operations. Industrial processing wastewater

streams consists

of the following:

• Non-radioactive

spent
acid
and rinsewater

from

the pickling

and anodizing

of metal components

and wastewater

from copper dissolution. • Radioactive

spent
acid solutions

from uranium recovery

and downblending operations, wastewaters

from chemical

and metallurgical
analyses, wastewaters

from
fuel fabrication,

and wastewater

from laundry operations.BWXT-FEPDelistingPetition03/22/02Non-industrialprocessingwastewaterstreamsconsistsofthefollowing:•Wastewaterfromtheproductionofnon-contactcoolingwateranddeionizedwater.•Domestic/sanitarywastewater.•Non-contactcoolingwater(notrecirculated,calledoncethroughnon-contactcoolingwater).1.4DelistingofNon-Radioactive“F006Listed”SludgeIn1990,theVirginiaDepartmentofWasteManagement(DWM)identifiedthesludgegeneratedfromneutralizationofnon-radioactivespentacidandrinsewaters,callthePickleAcid(PA)WasteTreatmentSystem,asa“F006”listedhazardouswaste.Atthattime,NNFDbeganhandlingthedewateredsludge(orfiltercake)generatedfromthePAWasteTreatmentSystemasalistedhazardouswaste.Priortothe1990“F006listing”ofthePAfiltercake,dewateredsludgewasplacedintwoonsitelandfills,Landfill1andLandfill2.NNFDperformedsamplingandanalysisofthefiltercakewhichindicatedthatthesludgedidnotcontainanyoftheconstituentscharacteristicofa“F006listed”waste.Therefore,in1994NNFDsubmittedadelistingpetitiontoaddressthecurrentandpastgenerationofthesludgegeneratedfromthePAWasteTreatmentSystem.NNED’sstrategy,whichwassupportedbyEPAheadquarters,wastodelistboththepastandcurrentsludge,therebyaddressingthepastlistedhazardouswastemanagementissuesaswellascurrenthazardouswastemanagement.In2000,BWXTwasgrantedafederaldelistingofthecurrentgenerationoffiltercake(sludge).ThedelistingwasadoptedbytheCommonwealthofVirginiaonMay1,2000.ThePAWasteTreatmentSystemincludestheadditionoflimetoformcalciumfluorideandvariousmetalhydroxidesolidsafterpHadjustmentinthebasicrange.Thesesolidsareremovedfromtheliquidwastestreambyclarification,filtration,anddewateringequipment.ThemajorityofthesludgewasaccumulatedasafiltercakefromthePAWasteTreatmentSystem.Sincenotreatmentprocessis100%efficient,asmallportionofthesolidsarecurrentlyandwerepreviouslynotremovedbytreatmentequipmentandweredepositedasasludgeintheFinalEffluentPonds(FEPs).Thispetitionseekstoexcludeall“F006”sludgeaccumulationsintheFEPsfromthehazardousregulationthatwasgeneratedpriortoMay1,2000.NNFDisconfrontedwithauniquehazardousandradioactivewastemanagementsituation.AnalyticaldatademonstratedthatboththepastandcurrentgenerationofPAfiltercakewasnonhazardous.NNFDoperationsarehighlyconstrainedbyprogramspecificationsandhaveremainedvirtuallyunchangedsincethe1960s.ThePAsolidsgeneratedpriortothe2000delistingareessentiallyidenticaltothecurrentlygeneratedsolids;however,thepreviouslygeneratedPAsolidswereexcludedfromthe2000delistingapproval.2BWXT-FEPDelistingPetition03/22/021.5Non-Radioactive“F006Listed”SludgeAccumulationsintheFEPsSincethe“F006listing”ofthePAnon-radioactivesludgewasretroactive,NNFDisfacedwithpreviousoperationsthathavebecomehazardouswastemanagementissues.Tofurthercomplicatethesituation,thePAfiltercakewasfoundtocontainsmallquantitiesoflow-levelradioactivematerial,thatresultedfromtheradioactivecontaminationofthefacility’srecyclewatersystem.Inaddition,thedischargelocationofboththePAandLowLevelRadioactive(LLR)WasteTreatmentProcesseshaveswitchedovertimesothatbothFEPshavereceivedthePAsuspendedsolids.BothFEPshavereceived,atsomepointintheirhistory,the“F006listed”andthelow-levelradioactive(LLR)suspendedsolidsthatwerenotremovedbytheirrespectivetreatmentsystems.1.6RegulatoryConcernswith“F006Listed”SludgeBforeSeptember2000,theradioactiveandhazardous(mixed)wasteissuesatNNFDweremanagedundertheauspicesofNRCregulationswithsupportfromtheCommonwealthofVirginiaDepartmentofEnvironmentalQuality(DEQ).AttheendofSeptember,theCommonwealthofVirginiawasauthorizedbyEPAfortheregulationofmixedwaste.NNFDisnowconfrontedwithmanagingthesludgeintheon-sitelandfillsandtheFEPsunderthehazardouswasteregulationsaswellasitsNRClicense.NNFD’sissuesareasfollows:•Landfill1wasclosedin1976,isconsideredtobeclosedandisnotanissueunderthehazardouswasteregulations.However,theNRChasrequestedthataportionofthematerialinLandfill1beremovedaspartoftheagency’stimelinessanddecommissioningpolicy.ThereopeningoftheLandfill1createsanumberofhazardouswastemanagementissues.•Landfill2,whichceasedoperationin1990,issubjecttohazardouswasteregulations.TheNRChasreleasedLandfill2andrequestedthatitbecappedtomeetdecommissioningclosurecriteria.BWXTisproceedingwiththeRCRAclosureofLandfill2.•TheFEPsaresubjecttothehazardouswasteregulations(theyreceivedF006solidsfromtheWWTP)andwillbesubjecttoNRCfacilitydecommissioningrulesattheendofthePlantlife.TheFEPsareanintegralpartofNNFD’sVPDESpermittedWWTPandthereisnoplantoremovethemfromservice.NNFDhasmetwithEPAandtheDEQtodevelopmanagementstrategiestoaddresstheseregulatoryissues.ThestrategiesaretosubmitaRCRAclosureplanforLandfill2toDEQforreviewandapprovalandtodelistLandfill1andtheFEPs.ThissubmittalisaddressingthedelistingoftheFEPs.1.7NNFD’sNeedtoDelisttheFEPsTheFEPsaresurfaceimpoundmentsthatprovideequalizationoftheliquideffluentforpHandtotalsuspendedsolidstoassistincompliancewiththeFacilities’existingVirginiaPollutantDischargeEliminationSystem(VPDES)permit.DelistingoftheFEPsisnecessarytorelievean3BWXT-FEPDelistingPetition03/22/02unnecessaryburdenonthepetitionertodisposeofthesolidsinthesurfaceimpoundments.TheburdenwilloccuriftheimpoundmentsaretoberetrofittedorclosedashazardouswasteunitsundertheVirginiaHazardousWasteManagementRegulations(VHWI\4R).SincebothFEPscontainradioactivematerial,bothpondsarecoveredunderthedecommissioningrequirementsofNNFD’sSpecialNuclearMaterialslicense.Evenafterasuccessfuldelistingdecision,bothFEPswillcontinuetoberegulatedbyboththeNRCandDEQWaterDivision.SuccessfuldelistingofthesolidswillallowfortheremovalofsolidsfromtheFEPsasradioactivematerial,withouttheregulatoryburdenofhazardouswastemanagement.Thedelistingwillprovidethefollowingbenefits:•EliminatetheneedtoapplytheVHWMRtotheoperation.•AllowforthecontinuedoperationoftheFEPswithperiodicsludgeremovalanddisposalasradioactivewaste.•AllowfortheeventualclosureofthesepondsundertheoversightoftheNRC,attheendofthePlantlife.1.8FEPDelistingPetitionMethodologyAprocessdescriptionofthemanufacturingprocessesthatcontributetotheFEPswillbepresented.Chemicalsandchemicalsubstancesutilizedinthevariousmanufacturingprocesseswereidentified,includingachemicalcompositionreview(basedonMSDSSheets)ofvariouschemicalsubstances.Alistofchemicalcohstituentsforwhichtheaccumulatedsludgearetobeanalzyedwasdevelopedasfollows:•ChemicalsusedinthemanufacturingprocessthatareknowntoposeorpotentiallyposeathreattohumanhealthortheenvironmentwereaddedtothelistofchemicalsinAppendixVIIIof40CFR261.oChemicalsthatarenotdischargedtotheWasteTreatmentFacility,suchasrefrigerantsandlubricants,arenotincludedtothelistofchemicalsusedinthemanufacturingprocess.•ChemicalslistedinAppendixVIIIof40CFR261thatwerenotusedand/ordischargedtotheFEPswereeliminatedfromanalysis.ThisdelistingpetitiondescribesthemethodsusedforcollectingandanalyzingrepresentativesamplesofthesolidsintheFEPsandthegroundwateraroundtheFEPs.TheanalysiswillshowthattheFEPsandthesolidsintheFEPs:•Donotcontainregulatorylevelsoftheconstituentsforwhichitwaslistedashazardous.•Donotexhibitthecharacteristicsofhazardouswasteasdefinedby40CFR261.4BWXT-FEPDelistingPetition03/22/02•DonotleachanyToxicityCharacteristicconstituentsaboveregulatorylimits.•Donotcontainanyotherconstituentsthatwouldmakethemhazardousasdefinedin40CRF261.Therefore,thesolidspresentintheFEPsarenothazardousanddonotposeathreattohumanhealthortheenvironment.Additionally,theFEPsdonotrepresenthazardouswastesurfaceimpoundments.AttheendofthePlantlifetheFEPswillbedecommissionedandclosedinaccordancewithNRCandVirginiaDEQcriteria.5BWXT- FEP Delisting Petition

03/22/02 2.0 WASTE WATER TREATMENT

SYSTEM 2.1 General BWX Technologies,

Inc., NNFD

is authorized

to discharge
treated wastewater

to the James River under Virginia Pollutant Discharge Elimination

System Permit (VPDES) Number VA0003697.

Five distinct wastewater

streams

are treated on-site.

As previously discussed,

these waste streams

are categorized

as radioactive

or non-radioactive wastewater.

Treated wastewater generated

from non-industrial processing operations

is discharged

to FEP

1 while treated wastewater generated

from industrial processing operations

is discharged

to FEP

2. The contributing

waste treatment systems

and other significant discharges

into each FEP

are identified

as follows: • FEP

1: Industrial Processing Operations Wastewater Discharges V Pickle
Acid (PA) Waste Treatment
System (Non-Radioactive) V Low Level Radioactive

(LLR) Treatment
System V Grit Blast Waste Treatment
System (Non-Radioactive) • FEP

2: Non-Industrial Processing Operations Wastewater Discharges (Non-Radioactive) V Water Production (Deionized

and Make-up Non-Contact

Cooling Water) Waste Treatment
System (including photographic wastewater) V Sanitary
Waste Treatment
System V Once Through Non-Contact

Cooling Water

(no treatment
system

is required). Thc manufacturing

areas
that contribute

to each wastewater

stream

are presented

in Figure

2-1, at the end

of this Chapter. A summary

of the estimated wastewater

flow contributions

from significant manufacturing

areas is presented

in Table

2-1.

6BWXT- FEP IJelisting Petition

03/22/02 TABLE

2-1 MANUFACTuRING

AREA WASTEWATER

FLOW CONTRIBUTIONS Source

of Wastewater

Average

Flow Rate— Gal./Month

(1)PAWasteTreatmentSystem(4) Metal Pickling

and Processing

332,000 Metal Anodizing

150 Copper Dissolution

Rinse Solutions

20,000 Hafnium/Inconel

Pickling

750 Aluminum Pickling/Anodizing

100 ACEL Target Fabrication

15,000LLRWasteTreatmentSystem(RadioactiveWasteStreams) Uranium Recovery

and Downblending

(2)

220,000 CRF Operations

and Chemistry

Lab

(2)

60,000 Fuel Assembly

Area, Metallurgy

Lab and

150 000 Laundry Research

Test Reactor

and Targets (RTRT)

100,000 LTC Laboratories

20,000 Uranium Recovery

Roof Drains

Intermittent

(3)GritBlastWasteTreatmentSystem(4) Grit Blast Wastewater

120,000WaterProductionWasteTreatmentSystem(4) DI and Service Water Wastewater

1,475,000 X-Ray
Film Processing Wastewater

25,000 Spring Water

<3,000SanitaryWasteTreatmentSystem Sanitary Wastewater

947,000OtherSignificantDischargestoFEP1 Once Through Non-Contact

Cooling Water

7,000,000Notes:(1)Averagemonthlyflowratesarebasedonflowdatafromcalendaryear2000.(2)ThesemanufacturingareascompriseUraniumProcessingServices.(3)Calculatedtobeapproximately5,000gallonsforaI”rainevent.(4)Wastewaterflowevaluatedin“F006”DelistingPetition,Approvedin2000.7BWXT-FEPDelistingPetition03/22/022.2FEPsHistoryEachFEPshasreceivedacombinationoftheaforementionedwastewaterstreamsduringtheiroperatinghistory.Table2-2summarizestheoperatinghistoryoftheFEPs.TABLE2-2OPERATINGHISTORYOFTHEFINALEFFLUENTPONDSTimeIntervalWastewaterStreams1973-1979All(LowLevelRadioactive,Pick1Acid,Sanitary,Misc.)FEP11980-1992PickleAcid,Sanitary,andWaterProductionWaterProductionandOnceThroughNon-ContactCooling1993-PresentWater1979All(LowLevelRadioactive,PickleAcid,Sanitary,Misc.)FEP21980-1992LowLevelRadioactive1992-PresentLow-LevelRadioactive,PickleAcid,andGritBlastFEP1wasputintoservicein1973,withanominalcapacityof2,000,000gallons.Thepondreceivedtreatedwastewaterfromallwastetreatmentsystemsfrom1973through1979.In1979FEP2,atanominalcapacityof1,900,000gallons,wasplacedintoservice.Bothpondswereconstructedusingaclay/soilliner.TreatedwastewaterfromallwastetreatmentsystemswasroutedtoFEP2whileaccumulatedsludgewasremovedfromFEP1.Aftercleaningoperationswerecompletedin1980,theeffluentsfromthewastetreatmentsystemsweredivided.From1979to1992,FEP1receivedtreatedwastewaterfromthePAWasteTreatmentSystem,theSanitaryWasteTreatmentSystem,andtheWaterProductionWasteTreatmentSystem.FEP2receivedtreatedwastewateronlyfromtheLLRWasteTreatmentSystem.In1992,thePAtreatmenteffluentwasdivertedtoFEP2.In1992,thesanitarytreatmentprocesswasimprovedandthetreatedeffluentnolongerdischargedtoFEP1.TheSanitaryWasteTreatmentSystemdischargesdirectlyintotheFinalMixingChamber(refertoFigure2-1).2.3HistoricalLLRandPAWastewaterTreatmentSystemsTheformerLLRandPAwastewatertreatmentsystemswereoperationalfrom1972through1991.TheLLRandPAwastestreamsweretreatedinseparatebutsimilarsystems.Wastewaterwaspumpedintooneoftwofiberglassequalizationtanks.Limeslurry(Ca(OH)2)andequalizedwastewaterwascontinuouslyfedtoamixedneutralizationtank.ForthePAtreatmentsystem,themixturewassubsequentlytransferredtoanagitatedreactiontankthatprovidedadditionalresidencetimeforthelimetoneutralizetheacidicsolutionandforcalciumfluorideandmetalprecipitatestoform.FortheLLRtreatmentsystem,theneutralizationtankwasprovidedwithatimedelaycontroltowaitbeforedischargetoaccomplishtheneutralizationandprecipitationreactions.Apolymerwasmixedwiththeneutralizedwastewatertoenhanceflocculationof8BWXT- FEP Delisting Petition

03/22/02 suspended

solids.

For the PA treatment system,

the neutralized

PA wastewater

was now mixed with

the wastewater

from

the Water Production Facilities.

Both solutions

were then piped

to separate Clarifiers

for solids settling

and the removal

of fluoride

and metals (including uranium in the LLR Treatment System)

from

the liquid waste stream. The Clarifier supernatant

was discharged

to

a sand filter(s)

for further reduction

of suspended solids prior

to being discharged

to one

of the FEPs.
Any particulates

and suspended

solids

that remained

in the treated effluent settled

out

in the FEPs.

The effluent

from

the FEPs

was mixed with other remaining
treated effluents

prior

to discharge

to the James River

in accordance

with the current VPDES permit. 2.4 Replacement

of Clarification

Systems

with Microfiltration

Systems The Memtek Advanced Microfiltration

Systems

were

put into operation

in 1992

to replace

the clarifiers

as the primary method

of solids removal (concentration)

from neutralized

LLR

and PA Wastewater Treatment Systems.

The systems

were installed

as

a means

of significantly
reducing the volume

of filter cake produced

from

the neutralization

of the LLR

and PA wastewater. Sludge generation

was reduced

since

the volume

of lime slurry added

was reduced

from

a large volume (required

for complete neutralization

of the acidic wastewater)

to

a small volume (required

to form calcium fluoride).
Liquid sodium hydroxide

is utilized

for the neutralization

of the acidic wastewater;

thus, resulting

in

a significant reduction

in the volume

of sludge produced for both

the PA and LLR waste treatment systems. 2.5
LLR Waste Treatment

System The LLR Waste Treatment

(WT) System receives

small quantities

of radioactive materials, generating

nuclear safety concerns.

To manage

the nuclear safety issues,

the LLR Waste Treatment
System

is operated

to maintain

a dynamic uranium-235
inventory

(mass balance)

for the entire facility.

Flow from

the Uranium Processing Services

enters

the Recovery

Side Retention

Tanks while flow from

all other radioactive wastewater

enters

the Plant Side Retention Tanks. Although

the Retention

Tanks provide

no actual treatment function,

they

are utilized

to measure

the uranium-235

mass added

to the LLR WT System dynamic inventory

when

the Tank volume

is discharged.

Refer

to Figure

2-2 for

a process

flow schematic

of the LLR
WT System. Wastewater discharged

from

the Retention

Tanks

is collected

in equalization

tanks. Each equalization

tank

is air sparged before processing

to provide mixing

of the contents

for uniform chemical concentration (specifically

acidity

and fluoride)

for the remaining treatment process. From

the equalization

tanks,

the wastewater

is pumped

to

a fluoride reaction

tank (formerly

the LLR Neutralization

Tank) where

lime slurry

is added

(in

an approximate

amount

to consume

the free fluoride present

in the waste stream). Chemically

treated wastewater

is pumped

from

the fluoride reaction

tank

to the LLR Memtek Microfiltration

System. Liquid caustic

is added

in

a series

of reaction

tanks

of the Memtek system

to neutralize

the wastewater

to

a pH

of approximately

10.5. This neutralization

allows

the precipitation

of calcium fluoride

and
the coincidental precipitation

of metals (zirconium, aluminum, uranium,

etc.). From

the Memtek reaction
tanks,
flow enters

the Memtek9BWXT-FEPDelistingPetition03/22/02concentrationtank,whichservesasareservoirforthemicrofilterfeedpumpandallowssolidsladenreturnflowfromthemicrofilterstobecollected.FiltratefromtheMemtekmicrofiltersisdischargedbygravityintoaLLReffluentdaytank.Solidsareoptimallyconcentratedattwotofiveweightpercentslurrybeforewastingintotwosludgeblendtanks.Ifchemicaltreatment(suchaspolymeroracoagulantaid)isrequired,thesludgeblendtanksallowforcompletemixingofthechemicalwiththeLLRsludge.Additionally,wastesludgefromtheSanitaryTreatmentProcesscanbeaddedtothesludgeblendtanks.ThesludgeblendtanksactasareservoirfortheLLRsludgefilterpresses.FilterpressfiltrateisdischargedbygravitytotheLLReffluentdaytank.ThecombinedMemtekandfilterpressfiltratesarepumpedtotwofinaleffluentequalizationtanksforfinalpHadjustmentandfluoridemeasurement.Theeffluentequalizationtanksdischargetotheformerregulated401Outfallsump,thenflowbygravitytoFEP2.FlowfromFEP2isdischargedthroughVPDESregulatedinternalOutfall701beforeenteringthefinalmixingchamber.ThemixingchambermixestreatedwastewaterfromFEP2,FEP1,andtheSanitaryWasteTreatmentSystembeforeflowingbygravitytotheJamesRiver.IfproblemsoccurwiththeMemtekmicrofilters,neutralizedwastewaterwillbepumpedtotheLLRClarifierforsolidsseparation.SupernatantfromtheClarifierisdischargeddirectlyintothe401Outfallsump.SettledsolidsarepumpeddirectlytotheLLRfilterpresses.Certainsectionsofbuildingroofsarecontaminatedwithradioactivity.Stormwaterfromtheseareasaresegregatedandsenttoaroofequalizationtank,thendischargedbygravityeithertotheLLRClarifierforsolidsremovalortothe401Outfallsump.Dewateredsludge(50to60percentsolids)fromtheLLRfilterpressesisprocessedintwopropanegasfiredsludgedryers.Driedsludgeisdischargedintoapugmillforparticlesizereductionandconveyingtoa55gallondrumpackagingstation.FulldrumsofdriedLLRfiltercake(calledTPsolids)areassayedviagammascanningforuranium-235concentration,thenshippedforultimatedisposalinanapprovedLLRlandfill.2.6PAWasteTreatmentSystemWastewaterdischargedfrommanufacturingoperationsiscollectedinequalizationtanks.Eachequalizationtankisairspargedbeforeprocessingtoprovidemixingofthecontentsforuniformchemicalconcentration(specificallyacidityandfluoride)fortheremainingtreatmentprocess.Fromtheequalizationtanks,thewastewaterispumpedtoafluoridereactiontank(formerlythePANeutralizationTank)wherelimeslurryisadded(inanapproximateamounttoconsumethefreefluoridepresentinthewastestream).RefertoFigure2-3foraprocessflowschematicofthePASystem.ChemicallytreatedwastewaterispumpedfromthefluoridereactiontanktothePAMemtekMicrofiltrationSystem.LiquidcausticisaddedinaseriesofreactiontanksoftheMemteksystemtoneutralizethewastewatertoapHofapproximately10.5.Thisneutralizationallowsthe10BWXT- FEP Delisting Petition

03/22/02 precipitation

of calcium fluoride

and
the coincidental precipitation

of metals (zirconium, aluminum,

etc.). From

the Memtek reaction
tanks,
flow enters

the Memtek concentration

tank, which serves

as

a reservoir

for the microfilter

feed pump

and allows solids laden return
flow from

the microfilters

to be collected.
Filtrate

from

the Memtek microfilters

is discharged

by gravity

into

a PA effluent

day tank. Solids

are optimally concentrated

at two

to five weight percent
slurry before wasting

into

a sludge blend tank. Also,

the Grit Blast Treatment
System sludge

is blended

with

the PA sludge

in the sludge blend tank.

If chemical treatment

(such

as polymer

or

a coagulant

aid)

is required,

the sludge blend
tank allows

for complete mixing

of the chemical

with

the combined
sludge.

The sludge blend
tank acts

as

a reservoir

for the PA sludge
filter press. Filter press filtrate

is discharged

by gravity

to the PA effluent

day tank.
The combined Memtek

and filter press filtrates

are pumped

to

a final reaction

tank

for final

pH adjustment

and fluoride measurement. The final reaction

tank discharges

to the former regulated

401 Outfall sump,

then flow

by gravity to FEP

2. Flow from FEP

2 is discharged
through VPDES regulated internal Outfall

701 before entering

the final mixing chamber.

The mixing chamber
mixes treated wastewater

from FEP

2, FEP

1, and the Sanitary
Waste Treatment
System before flowing

by gravity

to the James River. If problems

occur with

the Memtek microfilters, neutralized wastewater

will

be pumped

to the Grit Blast Treatment
System Clarifier

for solids separation. Supematant

from

the Clarifier

is discharged

to the PA effluent

day tank. Settled solids

are pumped directly

to the PA filter press. Dewatered

sludge

(50

to 60 percent solids)
from

the PA filter press

is placed

into

a roll-off shipping container,

then shipped

for ultimate disposal

in an approved industrial
landfill

in accordance

with

the approved “F006” Delisting Petition (approved

by EPA

in January

and

by VDEQ

in May 2000). 2.7

Grit Blast Waste Treatment

System Wastewater discharged

from manufacturing
operations

is collected

in an unmixed equalization tank (which

is

a small section

of the old Imhoff Treatment

Tank).

The equalization

tank allows for settling

of heavy particulates

and
for blending

of chemical concentrations.

When necessary, the equalization

tank

is drained

and the settled particulates removed

to

a concrete drying

bed. Dry solids

are removed

from

the drying

bed, packaged,

then shipped

for ultimate disposal

in an approved industrial landfill. From

the equalization

tank,

the wastewater

is pumped

to an inclined

plate Clarifier (Lanco Clarifier)

with separate

flash
mix and flocculation chambers.

If chemical treatment

(such

as polymer

or

a coagulant

aid)

is required,

the chemicals

are mixed

with

the wastewater

in the flash mix chamber.

The Clarifier provides

for solids separation. Supematant

from

the Clarifier

is discharged

to the PA effluent

day tank. Settled solids

are pumped directly

to the PA filter press. Dewatered

solids

are placed

into

a roll-off shipping container,

then shipped

for ultimate disposal in an approved industrial landfill.

11BWXT- FEP Delisting Petition

03/22/02 2.8 Water Production

Waste Treatment

System Deionized

(DI) water

is produced

from groundwater

pumped

from on-site wells.

The

DI water treatment
system utilizes filtration, softening,
reverse osmosis filtration,

and multiple

ion exchange

beds

to produce ultrapure

water

that

is used

in various manufacturing
operations. Make-up Non-Contact

Cooling (Service)

Water

is produced

from
raw water pumped

from

the James River.

In addition

to influent

from

the James River,

the Make-up Service Water receives effluent

from

a groundwater

pump

and treat system, installed

as part

of an existing corrective action.

The groundwater

pump

and treat system

is operated

for the removal

of trichloroethylene contamination

from

the groundwater

and utilizes

an air stripping

unit. The Service Water treatment
system utilizes chemical addition,

solids contact flocculation/clarification

units,

and sand filtration. Wastewater

from each

of these treatment s:stems

is discharged

by gravity

to an equalization

tank; called

the Imhoff
Tank (which

is two hge sections

of the old Imhoff Treatment

Tank). Ir the

1 980s, NNFD encountered

a low
pH sub-surface

spring during

the construction

of

a new building.

A sump

was installed

in the basement

of the building

to collect

the spring water.

The collected

water

is sent

to the lmhoff Tank.

In addition,

the Imhoff
Tank receives treated wastewater

from photographic processing operations.

The Imhoff
Tank

is continuously

air sparged

to provide mixing

of the contents

to minimize
settling

and

to provide blending

of the waste streams. From

the Imhoff Tank,

the wastewater

is pumped

to

a Lift Station,

then

to an inclined

plate Clarifier (Lamella Clarifier)

with separate

flash
mix
and flocculation chambers. Coagulation/flocculation

chemicals

are added

to the flash
mix chamber

for removal

of particulates (especially

River mud/silt).

The Clarifier provides

for solids separation. Supematant from

the Clarifier

flows

by gravity

to two sand filters

for effluent polishing

and solids removal. The sand filters continuously backwash,

with

the backwash

waste flowing

by gravity

to the Lift Sttion

for reprocessing. Effluent

from

the sand filters
flow

by gravity

to the former regulated

301 Outfall sump,

then flow

by gravity

to FEP

1. Flow from FEP

1 enters

the final mixing chamber.

The mixing chamber

mixes treated wastewater

from FEP

1, FEP

2, and the Sanitary
Waste Treatment
System before flowing

by gravity

to the James River. Settled sludge
from

the Clarifier

is pumped

to the Imhoff
filter press. Dewatered

solids

are placed

into

a roll-off shipping container,

then shipped

for ultimate disposal

in an approved industrial landfill. 2.9 Sanitary
Waste Treatment

System As previously

noted, treated effluent

from

the Sanitary
Waste Treatment
System

was discharged to the FEPs, prior

to 1992. Also,

as previously discussed,

it was discovered

that
the facility’s non-contact

cooling
water system (Service
Water system)

was found

to contain
small quantities 12BWXT-FEPDelistingPetition03/22/02oflowlevelradioactivematerial.Thisradiologicallycontaminatedwaterisusedtoflushthemajorityofthetoiletson-site.Therefore,theSanitaryWasteTreatmentSystemisdeemedtocontainverylowlevelsofradioactivecontamination.Hence,allsludgedisposedfromtheSanitaryWasteTreatmentSystemismanagedasLowLevelRadioactiveWaste.Wastewaterdischargedfromon-siterestroomsandfromcertainBuildingroofdrainsflowsbygravitytoaself-cleaningbarscreen(oralternatelytoacomminutor),thentoawetwell.Screeningsaredewateredusingascrewcompactor,thencollectedin55-gallondrums.DryhydratedlimeisaddedtothedrumsforodorcontrolandpHstabilization.Drumsofscreenings,consistingoforganicmaterials,areshippedtoaincinerationfacilitythatprocesseslowlevelradioactivematerialsfordisposal.Flowfromthewetwellispumpedtoanequalizationtanktoprovideauniformflowintotheremainderofthetreatmentsystem.Theequalizationbasinisalsocontinuouslyairspargedtop-ovidemixingtominimizesettlingandtheeffectsofwasteconcentrationfluctuations.Fromthee.ualizationtank,thewastewaterispumpedtoasplitterchamber,whereitismixedwiththercturnactivatedsludgefromtheSanitaryClarifier.Thiswastewaterstreamflowsbygravitytoanaerationbasin.Theaerationbasinisoftheextendedaerationcompletemixactivatedsludgedesign.Coagulationand/orflocculationchemicalscanbeaddedtotheaerationbasineffluenttoenhancesludgesettling.RefertoFigure2-4foraprocessflowschematicoftheSanitarySystem.FlowenterstheSanitaryClarifierbygravityfromtheaerationbasin,wherequiescentconditionsareprovidedfortheseparationofsolidsfromthewastewater.Settledsolids(calledactivatedsludge)arecontinuouslypumpedfromtheClarifiertotheSplitterBox.Approximately4timesperday,settledsolidsarewastedfromtheClarifiertoasludgeholdingtank.SupernatantfromtheClarifierflowsbygravitytotheUltraviolet(UV)DisinfectionSystemforpathogenreductioninaccordancewiththeVPDESpermit.FlowfromtheSanitaryWasteTreatmentSystemisdischargedthroughVPDESregulatedinternalOutfall101beforeenteringthefinalmixingchamber.ThemixingchambermixestreatedwastewaterfromtheSanitaryWasteTreatmentSystem,FEP1,andFEP2beforeflowingbygravitytotheJamesRiver.ThecontentsoftheSanitarysludgeholdingtankarepumpedtotheLLRsludgeprocessingsystemforblending,dewatering,drying,anddisposalasLLRwaste.2.10OnceThroughNon-ContactCoolingWaterNNTD’sservicewatersystemisseparatedintotwocomponents:•RecirculatedNon-ContactCoolingWater—whichincludesdischargesfromequipmentcoolingsystems•OnceThroughNon-ContactCoolingWater—whichincludesdischargesfromsomeequipmentcoolingsystems,stormwaterfromBuildingroofs,andstormwaterfrompavedaccessroads/alleywaysinsidetheFacility.13BWXT-FEPDelistingPetition03/22/02TheOnceThroughNon-ContactCoolingWaterdoesnotrequiretreatmentanddischargesbygravitytotheformerlyregulated301Outfallsump,thenflowsbygravitytoFEP1.FlowfromFEP1entersthefinalmixingchamber.ThemixingchambermixestreatedwastewaterfromFEP1,FEP2,andtheSanitaryWasteTreatmentSystembeforeflowingbygravitytotheJamesRiver.14

# FIGURE 

# 3-1 

# SChEMATIC OF 

# WATER FLOW

JAMES RIVER

(0 396 MGD)

REATED GROUND WA7 ER FRO

ScPLANTWATETvIENT

SOD Os

- ________________



# CONSUMPTION

DI WATER PLANT WELLS 0042MGD 0132MG0,,,J RECYCLE RESERVOIR &

EMERG

SOLIDS OVERFLOW STORAGE TANK

ANP

DRiNKING WATER OOLING COOLING ALLEYWAY USAGE RECOVERY PROCESS 

# ENUFACTUNG SING RECOVERY I MG 037 MGD)

iIO

— 

# 0090 MOD OPERATIONS ROOF DRAINS

OVERFLOW

OO DRAINS ACTIVE _______ ____________



# SETTLING ________ 

# _________

0 049 MOD 0007 MGD 0 391 ______________ _____________________



# EDLOOP

THROUGHROOF&SANITARY Framalorne URANIUM URANIUM PICKLING& GRIT SIL\ER SPRING



# FScREEN DRAINS 

# LIZA ________



# EQUAL

ANF) SPRING _______________



# MGD

WATER _______________



# REC. ______________



# TANK ______



# NEUTRALIZATj RALLZAT1ON (005 MGD)

ALIZATIONc:RATION OFTRN BYPASS IMHOPF LOOP

COOLIN _____________



# MAJOR STORM TOWER

EVENTS ONLY AORATI

RIFICATION (4.8 MGD P _________



# BY PA S S ________________ _______________



# CLARIFICATION SPLITTER OAK)

EVENTS ONLY ISINTIONJE THROUGH EQUALIZATION CLARIFICATION

SAND FILTER MAJOR STORM

(0.050 MGD PEAK)

- 

# COOLING WATER EQUALIZA EQUALIZATION (0.237 MGD) NO. 2 FOND NO. I OUTFALL 101

0,031 MGD BRYANT’S POND (0017 MGD AVG
0329 MOD PEAK) OUTFALL 701 OUTFALL 601 0.161 MGD 0.286 MGD



# ETFALL 005 

# j OUTFALL 004 FINAL OU rPALL 001

0003 MOD AVG 0020 MOD AVG. 0479 MGD 0081 MOD PEAK 0.287 MOD PEAK
Notes:



# 1 ‘ 

# DIFFUSER



# UNNAMED JAMES RIVER JAMES RIVER DITCH LEADING 

# 15
TO JAMES RIVER 1. All Flow Data is estill7ated fron7 flow data from 

# January, 2000 thl’ou December, 2000.

2. All average and peak flows are total daily flows except for 

# the once thlou 

# cooling water overflow to Biyant’s pond, whIch IS ais 

# estlmat instantaneous peak rate,


# 3. MGD

= 

# Millions Gallons per 

# Day.

# LEGEND

(A) 

# EQUALIZATION TANKS

(TWO -40,000 GAL.)



# (B) FLUORIDE REACTION TANK( 10.000 GAL)

(C) AIR DISPLACEMENT INFLUENT PUMPS (THREE TOTAL)

(D) CLARIFIER (19.000 GAL.)

(B) SLUDGE POLY. BLEND TANK (TWO)

(F) FILTER PRESS

(G) SLUDGE DRYER

(H) PUG MILL

(I) DRUM PACKAGING STATION

(J) 

# LLR MEMTEK

(K) FLOOR TRENCH SUMP

(L( POLYMER

(M) FUME SCRUBBER

(N) CRITICALITY MONITOR

(0) RETENTION TANKS (4-5,000 GAL.)

(F) SUMP



# (Q( FINAL EFFLUENT
TANKS (TWO

- 

# 15.000 GAL.)

(R) OUTFALL 601

(S) OUTFALL 701

(T) SANITARY SLUDGE HOLDING TANK

(U) PARSHALL PLUME (OUTFALL 201)

(V) MIXING CHAMBER (OUTFALL 001)

PROCESS

—

. — — —

_. 

# SLUDGE ASTEWATER FROM LYNCHBURG

TECI-INOLOGY CENTER

LLR WASTEWATER LLR WASTEWATER RECOVERY SIDE PLANT SIDE 

# Figure 3-2

LLR TREATMENT SYSTEM

LIQUID WASTE — - —

. 

# —.

—

. 

# —.

. 

# LLR SOLID WASTE

FOR DISPOSAL 

# r

R4 

# _

SLUDGE OPTIONAL
I FLOW ROUTE 

# -I SLUDGE

WASTE TRBATMENT/

BLDG (lOT FLOOR) L 

# J

DPI 4 TREATED WASTE WATER

PICKLE ACID TREATED WASTEWATER WASTE TREATMENT/

BLDG. (2ND FLOOR)



# H ‘vi 

# H 

# -J

FINAL EFFLUENT
TOJAMESRIVER FINAL EQUALIZATION

POND 412

I 900,000 GAL. 

# 16 OUTFALL 001

# NNFD PICKLE

OUTFALL 001

TO JAMES RIVER 

# LEGEND

(A) EQUALIZATION TANKS (TWO 25,000 GAL.)

(B) FLUORIDE REACTION

TANK (2,000 GAL.)

(C) PICKLE ACID MEMTEK

(0) SLUDGE BLEND TANK
(500 GAL.)

(E) FILTER PRESS

(F) FINAL pH REACTION

TANK

(0) OUTFALL 601

(H) OUTFALL 701

(I) MIXING CHAMBER (OUTFALL 001)

(J) PICKLE BYPASS I GRIT

BLAST SYSTEM CLARIFIER

(K) AIR DISPLACEMENT

INFLUENT PUMP

(L) SUMP ACID 

# Figure 3-3

PICKLE ACID TREATMENT SYSTEM

-I



# I WASTETREATMENT

BLDG (1ST FLOOR)

FORMER FEW SOLID

•—•* WASTEFOR

DISPOSAL (NOW DELISTED)



# H

17 PROCESS

SLUDGE

CONCENTRATED

SOLIDS

VALVES

NC NORMALLY CLOSED

NO NORMALLY OPEN

# Figure 3-4

SANITARY WASTEWATER SYSTEM LEGEND

(A) MECHANICAL BAR SCREEN

(B) COMM INUTOR



# (C) LIFT STATION



# (D) FLOW EQUALIZATION BASIN

(F) FLOW SPLITTER 

# BOX

(F) AERATION TANK #1

(G) STANDBY CLARIFIER #1

(H) AERATION TANK #2

(I) STANDBY CLARIFIER #2

(J) SECONDARY CIRCULAR CLARIFIER

(K) UV DISINFECTION SYSTEM (OUTFALL 101)

(L) SLUDGE PUMP BUILDING

(M) STANDBY WASTE SLUDGE

COLLECTION TANK

(N) CHLORINE ROOM

(0) SLUDGE HOLDING TANK

(P) PARSI-IALL FLUME



# (Q) MIXING CHAMBER (OUTFALL 001)

(R) OUTFALL 001 DIFFUSER

(5) SCREENINGS SCREW COMPACTOR

(T) FINAL EFFLUEN PONDS

PROCESS PIPING

—

. — — — — 

# SLUDGE PIPING CHLORINE

PIPING STANDBY

PIPING FRAMATDME AN?

SAN ITARY I3WXT NNFD

SANIrARY WASTE WATER

LYNCHBURG TECHNOLOGY CENTER
SANITARY WASTE WATER

SCREENINGS TO DISPOSAL INFLUENT FLOW METER



# A SUPERNATANT RETURN

I

z

I—

0

z <I H

- 

# I

I 

# I
I I

I I

STANDBY WASTE I STANDBY WASTE I
SLUDGE 

# 1————J SLUDGE I


# + M I

WASTE SLUDGE RETU RN S 

# LU DGE

............, 

# r WA STE S LUDGE AN D I REMOVED SCUM 0 01 D.



# H 1 Cd,



# V

TO LLR SYSTEM

SANITARY OUTFALL 101

FINAL EFFLUENT

TO JAMES RIVER 

# 18 OUTFALL 

# 001BWXT-FEPDelistingPetition03/22/02 3.0 MANUFACTURING
OPERATION PROCESS DESCRIPTIONS3.1OverviewTheStandardIndustrialClassificationCodeapplicabletoBWXTis3443,FabricatedMetalWork(BoilerShops).TheprimarymissionoftheBWXTisthefabricationofhighlyenrichednuclearelementsandcomponentsfortheU.S.DepartmentofEnergy.Secondaryactivitiesincludefabricationofelementsorcoresforresearchandtestactivitiesandresearchrelatedtomanufacturingoffuelelementsandrecoveryofuraniumfromscrap.Thefuelmanufacturingprocessincludesconfidentialprocessesandtechniques.Othersupportingactivitiesincludeuraniumrecoveryoperations,researchrelatedtotherecoveryofuranium,andawasteoperationsproramthatincludeswastecompaction,materialsrecycling,andwastewatertreatment.BVXT’sproductionprocessesaredescribedaseitherradioactiveornon-radioactive.Prozessdescriptionswillbepresentedformanufacturingoperations.However,manyofthemaaifacturingoperationsinvolveprocessesthatareclassifiedandcannotbediscussed.Incaseswheretheprocessdescriptioncarmotbeprovided,somegeneralizedprocessinformationwillbeprovided.ThechemicalsusedinmanufacturingwillbereviewedattheendofthisSection.Afteridentificationofthechemicalconstituentsusedonsiteandacomprehensivereviewofthe40CFR261,AppendixVIIIchemicals,alistofchemicalconstituentsfortheFEPsludgeanalysiswillbedeveloped.3.2ProductionProcessesGeneratingNon-RadioactiveWastewater3.2.1MetalProcessingandPicklingZirconiumalloycomponentsproducedatBWXTundergomachiningoperationsandsubsequentheattreatment.Gritblastingisconductedtoremovethezirconiumoxidefilmorscalethatdevelopsduringheattreatment.Inthepast,solventsincludingacetone,xylene,andtricliloroethylene(TCE)havebeenusedforpre-andpost-cleaningtoremovevarioussubstancessuchascuttingoilresidueandlayoutdyemarkingsadheringtothemetalcomponentsresultingdurrigthemachiningprocess.Themetalcomponentsarealsodegreased,whichhadpreviouslybeedoneusingeitherTCEoranultrasonicdetergentcleaning.AllTCEcleaningoperationswereseparatesystemsthatdidnotdischargeintoanyoftheWasteTreatmentFacilities.Since1995,BWXThaseliminatedtheuseofTCE,acetone,andxyleneforgeneralmetalcleaninganddegreasing.Zirconiumalloycomponentsarecurrentlycleanedanddegreasedwithaqueousbasedcleaningsolutions,soaps,and/orisopropylalcohol.Theremovalofoxidizedmaterialleavesaroughsurface.Toregaintheoriginalsurfaceconditionaftereachoftheheattreatmentandgritblastingsteps,themetalcomponentsarepickledinanaqueousacidsolutioncontaininghydrofluoricacidandnitricacid.Thepicklingisfollowedbyhotandcoldwaterrinses.ThespentpicklingsolutionsandwaterrinsesaredischargedtotheWasteTreatmentFacilities.3.2.2MetalAnodizing19BWXT-FEPDelistingPetition03/22/02Thefinalmetalproductisanodizedwithacausticsolutionfollowedbywaterrinses.ThespentcausticsolutionproducedfromthemetalanodizingprocesswassampledonApril7,1992,andanalyzedviaIon-coupledPlasmaSpectrophotometermethods,whichhaveadetectionlimitofapproximately1ppmforeachmetal.Thespentsolutionwasanalyzedfornickel,zinc,cadmium,barium,arsenic,lead,andselenium.Allofthesemetalswerepresentatlessthan1ppminthespentsolution,indicatingthattheneutralizationofthesolutionwouldgenerateonlyinfinitesimalquantitiesofsludge(filtercake).ThespentanodizingsolutionsandwaterrinsesaredischargedtotheWasteTreatmentFacilities.3.2.3CopperDissolutionBWXTdissolvescopperusinganitricacidsolution.Thespentnitricacidsolutionandtheprimarywaterrinsesolutionwerepreviouslycombinedandtreatedinacopperrecoveryprocessthatusedsodaashneutralization.Thecoppercarbonatewasthencalcinedandsoldasacopperoxideby-product.In1993,BWXTceasedthecopperrecoveryoperation.Since1993,thespentcoppernitratesolutionshavebeencollectedandshippedasahazardouswasteforrecoverytoavendor.TherinsesolutionsfromcopperdissolutionaredischargedtotheWasteTreatmentFacilities.3.2.4HafniumandInconelProcessingandPicklingHafniumcomponentsarepickledinthesamebathaftermetalcomponentsorinanidenticalfreshnitricandhydrofluoricacidsolution.Inconelcomponentsarecleanedinanaqueoussolutionofhydrofluoricandnitricacids,andsubsequentlyrinsedincoldandhotwater.TheseprocesswastewaterstreamsaredischargedtotheWasteTreatmentFacilities.In1994,an“acidcleanline”wasaddedaspartofanewmanufacturingprocess.Itconsistsofaseriesofwatercleaningandrinsetanks,ahydrochloricacidactivationbath,andanacidcleaningsolutiontocleanInconelcomponents.Theacidcleaningsolutionconsistsofhydrofluoric,nitric,hydrochloric,andphosphoricacidsandferricchloride.ThisspentsolutionisaccumulatedandshippedasahazardouswastetoE.I.DuPontfortreatment.Therinsesolutions,cleaningsoaitions,andspentactivationsolutionsaredischargedtotheWasteTreatmentFacilities.3.2.5AluminumPicklingandAnodizingAluminumcomponentsarepickledusingacausticsolution,cleanedwithanaqueousacidsolutionconsistingofnitricandhydrofluoricacids,andrinsedincoldandhotwater.Thefinalaluminumproductisanodizedwithacausticsolutionfollowedbywaterrinses.ThespentsolutionsandwaterrinsesaredischargedtotheWasteTreatmentFacilities.3.2.6X-RayFilmProcessingVariouscomponentsarex-rayedaspartofthenon-destructivetestingprogram.X-rayfilmisdevelopedatthefacility.Silveriselectrochemicallyremovedfromthewastestreamthatis20BWXT-

FEP Delisting Petition

03/22/02 generated

by film developing activities.

The recovered

silver

is collected

and sent off-site

for precious metals reclamation. The wastewater

is then discharged

to the Imhoff
Tank where hydrogen peroxide

is added

for oxidation

of x-ray chemicals

that exhibit

a Biochemical

Oxygen Demand

in the Waste Treatment Facilities. Additionally,

a defoamer chemical

is added

to the Imhoff
Tank

for foam control. 3.2.7

Grit Blasting

and Water

Jet Cutting Operations BWXT utilizes

an aluminum

oxide

grit blasting operation

to remove zirconium

oxide
film
and scale that develops

on metal components

during

heat treatment.

The grit blasting operation

is

a wet process

that uses water mixed

with aluminum

oxide

grit particles

to abrade

and clean metal components. Discharge

from each machine

flows

into

a small settling chamber.

Grit that settles out

is reused

or sent off-site

for disposal

as

a non-hazardous

waste, while

the wastewater

is decanted

and discharged

to the Waste Treatment Facilities.

A polymer

is added

in the grit blast equalization

tank

to enhance particle development

to improve settling. The water

jet cutting operation

uses

a high-pressure

jet

of water

and garnet

sand

to perform precise

cuts

in Inconel metal. Wastewater

from

the cutter flows through

a cyclone separator

to remove garnet

and metal before discharge

to the Waste Treatment Facilities.

The garnet

sand

is sent off-site

for disposal

as

a non-hazardous

waste.

A garnet

sand recovery

and recycle process

is scheduled

to begin before

the summer

of 2002. 3.2.8 Water Treatment A discussion

of the water production facilities

for BWXT

was previously presented

in Section 2.0. Chemicals

used

in the
DI water system include sodium chloride

for water softener regeneration, anti-scaling

agent

for protection

of the reverse osmosis membranes,

and sulfuric acid
and sodium hydroxide

for ion exchange

bed regeneration. Chemicals

used

in the make-up water treatment
system

for the Non-Contact

Cooling
Water include Alum,

for particulate coagulation,

and Bromine Chloride,

for algae control. 3.2.9 Sanitary (Domestic)

Waste Treatment Section

2.0 presented

a discussion

of the radioactive contamination

issues
with

the sanitary wastewater generated

on site.

As noted, sanitary wastewater

is generated

from on-site restrooms and from some roof drains
from

the BWXT Facility,

LTC,

and the
adj acent Framatome

ANP fuel fabrication
facility.

The sanitary wastewater collection

system

is

a gravity collection

until flow enters

the Sanitary Treatment Facility

wet well
and pumping station. Chemicals

used

in the Sanitary Waste Treatment
System include

a polymer

and

a flocculant

to enhance particle formation

and

to assist

in sludge settling. Chlorine

was used

for pathogen
control

until

the addition

of the TJV disinfection

system

in 1992. Also, chlorine

was
fed

to used

in the final mixing chamber

for pathogen control

until chlorination

was discontinued

with

the renewed VPDES Permit

in December

2001. 21BWXT-

FEP Delisting Petition

03/22/02 3.2.10 Once Through Non-Contact

Cooling Water The once-through

cooling
water system wastewater

results

from non-contact

process
water used for furnace cooling, welding equipment cooling,

and similar

uses. 3.3 Production Processes Generating Radioactive Wastewater It
is standard industrial practice

for

all radioactive production

areas generate radioactive wastewater

from

the handwashing

and showers required

prior

to exiting

all radiological controlled

areas. Additionally, radioactive wastewater

is generated

from

an on-site laundry facility

that washes

all of the protective clothing

used

in radiological controlled

areas. 3.3.1 Uranium Recovery Operations BWXT recovers uranium

using

an acid dissolution
process.

Clad
fuel components

are dissolved in

a solution

of nitric acid, hydrofluoric

acid,

and aluminum

nitrate.

The uranium

is then extracted

from

the acid solution

using

a solvent extraction process, consisting

of an organic solution containing

a phosphate

and “refined kerosene”.

In the solvent extraction process, uranium

is driven

into
the solvent
while impurities

are removed

from

the dissolved uranium,

to form

a concentrated

uranyl nitrate solution.

The organic solution

is stripped

from

the aqueous acid solution

prior

to discharge

of the depleted aqueous

acid solution

to the LLR waste treatment facility. Waste organic solution

is drummed

and sent off-site

for treatment

and disposal

as an LLR waste. Multiple uranium isotope counting

and measurement

systems provide nuclear safety of the waste solutions discharged

to the LLR waste treatment facility. Water
from

the concentrated

uranyl nitrate solution thermally evaporated

to form

dry uranyl nitrate crystals.

The wastewater generated

from

the crystallization

process

is discharged

to the LLR waste treatment facility. Additionally, wastewater

flow from

the Recovery ventilation system

wet fume scrubber

is discharged

to the LLR waste treatment facility. 3.3.2 Downblending Operations Beginning

in 2000, BWXT began Downblending
Operations

to produce

a dry low enriched uranium

fuel

for commercial

nuclear power application.

In the downblending

facility,

high enriched uranium

and low enriched uranium

are dissolved separately

in concentrated

nitric acid. The two uranyl nitrate solution streams

are then blended

to produce

a 4% enriched uranium solution.

The blended solution

is then heated

to drive

off the water

and produce

dry uranyl nitrate crystals.

The acidic wastewater

from

the Downblending
Operations

is discharged

to the LLR waste treatment facility.

The wastewater generated

from

the crystallization

process

is discharged to the LLR waste treatment facility.

The exhaust ventilation

from

the Downblending
Operations is scrubbed

by

a wet fume scrubber.

The wastewater

from

the scrubber

is discharged

to the LLR waste treatment facility.

22BWXT-

FEP Delisting Petition

03/22/02 3.3.3
CRF Development

Process The purpose

of the CRF Process

is to convert uranium solutions

into fuel. Operations

include uranium conversion,

nitric

acid dissolution,

and thennal drying. Wastes generated

from
this development operations
include acidic

and caustic wastewater,

and organic solutions. Aqueous wastewater

from
this process

is discharged

to the LLR waste treatment facility. Waste organic solution

is drummed

and sent off-site

for treatment

and disposal

as an LLR waste. 3.3.4 Chemistry Laboratory

Facility The Chemistry Laboratory
Facility (Chem

Lab) provides support services

of on-site Uranium Processing Operations, including

a wet chemistry

area,

gas analysis

area, uranium analysis

area, mass spectrometer

areas,

and x-ray fluorescence

area.
The purpose

of the Chem

Lab

is to de:tructive1y

evaluate

both
fuel and non-fuel bearing materials

for various chemical attributes. Urinium

fuel material

and zirconium

alloy samples

are routinely evaluated

for impurity analysis, ur-iium isotopic analysis, uranium concentration

testing, surface

area testing, density testing, and other process monitoring

tests. Various chemical analyses

and evaluations

are performed

in the Wet Chemistry

and gas analysis areas. Chemical analyses include

ion chromatography,

kinetic phosphorescence,

and spectrophotometry.

A variety

of chemicals

are used

in the Chem

Lab
and will

be presented

in the summary

of chemicals

used

for manufacturing
operations

later

in this Section. However,

based on the typically

small quantity

use,
the environmental

and health
risks

due

to accumulations

in the FEP sludge

are considered insignificant. The wastewater

from

the Chem

Lab

is discharged

to the LLR waste treatment facility. Additionally, wastewater

flow from

a small Chem

Lab ventilation

system

wet fume scrubber

is discharge

to the LLR waste treatment facility.

Solid wastes

are analyzed

as necessary, drummed, and sent off-site

for disposal

as LLR waste. 3.3.5 Research

Test Reactor

and Targets (RTRT) Th. RTRT facility manufacturers

both high

and low enriched

clad uranium

fuel used

for

a variety

of customers, including colleges, university, national laboratories,

and nuclear research test facilities throughout

the world. Uranium

oxide fuels

for the high-flux
isotope reactor

are manufactured

for the

U.

S. Department

of Energy’s (DOE’s) laboratory program,

the National Institute

of Standards

and Technology,

and the high-flux

beam reactor. Additionally,

fuel elements

for the DOE’s Advanced

Test Reactor

and fuel elements

for colleges

and universities are produced. Enriched uranium

fuel

is manufactured

in various forms. Other reactor components,

such

as graphite reflectors

and control

rods,

are manufactured.

Various

metal machining

and milling processes

are used

to produce

these products.

23BWXT-FEPDelistingPetition03/22/02AluminumpartsarecleanedusingadegreasingchemicalTritonDF-16Surfactant,etchedusingacausticsolution,rinsed,acidwashed(withnitricacidforremovalofthecausticresidue),thenrinsed.Priortoassembly,fuelcomponentsarecleanedusingawatersolubleoilconcentrate,acidwashed(withnitricacid),rinsed,pickledinahydrofluoric/nitricacidbathtoremovetheoxidelayerand/oretchedusingacausticsolution,rinsed,thenassembled.Afterassemblythefuelcomponentsareinspectedandcleaned.3.3.6AtomicEnergyofCanadaUnited(AECL)TargetFabricationTheTargetmanufacturingprocessdeliverssealedtubeassembliesofprescribedquantitiesofuraniumoxidetotheAECLfortheproductionofmedicalisotopes.Themanufacturingprocessutilizesnitricacidandsolventwipecleaning.AllspentacidsolutionsandwaterrinsesaredischargedtotheWasteTreatmentFacilities.Solventragsaredrummedandhandledashazardous(ornon-hazardous)wasteinaccordancewithBWXTenvironmentalprocedures.3.3.7FuelAssemblyAreaThepurposeoftheFuelAssemblyAreaistoassemblenuclearcomponents.ThewastewaterfromthismanufacturingareaisdischargedtotheLLRwastetreatmentfacility.3.3.8MetallographicLaboratoryTheMetallographicLaboratoryFacility(MetLab)providestestingservicesforvariousmanufacturingprocessareas.Testingservicesincludedestructiveevaluationoffuelandnon-fuelbearingcomponentsformicrostructuralanddimensionalattributesanddestructiveevaluationofweldqualities.Manyofthesamplesaremountedinanepoxybase(orsimilarbasematerials)forassaypurposes.ThechemicalsassociatedwiththemountingpreparationarenotplacedinanaqueoussolutionandarenotdischargedtotheWasteTreatmentFacilities.Thesamplesareground,polished,andbretchedforinspectionusingmicroscopics,comparators,and/ormetallographs.ThewastewaterfromthismanufacturingareaisdischargedtotheLLRwastetreatmentfacility.3.3.9LaundryBWXToperatesalaundryfacilitytowashanddryclothingusedinbothradiologicalandnonradiologicalprocessingareas.Examplesofitemslaunderedincludecoveralls,labcoats,rubbershoecovers,respirators,headcovers,andtowels.Chemicalsusedforlaunderingincludedetergent,souringcompound,printbuilder,andsoftener.3.4LynchburgTechnologyCenter(LTC)AspreviouslystatedinSection1.0,LTCishometoMTIResearch&DevelopmentDivisionandtotheBWXServices(BWXS)Division.OperationsattheLTCarewidelydiversifiedand24BWXT-FEPDelistingPetition03/22/02changeasresearchandlaboratorytestingneedschange.Workperformedisintheareaofprocess‘\)control,nondestructiveexaminationofmethodsandinstrumentdevelopment,non-nuclearceramics,andlaboratorytesting.MTIPressureSystemsandOperationResearchSectionoperatesprocessdevelopmentandmetallographylabOratoriesforresearchonlaboratoryscaleprocessdevelopment,machiningofspecialtestcoupons,andmaterialsevaluations.AScanningElectronMicroscopylabsupportsthisresearch.Inaddition,theSectionfocusesonthedevelopmentoffuelcellenergysystemsandnon-radioactivematerialsdevelopment.EquipmentprocesswaterandminorresearchsolutionsaredischargedtotheLLRWasteTreatmentFacilities.BWXSoperatesahotcellfacilitycoupledwithametallurgicalandradioanalyticallaboratory.Thesefacilitiesanalyzesamplesofirradiatedmetal,performmetallurgicalfailureanalysis,andperformspentfuelexamination.Asmallvolumeofradioactivewastewaterisgeneratedfromtheseoperations.Typically,allliquidwastegeneratedfromtheseoperationsissolidifiedfordirectdisposalasradioactivewasteatalicensedfacility.Atransfercanalandstoragepooiisusedtoreceive,unload,load,andprepareshieldedcasksforshipment.Radioactivematerialsarestorageandtransferredtoandfromthehotcellsthroughthecanalandstoragepooi.ThepoolisrecirculatedthroughionexchangecolumnstoremoveradioactiveisotopespriortoreleasewatertotheLLRWasteTreatmentFacility.Ionexchangeresinsarereplacedwhenexpendedthendisposedofasdryradioactivewaste.Particulatesthatsettletothepooibottomareperiodicallyremovedusingandunderwatervacuum,dried,anddisposedofadryradioactivewasteatalicensedfacility.Inaddition,BWXSoperatesaNuclearEnvironmentalLaboratory(NEL)thatisaVirginiacertified,anEPAcertified,andaUtahcertifiedradioanalyticallaboratory.TheNELisacommercialenvironmentallaboratorythatprovidesisotopicanalysisviahigh-resolutiongammaspectroscopy,alphaisotopicanalysis,and1OCFR61analysistosupportmanifestingofvariousLLRwastes.Inmostcases,NELreturnsradiologicalsamplestotheirpointoforigin.Basedonthesamplereturnprocedureandsamplesizeusedforradiochemicalanalyses,insignificantwastewatervolumesaregeneratedandthechemicalconcentrationsofthiswastewaterareconsideredinsignificant.Themajorityofwastewaterisgeneratedfromlaboratoryequipmentwashing,handwashing,showers,launderingofradiologicalareaprotectiveclothing,andanalyticalequipmentcooling.25