ML19262C634
| ML19262C634 | |
| Person / Time | |
|---|---|
| Site: | 07001113 |
| Issue date: | 12/27/1979 |
| From: | Kaplan A GENERAL ELECTRIC CO. |
| To: | |
| References | |
| 15051, NUDOCS 8002150170 | |
| Download: ML19262C634 (21) | |
Text
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GEN ER AL h ELECTRIC NUCLEAR ENERGY PRODUCTS DIVISION WILMINGTON MANUFACWRING DEPA N E W CASTLE HAYNE ROAD e P. O. 80X 780 WILMINGTON. N. C. 22401 (919) 343-5000 December 27, 1979 Director Office of Nuclear Material Safety & Safeguards U.
S.
Nuclear Regulatory Commission Washington, D. C.
20555 Attention:
.'Ir.
W. T.
Crow, Section Leader Uranium Process Licensing Section M/S 396-SS Gentlemen:
Reference:
NRC License SNM-1097, Docket #70-1113 Subj ect :
Application Amendment N-4/S-15 deplacement Incinerator Facility With reference to activities authorized by SNM-1097, General Electric Company hereby applies for authorization to replace the original incinerator f acility previously approved by the NRC on May 14, 1971, with a new facility.
In January 1978, an explosion occurred in the shredder section of the existing i nc in erato r, causing the shutdown of the facility.
Investigation of the incident resulted in a decision not to repair the existing equipment, but to design a new incinerator incorporating new, improved operational and safety features.
The information supporting the requested authorization is contained in the attachment to this letter.
As the plans for the proposed new incinerator facility are developed, additional pages and page revisions for the license renewal application dated 12/19/75 (as amended 3/3/76 and 10/6/78) and proposed revisions to license conditions in Appendix A to SNM-1097 pertaining to this request will be submitted.
Present plans call for startup of the new incinerator facility in April 1981.
Pursuant to 10 CFR 170.31, enclosed is General Electric check
- 852045 in the amount of $41,500 for processing this amendment.
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G E N E R A L (@ F LE CTRIC Director December 27, 1979 Page 2 General Electric Company personnel would be pleased to discuss this matter with you and members of your staff as you may deem necessary.
Very truly yours, GENERAL ELECTRIC COMPANY Arthur L.
- Kaplan,
'!anager Licensing & Compliance Audits M/C J26 ALK:bmw Attachment NSD-L + CMV e
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GENER AL @ ELECTRIC Director December 27, 1979 Attachment - Page 1 INFORMATION SUPPORTING REQUESTED AUTHORIZATION 1.0 INITODUCTION In connection with the manuf acturing of nuclear fuel at the Wilmington plant, a quantity of combustible waste contaminated with uranium is generated.
Approximate quantities of combustible waste generated are as follows:
Number of waste boxes, each 60 cubic feet (1.7 cubic meters) in volume 400 Volume, total 24,000 cubic feet (1,020 cubic meters)
Net weight per box (average) 1,000 lbs (450 kgs)
Total 400,000 lbs (180,000 kgs)
Net UO2 content per box (average) 25 lbs (11.3 kgs)
Total 10,000 lbs (4,500 kgs)
Net U content, total 4,000 kgs U Net U-235 content, total 1,000 kgs U-235 In May 1971, the AEC authorized General E]ectric to incinerate combustible waste at its fuel fabrication plant in Wilmington, North Carolina.
The incinerator operated satisfactorily until January 1978, when an explosion in the shredder section occurred.
The facility was shut down and, following an extensive investigation into the cause for the incident, we decided not to repair and restart the existing facility.
Instead, a new incinerator would be designed and built incorporating new, improved operation and saf ety f eatures.
Information related to the proposed new incinerator facility is presented in this attachment.
Director December 27, 1979 Attac hmen t - Page 2 2.0 FACILITY DESCRIPTION The following are some of the design criteria provided to the architect engineer for consideration in developing a design for the proposed incinerator facility.
A diagram of the proposed incinerator facility is shown in Figure 1.
2.1 Design Criteria, Incinerator
- 1) Combustible solid waste will be incinerated "as is" within 4' x4' x4' wooden boxes.
- 2) Boxes will be queued ahead of the incinerator for release on a batch-burn basis.
- 3) Maximum input batch to the incinerator shall be 1,000 gms U-235 (equivalent to 10 boxes at 100 gms U-235 per box).
- 4) The incinerator hold-up at any time cannot exceed 1,000 gms U-235 (input U-235 in boxes /ou t pu t as ash),
If this limit reaches 1,000 gms U-235, the incinerator.must be shut down and cleaned out.
- 5) The incinerator must be equipped for burning oils which is stored in 5-gallon pails.
- 6) The front end feeder must be capable of stoking one (1) 4' cube box into the combustion chamber at a t im e.
- 7) The front end loader of the incinerator must be equipped with a hydraulic pusher ram with 900 off-set sliding guillotine loading door.
- 8) The incinerator capacity operating at (first year) 3-shifts, 5 days per week, must be capable of incinerating within a one year time frame 2,500 boxes (1,000 boxes backlog plus 600 generated).
- 9) The operating mode for the first year:
a) Burn 10 boxes in two shifts b) Cool down and clean out the ash on the third shift.
- 10) The incinerator shall be a dual stage unit ( snokeless type) guaranteed to meet EPA stack emission criteria of.08 grains per standard dry cubic feet of gas corrected for 12% CO2
- 11) The incinerator should be nomirally rated for 1,500 lbs per hour, type (1) waste at 6,500 Btu per lb per hour.
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- 12) The incinerator shall be equipped with an external heat recovery shroud and the external heat loss shall not exceed 7% of the rates heat capacity of the incinerator, estimated at 9.6 x 106 x 7% = 670,000 Btu /hr.
- 13) The incinerator shall be equipped with:
a) Dual hearth with internal hydraulic ash mover b) Brick-lined hearth c) Modulating combustion air and fuel d) Steam injection e) Manifold air distribution to secondary chamber f) High temperature case in-place refractory liner rated at 2,5000 F.
The liner must be attached to the shell with stack-fas mastic and 304 stainless steel anchors.
g) Shell casing shall be 3/8" thick, hot rolled steel.
h) Modular control panel i) All gas and electric components meeting Factory Mutual approval j) Reinforced, hinged rear end door with quick opening clamps to f acilitate ash clean out
- 14) Flue duct stack section shall be five feet in length, lined with three inches of 50 lbs per cubic feet density, 2,0000 F castable refractory.
2.2 Design Criteria - Flue Gas Scrubber System
- 1) The system must be capable of meeting a stack discharge concentration limit for uranium of 3 x 10-12 uCi/ml.
- 2) Must be capable of handling 2,0000 F corrosive flue gas at the conditions and volume as discharged from the incinerator.
- 3) Must have draft controls (automatic with manual override) so as to maintain the incinerator flue duct pressure within a range of 0.15-0.50 inches W.
G.
negative.
- 4) Wet off-gas scrubbing system must be constructed of materials which will best withstand the corrosive effect of HC1, HF and HNO3 in the aqueous phase.
Caustic addition using potassium hydroxide coupled with close pH range control is an acceptable approach to corrosion control.
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Director December 27, 1979 A t tac hmen t - Page 5
- 5) Medium efficiency Venturi scrubbers should be considered in view of demonstrated scrubbing efficiency on other incinerator / scrubber systems.
- 6) Pumps should be low rpm (1,750 maximum) and Teflon-lined.
- 7) Spray bars should be easily removable for cleanout on a daily basis.
- 8) Level controls should be external to the vessel non-contact slide arm-type, where possible.
- 9) All vessels and piping should be designed for minimum solids hold-up.
- 10) Scrub water filters should be 99"o efficient for particulate
<5 microns.
- 11) The final of f-gas scrubber (packed-bed type) must be capable of reducing the hcl concentration in the off-gas effluent to 25-ppm.
- 12) The centrifugal exhaust fan must be heavy duty, industrial type Class 1, capable of handling actual flue gas volume x 150?o at 20" W. G.
negative.
- 13) In case of power failure, plant potable water must be fed automatically to the wet scrubber train.
Backflow preventors must be installed on this line.
- 14) The discharge stack is to be constructed of PVC and is to be equipped with a continuous air sampling monitor.
2.3 Design Criteria - Ash Collection System
- 1) The ash collection system must be capable of vacuum
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removing hot ash f rom the incinerator combust ion chamber using a siphon wand.
- 2) Data:
a) Ash generated per burn batch 35-40 kgs b) Ash temperature 4000 F maximum c) Particulate size 300 mesh to 13" diameter d) Bulk weight, esthnated 80 lbs/ft3 e) Specific weight 130 lbs/ft3 f) Cleanout t ime 30 minutes g) Material Very abrasive e
Director December 27, 1979 Attachment - Page 6
- 3) Vacuum data - preliminary:
a) Hose size 13" diameter b) Hose length 25 feet c) Maximum air volume 150 CFM d) Press drop 9.8" Hg e) Recommended vel.
3,200 ft/ min
- 4) The cyclone separator unit shall be sized so as to maintain a linear velocity 5 ft/ min through micrometallic filters.
Ash discharge from the cyclone separator will be through two interconnected GEMCO valves into a 5-gallon bucket.
' be controlled
- 5) Ash collection in the 5-gallon bucket wil.
at 25 kgs using a Toledo platform scale with trip set control of the GEMCO discharge valves.
- 6) The bucket load station will be totally enclosed within a glove box and vented through an absolute filter.
- 7) The exhauster for the vacuum system will; be multi-stage centrifugal exhauster (Hof fman) or equal, belt-driven at 3,500-rpm with a 480V, 60 HZ motor.
- 8) The exhauster discharge will be vented to the intake side of the wet Venturi scrubber.
- 9) Ash will be conveyed by mechanical lift to a bucket dump station (GE design) and fed directly to a mill for grinding.
- 10) The mill shall be a DM-10 SWECO vibromill (150 kg capacity).
Discharge from the mill will be to a 5-gallon pail, and ash addition shall be controlled by a Toledo platform scale equipped with trip set controls.
2.4 Design Criteria - Facility
- 1) 100"o fireproof structure equipped with a sprinkler system
- 2) Must have explosion blow-out panels
- 3) Must have change rooms, toilets / showers for both sexes
- 4) Interior of the building should have smooth finish where possible for easy hose-down to floor sumps.
- 5) The entire facility will be treated as a controlled area and operated at negative pressure.
Director December 27, 1979 Attachment - Page 7
- 7) Transport of boxes by forklif t truck within the building should be eliminated.
- 8) Emergency power must be provided to operate the incinerator during a power outage.
- 9) Routine operations must be performed without use of respiratory protection devices by operators.
- 10) Continuous monitoring of uranium concentrations in room air and stack discharge must be provided.
- 11) All requirements for contamination control related to operation of a controlled area must be met (e.g.,
change room, shower f acility, step-off pads, etc.).
- 12) Emergency power must be provided for safe operation or shutdown in the event of a power outage.
Without emergency power, there would be a potential for in'cinerator blow-back and for an uncontrolled (i.e.,
unmeasured) release from the stack in case of a power outage.
- 13) Interlocks must be provided to assure safe startup and shutdown.
9
Director December 27, 1979 Attachment - Page 8 3.0 PROCESS DESCRIPTION The proposed incinerator facility has been designed for the incineration of contaminated combustible waste generated at the Wilmington nuclear fuel plant, according to the design criteria described in Section 2.0.
The process is divided into three systems:
incineration, scrubbing and ash collection.
Figure 2 shows a conceptual schematic of the proposed process flow for this incinerator facility, while figure 3 shous the details of the proposed process flow.
3.1 Incineration The contaminated waste incinerator will have a nominal rating of 1,500 lbs/hr of type 1 waste (paper, wood plastics, etc.,
no organics).
The boxes of combustible waste will be delivered f rom storage by forklift and placed on a gravity roller conveyor.
From the gravity roller conveyor, the crates will be transferred to a powered conveyor and conveyed to the incinerator via a single ram feeder.
A pumping station will be installed for burning contaminated waste. oils from 5-gallon pails.
The incinerator will be fired with natural gas or propane from the existing storage facilities.
Exhaust from the incinerator will be passed through a refractory-lined pipe to the scrubbing section of the facility.
3.2 Scrubbing Incinerator flue gas will pass through a refractory-lined Hastelloy "C" gas quencher where the temperature will be reduced from 2,0000 F to 3000 F.
Quenched gas is passed through a Hastelloy "C" adjustable-throat Venturi scrubber for part iculate matter removal.
From the Venturi, the gas stream will enter a packed scrubber where it will be scrubbed with a potassium hydroxide solution (pH 7.0).
The scrubber will ce constructed of a fire retardant FRP with polypropylene packing.
The scrubbing NH F and HNO3; efficiency will be 99.5% of the entering hcl, 4
the discharge f rom the scrubber will be passed through a mist separator, heated to 2000 F and discharged through the stack.
Stack emissions level will be continuously monitored to measure activity levels in the gaseous effluent.
Plant water will be used for emergency quenching if re-circulating water flow has been interrupted.
A diesel powered emergency generator and a compressor will also be installed to ensure continuity of all critical process equipment.
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director December 27, 1979 At tac hment - Page 11 3.3 Ash Collection The incinerator will be shut down once per day for ash removal.
The ash will be vacuumed and passed through a cyclone separator fitted with micrometallic filter elements to remove fines.
The discharge ash from the cyclone separator will be transferred to 5-gallon buckets and ground in a SWECO vibromill.
The ash from the vibromill is discharged to 5-gallon buckets, the uranium content is assayed, and accountability weighed.
The buckets are then transferred to pad storage pending offsite recovery of the uranium.
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irector December 27, 1979 A t t ac hmen t - Page 12 4.0 CRITICALITY SAFETY Various components of the proposed incinerator facility cannot be designed to be geometrically safe.
Therefore, criticality saf ety will depend upon a number of administrative controls related to a continual measured U-235 material balance throughout the facility, including scanning of waste boxes fed into the incinerator and nondestructive assay of U-235 content in the ash.
Detailed criticality safety analyses are ongoing, as facility and equipment designs are being finalized.
As these analyses are completed, we will submit them to the NRC for review.
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9
Birector December 27, 1979 Attachment - page 13 5.0 RADIOLOGICAL SAFETY Section 3.0 of the liceroe.eaewal application contains a descript ion of radia tion protection facilities and equipment in use at General Electric 's Wilmington plant.
Section 4.0 contains a description of radiation protection procedures.
Section 6.0 describes the plant operating history related to occupational radiation exposures *o workers, including exposures to airborne uranium and to wholebody gamma radiation.
The activities described in these sections are carried out in accordance with the administrative and technical require-ments in Section 6.0 of Appendix A (to SNM-1097), " Nuclear (Criticality and Radiation) Safety License Conditions for the Wilmington Site."
There are no expected significant changes in radio'ogical safety practices or conditions associated with operation of the proposed incinerator facility.
A detailed demonstration supporting this statement is currently being prepared and will be submitted to the NRC for review.
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Director December 27, 1979 A t tac hmen t - Page 14 6.0 ENVIRONMENTAL EFFECTS 6.1 General The emissions generated by operation of the incinerator are subj ec t to various local, state and federal environmental protection regulations.
General Electric will obtain all of the necessary permits and licenses prior to startup of the incinerator facility.
6.2 Air Emission Quantities Estimated quantities of different materials in air emissions f rom the propc sed incinerator f acility are shown in Table 1.
These quantities are well within limits set by state and federal agencies for such discharges.
Table 1 Air Emission Quantities Emission Quantity, ' tax imum Uranium 3 x 10-12 uCi/ml at the stack hcl 50 lbs/hr NH F 120 lbs/hr 4
HNO3 70 lbs/hr 6.3 Liquid Waste Quantitative estimates of liquid waste generation are shown in Table 2.
Table 2 Wastewater Sources Source Name Quant'ity Cooling water blowdown 10 gal / min Waste heat boiler blowdown 1 gal / min Scrubbing liquid waste 1 gal / min Sanitary wastewater 15 gal / min
Director December 27, 1970 A t t ac hmen t - Page 15 Scrubber waste liquid will be stored in a 1,000 gallon storage tank in the incinerator facility.
Liquids with a uranium content low enough to meet action level limits set for disposal of liquid radwaste will be drained to the existing liquid radwaste disposal system.
Liquid with uranium levels in excess of these limits will be transferred to the liquid waste treatment system.
Cooling tower and waste heat boiler blowdown will be drained to the industrial sewer system.
Sanitary waste will be drained to the existing sanitary sewer.
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Director December 27, 1919 A t tac hment - Page 16 7.0 SAFEGUARDS Safeguarding of special nuclear material at the Wilmington plant is accomplished in accordance with the NRC regulatory requirements of 10 CFR 70 and the amendment MPP-2 to NRC License SNM-1097.
A description of the safeguards systems is given in the Fundamental Nuclear Material Control (FNMC)
Plan for the Wilmington plant.
The same system described in the FNMC Plan will be applied in the same manner to the proposed incicerator facility, as it was to the original incinerator facility prior to its shutdown in January 1978.
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birector December 27, 1979 A t tac hnent - Page 17 8.0 PIIYSICAL PROTECTION Pursuant to 10 CFR 73.47, a physical protection plan for the Wlmington plant will be submitted by March 20, 1980.
No changes to the plan will be required to accommodate the proposed incinerator f acility.
The plan will cover all existing plant areas including the one in which the proposed incinerator facility will be installed.
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61 rector December 27, 1979 A ttac hment - Page 18 9.0 DECOm!ISSIONING In accordance with Amendments 3 and 9 to License SN!!-1097, General Electric submitted a general plan for decontamination of the places of use and sites authorized by the license, so that such places and sites could be released for unrestricted use following cessation of licensed activities.
The facility and equipment planned for the proposed incinerator facility do not represent a significant enough increase in equipment and building area to warrant a change at this time in the general decontamination and decommissioning plan.
Pursuant to Amendment 9, the NRC requested that additional details of our decommissioning plans be submitted to them by July 1, 1980.
When these details are submitted, they will reflect, as necessary, the additional equipment and the additional area occupied in the fuel manufacturing building.
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Director December 27, 1979 A t tac hment - Page 19 10.0 EMERGENCY PLANNING In accordance with Amendment 8 to License SNM-1097, General Electric upgraded its emergency plan for the nuclear fuel manufacturing plant in Wilmington, North Carolina, and silbmitted the revised plan to the Nuclear Regulatory Commission on Apri' 19, 1979.
This plan covers all areas of the fuel manuf ac tur ing facility.
We believe that the present emergency plan covers the handling of the type of emergency situations that could be anticipated or considered as credible in an incinerator facility of the type being considered for the Wilmington plant.
If we find that there are any potential emergency situations associated with the proposed incinerator facility which are not covered in the present emergency plan, we will revise the plan as necessary.
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