Abstract:
The invention is a product and a process for making a fireproof, impact limiter, homogeneous aggregate material for casting inside a hazardous material shipping container, or a double-contained Type-B nuclear shipping container. The homogeneous aggregate material is prepared by mixing inorganic compounds with water, pouring the mixture into the void spaces between an inner storage containment vessel and an outer shipping container, vibrating the mixture inside the shipping container, with subsequent curing, baking, and cooling of the mixture to form a solidified material which encapsulates an inner storage containment vessel inside an outer shipping container. The solidified material forms a protective enclosure around an inner storage containment vessel which may store hazardous, toxic, or radioactive material. The solidified material forms a homogeneous fire-resistant material that does not readily transfer heat, and provides general shock and specific point-impact protection, providing protection to the interior storage containment vessel. The material is low cost, may contain neutron absorbing compounds, and is easily formed into a variety of shapes to fill the interior void spaces of shipping containers.

Description:
United States Government has rights in this invention pursuant to Contract No. DE-AC05-84OR21400 between the U.S. Department of Energy and Lockheed Martin Energy Systems, Inc. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention relates generally to a packaging for shipping containers. Specifically, the present invention relates to a product for preventing damage to an interior containment vessel from impacts to exterior shipping containers. The invention is more specifically related to a product which is fireproof, castable, crushable, and non-toxic, which provides protection for nuclear material and/or other hazardous materials inside an interior containment vessel, when the exterior container is utilized for shipping of hazardous or radioactive materials. 
     Shipping containers with single, double, and triple containment have been utilized extensively in the nuclear materials and hazardous waste shipping industry. There continues a need for a product that provides shock and fire-resistant material for placement inside the exterior container, to protect and cradle the interior containment vessel. Ragland, et al., U.S. Pat. No. 5,658,634, describes a thin laminated metal foil and nonwoven fiber material that provides insulation for automotive systems. Barger, et al., U.S. Pat. No. 5,626,665, describes a cementitious system which utilizes low amounts of water plus calcined clay and other materials to produce high strength cement. MacNeill, U.S. Pat. No. 5,385,873, describes a high temperature resistant material containing ceramic fibers and inorganic vermiculite to withstand the high temperatures within catalytic converters. Orcutt, U.S. Pat. No. 4,612,046, describes an insulating composition formed from a mixture of Kaolite™ and amorphous quenched slag, to thermally insulate the exposed surface of molten metal in a cast vessel or furnace vessel. Householder, et al., U.S. Pat. No. 3,982,134, describes a container for nuclear materials transport that has on the interior, a pressure vessel, gamma radiation protection, insulating material, and neutron absorbing shielding in the form of beads or globules of water encapsulated in plastic. The prior art provides for materials that are heat insulating, shock protective, or radiation shielding when placed in separate layers into the interior of a nuclear materials shipping container. These and other materials, when added to containers, have shortcomings based on the inability to provide a light-weight, low-cost, heat insulating, shock protective, and radiation shielding material that can be castable inside the interior void spaces of a nuclear materials shipping container. Thus there exists room for improvement within the art. 
     SUMMARY OF THE INVENTION 
     It is an object of this invention to provide a process for making a product for encapsulating containers for shipping. 
     It is a further object of this invention to provide a process for making a product for encapsulating containers of nuclear materials and/or hazardous materials for shipping. 
     It is a further object of the present invention to provide a process of encapsulating a container for shipping. 
     It is an additional object of this invention to provide a product for encapsulating containers for shipping that is not flammable. 
     It is a further additional object of this invention to provide a rigid product that provides shock and impact protection to encapsulated containers by compaction of the rigid product. 
     It is yet a further and more particular object of this invention to provide a product that insulates an encapsulated container. 
     It is yet an additional and more particular object of this invention to provide a product that serves as a radiation absorber to reduce the amount of radiation measured at the exterior surface of the shipping container. 
     These and other objects of the present invention are accomplished by a process for making an aggregate product, and the aggregate product composed of a rigid homogeneous aggregate material utilizing portland cement and inorganic vermiculite. The material made by the process is non-flammable, provides both thermal insulation and impact protection to any containment vessel that the material surrounds. 
     The above and other objects of the present invention are also accomplished by a process of protecting a containment vessel inside a container for shipping nuclear materials, comprising the steps of: mixing a portland cement material with an inorganic vermiculite and water; pouring the mixture into the interior voids of an outer container for shipping; vibrating the mixture inside the outer container for shipping; curing the vibrated mixture at ambient temperature inside the exterior container for shipping; baking the cured mixture inside the exterior container for shipping at elevated temperatures; cooling the baked mixture to ambient temperature; welding a cover plate over the fill hole; and assembling the shipping package. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention&#39;s features and advantage will become apparent from a reading of the following detailed description, given with reference to the various figure of drawing, in which: 
     FIG. 1 is a view of the aggregate product of the present invention in a mixing container; 
     FIG.1 a  is a view of the aggregate product poured into a top plug unit; 
     FIG. 2 is a cross-sectional view of the aggregate product poured into the exterior container of the present invention; 
     FIG. 3 is a cross-sectional view of the solidified product of the present invention inside a double-containment nuclear shipping container; and 
     FIG. 4 is a graph of the compressive stress and fractional volume change when compressive stress is applied to the solidified product of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In accordance with this invention, it has been found that a protective material is needed that is fire-resistant and is crushable to serve as an shock absorbing and impact limiting material for insertion into the void spaces  5  formed between the inside walls of a shipping container  1 , and the outer walls of a containment vessel  7  for hazardous and/or nuclear materials. In accordance with FIGS. 1-4, the preferred embodiment for the present invention is a fireproof, impact limiting, homogeneous aggregate material (HAM) 3 . The homogeneous aggregate material  3  is in a granular form when dry, and is in a porable form after water is mixed in (see FIG.  2 ), until the mixture is poured into a shipping container, vibrated and allowed to stand, cure and solidify for numerous days, and baked at high temperatures for numerous days, forming a solid mass inside the shipping container (see FIG. 3) after a cover plate is welded over the fill hole. 
     The homogeneous aggregate material is a combination of portland cement and inorganic vermiculite. The material of the present invention does not contain hydrocarbon compounds as does the prior art. Most existing, commonly-used, internal packaging materials utilized in hazardous and/or radioactive shipping containers, contain some type of carbon, or hydrocarbon-based, internal packaging and insulating material which is flammable after the appropriate combustion temperature is reached during test scenarios. The internal impact limiting and insulating material  3  (HAM) is placed in the void spaces  5  of an outer container  1  which occur between: 
     (a) the interior surface  6  of the walls of the outer shipping container  1 ; 
     (b) the walls of an interior encapsulating jacket  6  or stainless steel liner of material that covers the exterior surface of the internal nuclear material containment vessel  7  placed inside the outer shipping container  1 ; and 
     (c) the top lid  29  and top plug unit  21  that seals the upper portion of the shipping container  1 . 
     The homogeneous aggregate material  3  is also placed in the void space  5  in the top plug unit  21  of the shipping container  1 . The top plug unit  21  forms an upper barrier for impact absorption and insulation from the top of the interior containment vessel  7 , then a drum lid  8  is bolted onto the top of the outer shipping container  1  (see FIGS.  2  and  3 ). The lid  8  of the interior containment vessel  7  has separate bolts, and O-ring seals made of ethylene-propylene material, for sealing of the lid  8  of the interior vessel  7  onto the interior containment vessel  7 . 
     The invention provides for utilization of a homogeneous aggregate material  3  as an internal containment vessel  7  packing or encapsulating material, which solves numerous problems incurred by the use of hydrocarbon-based packaging materials because the invention is fireproof, shock absorbent, and castable into any shape, providing additional safety to reduce the possibility of a worst-case breach of nuclear material transport containers. 
     The homogeneous aggregate material  3  is composed of two main inorganic components. One of the main inorganic components is portland cement, which is typically composed of: lime, alumina, silica, iron oxide, tetracalcium aluminoferrate, tricalcium aluminate, tricalcium silicate, and dicalcium silicate in varying amounts, along with small amounts of magnesia, sodium, potassium, and sulfur. The other main component of the homogeneous aggregate material is an inorganic vermiculite, which is mixed with the portland cement. 
     One type of inorganic vermiculite and portland cement mixture utilized in tests is commercially available from Thermal Ceramics, Inc., of Augusta, GA, under the trade name of Kaolite™ 1600. The inorganic mixture tested was composed of: 
     approximately 10% aluminum oxide (alumina), 
     approximately 37% of silicon dioxide (silica), 
     approximately 6.7% of ferric oxide, 
     approximately 1.2% of titanium oxide, 
     approximately 30% of calcium oxide, 
     approximately 13.1% of magnesium oxide, and 
     approximately 2% of sodium monoxide. 
     The portland cement and inorganic vermiculite aggregates form a homogeneous, rigid mass after water is added and the mixture is allowed to stand in a shipping container and cure for approximately two days, followed by a high temperature baking for approximately two days. 
     One preferred embodiment of the process of mixing and forming the homogeneous aggregate material  3  in an outer shipping container  1 , for protection of the interior containment vessel  7 , includes the following steps in reference to FIGS. 1-3. 
     (A) Provide a stainless steel shipping container  1  weighing approximately 95 pounds and having approximately 5.0 cubic feet of void space  5  between the outer shipping container  1 , and the walls of an interior encapsulating jacket  6  or stainless steel liner, into which an inner containment vessel  7  is placed. The void space  5  is to be filled with the wet mixture  35  of inorganic vermiculite, portland cement and water, for a wet cast weight of approximately 400 pounds. 
     (B) Mix approximately 122 pounds of inorganic vermiculite and portland cement with approximately 183 pounds of water slowly in a mixer container  11  until thoroughly mixed (see FIG.  1 ). 
     (C) Place the drum shipping container  1  upside down  13  onto a shaking or vibrating table (not shown). Shake or vibrate the shipping container  1  at approximately 1.5 to 2 times the wet cast weight (750 pound-force) at 2,000 vibrations per minute, while pouring the wet mixture  35  into the drum shipping container void space  5  through a bottom pour hole  15  (see FIG.  2 ). 
     (D) Continue the vibrations for a time period of at least five minutes after the drum of the shipping container  1  is full. 
     (E) Shake or vibrate the shipping container  1  at approximately 750 pound-force at 2,000 vibrations per minute, while pouring the wet mixture  35  into the bottom pour hole  15  in the bottom surface or bottom head  17  of the outer shipping container  1 , and vibrate for at least 5 minutes after filling. 
     (F) While the mixture  35  is solidifying inside the shipping container  1  (see next step), a similar wet mixture  35  of inorganic vermiculite, portland cement, and water is poured into the top plug unit  21 , through an opening, into the void space  23  (see FIG.  1 A), while vibrating the top plug unit  21  for at least 5 minutes after filling. 
     (G) Allow the mixture to solidify within the shipping container  1  and within the top plug unit  21 , over approximately 24 to 48 hour period, at room temperature. The temperature of at least approximately 60, and up to approximately 90 degrees fahrenheit is preferable. 
     (H) Bake the solidified mixture  31  (FIG.  3 ), inside the shipping container  1 , and in the top plug unit  21 , in a gas-fired or forced convection fresh air circulating electric furnace (not shown), over at least approximately 48 hours, beginning at 200 degrees fahrenheit for approximately 4 hours, and increasing the temperatures by approximately 75 degrees every hour, until approximately 500 degrees is reached, with baking at approximately 500 degrees for approximately 36 to 40 hours, for a total bake period of approximately 48 hours. 
     (I) Cool the solidified and baked mixture  31  within the shipping container  1 , and within the top plug unit  21 , to approximately room temperature. The finished weight for the solidified and baked mixture  31  in the shipping container  1  is approximately 245 pounds, and the finished density is approximately 30 pounds per cubic foot. 
     (J) Weld a bottom cover plate  25  over the bottom pour hole  15  in the outer shipping container  1  (see FIGS.  1  and  3 ). 
     (K) Weld the fill hole cover plate  22  over the top pour opening in the top plug unit  21  (see FIG. 1 a ). 
     (L) Assemble the finished shipping container  1  (FIG. 3) in the following order; load the containment vessel  7  with the radioactive and/or hazardous materials, seal the containment vessel top  8 , and fasten with bolts, lower the assembled containment vessel  7  into the interior encapsulating jacket  6  inside the outer containers center void  9  (now filled with solidified homogeneous material  31 , place the top plug unit  21  over the containment vessel  7 , install the shipping container lid  29  with its fasteners  27 . 
     After baking, cooling, and assembly of the shipping container, the homogeneous aggregate material has approximately 4-5 pounds per cubic foot of residual water bound in the solidified material, potentially serving as a neutron absorbing and heat dissipating component of the homogeneous aggregate material  31 . 
     A second embodiment for shipping containers utilized for transport of neutron emitting nuclear materials, is the addition of natural boron, enriched boron, compounds containing boron (i.e. boron carbide), or compounds containing gadolinium, cadmium, europium, hafnium, samarium, indium alloys, or other neutron absorbing compounds mixed into the homogeneous aggregate material. The addition of boron compounds, or other neutron absorbing compounds, to the mixture before solidification, provides a nonvolatile neutron absorbing additive to the homogeneous aggregate material  3 . The above described steps of mixing, pouring, curing, baking, and cooling are utilized, with the boron compounds, or other neutron absorbing compounds, mixed into the mixture of portland cement, vermiculite, and water at the mixing step, before the wet mixture is poured into the voids of the shipping container. The percentage of boron, boron containing compounds, or other neutron absorbing compounds added to the wet mixture is variable and is dependent on the radioactivity of the materials stored in the inner containment vessel. As explained earlier, the baked and cooled homogeneous aggregate material  3  has approximately 4-5 pounds per cubic foot of water remaining in the solidified material, potentially serving as a neutron absorbing component of the homogeneous aggregate material  3 . 
     The benefits of the homogeneous aggregate material  3  are numerous when compared to the prior art. Current packaging and shock-inhibiting materials utilize hydrocarbon- or carbon-based materials for the interior voids  5  of shipping containers  1  containing interior nuclear material containment vessels  7 . The carbon-based materials will eventually burn and release toxic fumes, or may add to the internal heating of a containment vessel  7  of nuclear materials. The silicon, aluminum, ferric, magnesium and calcium composition of inorganic vermiculite and portland cement will not burn when cured and hardened inside a shipping container  1 . The cured mass of homogeneous aggregate material provides a castable, non-flammable, packaging material that serves as a thermal insulator for any enclosed containment vessel  7  of hazardous chemical and/or nuclear materials. The cured mass has a very low capacity to store heat, therefore providing outstanding insulating properties from exposures to high or low temperatures. The cured mass does not expand appreciably when heated to high temperatures. The melting temperature of the cured mass is approximately 2335 degrees fahrenheit, which is higher than the stainless steel outer container  1  that is typically utilized for transport of nuclear materials. 
     Testing results for the solidified, cured, and baked homogeneous aggregate material  3  inside a shipping container  1  have verified the insulating capabilities of the claimed invention. Testing has subjected stainless steel shipping containers  1 , with an internal containment vessel  7  surrounded by the solidified, cured, and baked homogeneous aggregate material  31  encapsulated by a ductile jacket  6 , to temperatures of 1525 degrees Fahrenheit at the outer surface of the walls of the shipping container  1  for over 34 minutes. The ductile jacket  6  is composed of the stainless steel interior wall and the exterior wall of the drum shipping container (see FIG. 2)  1 . The maximum temperature measured on the interior wall  6  of the encapsulated material was approximately 215 degrees Fahrenheit, with a maximum measured temperature at the exterior of the containment vessel  1  of 150 degrees Fahrenheit. The heat is also dissipated by some of the approximate 4-5 pounds per cubic foot of water left inside the HAM after curing and baking, that evaporates during the fire test, venting steam away through vent holes from the interior wall that protects the containment vessel. Vent holes in the containment vessel  7  and shipping container  1  are drilled after the HAM  3  is cured, and fusible plastic hole plugs  33  are placed in the vent holes. In summary, internal nuclear and/or other hazardous containment vessels  1  are protected from destructive temperatures at the containment vessel lids  8 , which have O-ring seals which deteriorate over 350 degrees Fahrenheit, by the homogeneous aggregate material, placed inside the shipping container  1  and serving as an encapsulating jacket  6  around the containment vessel  7 . 
     A second major benefit is the impact limiting properties of the homogenous aggregate material  3  when solidified in a ductile jacket  6  within the shipping container  1 , provides a brittle structure that is frangible when subjected to impacts (see FIG.  4 ). As the shipping container  1  is subjected to impacts, the brittle structure of the HAM fractures, crushes, and powders, dissipating the force around the interior containment vessel  7 . Because the brittle homogenous aggregate material  3  directs fractures from the impact in many different directions, the HAM  3  does not delaminate along one specific plane. The stress-strain curve (see FIG. 4) shows the energy absorbing capabilities of the brittle structure of the homogenous aggregate material  3  formed into an encapsulating jacket  6 . Therefore, the encapsulating jacket  6 , and the brittle structure of the homogenous aggregate material  3 , provides insignificant pathways for flames, radiation of heat, or hot gasses to reach the internal containment vessel  7 . 
     A third and less obvious benefit of the homogeneous aggregate material  3  is that the inorganic vermiculite material is non-toxic in a dry condition, and is castable into a multitude of shapes when water is added, with the final form being non-toxic also. During curing of the aggregate material inside the shipping container  1 , and during any thermal testing for package certification purposes of the shipping container  1  with the aggregate material inside, the only offgas formed is water vapor, which is non-toxic. As discussed above, the cured inorganic mass does not burn, and no toxic offgasses such as hydrocarbons or tars are formed when the cured mass approaches its melting temperature. 
     A fourth benefit of the homogeneous aggregate material  3  is the low cost for the materials, and the low cost to prepare a rigid mass of the material. Costs of $12.00 to $14.00 per cubic foot have been calculated for the raw materials, which is significantly less than current rigid polyurethane foam and high-density fiberboard insulation utilized for Type-B nuclear and/or hazardous material shipping containers  1 . As emphasized above, insulating material with hydrocarbon- or carbon-based materials, such as wood, polyurethane foam, and high-density fiberboard insulation, are prone to ignite above each material&#39;s combustion temperature, which requires complete removal and cleaning of a container containing hydrocarbon-based insulation when subjected to high, ignition temperatures. The invention of homogeneous aggregate material  3  does not ignite, and will not require interior cleaning of a container utilizing the material when subjected to high temperatures up to the material&#39;s melting point, which is above the melting point of the exterior stainless steel shipping container  1 . 
     A fifth benefit of the homogeneous aggregate material  3  encapsulated inside a stainless steel shipping container  1  is the low cost to maintain the shipping container  1 . The organic compounds described earlier for use as impact limiting and thermal insulating materials tend to age and breakdown when exposed to severe temperature, humidity changes, and rough handling, will require periodic replacement. Replacement of the impact limiting and thermal insulating material generates a recurring maintenance cost for the life of the shipping package  1 . The homogeneous aggregate material  3  of the present invention, when placed inside the exterior shipping container  1 , has been subjected to over 42,000 miles of simulated endurance vibration testing with a fully loaded containment vessel  7 . Radiographs have shown that the internal structure of the homogeneous aggregate material  3  will fracture, crush, and be reduced to powder from the endurance vibration and impact testing. Additional thermal (direct flame or indirect heating) testing on this container  1  has shown no significant loss of effectiveness in its impact limiting and thermal insulating properties, when incorporated with the internal homogeneous aggregate material  3 . Therefore, there is no projected cost to replace the internal contents of the exterior shipping container  1 , even if the structure of the internal homogeneous aggregate material fractures. There is no appreciable loss of reduction of properties of the internal homogeneous aggregate material  3  within the shipping container  1  over the life of the shipping container  1 . 
     Although the present invention has been described in considerable detail with reference to a preferred version thereof, other versions are possible. For example, the materials of the apparatus may utilize a different inorganic vermiculite composition, or a similar composition of a non-carbon based, homogeneous aggregate of materials which include a solidifying agent such as portland cement. The percentage of alumina, silica, and other non-carbon oxide compounds may be varied from the percentages described above. 
     The configuration of the inorganic homogeneous aggregate material can be of any shape when solidified, providing impact protection and crush limitations for any stress on the exterior shipping container  1  in any direction. The shape of the material conforms to the shape of the container in which the material is cured (see FIG.  3 ). The solidified inorganic homogeneous aggregate material  3  fills the void spaces  5  between the interior contaminent vessel  7 , and the exterior walls of the outer shipping container  1 . The containment vessel  7  is placed inside the outer container  1  with the top plug  21  over the containment vessel&#39;s lid  8 . By this method of encapsulating a container  1  with a rigid, nonflammable, inorganic matrix of crushable material, the internal containment vessel&#39;s high hazard materials is protected from temperature extremes and from impacts to the exterior shipping container  1 . 
     The process mixing and curing steps can be varied by allowing for additional mixing and vibrating time for the mixture inside the shipping container  1 , and by providing a longer curing and heating time without detriment to the final rigid form of the inorganic homogeneous aggregate material  3 . 
     Many variations will undoubtedly become apparent to one skilled in the art upon a reading of the above specification with reference to the drawings. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.