This study explores the profound impact of varying oxygen content on microstructural and mechanical properties in specimens HO and LO. The higher oxygen concentration in specimen HO is found to significantly influence alpha lath sizes, resulting in a size of 0.5-1 μm, contrasting with the 1-1.5 μm size observed in specimen LO. Pore fraction, governed by oxygen concentration, is high in specimen HO, registering a value of 0.11%, whereas specimen LO exhibits a lower pore fraction (0.02%). Varied pore types in each specimen further underscore the role of oxygen concentration in shaping microstructural morphology. Despite these microstructural variations, the average hardness remains consistent at ~370 HV. This study emphasizes the pivotal role of oxygen content in influencing microstructural features, contributing to a comprehensive understanding of the intricate interplay between elemental composition and material properties.

The critical hazards generated from operation of a melting facility for metal radioactive waste are mainly assumed to be such as vapor explosion, ladle breakthrough and failure in the hot-cell or furnace chamber using remote equipment. In case of vapor explosion, material containing moisture and/or enclosed spaces may, due to rapid expansion of gases when heated, cause an explosion and/or violent boiling. The rapid expansion of gases may lead to ejection of molten radioactive metal from the furnace into the furnace hall. If there is a large amount of liquid the explosion may damage or destroy technical barriers such as facility walls. The consequences for the facility ranges from relatively mild to very severe depending on the force of the explosion as well as the type of waste being melted. Nonradiological consequences may be physical damage or destruction of equipment and facility barriers, such as walls. Due to the radiological consequences a longer operational shutdown would likely be required. Cleanup efforts would include cutting of solidified metal in a problematic radiological environment requiring use of remote technology before damage and repair requirements can be assessed. Even though there is a risk for direct physical harm to operators for example in the control room and hot-cell, this analysis focuses mainly on the radiological impact. The extent to which remote equipment could be used in the decontamination effort will largely determine the health consequences to the workers. It is reasonable to assume that there will be a need for workers to participate manually in the effort. Due to the potentially large dose rates and the physical environment, it is possible that the maximum allowable dose burden to a worker will be reached. No major consequence for the environment is expected as most of the radioactivity is bound to the material. In case of ladle breakthrough, a ladle breakthrough involves loss of containment of the melt due to damage of the ladle. This may be caused e.g. by increased wear due to overheating in the melt, or from physical factors such as mechanical stress and impact from the waste. A ladle breakthrough may lead to spread of molten metal in the furnace hall. Molten metal coming into contact with the surrounding cooling equipment may cause a steam explosion. The consequences of a ladle breakthrough will depend on the event sequence. The most severe is when the molten metal comes into contact with the cooling system causing a vapor explosion. The basic consequences are assumed to be similar to those of the vapor explosion above. While the ejection of molten metal is likely more local in the ladle breakthrough scenario, the consequences are judged to be similar. In case of failure in the hot-cell or furnace chamber using remote equipment, the loss of electric supply or technical failure in the furnace causes loss of power supply. If not remedied quickly, this could lead to that the melt solidifies. A melt that is solidified due to cooling after loss of power cannot be removed nor re-melted. This may occur especially fast if there is not melted material in the furnace. An unscheduled replacement of the refractory in the furnace would be required. It could be unknown to what degree remote equipment can be used to cut a solidified melt. It is therefore assumed that personnel may need to be employed. This event could not have any impact on environment

Working with molten metal has always been and will always be a dangerous workplace. No matter how carefully equipment is designed, workers are trained and procedures are followed, the possibility of an accident can occur in melting workplace. Some primary causes of melt splash and furnace eruptions include wet or damp charge material, dropping heavy charge into a molten bath, wet or damp tools or additives and sealed scrap or centrifugally cast scrap rolls. Induction melting brings together three things (water, molted metal and electricity) that have the potential for concern if the furnace is not properly working. Induction furnace must have a water cooling system built into the coil itself. Water picks up the heat caused by the current as well as heat conducted from the metal through the refractory. The water carries the heat to a heat exchange for removal. Spill pits serve to contain any molten metal spilled as a result of accident, run out or dumping of the furnace in an emergency. If a leak is suspected at any time, cease operation and clear the melt deck area of all personnel and empty the furnace. Molten metal fins can penetrate worn or damaged refractory and come into contact with the coil. A furnace or a close capture hood which suddenly swings down from a tilted position will cause injury or death. Whenever workers are working on a furnace or close capture hood when it is in the tilted position, be sure that it is supported with a structural brace that is strong enough to keep it from dropping if hydraulic pressure is lost. In theory refractory wear should be uniform, however, in practice this never occurs. The most causes of lining failure are improper installation of refractory material, inadequate sintering of refractory material, failure to monitor and record normal lining wear, allowing the lining to become too thin, installation of the wrong refractory, improper preheating of a used cold lining, failure to properly maintain the furnace the sudden or cumulative effects of physical shocks or mechanical stress, and excessive slag or dross buildup. Pouring cradles provide bottom support for crucibles. A crack in the crucible occur below the bottom ring support, the bottom of the crucible can drop and molten metal will spill and splash, possibly causing serious injury or death. To reduce this danger, a pouring cradle that provides bottom support for the crucible must be used. Power supply units must have safety locks and interlocks on all doors and access panels. Workers who work with low voltage devices must be made aware of the risk posed by high levels of voltage and current. The most causes of accidents are introduction of wet or damp material, improper attention to charging, failure to stand behind safety lines, coming into contact with electrically charged components and lack of operator skills and training. Only trained and qualified personnel are to have access to high risk areas. Safety lockout systems are another effective measure to prevent electrical shock

Once decommissioning begins, it is expected that large amount of radioactive wastes will be produced in a short period of time. The expected amount of radioactive wastes from Kori unit 1 NPP are approximately 80,000 drums (base on 200 L). By minimizing the amount of radioactive wastes generated through decontamination and reduction, KHNP has set the final target for the amount of radioactive wastes to be delivered to the disposal site at approximately 14,500 drums. Here, plasma torch melting technology is an essential technology for radioactive wastes treatment during nuclear power plants decommissioning and operation, because of its large volume reduction effects and the diversity of disposable wastes. KEPCO KPS was able to secure experience in operating Plasma Torch Melter (PTM) by conducting a research service for ‘development of plasma torch melting system advancement technology’ at KHNP-CRI. This study will compare kilo and Mega-Watt class PTM, largely categorized into facility configurations, operating parameters, and waste treatment. Based on this study, it would be desirable to operate PTM with approximate capacity according to the frequency and amount of waste production, and suggest volume for a kilo and Mega-watt class plasma torch in the melting furnace respectively. This plays to its strengths for both a kilo and Mega-watt class PTM.

A disposal of radioactive wastes is one of the urgent issues in worldwide. Considering upcoming plans for decommissioning of nuclear power plants, this problem is unavoidable and should be discussed very thoughtfully before long. There are variety of methods to deal with radioactive wastes, including Incineration process, conventional gasification process and plasma gasification process and so on. Among them, plasma gasification process is in the limelight due to its ecofriendly features and very large volume reduction effects. So, lots of countries like Japan, Taiwan, Russia, Bulgaria are already utilizing commercial plasma melting facilities and researching their own characteristics & disposal abilities and so on. Within the scope of this paper, I would like to introduce other countries current status of plasma melting facilities, and reach the conclusion on the directions to go for realistic radioactive wastes treatment.

Various radioactive metal wastes are generated during operation and decommissioning of nuclear facilities. Radioactive metal wastes with complex geometries or volumetric contamination can be difficult to decontaminate and disposal costs may increase. To solve these problems, the radioactive metal wastes can be treated by melting method. In this study, we designed a melting furnace system of air induction melting type, which is widely utilized due to its advantages of good thermal efficiency, uniform heating and guaranteed safety for radioactive material. By utilizing the melting furnace system, volatile radionuclides existed in the base material can be captured in the form of gas or dust by the filter. The radionuclides whose chemical properties can easily form metal oxides present as slag. For this reason, the specific radioactivity of the base material can be reduced. Radionuclides that are difficult to transport to slag and dust are uniformly distributed in the base material. A dedicated power supply and a transformer were necessary to be included in the melting furnace system since the induction furnace uses high-frequency currents. In addition, a hood is placed on top of the furnace to capture fumes generated during melting, and additional hoods were installed around the furnace to remove airborne dust. In particular, a dust collection unit consisting of a cyclone and a HEPA filter were constructed to effectively collect dust containing radionuclides. During the melting process, the slag is removed and accumulated separately, and the ingot production system was designed to produce the ingot using molten metal. The furnace was constructed for tilting the molten metal by moving the furnace using hydraulic system. The water cooling system and cooling tower were prepared to cool off the equipment with high temperature during melting is cooled off. The above process was specified in the operating procedure developed for this melting furnace system, and the operator shall operate and inspect according to the prescribed procedures. The radioactivity concentration in the sample taken in the step of tilting shall be analyzed whether they meet clearance level for self-disposal determined and publicly announced by the Commission. We can conduct self-disposal for the product of melting furnace system confirmed by the Commission as having the radioactivity concentration by nuclide not exceeding the value determined by the Commission.

Plasma torch melting technology has been considered as a promising technology for treating or reducing the radioactive waste generated by nuclear power plants. In 2006, IAEA announced that the technology is able to treated regardless of the type of target wastes. Because of the advantage, many countries have been funding, researching and developing the treatment technology. In this study, oversea plasma torch melting facilities for radioactive wastes treatment are reviewed. Also, plasma torch melting facility developed by KHNP CRI is briefly introduced.

Republic of Korea is preparing to decommission Kori Unit 1 and Wolsong Unit 1. Decommissioning of a nuclear power plant proceeds in the following stages: shutdown, transition period, decontamination, cutting, waste treatment, and site restoration. When nuclear power plant is decommissioned, It is expected that approximately 80,000 drums of radioactive waste will be generated per nuclear power plant. Therefore, various technologies are being researched and developed to reduce this to approximately 14,500 drums. Technologies for waste volume reduction are largely mechanical and electrical/thermal methods. Representative examples of mechanical volume reduction technologies include super compactors and electrical/thermal volume reduction technologies include induction and plasma torch furnaces. Both technologies are effective reduction technologies, but the reduction ratio varies depending on the type or condition of waste before treatment. For example, as a result of testing waste reduction using a super compactor at NUKEM in Germany, the reduction ratio was found to be between 1.3 and 7 depending on the type or condition of waste such as chips, ash, scrap metal, sand, etc. And according to IAEA-TECDOC-1527, when reducing the volume of metals, aluminum, lead, copper, brass, etc. using induction melting, the waste volume reduction ratio is 5 to 20. In this paper, referring to these results, a melting test was conducted using a previously developed plasma torch with an output of more than 100 kW. And volume reduction characteristics of this plasma torch was considered depending on waste type or condition.

An irradiation hardening of Inconel 718 produced by selective laser melting (SLM) was studied based on the microstructural observation and mechanical behavior. Ion irradiation for emulating neutron irradiation has been proposed owing to advantages such as low radiation emission and short experimental periods. To prevent softening caused by the dissolution of ' and '' precipitates due to irradiation, only solution annealing (SA) was performed. SLM SA Inconel 718 specimen was ion irradiated to demonstrate the difference in microstructure and mechanical properties between the irradiated and non-irradiated specimens. After exposing specimens to Fe3+ ions irradiation up to 100 dpa (displacement per atom) at an ambient temperature, the hardness of irradiated specimens was measured by nanoindentation as a function of depth. The depth distribution profile of Fe3+ and dpa were calculated by the Monte Carlo SRIM (Stopping and Range of Ions in Matter)-2013 code under the assumption of the displacement threshold energy of 40 eV. A transmission electron microscope was utilized to observe the formation of irradiation defects such as dislocation loops. This study reveals that the Frank partial dislocation loops induce irradiation hardening of SLM SA Inconel 718 specimens.

Normally, non-metallic wastes, such as sands, concrete and asbestos are regarded as electrically non-conductive materials. However, when the temperatures are increased up to the melting point, their electrical conductivities can be greatly improved, flowing arc current. Accordingly, these nonmetallic wastes can be efficiently treated by heating them up to the electrically conducting temperatures by using a non-transferred type plasma torch, and then, melting them completely with arc currents in transferred mode of plasma torch. For this purpose, we propose a convertible plasma torch consisting of three cylindrical electrodes (rear electrode, front electrode and exit nozzle). Compared with conventional plasma torch with two cylindrical electrodes (rear electrode and front electrode), the proposed plasma torch can provide more stable plasma jet in high powered and non-transferred mode due to the presence of exit nozzle, resulting in rapid heating of the non-conductive materials.

Nowadays, transferred type arc plasma torches have been widely present in industrial applications, in particular, using melting pool of electrically conducting materials such as arc furnace, welding and volume reduction of radioactive wastes. In these applications, the melting pools are normally employed as an anode, thus, heat flux distributions on anode melting pool need to be characterized for optimum design of melting pool system. For this purpose, we revisited the one-dimensional model of the anode boundary layer of arcs and solved governing equations numerically by using Runge-Kutta method. In addition, the direct melting process of non-combustible wastes in the crucibles were discussed with the calculation results.

In this work, we report test results for direct melting of non-combustible wastes by using a 100 kW class transferred type plasma torch. For this purpose, non-combustible wastes consisting of metals and sands were prepared, weighed and melted by a transferred arc in a ceramic crucible with inner diameter of 150 mm. Test results reveal that 75wt% M6 iron bolts mixed with 25wt% sands were completely melted down within 140 seconds at the plasma power level of 83.8 kW, producing melting speed of 100 kg/hr and volume reduction rate of 62.8%. In addition, for simulated wastes consisting of 77.3wt% metal chips and 22.7wt% sands, the volume reduction rate high than 88% was achieved at 50 kW plasma power. These results indicate that non-combustible wastes can be treated efficiently when directly melting them by using transferred type plasma torch.

Air conditioning facilities in nuclear power plants use pre-filters, HEPA filters, activated carbon filters, and bag filters to remove radionuclides and other harmful substances in the atmosphere. Spent filters generate more than 100 drums per year per a nuclear power plant and are stored in temporary radioactive waste storage. Plasma torch melting technology is a method that can dramatically reduce volume by burning and melting combustible, non-flammable, and mixed wastes using plasma jet heat sources of 1,600°C or higher and arc Joule heat using electric energy, which is clean energy. KHNP CRI & KPS are developing and improving waste treatment technology using MW-class plasma torch melting facilities to stably treat and reduce the volume of radioactive waste. This study aims to develop an operation process to reduce the volume of bag filter waste generated from the air conditioning system of nuclear power plants using plasma torch melting technology, and to stably treat and dispose of it. It is expected to secure stability and reduce treatment costs of regularly generated filter waste treatment, and contribute to the export of radioactive waste treatment technology by upgrading plasma torch melting technology in the future.

After the Fukushima accident, significant amount of radioactively contaminated waste has been generated with 50~250 m3/day and stored in tanks of the Fukushima Daiichi nuclear power plant site. The contaminated water is treated by various treatment facility such as KURION, SARRY, Reverse Osmosis, and ALPS to remove 62 radioactive nuclides except H-3. For the contaminated water treatment process, massive secondary wastes such as sludge, spent adsorbent, and so on as by-product are being generated by the facilities. In Japan, to treat the secondary wastes, melting technologies such as GeoMelt, In-can vitrification and Cold Crucible Induction Melting vitrification are considered as a candidate technologies. In this study, the technologies were reviewed, and the advantage and disadvantage of each technology were evaluated as the candidate technologies for treatment of the secondary wastes.

A disposal of radioactive wastes is one of the critical issues in our society. Considering upcoming plans for dismantling of nuclear power plants, this problem is inevitable and should be discussed very carefully. There are variety of methods to handle with radioactive wastes, including Incineration, conventional gasification and plasma gasification. Among them, plasma gasification process is in the limelight due to its eco-friendly & stable operation, and large volume reduction effects. However, a fatal disadvantage is that it consumes more electric power than other methods, this leaves us a question of whether this process is indeed economical. Within the scope of this paper, I would like to introduce 4 cases which plasma facilities were evaluated economically in worldwide, and reach the conclusion on the economic feasibility of plasma process.

Currently, KHNP-CRI has developed 100 kW plasma torch melting facility to reduce the amount of radioactive waste in nuclear power plant. Plasma torch melting technology uses electric arc phenomena like lightning to melt the target material at a high temperature of about 1,600°C. The technology is applicable to treatment for various types of waste such as combustible, non-combustible and mixed wastes. The volume reduction ratio by the technology is respectively expected to be about 1/60 of combustible wastes and about 1/5 for non-combustible wastes. It is important to discharge the melt without problems in the melting technology. In general, molten slag has properties such as high viscosity and quick solidification. Because of the properties, when discharging into slag container, the final product is accumulated like a mountain. To improve this problem, there is three suggestions; 1) rotation of the slag container, 2) vibration of the slag container, and 3) heating of the slag container.

By developing plasma torch melting technology in 1996, our company has developed the first generation 150 kW (’96~’02), the second generation 500 kW (’08~’12), and the third generation MW plasma torch melting facility (’14~’18), and completed facility upgrading (’20~’23). The MW plasma torch melting facility is equipped with CCTV to monitor waste input, melting, torch integrity, and melt discharge. The lens is installed inside a metal housing made of stainless steel to prevent damage caused by external impacts and high temperatures, and supplies nitrogen to prevent cooling and lens contamination. As a result of the demonstration test, as the temperature inside the melting furnace increased after starting the plasma torch, the resolution decreased along with noise in the CCTV, and facility monitoring was difficult due to high temperatures and foreign substances (fume). Based on the test results, CCTV was changed to a non-insertion type that was not directly exposed to high temperatures, and a filter (quartz) was additionally applied to monitor the melt smoothly. As a result of applying the newly manufactured CCTV to the demonstration test, smooth monitoring ability was confirmed even at normal operating temperature (above 1,500°C). Through this facility improvement, the operation convenience of the plasma torch melting facility has been secured, and it is expected that it will be able to operate stably during long-term continuous operation in the future.

Plasma melting technology is a high-temperature flame of about 1,600°C or higher generated using electrical arc phenomena such as lightning, and radioactive waste generated during the operation and dismantling of nuclear power plants is not classified according to physical characteristics. It is a technology that can meet waste disposal requirements through treatment and reduction. Plasma torch melting technology was used for volume reduction and stable treatment of HVAC filters generated from nuclear power plants HVAC (Heating Ventilation and Air Conditioning). filter was treated by placing 1 to 3 EA in a drum and injecting it into a plasma melting furnace at 1,500°C, and the facility was operated without abnormal stop. A total of 132.5 kg of filter was treated, and the high-temperature melt was normally discharged four times. It was confirmed that the plasma torch melting facility operates stably at 500 LPM of nitrogen and 370-450 A of current during filter treatment. Through this study, the possibility of plasma treatment of filters generated at nuclear power plants has been confirmed, and it is expected that stable disposal will be possible in the future.

Plasma torch melting has been considered as a promising treatment technology for radioactive waste generated by nuclear power plants. The IAEA reported in 2006, the plasma melting technology could be treated regardless of the type of radioactive wastes such as combustible, non-combustible and liquid. Also, the technology has the advantage of being an eco-friendly technology. It emits less harmful gases such as NOx, SOx, HCl and CO because it does not use fossil fuels. In KHNP CRI, the plasma torch melting system was developed as the new radioactive waste treatment technology. In this study, to evaluate the long-term integrity of the new facility, a demonstration test with concrete as a simulant was carried out for about 3 days. For the 3 days, the evaluation was conducted in view of abnormal shutdown, soundness of waste feeding device, electrode consumption, and so on.