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The remaining contents of Tank 51 from Sludge Batch 4 will be blended with Purex sludge from Tank 7 to constitute Sludge Batch 5 (SB5). The Savannah River Site (SRS) Liquid Waste Organization (LWO) has completed caustic addition to Tank 51 to perform low temperature Al dissolution on the H-Modified (HM) sludge material to reduce the total mass of sludge solids and Al being fed to the Defense Waste Processing Facility (DWPF). The Savannah River National Lab (SRNL) has also completed aluminum dissolution tests using a 3-L sample of Tank 51 sludge slurry through funding by DOE EM-21. This report documents assessment of downstream impacts of the aluminum dissolved sludge, which were investigated so technical issues could be identified before the start of SB5 processing. This assessment included washing the aluminum dissolved sludge to a Tank Farm projected sodium concentration and weight percent insoluble solids content and DWPF Chemical Process Cell (CPC) processing using the washed sludge. Based on the limited testing, the impact of aluminum dissolution on sludge settling is not clear. Settling was not predictable for the 3-L sample. Compared to the post aluminum dissolution sample, settling after the first wash was slower, but settling after the second wash was faster. For example, post aluminum dissolution sludge took six days to settle to 60% of the original sludge slurry height, while Wash 1 took nearly eight days, and Wash 2 only took two days. Aluminum dissolution did impact sludge rheology. A comparison between the as-received, post aluminum dissolution and washed samples indicate that the downstream materials were more viscous and the concentration of insoluble solids less than that of the starting material. This increase in viscosity may impact Tank 51 transfers to Tank 40. The impact of aluminum dissolution on DWPF CPC processing cannot be determined because acid addition for the Sludge Receipt and Adjustment Tank (SRAT) cycle was under-calculated and thus under-added. Although the sludge was rheologically thick throughout the SRAT and Slurry Mix Evaporator (SME) cycles, this may have been due to the under addition of acid. Aluminum dissolution did, however, impact analyses of the SRAT receipt material. Two methods for determining total base yielded significantly different results. The high hydroxide content and the relatively high soluble aluminum content of the washed post aluminum dissolution sludge likely contributed to this difference and the ultimate under addition of acid. It should be noted that the simulant used to provide input for the SRAT cycle was an inadequate representation of the waste in terms of acid demand, likely due to the differences in the form of aluminum and hydroxide in the simulant and actual waste. Based on the results of this task, it is recommended that: (1) Sludge settling and rheology during washing of the forthcoming Sludge Batch 5 qualification sample be monitored closely and communicated to the Tank Farm. (2) SRNL receive a sample of Tank 51 after all chemical additions have been made and prior to the final Sludge Batch 5 decant for rheological assessment. Rheology versus wt% insoluble solids will be performed to determine the maximum amount of decant prior to the Tank 51 to Tank 40 transfer. (3) As a result of the problem with measuring total base and subsequently under-calculating acid for the DWPF CPC processing of the post aluminum dissolution sludge; (4) Studies to develop understanding of how the sludge titrates (i.e., why different titration methods yield different results) should be performed. (5) Simulants that better match the properties of post aluminum dissolution sludge should be developed. (6) Work on developing an acid calculation less dependant on the total base measurement should be continued

WASHING AND DEMONSTRATION OF THE DWPF FLOWSHEET IN THE SRNL SHIELDED CELLS USING POST ALUMINUM DISSOLUTION TANK 51 SLUDGE SLURRY