Efficient Recycling and Waste Management» EnBW KernkraftGmbH Jörg Klasen, Head of Nuclear Decommissioning Services with Frank Bolles, Burkhard Hartmann, Sönke Pingel 46th Annual Meeting on Nuclear Technology Berlin, 5th May 2015
Agenda 1. Introduction to treatment of residual radioactive materials and its challenges 2. Choices in residual material treatment 3. Approach to residual material treatment and waste management @ EnBW 4. Conclusion 2
1. Introduction to treatment of residual radioactive materials and its challenges 3
Effective and efficient residual material treatment significantly reduces the volume of nuclear waste Limited capacities of radioactive waste repositories in Germany require: Treatment of residual materials and recycling into conventional material cycle Radiological clearance according to German Radiation Protection Ordinance Example: dismantling of Obrigheim overall mass about 275,000 tons approx. 1 % clearance for specific purposes, delivery to disposal sites approx. 98% less than 1 % radioactive waste, interim and final storage conventional material cycle resources for reuse and residual materials for disposal 4
Residual material treatment is a key issue for the entire dismantling process Flow of residual radioactive materials (process perspective) Radiological clearance measurement Conventional material cycle Buffer storage for residual materials Residual material treatment Waste storage on-site Radioactive waste repository On-site Depending on treatment strategy Off-site 5
Treatment processes and technologies are mostly established (1/2) Radioact. waste Conditioning Radiological clearance Conventional disposal Main gate Further cutting Decontamination Residual materials 6
Treatment processes and technologies are mostly established (2/2) Example: decontamination Disassembled contaminated plant components are mainly decontaminated by three processes washing sandblasting ultrasonic bath 7
Residual material treatment faces three main types of challenges Overview Technical challenge: treatment process considerably varies depending on Type, size and shape of material Surface conditions (i.e. decontamination paint) Type of radioactivity and contamination level Presence of conventional pollutants Economic challenges Cost minimization due to limited provisions for nuclear plant decommissioning Availability of market capacity, with parallel decommissioning projects in Germany Organizational challenges No interaction between dismantling and residual material treatment Guaranteed process stability (e.g. small number of transports) 8
2. Choices in residual material treatment 9
A utility principally has four basic strategic options for residual material treatment In case of direct dismantling: with new, adapted infrastructure New on-site center In cooperation with other utilities Kind of infrastructure with existing infrastructure Integration in existing buildings (e.g. power house) With existing service providers on-site (alone or in cooperation) off-site Location of residual material treatment 10
Process profitability is mainly affected by operational costs and utilization rate Comparison of different decontamination methods Euro/kg Operational costs Capital expenditure ~ -30% Capacity scheduling # Personnel resources Mass over time Peak load Base load Selected primary method Additional investment in secondary methods to enhance operational flexibility Main focus on low specific costs, high availability and proven technology Main focus on constant workload, optimal buffer use and flexible access at peak load 11
3. Approach to residual material treatment and waste management @ EnBW 12
EnBW offers holistic on-site solutions for treatment and recycling of residual radioactive materials EnKK solution by GNR (Gesellschaft für nukleares Reststoffrecycling mbh): 2 separate plants (GKN & KKP) Additional radioactive waste storage building on-site Total mass to be treated (GKN I+II and KKP 1+2) approx. 80.000 Mg within 20a Contracting Modell with /kg-price GNR will plan, build, operate and finance treatment centers to Cut, decontaminate & clear residual materials Condition low and intermediate level waste Sell cleared materials for reuse and dispose of cleared residual materials Elevated Dose rate Low 13
EnBW sapproach offers stable long-term planning and minimize risks for the customer EnKK requirements to the infrastructure Uninterrupted mass flow during dismantling On-site availability to minimized risk in transportation Clear responsibility Stable long-term planning with locked profitable conditions Contracting-solution on a /kg On-site but outside plant area regulations Benefitting from efficiency and synergy effects Single-design approach, Modular/Adaptable internals Treatment of large components at one site Site specific extension of waste storage capacities in GKN and KKP by EnKK Aim: Bundling up all low and intermediate level radioactive waste in a single building per site Requirement: Treatment centers and waste storage facilities to be built as joint project 14
Operational flexibility for varying material types, forms, surface conditions and contamination levels is the key issue for efficient residual material treatment Overview of planned treatment areas No. Treatment area Function 1 Thermal, mechanical and manual cutting Further cutting of disassembled components 2 Large component caisson Cutting steam generators and large components 3 Cable processing, Asbestos conditioning, waste sorting, conventional pollutants Separating and sorting of various cable parts as well as mixed, special and toxic waste 4 Concrete treatment, concrete breaker Surface treatment as well as crushing concrete, filling up interspace of Konrad containers 5 Blasting decontamination Decontamination of metal surfaces 6 Wet decontamination, chemical decontamination, ultrasonic bath, box washing 7 Vaporizer, high pressure compactor, drying system, Konrad container loading, exclusion area storage Wet decontamination of metal surfaces Treatment and buffer of radioactive waste 8 Buffer storage Buffer storage and handling space Some equipment is principally redundant. However, each method is not equally efficient depending on the residual materials. Thus, additional capital expenditure is economically reasonable to enhance operational flexibility. Moreover, they add up at peak workload. 15
Long-term adaptation by modularity Dismantling mass flow changes constantly and substantially with dismantling progress: First: large metal components, easy to disassemble much further cutting effort, less decontamination (e.g. chemical decontamination), in parallel treatment of large concrete blocks Later: smaller metal objects, more difficult to disassemble and potentially higher contaminated less cutting effort, however, much more decontamination with differing effective methods Eventually: concrete parts from building decontamination EnBW s approach counts on modularity for operational adaptation to changes in mass flow: Two-nave treatment hall with separate caissons for individual process steps, partly several caissons per activity Only one fixed installation: the conditioning area with elevated dose rate, protected by barriers. Inter-site use of selected equipment in batch operation Equipment is procured after optimization by site specific needs assessment 16
GKN-site: compound planned on former cell cooler area of GKN I (1/2) Building site at GKN Company premises at GKN (outside external security area) Size: approx. 90 m x 200 m 3 building projects: Residual material treatment center (RBZ-N) (including exterior grounds and buffer areas) On-site waste storage facility (SAL-N) Joint social and infrastructure building (SIG-N) New treatment and storage compound on former cell cooler area of GKN I former cell cooler area of GKN I 17
GKN-site: compound planned on former cell cooler area of GKN I (2/2) Example: treatment and storage compound at GKN-site Building sizes: SAL: ~ 4,000 m² RBZ: ~ 5,000 m² SIG: ~ 500 m² Stack height: 60 m Preclearance area Buffer area Clearance area Material locks Layout of buildings RBZ-N, SAL-N and SIG-N with RBZ-N subsections treatment hall (RBH), clearance hall (FMH) and transition area (UEB). 18
Planning/Construction/Commissioning of new centers will take about 4 years; Time-reduction possible Time schedule Implementation phases for residual material treatment centers (total of 4 years based on free building sites) Concept and application documents (0,5 a) Detailed planning (0,5 a) Tenders and assigning construction incl. BSE 1 (0,5 a) Construction of building envelope (1,5 a) Installation of equipment (0,75 a) Commissioning (0,25 a) Possibly time reduction if choosing an existing concept Planning, construction and commissioning of on-site waste storage facilities are integrated in overall dismantling schedule 1 Building services equipment 19
4. Conclusion 20
Conclusion Residual material treatment significantly reduces the volume of nuclear waste and is essential for the dismantling process Residual material treatment processes and technologies are mostly established; however, only limited external treatment capacities exist on today s market Four strategic options for residual material treatment to be evaluated by the utility EnBW D&D-Service supports its clients to find the most suitable solution 21
Thank you for your kind attention We provide decommissioning and dismantling Effective. Efficient. Reliable. 22