Hot Isostatic Pressing of Radioactive Nuclear Waste The

Hot Isostatic Pressing of Radioactive Nuclear Waste: The Calcine at INL. Dr. Anders Eklund and Dr. Regis Matzie Quintus Technologies AB Confidential I I 1

Agenda • • • What is Hot Isostatic Pressing Safety Basic use and benefit of HIPing HIP system Application • HIP of High Level Waste (HLW) • INL study • Summary and Conclusions Confidential I I 2

Hot Isostatic Pressing A combination of temperature (300 -2500 ºC) and pressure (50 -300 MPa) to heal internal voids in metal and ceramic materials to substantially improve strength Confidential I I 3

Most Important Considerations for Isostatic Press Installations • Safety • Lowest possible LCC (ROI) • Others Confidential I I 4

The Wire-Wound Pressure Vessel • The pressure vessel is a thin walled forged cylinder. • The pressure vessel and the frame are pre-stressed with high strength steel wire. • Wire winding enables the possibility to withhold extreme pressure to a comparably low weight. • With this design the need for frequent safety related inspections is drastically reduced. • Wire winding gives maximum safety and enables unmatched performance I I 5

Most Common HIP Usage Today Powder Metallurgy - NNS product Hot Isostatic Pressing Pores eliminated Properly used, HIP will • Increase your profit • Increase your quality • Increase your competitiveness As cast / MIM / 3 D print Confidential I 6/18/2021 I 6 HIP: ed

The benefit of HIP • The core value using HIPed material • ~100% of theoretical density • Longer life time • Predictive life time • Lighter and low weight designs • Improved material properties • Increased mechanical properties • Ductility can be greatly improved • Fatigue life can be improved 3 -10 times • Scattering in data is significantly decreased • Residual stresses • Low warping (sintering temperature can be lowered) • Thermal stresses are non-existent • Increased corrosion properties • HISC • Lead time • HIP vs forging/casting • Shape geometry complexity • HIP vs forging/casting Confidential I I 7 Data from Bodycote

An artificial pore#1 Two steel cylinders with drilled holes in each end … are welded together to create a big hollow space inside to represent a huge pore. No evacuation of the pore! 22 mm 45 mm The cylinder is HIP: ed and cut in half to reveal the result. The huge pore is gone! Before HIP Confidential I I 8 After HIP

An artificial pore#2 Two steel blocks with many small drilled holes (1/8”x 1”) … are welded together to create many small hollow space inside to represent a huge pore. No evacuation of the pores! 22 mm 45 mm Difference 0. 005” (0. 17%) Difference 0. 006” (0. 30%) Confidential I I 9 The block is HIPed and cut in half to reveal the result. The pores are gone!

HIP System The Pressure Vessel is the Backbone of any HIP System Leak-before-break No built-in stress concentrations No real size and pressure limitations for vessels and frames Efficient cooling of the cylinder The need for frequent safety related maintenance is eliminated All QUINTUS® vessels are based upon design criteria given in ASME B&PV Code, Section VIII, Division 3 All CE-marked QUINTUS® vessels meet the European Pressure Equipment Directive (PED) For the US market, U 3 stamp is applied. Confidential I I 10

HIP System Installation Quintus HIP unit installed in the HFEF hot-cell at the INL Confidential I I 11 2, 05 m x 4. 2 m HIP System installed at MTC, Japan

HIP System Furnaces HIP Furnaces If the pressure vessel is the backbone of every HIP system then the furnace is the heart HIP furnaces can be supplied as either multi-zone radiation furnaces or single level heated (patented) convection furnaces Elaborate designs and experience are necessary in order to satisfy insulation, temperature accuracy, rapid cooling and reliability requirements Quintus furnaces are outstanding in all respects and offer great value to HIP system users HIP furnaces are mainly built of Confidential I I steel, molybdenum or graphite depending on operating 12

HIP System Efficiency URC® Uniform Rapid Cool HIP furnaces must have excellent insulation capacity to protect the pressure vessel from overheating URC means interrupting the insulating capacity of the furnace in a controlled manner to shorten cycle time or to achieve some kind of heat treatment as an add on to the HIP cycle During URC vast amounts of energy are transferred out of the HIP vessel in a short period of time Only thin-walled vessels will allow URC at rates of 100 °C/min or more can easily be achieved Confidential I I 13

HIP System Efficiency URC ® Uniform Rapid Cool HIP Cycle: Conventional Cooling Versus URC Typical HIP Cycle with and without URC 1 Vacuum 2 Equalization 3 Pumping Confidential I I 14 4 Heating 5 Holding 6 Cooling 7 Equalization 8 Backpumping 9 Release

HIP Applications Typical HIP Applications • • • • P/M Tool Steel Aerospace castings (SA and Ti) Aluminium castings (Densal with Bodycote) Body implant castings (Ti and Co-Cr-Mo) Body implant ceramics (Alumina and Zirkonia) Advanced engineering ceramics Armour ceramics Composite P/M materials Near net shape (NNS) alloy steel products Super alloy billets and NNS P/M products Diffusion bonding of dissimilar materials Sputtering targets Metal matrix diamond tools Metal matrix composites HIP brazing • Nuclear waste • etc. Confidential I I 15

Application of HIP to HLW Slide taken directly from Do. E Idaho Clean-up Project presentati on Confidential I I 16

DOE Decision Analysis • DOE conducts Decision Analysis (November 2009) • Multi-discipline DOE-ID and DOE-HQ personnel performed Decision Analysis • 2009 “Tabletop” option evaluated and scored • “Tabletop” evaluation criteria weighted and used in scoring • HIP scored highest and recommended and used in scoring • HIP treatment scored higher than all options for waste form performance • HIP scored higher than vitrification • • Confidential I Safety and complexity Minimize secondary waste Total life-cycle cost Final waste volume I 17

2009 Amended ROD Issued • DOE elects to issue “Single-Path” ROD (record of decision) • DOE issues ROD for calcine treatment (December, 2009) • Selects HIP treatment as technology to “cost effectively” treat calcine • Provides technological capability to further treat Sodium-Bearing Waste (SBW) • Steam-Reformed carbonate waste form, should such treatment be necessary • IWTU facility, after completion of SBW mission and suitable configuration, used to support treatment of calcine • State of Idaho consulted prior to decision and concurrence received • Satisfies Settlement Agreement milestone • Selection leads to submittal of RCRA (Resource Conservation and Recovery Act) Part B application by December 1, 2012 (Settlement Agreement Milestone) Confidential I I 18

Application of HIP to HLW Quintus Involvement with INL: • March 2010: Quintus was contacted regarding manufacturing of HIPs for calcine waste at INL. • April 2010: RFQ discussed. • April 2010: Quintus took INL (6 consultants from CH 2 M-WG) to Howmet to see equipment and discuss Quintus capabilities. • July 2010: Quintus visited INL during an open invitation meeting for those who were interested to work on this project, especially the HIP. Quintus was the only HIP company to attend. All others declined. • September 2010: Quintus meets with CH 2 M in Chicago to discuss project. Confidential I I 19

Application of HIP to HLW Quintus Involvement with INL: • During this time period there were multiple daily calls from INL asking questions about the HIP and wanting to run more test cans in Columbus to verify the initial design. • Several meetings in Idaho Falls took place to discuss the continued design. • September, 2012: only 3 -4 people were left with the project as funds were being diverted from the calcine HIP project to the Hanford Nuclear cleanup site where liquid waste was leaking into local water supplies and river. • The Idaho state mandate of having all calcine road ready by 2035 has not changed!! Confidential I I 20

Test runs at INL and Quintus The Hot Fuel Examination Facility (HFEF) is one of the largest hot cells dedicated to radioactive materials research at Idaho National Laboratory (INL). HIPed treated zirconia calcine canister inside the MFC HFEF hot cell at INL Confidential I I 21

INL’s Summary Statement on Application of HIP to HLW Processing Quintus Involvement with INL: Slide from INL’s Project Team showing Quintus HIP model and a test can run in the QIH-9 Confidential I I 22

Benefits of HIP to HLW Processing • Cost comparison – data from Idaho Cleanup Project. • Note: Complete definitions not documented • Strong value proposition for HIP Confidential I I 23

Potential Market – U. S. HLW • Comparison of waste volumes – data from Idaho Cleanup Project. • INL volume is minor compared to Hanford and Savannah River. Confidential I I 24

Confinement system tests with HEPA-filters for INL Calcine Project New Filter Hipped Filter New Filter Confidential I I 25 Hipped Filter

INL Calcine Waste Process Layout Design Confidential I I 26

HIP Produces Glass-Ceramic Waste Form • Calcine mixed with additives to mineralize the calcine into a glass-ceramic form • HIP treatment of calcine to be performed at 1050 -1250 °C and 7, 200 -15, 000 psi • HIP treatment of calcine converts the RCRA metals and constituents of concern (COCs) into low leachable minerals Confidential I I 27

Summary • Wire-Wound Technology is the Safest Solution for HIPing of High Level Waste (HLW). • Superior safety ”Leak before break” • Longest cyclic life and lowest weight • Unmatched HIP furnace performance • Wide variety of HIP furnace options e. g. molybdenum, graphite, stainless steel and “black steel” • Un-paralleled rapid cool performance due to thin-walled pressure vessel design • Cold or hot load/unload furnaces • Advanced system control with cascade control of furnace temperature • Advanced and operator friendly HMI solutions • Outstanding documentation • Internet based remote diagnostics Confidential I I 28

CONCLUSION - Choice of HIP solution by INL is the Wire-Wound Technology Confidential I I 29

Acknowledgements • The authors which to thank CH 2 M-WG Idaho, LLC for permission to publish the results of this work. This work was supported by U. S. Department of Energy, Idaho Cleanup Project, and Project No. 23582. Confidential I I 30

Quintus Technologies Thank you for your attention! How can we help? Confidential I I 31