Decommissioning waste is generated with various types and large quantities within a short period. Concrete, a significant building material for nuclear facilities, is one of the largest decommissioning wastes, which is mixed with aggregate, sand, and cement with water by the relevant mixing ratio. Recently, the proposed treatment method for volume reduction of radioactive concrete waste was proven up to scale-up testing using unit equipment, which involved sequentially thermomechanical and chemical treatment. According to studies, the aggregate as non-radioactive material is separated from cement components with contaminated radionuclides as less than clearance criteria, so the volume of radioactive concrete waste is decreased effectively. However, some supplementation points were presented to commercialize the process. Hence, the process requires efficiency as possible to minimize the interface parts, either by integration or rearranging the equipment. In this study, feasibility testing was performed using integrated heating and grinding equipment, to supplement the possible issue of generated powder and dust during the process. Previously, heat treatment and grinding devices were configured separately for pilot-scale testing. But some problems such as leakage and pipe blockage occurred during the transportation of generated fine powder, which caused difficulties in maintaining the equipment. For that reason, we studied to reduce the interface between the equipment by integrating and rearranging the equipment. To evaluate the thermal grinding performance, the fraction of coarse and concrete fines based on 1mm particle size was measured, and the amount of residual cement in each part was analyzed by wet analysis using 4M hydrochloric acid. The result was compared with previous studies and the thermomechanical equipment could be selected to enhance the process. Therefore, it is expected that the equipment for commercialization could be optimized and composed the process compactly by this study.

When decommissioning and operating nuclear power plants, a lot of radioactive waste in concentrated waste powder, slurry, sludge, and powder is generated. The radioactive waste, non-conformity for disposal, cannot be treated or disposed of, but is currently being stored instead. To dispose of the waste, the waste can be solidified by mixing with an appropriate solidification agent. However, when the solidification agent and powder particles are mixed as in the conventional method, the final volume of the waste form to be disposed of increases. In order to solve this problem, in this study, volume reduction was achieved, compared to the existing powder, by applying the roll compaction technology to mold the radioactive waste into compressed pellets. Soil, concrete, concentrate waste, and contaminated soil powder were used as test materials, and pellets were prepared under different operating conditions. Subsequently, a compressive strength test was performed to confirm the integrity and optimal process conditions of the manufactured pellets. However, in order to perform the compressive strength test, the upper and lower surfaces of the pellets must be horizontal, but the pellet has the shape of two tetrahedrons joined together. Hence, test specimens for measuring compressive strength were prepared by making a surface treatment jig. The compressive strength test showed a high strength of 5.20~28.20 MPa. The process conditions showing high compressive strengths were selected as the optimal process conditions. Finally, the volume reduction ratios were calculated by measuring the weight, density and volume of the manufactured pellets. The degrees of volume reduction of the manufactured pellets compared to the existing powder were checked. When the roll gap was 0 mm, the average reduction ratios of the test materials were 3.7 for the soil, 4.0 for the concrete, 4.6 for the concentrate waste, and 3.8 for the contaminated soil. When roll gap was 1 mm, the ratios were 2.7 for the soil, 2.9 for the concrete, 3.4 for the concentrate waste, and 2.8 for the contaminated soil. Therefore, from a conservative point of view (Roll gap = 1 mm), when powdered waste is formed into pellets, it means that the volume is reduced by 1/2.7 for soil, 1/2.9 for concrete, 1/3.4 for concentrated waste, and 1/2.8 for contaminated soil.

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.

Radioactive waste generated in large quantities from NPP decommissioning has various physicochemical and radiological characteristics, and therefore treatment technologies suitable for those characteristics should be developed. Radioactively contaminated concrete waste is one of major decommissioning wastes. The disposal cost of radioactive concrete waste is considerable portion for the total budget of NPP decommissioning. In this study, we developed an integrated technology with thermomechanical and chemical methods for volume reduction of concrete waste and stabilization of secondary waste. The unit devices for the treatment process were also studied at bench-scale tests. The volume of radioactive concrete waste was effectively reduced by separating clean aggregate from the concrete. The separated aggregate satisfied the clearance criteria in the test using radionuclides. The treatment of secondary waste from the chemical separation step was optimally designed, and the stabilization method was found for the waste form to meet the final disposal criteria in the repository site. The final volume reduction rates of 56.4~75.4% were possible according to the application scenario of our processes under simulated conditions. The commercial-scale system designs for the thermomechanical and chemical processes were completed. Also, it was found that the disposal cost for the contaminated concrete waste at domestic NPP could be reduced by more than 20 billion won per each unit. Therefore, it is expected that the application of this technology will improve the utilization of the radioactive waste disposal space and significantly reduce the waste disposal cost.

Decommissioning waste is generated at all stages during the decommissioning of nuclear facilities, and various types of radioactive waste are generated in large quantities within a short period. Concrete is a major building material for nuclear facilities. It is mixed with aggregate, sand, and cement with water by the relevant mixing ratio and dried for a certain period. Currently, the proposed treatment method for volume reduction of radioactive concrete waste was involved thermomechanical and chemical treatment sequentially. The aggregate as non-radioactive materials is separated from cement components as contaminated sources of radionuclides. However, to commercialize the process established in the laboratory, it is necessary to evaluate the scale-up potential by using the unit equipment. In this study, bench-scale testing was performed to evaluate the scale-up properties of the thermomechanical and chemical treatment process, which consisted of three stages (1: Thermomechanical treatment, 2: Chemical treatment, 3: Wastewater treatment). In the first stage, lab, bench, and pilot scale thermomechanical tests were performed to evaluate the treated coarse aggregate and fines. In the second stage, the fine particles generated by the thermomechanical treatment process, were chemically treated using dissolution equipment, after then the removal efficiency and residual of cement in the small aggregate was compared with laboratory results. The final stage, the secondary wastewater containing contaminant nuclides was treated, and the contaminant nuclides could be removed by chemical precipitation method in the scale-up reactors. Furthermore, an additional study was required on the solid-liquid separation, which connected each part of the equipment. It was conducted to optimize the separation method for the characteristics of the particles to be separated and the purpose of separation. Therefore, it is expected that the basic engineering data for commercialization was collected by this study.