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

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.

An induction melting facility includes several work health and safety risks. To manage the work health and safety risks, care must be taken to identify reasonably foreseeable hazards that could give rise to risks to health and safety, to eliminate risks to health and safety so far as is reasonably practicable. If it is not reasonably practicable to eliminate risks to health and safety, attention have to be given to minimize those risks so far as is reasonably practicable by implementing risk control measures according to the hierarchy of control in regulation, to ensure the control measure is, and is maintained so that it remains, effective, and to review and as necessary revise control measures implemented to maintain, so far as is reasonably practicable, a work environment that is without risks to health or safety. The way to manage the risks associated with induction melting works is to identify hazards and find out what could cause harm from melting works, to assess risks if necessary – understand the nature of the harm that could be caused by the hazard, how serious the harm could be and the likelihood of it happening, to control risks – implement the most effective control measures that are reasonably practicable in the circumstances, and to review control measures to ensure they are working as planned.

The type of accidents associated with the operation of a melting facility for radioactive metal waste is assumed to only marginally differ from those associated with similar activities in the conventional metal casting industry or the current waste melting facility. However, the radiological consequences from a mishap or a technical failure differ widely. Three critical and at the same time possible accidents were identified: (1) activity release due to vapor explosion, (2) activity release due to ladle breakthrough, (3) consequences of failure in the hot-cell or furnace chamber not possible to remedy using remote equipment.

Carbon material shows relatively high strength at high temperature in vacuum atmosphere and can be easily removed as CO or gas in oxidation atmosphere. Using these characteristics, we have investigated the applicability of carbon mold for precision casting of high melting point metal such as nickel. Disc shape carbon mold with cylindrical pores was prepared and Ni-base super alloy (CM247LC) was used as casting material. The effects of electroless Nickel plating on wettability and cast parameters such as temperature and pressure on castability were investigated. Furthermore, the proper condition for removal of carbon mold by evaporation in oxidation atmosphere was also examined. The SEM observation of the interface between carbon mold and casting materials (CM247LC), which was infiltrated at temperature up to , revealed that there was no particular product at the interface. Carbon mold was effectively eliminated by exposure in oxygen rich atmosphere at for 3 hours and oxidation of casting materials was restrained during raising and lowering the temperature by using inert gas. It means that the carbon can be applicable to precision casting as mold material.

원자력시설의 해체 시 발생되는 금속폐기물의 양은 전 세계적으로 향후 50년 동안 스테인레스강 약 95 만톤, 탄소강 870 만 톤, 구리 220 만 톤으로 총 1,200 만 톤 정도 발생할 것으로 예측되고 있다. 해체 시 발생하는 금속 조각은 대부분 방사능에 아주 미미하게 오염되어 있기 때문에 이중에서 대부분은 무구속 방출이나 약간의 제염 처리 후 일정한 공정을 거쳐 핵 시설내의 폐기물 저장 용기나 처분 상자, 폐기물 드럼, ISO 컨테이너 등으로 재활용되고 있거나, 앞으로 재활용할 수 있다고 보고되고 있다. 국내 원자력시설 해체 시 다량으로 발생될 것으로 예상되는 금속 조각을 수용하기에는 폐기물 처리장이 매우 부족할 뿐만 아니라, 지속적으로 처분 단가의 증가가 예상되므로 이러한 문제를 해결하기 위해서 방사성 금속폐기물의 효과적인 감용 및 재활용 기술이 요구되고 있다. 금속 폐기물의 감용 및 재활용 기술 중 현재까지 가장 적절한 기술로서 용융 기술이 있다. 유럽을 주축으로 미국과 일본에서 활발히 연구되어져 온 용융 기술은 다른 처분 방법에 비해 부피 감용비가 가장 높아 최종처분시설 공간을 절약할 수 있으며 탄소강, 스테인레스강 및 인코넬 등 많은 양의 금속을 회수하는 것이 가능하다. 또한, 이 기술은 휘발성 핵종(Cs 등)이나 금속과 반응성이 적은 핵종(U, Pu 등)을 슬래그 속에 포집하여 제염하거나, 방사성 핵종들이 주괴에 균일하게 분포하고 금속의 결정 격자속에 고정화시킬 수 있기 때문에 보다 안정화시킬 수 있다는 장점들을 가지고 있다.