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The Defense Waste Processing Facility (DWPF) is presently vitrifying Sludge Batch 3 (SB3) and preparing to process Sludge Batch 4 (SB4) in late 2006 or early 2007. Previous laboratory testing and DWPF operational experience has indicated that the maximum waste throughput peak for the Sludge Batch 2 (SB2) system occurs at a waste loading in the mid-30's. This trend has been shown as well for SB3 on a lab-scale basis. These SB3 tests used SRAT product that targeted a REDuction/OXidation (REDOX) of 0.2 and an acid stoichiometry of 135%. Acid stoichiometry, however, has been shown to impact melt rate of MRF tests at one waste loading (35%). Due to the impact of acid stoichiometry on melt rate, it is possible that the current target acid stoichiometry (155%) with SB3 may not exhibit the same maximum waste throughput peak, or there may not even be a discernable peak. In fact, current DWPF operational experience with SB3 and Frit 418 has not shown the same drop off in melt rate and hence waste throughput as was observed with SB2 and Frit 320. The objective of this testing is to determine if increasing the overall alkali content in the feed (via using the higher alkali Frit 320 versus Frit 418) will either result in a shift in the waste throughput to higher waste loadings or an increase in the overall waste throughput at waste loadings of interest (31 to 41%). For these tests, the target Sludge Receipt and Adjustment Tank (SRAT) product REDOX was 0.2 and the target acid stoichiometry was 155%. The incentive for this series of tests stems from a previous Slurry-Fed Melt Rate Furnace (SMRF) test with SB3/Frit 320 feed which showed an increase in melt rate versus SB3/Frit 418 at 35% waste loading. This single data point suggests that overall waste throughput for the SB3/Frit 320 system is higher at 35% waste loading (i.e., the melt rate versus waste loading curve has potentially shifted upward). To address the potential shift in waste throughput, the strategy was to fully characterize the impact of waste loading (ranging from about 30 to 40%) on melt rate for the SB3/Frit 320 and SB3/Frit 418 feed systems. This will allow for potential shifts in waste throughput to be assessed via a change in frit composition. Initially, the dry-fed Melt Rate Furnace (MRF) was utilized. Based on the MRF results, the tests had a decision point on whether or not to continue testing using the SMRF

Maximizing SB3 Waste Throughput Melt Rate Tests