Rough order of magnitude cost estimate for immobilization of 18.2 MT of plutonium sharing existing facilities at Hanford with pit disassembly {ampersand} conversion facility: alternative 2

The purpose of this Cost Estimate Report is to identify preliminary capital and operating costs for a facility to immobilize 18.2 metric tons (nominal) of plutonium as a ceramic in an existing facility at Hanford, the Fuels and Materials Examination Facility (FMEF). The Pit Disassembly and Conversion Facility (PDCF), which is being costed in a separate report will also be located in the FMEF in this co- location option. The technical engineering data used as the basis for this study is presented in the EIS Data Call Input Report, `Plutonium Immobilization Plant Using Ceramic in Existing Facilities at Hanford.` The FMEF will require minimal facility modifications to accommodate the Plutonium Immobilization Plant (PIP). Adequate space is available within the FMEF for installation of the immobilization process equipment. Facility HVAC, utility, and support systems exist to support the immobilization operations. Building modifications are primarily the removal of the SAF line (gloveboxes and support equipment) on the 70` level and building interior changes. The plutonium immobilization equipment will primarily occupy the 42` and 70` levels of the FMEF, with the same equipment layout as in the sole occupancy case. The Pit Disassembly and Conversion Facility would occupy the 21` and O` (Entry) levels. Elements of the FMEF and adjacent Fuel Assembly Area (FAA) that will be shared by PIP and PDCF include shipping and receiving, laboratory, waste handling, security, offices, maintenance shops, SNM storage vault, and utilities. It was assumed that the existing utilities and support systems are adequate or only need minor upgrades to support both the PIP and PDCF. The PIP cost estimate was reconciled with the PDCF cost estimate to confirm the use and costs of shared systems and personnel. The facility design for a 50 metric ton plutonium throughput plant will be used for the 18.2 metric ton facility. Plutonium conversion operations will operate at the same design rate as the 50 metric ton facility over the 10 year operating period. Some of the process equipment will operate for a shorter period of time and fewer operators will be required. The assumptions, missions, design bases, facility and process descriptions, and accident analyses are the same. Therefore it is assumed that the capital cost for the 18.2 metric ton facility is identical to that of the 50 metric ton facility. However, the following operating costs will be less: consumable materials, equipment replacement and maintenance labor, employment requirements, and waste generation