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.

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.

During the decommissioning of a nuclear power plant, the structures must be dismantled to a disposal size. Thermal cutting methods are used to reduce metal structures to a disposal size. When metal is cut using thermal cutting methods, aerosols of 1 μm or less are generated. To protect workers from aerosols in the work environment during cutting, it is necessary to understand the characteristics of the aerosols generated during the cutting process. In this study, changes in aerosol characteristics in the working environment were observed during metal thermal cutting. The cutting was done using the plasma arc cutting method. To simulate the aerosols generated during metal cutting in the decommissioning of a nuclear power plant, a non-radioactive stainless steel plate with a thickness of 20 mm was cut. The cutting condition was set to plasma current: 80 A cutting speed: 100 mm/min. The aerosols generated during cutting were measured using a highresolution aerosol measurement device called HR-ELPI+ (Dekati®). The HR-ELPI+ is an instrument that can measure the range of aerodynamic diameter from 0.006 μm to 10 μm divided into 500 channels. Using the HR-ELPI+, the number concentration of aerosols generated during the cutting process was measured in real-time. We measured the aerosols generated during cutting at regular intervals from the beginning of cutting. The analyzed aerosol concentration increased almost 10 times, from 5.22×106 [1/cm3] at the start of cutting to 6.03×107 [1/cm3] at the end. To investigate the characteristics of the distribution, we calculated the Count Median Aerodynamic Diameter (CMAD), which showed that the overall diameter of the aerosol increased from 0.0848 μm at the start of cutting to 0.1247 μm at the end of the cutting. The calculation results were compared with the concentration by diameter over time. During the cutting process, particles with a diameter of 0.06 μm or smaller were continuously measured. In comparison, particles with a diameter of 0.2 μm or larger were found to increase in concentration after a certain time following the start of cutting. In addition, when the aerosol was measured after the cutting process had ended, particles with a diameter of 0.06 μm or less, which were measured during cutting, were hardly detected. These results show that the nucleation-sized aerosols are generated during the cutting process, which can explain the measurement of small particles at the beginning of cutting. In addition, it can be speculated that the generated aerosols undergo a process of growth by contact with the atmosphere. This study presents the results of real-time aerosol analysis during the plasma arc cutting of stainless steel. This study shows the generation of nucleation-sized particles at the beginning of the cutting process and the subsequent increase in the aerosol particle size over time at the worksite. The analysis results can characterize the size of aerosol particles that workers may inhale during the dismantling of nuclear power plants.

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.

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.

KHNP-CRI has developed small-capacity and Mega-Watt Class PTM (Plasma Torch Melter) for the purpose of reducing the volume of radioactive waste and immobilizing or solidifying radioactive materials. About 1 MW PTM is a treatment technology that operates a plasma torch and puts drumshaped waste into a melter and radioactive waste in the form of slag is discharged into a waste container. The small-capacity PTM is a treatment technology that operates a plasma torch and puts small amounts of radioactive waste by directly putting it into the melter through a waste input machine. Mega-Watt Class PTM was able to inject radioactive waste in drums, so it was disposed of without backloging. On the other hand, The small-capacity PTM put radioactive waste without a package, and the waste input was blocked. If even small-capacity PTM put radioactive waste in the form of small packages such as drums, it is expected that various types of radioactive waste can be processed for a long time. Packaging also reduces the risk of radioactive contamination.

Depending on the type of waste, DC plasma torch uses a transfer type operation for conductive waste and a non-transfer type operation for non-conductive waste. The transfer mode plasma torch can secure high throughput because the arc directly contacts the object and has high thermal efficiency. However, since the non-transfer mode does not have a higher thermal efficiency than the transfer mode, higher output is required to secure high throughput. A method of increasing the output of the plasma torch is increasing the current or extending the length of the plasma arc. However, the method of increasing the current affects the life of the electrode, and there is a limit to extending the arc length in the positive polarity plasma torch. Therefore, it is effective to design the plasma torch with reverse polarity to secure life and extend the arc length. In the reverse polarity plasma torch, the front electrode serves as the cathode, and the cathode point is not easy to control compared to the anode point, which may cause abnormal arcing and damage the plasma torch. This paper was conducted to investigate the conditions for securing the safety of these non-transferable reverse polarity plasma torch. The plasma torch is designed to have an output of 100 kW or less and to use the detachable nozzle to control the cathode point. The test showed that the shape of the nozzle prevented the cathode point moving outside of plasma torch and the excessive extension of the arc. Thanks to this, it was confirmed that plasma could be stably formed and abnormal arcing could also be prevented.

It is important that the plasma torch used in the waste treatment field has a high output to increase throughput. In order to increase the output of the plasma torch, there is a method of increasing the current or extending the length of the plasma arc. Among these methods, high power can be easily achieved simply by increasing current, but it is difficult to ensure electrode life. Therefore, it is necessary to check the appropriate current and arc length conditions to achieve high power and stable operation. In this paper, the power performance according to the arc length, current, and operation mode was confirmed in the transfer mode plasma torch. The test conditions are the distance (arc length) between the plasma torch and the external electrode was set to 5-180 mm, and the current was set to be in the range of 90-460 A. As a result of the test, it was confirmed that the reverse polarity operation had a maximum output of 159 kW depending on the arc length and current, and the positive polarity operation had a maximum output of 138 kW. Through this result, it was confirmed that the arc length had an effect on increasing the output, and that the reverse polarity operation had a longer arc than the positive polarity operation.

DC plasma torch is reported as a technology that can be treated regardless of waste types because it can select transfer or non-transfer operation modes depending on the electrical conductivity of waste. Thanks to this characteristic, countries that operate nuclear power plants such as Switzerland, Japan, and Taiwan have developed high-power DC plasma torch to dispose of radioactive waste. And also in korea, a plasma torch is being developed to dispose of radioactive waste. This study was conducted to investigate the characteristics of the reverse polarity plasma torch according to the conditions of interelectrodes. The inter-electrodes of plasma torch used in the study was designed to be 25, 37 mm in diameter and 180 to 400 mm in length. As a result of the test, it was confirmed that the smaller the diameter and the longer the length of the inter-electrode, the more advantageous it was to achieve a high output power. And it was confirmed that the power torch would be 500 kW when the diameter of the inter-electrode was 25 mm, the length was 400 mm, and the current was 500 A.

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.

In KHNP CRI, the PTMs (plasma torch melting system) was developed as a treatment technology of a wide variety of radioactive wastes generated by nuclear power plants. The facility is made of melting zone, thermal decomposition zone, melt discharge zone, waste feeding device, MMI, and offgas treatment system. In this study, demonstration test was conducted using NaOH solution as liquid waste to evaluation the applicability of the PTM system. For demonstration test of NaOH solution treatment, the plasma melting zone is sufficiently pre-heated by the plasma torch for 5 hours. The temperature inside the plasma melting zone is about 1,600°C. The NaOH solution as simulant was put into the thermal decomposition zone by the spray feeding device with the throughput of maximum 30 liter/hour. During the test, the power of plasma torch is about 100 kW on the transferred mode. The 160 liters of liquid waste was treated for 500 minutes. After the demonstration test, the final product in the form of salt was remained in the melting zone, and the disposal of the final product are still under consideration.