Method of reducing the volume of low level radioactive waste material

Abstract: A method of reducing the volume of spent ion exchange resins containing radioactive contaminants, and a filter aid having groups reactive with the functional groups of the resins. Spent ion exchange resin and the filter aid are dewatered, then subject to a pressure of about 2000 psi in conjunction with 250°C heat to reduce the volume occupied by the resin by up to a factor of 5 and impart rewet stability.

Description: This invention relates to a method of reducing the volume of low level radioactive waste material, in particular the compaction and disposal of bead and powdered ion exchange resins mixed with a filter aid. Common among the low-level radioactive waste products produced by nuclear power plants are ion exchange resins. These resins are used to process water that circulates through the core of the nuclear reactor or steam generator. While ion exchange resin remove ion contaminants from plant coolant water, the filter aid removes undissolved particulates. A filter aid is any material such as cellulose layered on a filter cartridge along with the powdered resin to remove solid material. The resin and filter aid do not react chemically at the water temperature encountered in processing water from the nuclear plant, usually below about 60°C. Elevated temperatures, those much above about 60°C, are not usual and water of 100°C or greater is not encountered because the processing system is not pressurized. Bead type resins are usually used in pressurized water reactor type plants to remove ions, but are not mixed with a filter aid since filtration is not intended. Boiling water reactor type plants use the powdered resin with cellulose filter aid for the dual purpose of ion exchange and filtration. The resins, and cellulose when spent retain residual radioactivity and have to be disposed of in a safe manner which usually requires burial in a land fill. The current practice is to encapsulate the resin in a matrix of cement of polymer to ensure adequate mechanical integrity as well as preventing leaching of radioactive substances from the resin by ground water. The disadvantage of this method is that it increases the volume of material that needs to be disposed. The price of disposal is closely related to the volume of material. Another method recently developed uses high integrity containers to hold the resins and cellulose without the addition of cement. The containers are designed to maintain boundary integrity for several hundred years. However, the cost of transporting and burying the wastes is based upon their volume. Significant cost savings can be realized if the volumes are reduced. The invention consists in a method of reducing the volume of low level radioactive waste material comprising from 30 w% to 60 w% spent ion exchange resin containing acidic and/or basic reactive groups and from 40 w% to 70 w% of a filter aid reactive with said groups at an elevated temperature of at least 230°C, characterized by dewatering the spent ion exchange resin, heating the dewatered resin to the elevated temperature, and compressing the dewatered resin heated to the elevated temperature with a force of at least 13790 kPa (2000 psi) for a period of at least 20 minutes sufficient to cause the resin to sinter and become rewet stable. The spent ion exchange resins are particulates having a void factor of approximately 30-40%. By applying the proper mechanical force of pressure the particles can be forced closer together, reducing the void fraction and thereby the total volume. At an elevated temperature cross-link bonds in the resin are broken and the resin does not spring back. Conveniently, a mixture of depleted resins of either a bead of powdered form and cellulose filter aid containing radioactive residue are drained of excess liquid. The mixture may be simply a drained slurry or can be completely dried. The mixture to be processed may be of a single type, such as an anion or cation resin or it may be a mixture of these different types. Acidic reactive groups remove positively charged ions/cations, from solution making it a cation resins. A commonly used acidic reactive group on ion exchange resin is the carboxyl radical, Another frequently used acidic reactive group is the sulfonic radical, As the solution is passed through the cation exchanger, cations replace the H on the resin. A resin having basic reactive groups such as hydroxy, -OH, remove anions which are negatively charged in solution from the solution by exchange with the OH group. Other basic reactive groups such as primary amino, secondary amino; tertiary amino, or quaternary ammonium, may also be utilized to create an anion resin. Filter aids employed in processing water from a nuclear power plant comprise a wide range of natural and man-made materials, having in common the ability to trap undissolved particles in the water. The filter aids to which the process of the present invention is applicable are reactive with the acidic or basic groups on the ion-exchange resin. The commonly used filter aid with powdered resins is plant cellulose, Other polymeric materials based on the cellulose chain but having other groups substituted for the H and OH groups are acceptable substitutes. In the preferred embodiment the resin contains cellulose filter aids that were used in processing water from the nuclear plant in the amount from 40 w% to 70 w% of the mixture. The process of volume reduction is relatively insensitive to the presence of some amount of crud that may result from ion exchange processing of the water. In short, the mixture may be unused or it may be exhausted resin and filter aid that contains extraneous material. Should the resin not contain cellulose filter aid, it would need to be added. Further, bead type resin would benefit from size reduction of the beads. Some benefit in volume reduction is obtained simply by compression resin with or without filter aid at ambient temperatures. The compaction may be in a single or multiple compression stages with a force ranging from 13790 kPa to 44816 kPa (2000 psi to 6500 psi). While pressure is being applied the resin occupies a compacted reduced volume. After the pressure is removed the resin then occupies a generally larger released volume. For compactions done at ambient temperatures volume reduction factors (that is, original volume divided by reduced volume) of the released resin ranges from approximately 1.2 to approximately 3. It has been found that an increase in the volume reduction factor can be obtained if the resins are dewatered and are heated during the compression. By applying heat, particles can be deformed further for a given pressure causing them to come closer together, thus reducing the void percentage and thereby the total volume even more than by the simple application of high mechanical pressures. At a temperature of approximately 250°C, for instance, the released volume reduction factor increases from approximately 1.75 to greater than 5. Any method of applying a compressive force to the ion exchange resin may be used. One method, that used in obtaining the experimental results, is the application of the compressive force by a ram press, such as a hydraulically driven piston inside a cylinder. A second method, the method deemed to be preferred in commercial applications, is the employment of an extrusion press. This method would allow the continuous processing of ion exchange resin by feeding the dewatered resin into one end of the extruder, heating, compressing, and removing the sintered material from the other end of the extruder. A third method of heating and compressing the resin is to use heated inert gas to apply isostatic pressure to the resin. The resin is volume reduced by the pressure and heat contained in a gas such as argon. The benefit realized for powdered resins mixed with cellulose filter aid representing 40 to 70 w% of the mixture which is heated to an elevated temperature of approximately 230°C during the compression and held at that temperature and pressure for at least 20 minutes, is that in addition to increasing the volume reduction factor for powdered resins, the combination greatly increases the resins' stability in the presence of water by making it rewet stable. The rewet stable resin forms a monolith that is physically stable in the presence of water and will not fall apart. This gives a waste form that is more desirable for burial since any intrusion of water will not destroy the stability or integrity of the waste form and cause leaching of the radioactive material into the water. A similar benefit is expected for bead resins mixed with filter aid. EXPERIMENTAL RESULTS Several tests were performed on the process in a piston and cylinder apparatus using a calibrated testing machine to measure the force applied and the resultant deflection. The volume reduction factor was then calculated from the original volume of resin and the amount of deflection either under pressure or after release for various applied pressures. A temperature controlled clam shell type oven was also used around the piston cylinder assembly to allow heat to be applied during the compression. Both the piston and cylinder apparatus and the oven are of designs commonly known to those skilled in the art and the particulars are not critical to the process. Table 1 summarizes the results of the compaction process performed upon wet vacuum dewatered bead resin at ambient temperature. Tests No. 1, 2 and 3 were done with single compression and resulted in released volume reduction factors of up to 1.45. Test No. 4 compaction consisted of multiple compressions of the same sample of bead resin. In this case the released volume reduction factor achieved was 1.77. Wet, Vacuum Dewatered Bead Resin Test No. Compaction Force kPa (psi) Volume Reduction Factor Temp (°C) Rewet Stable Compacted Released 1 21925 3180 1.95 1.32 21 No 2 32061 4650 2.05 1.36 21 No 3 34681 5030 2.11 1.46 21 No 4 31578 4580 2.13 1.54 21 30957 4490 2.21 1.63 21 29854 4330 2.25 1.69 21 30751 4460 2.29 1.73 21 30061 4360 2.29 1.75 21 44954 6520 2.41 1.77 21 43230 6270 2.45 1.77 21 No Table 2 describes the results of compaction at ambient and elevated temperature on dry bead resin. Test 1 was a single compression, whereas tests 2 and 3 were multiple compressions. In this series of tests, the resin samples were heated in tests 2 and 3. heating to 125°C achieved a released volume reduction factor of 1.49, while heating to 250°C obtained a released volume reduction factor of 1.75. From this series of tests it is expected that worthwhile volume reductions can be obtained from minimum temperatures from about 100°C and minimum pressures from about 13790 kPa (2000 psi). Dry Bead Resin Test No. Compaction Force kPa (psi) Volume Reduction Factor Temp (°C) Rewet Stable Compacted Released 1 34681 5030 1.35 1.19 21 No 2 30475 4420 1.29 -- 125 31854 4620 1.32 -- 125 33164 4810 1.34 -- 125 30475 4420 1.47 -- 125 32957 4780 1.51 -- 125 33164 4810 1.53 1.49 125 No 3 30475 4420 -- -- 250 30957 4490 -- -- 250 30475 4420 -- -- 250 30061 4360 -- 1.75 250 No Table 3 describes the results of compaction at ambient temperature upon wet vacuum dewatered powdered resins with a filter aid. A released volume reduction factor of 2.16 was obtained with multiple compressions. Wet, Vacuum Dewatered Bead Resin, with Filter-Aid Test No. Compaction Force kPa (psi) Volume Reduction Factor Temp (°C) Rewet Stable Compacted Released 1 32061 4650 2.51 1.20 21 No 2 32061 4650 2.63 1.67 21 No 3 34681 5030 2.38 1.50 21 No 4 30957 4490 2.60 1.83 21 29854 4330 2.62 1.86 21 44333 6430 2.89 2.04 21 44747 6490 3.12 2.07 21 44954 6520 3.29 2.16 21 44333 6430 3.50 2.16 21 43437 6300 3.54 2.16 21 No Finally, compaction of dry powdered resin with a filter aid was tested using both single and multiple compressions and heating the powdered resin to either 200 or 250°C before applying the compression force. A released volume reduction factor as high as 5.36 was obtained and, in addition, those samples heated to 250°C were rewet stable upon release. Dry Powdered Bead Resin, with Filter-Aid Test No. Compaction Force kPa (psi) Volume Reduction Factor Temp (°C) Rewet Stable Compacted Released 1 31164 4520 3.38 2.98 21 No 2 32061 4650 3.81 3.30 21 No 30061 4360 3.91 -- 21 37783 5480 4.14 3.45 21 30061 4360 4.14 3.45 21 No 3 31854 4620 -- 4.14 200 No 4 29647 4300 -- 4.82 250 Yes 5 30751 4460 -- 4.89 250 Yes 6 43644 6330 -- 5.36 250 Yes 7 30475 4420 -- 4.76 230 Yes In summary, an advantage is gained by multiple compression of the resin leading to increased released volume reduction factors. The use of 230°C temperature during the compression of the powdered resins mixed with filter aid (cellulose) yielded a material that was rewet stable. It is expected that this property would also be obtainable for bead-type resins where the bead type resin is first size reduce and mixed with recommended amount of cellulose. It should be kept in mind that this process can be carried out in any type of equipment that can provide the desired compaction forces and the desired temperature. For example, another system that may be used is an isostatic press that utilizes an inert gas, such as argon, at elevated temperatures and pressures to compress the resin within a chamber, or the resin may be passed through an extrusion press for heating and compaction.

Claims: A method of reducing the volume of low level radioactive waste material comprising from 30 w% to 60 w% spent ion exchange resin containing acidic and/or basic reactive groups and from 40 w% to 70 w% of a filter aid reactive with said groups at an elevated temperature of at least 230°C, characterized by dewatering the spent ion exchange resin, heating the dewatered resin to the elevated temperature, and compressing the dewatered resin heated to the elevated temperature with a force of at least 13790 kPa (2000 psi) for a period of at least 20 minutes sufficient to cause the resin to sinter and become rewet stable. A method according to claim 1, characterized in that the acidic reactive groups are carboxylic acid groups. A method according to claim 1, characterized in that the acidic groups are sulfonic acid groups. A method according to claim 1, characterized in that the basic reactive groups are primary amino, secondary amino, tertiary amino, quaterny ammonium or mixtures thereof. A method according to claim 1, characterized in that the basic groups are hydroxy. A method according to any of claims 1 to 5, characterized in that the filter aid contains hydroxy groups. A method according to any of claims 1 to 6, characterized in that the filter aid is composed of a material based on cellulose. A method according to any of claims 1 to 7, characterized in that the resin is compressed with a force of at least 29647 kPa (4300 psi). A method according to any of claims 1 to 8, characterized in that the compressive force is applied by a ram press of an extrusion press. A method according to any of claims 1 to 9, characterized in that the heating and compressing is performed by using heated inert gas to apply isostatic pressure to the resin. A method according to any of claims 1 to 10, characterized in that compressing is performed by a plurality of compression steps.

Inventors: MCDANIEL KEITH KENT, SKRIBA MICHAEL CHARLES, SMELTZER EUGENE EARL, MCDANIEL, KEITH KENT, SKRIBA, MICHAEL CHARLES, SMELTZER, EUGENE EARL
Applicants: WESTINGHOUSE ELECTRIC CORP, WESTINGHOUSE ELECTRIC CORPORATION
Application year: 1987
Main classification: G21F9
IPC codes: G21F9