Transcript Diapositiva 1

PLASMA TECHNOLOGY
An Optimal Solution for
Radioactive Waste Minimization
UKRAINIAN NUCLEAR FORUM 2012
27-28 March - KIEV
PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
INDEX
1. BACKGROUND
2. PLASMA TECHNOLOGY
2.1 Introduction to the Technology
2.2 Applicable Waste Types
2.3 Advantages and Disadvantages
2.5 Main Equipment
3. PLASMA TREATMENT PLANTS
3.1 Operational Experience - ZWILAG
3.2 Plasmatek Pilot Plant
3.3 Plasma Melting Facility – KNPP Bulgaria
UNF International Conference
27-28 March 2012
KIEV
2
PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
1. BACKGROUND
2. PLASMA TECHNOLOGY
2.1 Introduction to the Technology
2.2 Applicable Waste Types
2.3 Advantages and Disadvantages
2.5 Main Equipment
3. PLASMA TREATMENT PLANTS
3.1 Operational Experience - ZWILAG
3.2 Plasmatek Pilot Plant
3.3 Plasma Melting Facility – KNPP Bulgaria
UNF International Conference
27-28 March 2012
KIEV
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
1 Background
• The main purpose of treatment, conditioning and packaging is volume reduction
and physical-chemical and mechanical stabilisation of the waste in view of its
confinement in the final repository.
• The reduction in disposal costs is often the main reason to promote volume
reduction
• Volume reduction technologies such as supercompaction and incineration are
widely applied
• Plasma technology offer higher volume reduction and is applicable for organic
and inorganic waste.
• High efficiency volume reduction technologies typically require a large input
volume to operate economically
• The largest potential benefit from waste reduction efforts can be expected for
new nuclear plants and for decommissioning.
UNF International Conference
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
INDEX
1. BACKGROUND
2. PLASMA TECHNOLOGY
2.1 Introduction to the Technology
2.2 Applicable Waste Types
2.3 Advantages and Disadvantages
2.5 Main Equipment
3. PLASMA TREATMENT PLANTS
3.1 Operational Experience - ZWILAG
3.2 Plasmatek Pilot Plant
3.3 Plasma Melting Facility – KNPP Bulgaria
UNF International Conference
27-28 March 2012
KIEV
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
2 Plasma Technology
2.1 Introduction to the technology
Plasma treatment uses an electric arc to generate temperatures in the gas stream
that can achieve several thousand degrees centigrade causing the rupture of
molecular structures of materials into their constituent atoms.
In a temperature range of 7.000 – 1.0000 °C, the organic material is vaporised in
volatile hydrocarbons, carbonmoxide, etc. while non-combustible and other
inorganic constituents are melted and transformed into glassy slag
o
The treatment of solid radioactive waste using plasma heating sources
occurs in primary chambers.
o
The resulting vapour phase is passed through an afterburner followed by
appropriate treatment in the off-gas.
o
The molten residues (slag), which contain most of the radioactivity, are
transferred into an external vessel and cooled.
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
2 Plasma Technology
2.1 Introduction to the technology
• Developed into the sixties for testing heat shields for the
space industry.
• After more than 4 decades, plasma technology is being
utilised worldwide in many industrial processes (e.g.
metal cutting, metallurgical application, vitrification of fly
ash from municipal incinerators, treatment of
problematic chemical wastes, etc).
• First application for Radioactive waste treatment was taken into operation in
2004 in ZWILAG.
Having completed testing for the regulators, in 2004 ZWILAG was granted
permission to process low level radioactive waste. From 2004, ZWILAG has
had many successful campaigns processing radioactive waste.
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
2 Plasma Technology
2.2 Applicable Waste Types
Due to the higher temperature range of the plasma compared to conventional
methods of incineration, the range of applicable waste types is much greater
The waste feed can include organic waste and also inorganic and mixed materials
Technology
Calcination
High temperature incineration
Incineration
Melting
Molten salt oxidation
Plasma
Pyrolysis
Synroc
Thermo-chemical treatment
Vitrification
Wet combustion
Organic Liquids
Inorganic Liquids
Organic Solids
Waste type
Inorganic Solids
NA
A
A
NA
A
A
A
NA
NA
NA
A
A
A
A
NA
NA
A
NA
NA
NA
A
NA
NA
A
A
NA
A
A
A**
A
A
A**
A
NA
NA*
NA*
A
LA
A
A**
A
A
A**
NA
A Technology is applicable to this waste type.
NA Technology is not applicable to this waste type.
LA Technology has limited applicability to this waste type.
* Small pieces of inorganic are acceptable without causing damage or plugging of the system
** Applicable only for the granular or powder form of this waste type.
*** Applicable only to organic spent resins
UNF International Conference
Mixed Organicinorganic solids
NA
A*
A*
NA
LA
A
A**
A
A
A**
NA
Mixed organicinorganic liquids
NA
A
A
NA
LA
A
A
NA
NA
NA
NA
Spent resins
NA
A
A
NA
A
A
A
NA
A
A
A***
TECDOC 1527
27-28 March 2012
KIEV
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
2 Plasma Technology
2.3 Advantages and Disadvantages
Advantages
Applicable to solid organic and inorganic waste and also to other waste type such as
drummed spent resins and liquid waste
One single process can treat the waste as generated (no prior treatment).
This implies less dose uptake and risk for contamination
The final waste form is robust, free of organic material, and suitable for long term
storage and disposal.
High volume reduction  lower disposal cost
• VRF~ 6 waste containing mostly metals and debris
• VRF~10 mixed waste
• VRF~100 primarily organic waste.
The heat source is a plasma  less production of certain flue gasses and the
greenhouse gas CO2
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
2 Plasma Technology
2.3 Advantages and Disadvantages
Disadvantages
Gaseous effluent restrictions - EC Directive 2000/76/EC (off-gas design)
Cost (justifiable when volume of waste to be treated is large)
Annual combustible
waste generation
50,000 m³/a
500 m³/a
5 m³/a
Amortized cost
Economic
feasibility
$ 40/m³ Very economical
$4000/m³ Marginal; competes
with direct disposal
$400,000/m³ Not economically
feasible
There is limited full-scale plant experience with radioactive waste:
o ZWILAG is the only plasma facility for the treatment of radioactive waste in the
world with a wide experience in industrial operation.
o PMF (Plasma Melting Facility) in Kozloduy (Bulgaria) – On going project
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
2 Plasma Technology
2.5 Main equipment
Feeding system options:
– Continuous feed system
Continuous by shreddermore constant flow rate and able to
homogenize all types of wastes
– Batch feed system
Batch feed by drum feederhigh instantenuous flow rate so off gas
must have higher dimensions
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
2 Plasma Technology
2.5 Main equipment
PLASMA TORCH
• Transferrable torch
• Non transferrable torch: most used and less complex (anode and
cathode are in the torch)
• Typical temp: 5.000°C organic material is gasified and iron, concrete,
glass and other inorganic material are melted to form a slag
• Power 100 kW to 2.000 kW
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
2 Plasma Technology
2.5 Main equipment
OFF-GAS SYSTEM
• Afterburner the syngas, hydrocarbons containing Cl and S are oxidized to
primary components such as CO2, H20, SO2 and HCl
• After complete oxidation, the flue gases are routed to an off-gas treatment
system:
o Boiler: Gases are cooled down (recovery can be used for heating)
o Scrubber: Gases are washed to absorb remaining portions of acids,
inorganic contaminants and sulphur dioxide (SO2).
o Filters: Trap radioactive dust particles
o DENOX: N0x concentration is reduced by means of selective catalytic
reduction
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
2 Plasma Technology
2.5 Main equipment
EMISSION CONTROL
There are two different emission control systems:
• Radiological emission control
To monitor the off-gas system exhaust air in terms of radioactivity
The system has to ensure that the measured data never exceed the maximum
permissible values.
• Conventional emission control.
To monitor that the complete off-gas stream flowing out of the plant stack
The measurement system covers the following categories: CO, SO2 , HCI, NOx,
NH3, Hg, dust, moisture and flow rate.
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27-28 March 2012
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
1. BACKGROUND
2. PLASMA TECHNOLOGY
2.1 Introduction to the Technology
2.2 Applicable Waste Types
2.3 Advantages and Disadvantages
2.5 Main Equipment
3. PLASMA TREATMENT PLANTS
3.1 Operational Experience - ZWILAG
3.2 Plasmatek Pilot Plant
3.3 Plasma Melting Facility – KNPP Bulgaria
UNF International Conference
27-28 March 2012
KIEV
1
PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
3 Plasma Treatment Plants
3.1 ZWILAG
ZWILAG is the only plasma facility for the treatment of radioactive
waste in the world with a wide experience in industrial operation
• Nuclear start up: 2004
• Run on a commercial base
• 100 ton per campaign (500 drums)
o 200 kg/h for burnable waste
o 300 kg/h for meltable waste.
• About 140 pours per campaign
• Nowadays: 2 campaigns of 10 weeks per year
• End 2009: Total 4000 drums or 690 ton
UNF International Conference
27-28 March 2012
KIEV
PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
3 Plasma Treatment Plants
3.1 ZWILAG
UNF International Conference
27-28 March 2012
KIEV
PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
3 Plasma Treatment Plants
3.2 PLASMATEK PILOT PLANT
Plasmatek is a pilot plant of plasma technology to treat low and
intermediate level wastes
From 1995, IBERDROLA INGENIERÍA has participated in the design and
commissioning of Plasmatek.
UNF International Conference
27-28 March 2012
KIEV
PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
3 Plasma Treatment Plants
3.3 PMF – KNPP BULGARIA
In 2009 the Joint Venture formed by IBERDROLA Ingeniería and
BELGOPROCESS was awarded with a contract to “Supply of a facility for
treatment and conditioning of solid and liquid radioactive wastes with a
high volume reduction factor at Kozloduy NPP”
Turnkey project co-funded by EBRD and KNPP.
Joint Venture formed by IBERDROLA Ingeniería and Belgoprocess.
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27-28 March 2012
KIEV
PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
3 Plasma Treatment Plants
3.3 PMF – KNPP BULGARIA
• Capacity: 65kg solid waste per hour and 5 to 10kg liquid waste per hour.
• Primary Treatment Chamber temperature: 1100 – 1500 ºC
• Non tranferrable Plasma Torch power: 500KW
• Gas residence time in Secondary Chamber: > 2 sec
• Secondary Chamber outlet temperature: 950 – 1200 ºC
• Off gas nominal flow:1.200Nm³/h
• Effective operation hours per year: 4000h
• Volume Reduction Factors (VRFs):
o Bags
VRF ~80
o 220 l drums
VRF ~20
o Pellets
VRF ~2
UNF International Conference
27-28 March 2012
KIEV
PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
3 Plasma Treatment Plants
3.3 PMF – KNPP BULGARIA
Category 2a waste delivered
in bags, 200 l drums and
super-compacted drums.
Material
Textile
Wood
Polymer
Volumetric %
90.3
5.4
4.3
Weight %
87.7
7.3
5
Radiation
(av.)
(mSv/h)
Specific
Activity
(Bq/kg)
Co60
Ag110m
Cs134
Cs137
Nb95
Mn54
Fe59
Co58
Mixed
0.69
3.87E+05
59
4
4
24
1
5
1
2
Polymers
0.33
2.98E+05
64
7
9
9
1
7
1
2
Wool
0.30
5.17E+05
63
9
6
9
1
8
1
3
Textile
0.29
4.02E+05
55
8
7
18
1
7
1
3
Turnings
0.24
3.64E+05
66
6
9
8
1
8
0
2
Rubber
0.24
1.80E+05
65
3
5
20
0
5
0
2
Wood
0.10
1.83E+05
51
1
8
34
0
5
0
1
Metal
0.09
1.30E+05
58
2
8
21
0
9
1
1
Construction Debris
0.05
2.96E+05
58
2
5
30
0
4
0
1
All Measured
Radwaste
0.25
3.23E+05
57
6
6
20
1
6
1
3
Material
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Radionuclide Contents (%)
27-28 March 2012
KIEV
PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
3 Plasma Treatment Plants
3.3 PMF – KNPP BULGARIA
Most significant equipments in KNPP PMF:
• Plasma treatment chamber  fix furnace with tilt design
• Torch  500 kW non-transferred arc plasma torch
• Feeding system  continuos through a shredder
• Off-gas system  based on Cilva facility (Belgoprocess)
• SCC (Slag collection chamber) based on Zwilag design
Plasma torch
Shredder
SCC
Plasma treatment chamber
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
3 Plasma Treatment Plants
3.3 PMF – KNPP BULGARIA
PMF FLOW DIAGRAM
Afterburner
Shredder
Plasma
torch
Off-gas
Plasma
furnace
Feeder
Ash collection system
Conveyor & Lift
Slag collection and cooling chamber
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PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION
3 Plasma Treatment Plants
3.3 PMF – KNPP BULGARIA
(Technological consultant – Switzerland
(Feeding System + Shredder) – Belgium
(Furnace w/Plasma Torch) – France
(Slag Collection Chamber) – Spain
(SCADA + C.E.M.) – Spain
(STC + Off-gas) – Netherlands
(Civil Works + Utilities + Construction) – Bulgaria
UNF International Conference
27-28 March 2012
KIEV
THANK YOU
Susana Gutiérrez
Waste Management and
Decommissioning Department