Validation Testing of the Nitric Acid Dissolution Step Within the K Basin Sludge Pretreatment Process

The work described in this report involved comprehensive bench-scale testing of nitric acid (HNO3) dissolution of actual sludge materials from the Hanford K East (KE) Basin to confirm the baseline chemical pretreatment process. In addition, process monitoring and material balance information was collected to support the development and refinement of process flow diagrams. The testing was performed by Pacific Northwest National Laboratory (PNNL)for the US Department of Energy's Office of Spent Fuel Stabilization (EM-67) and Numatec Hanford Corporation (NHC) to assist in the development of the K Basin Sludge Pretreatment Process. The baseline chemical pretreatment process for K Basin sludge is nitric acid dissolution of all particulate material passing a 1/4-in. screen. The acid-insoluble fraction (residual solids) will be stabilized (possibly by chemical leaching/rinsing and grouting), packaged, and transferred to the Hanford Environmental Restoration Disposal Facility (ERDF). The liquid fraction is to be diluted with depleted uranium for uranium criticality safety and iron nitrate for plutonium criticality safety, and neutralized with sodium hydroxide. The liquid fraction and associated precipitates are to be stored in the Hanford Tank Waste Remediation Systems (TWRS) pending vitrification. It is expected that most of the polychlorinated biphenyls (PCBs), associated with some K Basin sludges, will remain with the residual solids for ultimate disposal to ERDF. Filtration and precipitation during the neutralization step will further remove trace quantities of PCBs within the liquid fraction. The purpose of the work discussed in this report was to examine the dissolution behavior of actual KE Basin sludge materials at baseline flowsheet conditions and validate the.dissolution process step through bench-scale testing. The progress of the dissolution was evaluated by measuring the solution electrical conductivity and concentrations of key species in the dissolver solutions as a function of reaction (dissolution) time, by analyzing offgas generation rate and composition, and by analyzing intermittent and final acid-insoluble solids at the end of the dissolution. The testing was conducted in a system designed to assess parameters that can influence sludge dissolution and provide information that can be used to determine operating conditions for the actual system