ML20247R681

Supplemental Environ Impact Info Re Revitalization of Nuclear Fuel Mfg Facility

ML20247R681
Person / Time
Site:	07000036
Issue date:	03/31/1989
From:	ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY
To:
Shared Package
ML20247R655	List: LD-89-032, Provides Environ Info Supporting Startup Testing & Production Operations of Revitalized Facility,Including Encl Supplemental Environ Impact Info Re Revitalization of Nuclear Fuel Mfg Facility ML20247R681
References
25365, NUDOCS 8904100032
Download: ML20247R681 (38)

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t License No. SNM-33 Docket No. 70-36 l

SUPPLEMENTAL l

j ENVIRONMENTAL IMPACT INFORMATION RELATED TO REVITALIZATION OF THE NUCLEAR FUEL MANUFACTURING FACILITY q

l COMBUSTION ENGINEERING, INC.

HEMATITE, MISSOURI FACILITY i

March, 1989

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~8904100032 890329 FfDR ADOCK0700gg36 J

• t TABLE OF CONTENTO SECTION PAGE NO.

TABLE OF CONTENTS i

LIST OF TABLES iii LIST OF FIGURES iv

1.0 INTRODUCTION

1.1 Purpose of Report 1-1 1.2 Scope of' Report 1-1 1.3 Summary of Changes at Hematite 1-1 2.0 SITE MODIFICATIONS 2.1 Phase I - Preliminary Construction 2-1 2.2 Demolition and Decontamination 2-1 l

2.3 Phase II - New Building Construction 2-2 3.0 BUILDING USE i

3.1 Building Location and Identification 3-1 l

3.1.1 New Pellet Building 254 Description 3-1 3.1.2 New Storage / Utilities / Office Building 253 Description 3-2 3.1.3 New Warehouse Building 256 Description

,3-2 3.2 Building Utilization 3-2 3.2.1 Existing Oxide Building and Dock Utilization 3-2 3.2.2 Building 255-Existing Pellet Building l

Utilization 3-3 3.2.3 Building 254-New Pelletizing Building Utilization 3-3 3.2.4 Building 256-New Warehouse Building I

Utilization 3-4 3.2.5 Building 253-New Storage / Utilities /

Office Building Utilization 3-4 l

4.0 CHANGES TO HEMATITE PELLETIZING 4-1 4.1' Erbia - UO Pellets 4-1 2

4.2 Changes to Powder Preparation 4-1 I

5.0 SITE WATER SUPPLY, UTILIZATION AND DISCHARGE 5.1 Water Supply 5-1 5.2 Water Utilization 5-1 5.3 Water Discharge 5-1 i

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TABLE OF CONTENTS (Cont'd)

SECTION M E NQ.

6.0 RADIOLOGICAL EFFLUENTS 6.1 Radiological Waste Water Effluent 6-1 6.2 Radiological Airborne Effluent 6-1 6.3 Radiological Solid Effluent 6-2 7.0 CHANGES TO NON-RADIOLOGICAL CHEMICALS AND EFFLUENTS 7.1 Ammonia 7-1 7.2 Cranko 7-1 7.3 Trichloromethane 7-3 7.4 Ammonium Oxalate 7-2 7.5 Zinc Stearate 7-2 8.0 ENVIRONMENTAL MONITORING 8-1 9.0 DOSE COMMITMENT 9-1 10.O REFERENCES 10-1 t

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LIST OF TABLES Table No.

Pace No.

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3-1 Buildings and Facilities 3-5 i

l 4-1 Comparison of Pelletizing Process Steps 4-3 1

5-1 Water Utilization and Effluents 5-3 9-1 Population Trends 9-3 l

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I LIST OF FIGURES Ficure No.

Pace No.

2-1 Site Plan and Fenced Area 2-3 l

2-2 Existing Fenced Area and Building Layout 2-4 2-3 New Fenced Area and New Building Layout 2-5

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l 3-1 Building and Equipment Layout 3-6 1

5-1 Sanitary and Storm Drain Lines 5-4 6-1 Existing Exhaust Stack Locations 6-3 l

6-2 New Exhaust Stack Locations 6-4 i

9-1 Area Within 5 Mile Radius of Plant Site 9-4 j

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1.0 INTRODUCTION

1.1 Purpose of ReDort This report provides environmental information related to changes in the buildings and equipment at the Hematite, MO plant site of Combustion Engineering, Inc., operated under License SNM-33.

These changes are part of a revitalization program for nuclear l

fuel manufacturing facilities at both the Hematite site and at the Windsor site of C-E.

1 1.2 ScoDe of ReDort This report supplements environmental information provided

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previously in References 1, 2,

3, 4,

5 and 6.

It describes the 1

facility changes that are part of the revitalization program at Hematite and it provides information that allows an assessment of their effects on the environment.

1.3 Summary of Chances at Hematite The existing Hematite plant receives UF enriched up to 5 percent 6

in U and converts it to UO powder A recent modification to the $35 reactor will reduce c$rryover. minimize recycle and reduce material handling.

Other than this modification, the facilities and processes for conversion remain essentially unchanged in the revitalization program.

Capacity for conversion at the maximum rate is equivalent to 400 MTUO per year.

Allowing for enrichment cleanout and producti$n scheduling, the annual thru-put capacity is estimated at 300 MTUO2 per year.

Most of the UO powder produced in the existing facility is shipped as pow $er to Windsor, CT for fabrication into pellets.

The remainder is fabricated into pellets in the existing pellet line at Hematite and shipped to Windsor as pellets.

After revitalization, all C-E pellets will be fabricated at Hematite.

The existing pellet line at Hematite will remain.

It will be used for special pellet runs including pellets containing erbium as a burnable neutron absorber.

To increase p$11et production at Hematite, two existing buildings were demolished and will be replaced with three new buildings.

They include a new warehouse and shipping dock, a new storage / utilities / office building and a new pellet building.

The new pellet building contains two parallel pellet production lines.

Existing pelletizing processes in use at Hematite and/or Windsor are the primary bases for the new lines.

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objective for the new buildings and pelletizing equipment'is to j

increase pellet production with'no significant increase in the existing rates of effluent release.

Improvements that will reduce the potential for adverse environmental impact include the containment of traffic within the buildings and the enclosure of the UF vaporization area.

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2.0 SITE MODIFICATIONS Site modifications are divided into two sequential phases of construction.

The sequencing allows routine oxide and pellet production to proceed while new construction is underway in a separated, bounded area.

2.1 Phase I - Preliminary Construction The Hematite site comprises about 154 acres after addition in 1983 of about 1-1/2 acres on the north-east boundary.

Approximately 4-1/2 acres in the center of the site are enclosed by a security fence.

All production activities take place within the fenced area.

In Phase I of the revitalization program at l

Hematite, new fence increases the castern half of the existing fenced area by about 1-1/2 acres and a new warehouse and shipping dock is constructed.

I Figure 2-1 shows the existing and increased fenced area located on the overall site plan.

Figure 2-2 shows the building layout within the existing fenced area.

Figure 2-3 shows the new fenced area and the now building layout after both Phase I and Phase II l

are completed.

The revitalization program does not include any l

site changes outside the new fenced area (except for the addition j

of a water hydrant connected to city water).

l The increased fenced area serves two purposes.

First, on the l

north and east it provides clear area roadway access and maneurcring for trucks to the new warehouse building, improving security and the control of contamination.

Second, it provides additional space south of existing buildings for traffic and for temporary storage during Phase II construction.

2.2 Demolition and Decontamination All Phase II construction activities take place in the area between existing buildf.ngs 240 and 255 where a clean construction area was established.

The area was restricted on the south by a temporary' fence between buildings 240 and 255 and on the north by the main site: gates (see Figure 2-3).

Following Phase I, buildings 250 and 251 located there were decontaminated in accordance with SNM-33 License Condition #14 and radiological surveys were made (Reference 7).

After the buildings were released for unrestricted use (Reference 8) they were demolished except for two clean portions of building 251 that contain the pump house and the boiler facility.

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The new pellet building 254 will be constructed before building 253.

In preparation for excavation, construction workers received health physics training because of the potential soil contamination.

Soil sampling was performed before and during the building excavation (Reference 9).

An independent audit was performed by Oak Ridge Associated Universities and the building 254 area wa. released by the NRC (Reference 10).

As of this writing the ponting of the concrete floor slab is in progress.

During the excavation, a storm drain under building 254 was removed, decontaminated and replaced with new drain pipe.

$nother similar drain existing under the location of new building 253 will also be replaced.

Soil sampling and decontamination for construction of building 253 will be similar to that completed for building 254.

2.3 Phas_e.II - New Buildina Construction

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l Phase II of the revitalization program comprises construction of j

new buildings 253, 254 and the extension of the new warehouse f

building 256 begun in Phase I (See Figure 2-3).

It also includes i

the installation and startup of the two new pelletizing lines.

The new buildings and their utilization are described in 3

l Section 3.

After revitalization is completed, the six major plant buildings adjoin one-another.

Routine traffic among the buildings is contained within the buildings, eliminating the outside l

controlled area and the potential for tracking contamination between buildings, l

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l 3.0 BUILDING USE 3.1 Duildino Location and Identification This section describes the changes and additions to the existing buildings under the revitalization program.

Buildings described in license SNM-33 in 1988 are referred to as existing buildings, even though the physical changes described herein may already be underway prior to submittal of this document.

Figure 2-2 shows the layout of the existing buildings on the plant site and Figure i

2-3 shows the building layout after the revitalization.

Existing buildings 250 and 251 were decontaminated, demolished i

and removed from the site except for pump and boiler facilities l

in building 250.

These facilities will be incorporated into a new building.

Two new buildings, the pelletizing building numbered 254 and the storage / utilities / office building 253 fill the cleared space between the existing pellet building 255 and the existing recycle and recovery building 240.

A new warehouse building 256 adjoins the south end of these buildings.

3.1.1 New Pellet Buildina 254 Description The new pelletizing building 254 is surrounded on three sides.

It adjoins the existing pelletizing building 255 on the east I

side, the new storage / utilities / office building 253 on the west l

side and the new warehouse building 256 on the south side.

The production area has approximately the same floor area as the existing pelletizing building 255, measuring 83 feet wide by 161 feet long, but it is higher; 23 feet high on the south end and stepped to 36 feet high on the north end.

An additional one story section on the north end, containing the women's locker room, extends the building length by 20 feet to about 181 feet l

overall.

Building 254 is constructed with a free standing steel frame supported on shallow poured concrete spread footings with l

connecting grade beams, a concrete slab floor on grade and concrete block walls laterally tied to the steel frame.

The block walls are shared where building 254 adjoins other buildings'.

Metal curtain walls with insulation are used on the exposed exterior walls of the high north end and on the high portions that' rise above the block walls shared with adjoining buildings.

Roofing is rigid insulating board over metal decking supported on prefabricated trusses carried on the steel building frame.

The building is designed using a BOCA seismic zone 2 earthquake occupancy importance factor of 1.5.

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3.1.2 New Storace/ Utilities / Office Buildina 253 Description The new storage / utilities / office building 253 is located between the new pelletizing building 254 and the existing recycle-recovery building 240.

On the east side it adjoins the new pelletizing building 254 and the new warehouse building 256.

On the west side it adjoins the existing recycle-recovery building 240.

New building 253 measures approximately 77 feet wide by 133 feet long by 17 feet high and is constructed similarly to existing building 240.

It has a concrete slab floor, concrete block walls and metal supporting roofing.

3.1.3 New Warehouse Buildina 256 Description The new warehouse building 256 extends westward along the south end of the existing pelletizing building 255 and the south end of the new pelletizing building 254 to adjoin the east wall of new i

building 253.

Building 256 measures approximately 151 feet by 50 feet.

It is constructed of concrete slab floor on grade with concrete block walls and roofing of rigid insulating board over metal decking supported on prefabricated steel trusses.

3.2 Buildina Utilization This section provides a description of the utilization of the new a

buildings and of changes to the utilization of existing i

buildings.

Generally, the types of processing and other functions performed in the buildings after revitalization are the same as those existing before revitalization.

Additions are made to increase the capacity for pellet production and to provide for increases in the related storage and shipping support functions and in staff facilities.

Table 3-1 lists the existing buildings by name and number and gives their present utilization.

Table 3-1 alco lists the changes after ;e. vitalization and Figure 3-1 shows the building and equipment layout.

3.2.1 Existina Oxide Buildina and Dock Utilization l

In the existing oxide building, UF is received by truck l

transport, processed into UO2 granbles, milled to powder and the powder is stored in vertical cylindrical blenders until it is withdrawn for processing or for shipment to Windsor.

Following revitalization the UO granules will be stored in 1000 kg batches 7

in portable containers that will be located primarily in building 254.

Milling and blending will be primarily performed in bu'lding 254, although the pre-revitalization capacity will be maintained for the special pellet line 3-2 l

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Subsequent to previous environmental information supplements, the receiving dock area where the UF cylinders are heated to vaporize the UF has been upgradhd.

This area previously had a 6

metal roof on a steel frame.

Metal walls and overhead doors have been added to enclose the dock area.

This enclosure serves to retard fluoride dispersion should a leak occur.

3.2.2 Buildina 255 - Existina Pelletizing Buildina Utilization In Building 255, the milled and blended UO powder withdrawn from storage in the adjacent oxide building is a, agglomerated with a wax-like binder, granulated to flow freely and pressed into green pellets.

The green pellets are dewaxed, sintered, ground to size and packaged for shipment.

Existing equipment for this pellet line remains unchanged in Building 255 but is utilized for special pellet production that includes production of pellets containing erbia as a burnable neutron poison.

The function of Building 255 for routine production of UO2 pellets is moved to the new Building 254.

Existing powder storage conveyors in the north end of building 255 are not required after revitalization because UO2 powder is no longer stored in cans on these conveyors awaiting shipment to Windsor, CT for pelletizing.

Some of the existing conveyors are removed to allow passage for wheeled transport of oxide granules from the oxide building, through the existing pellet building and into the adjoining new pellet building (see Figure 3-1).

3.2.3 Buildina 254 - New Pelletizing Buildina Utilization In new Building 254, UO2 granules are processed into pellets in two new parallel pellet production lines.

The granules are received in 1000 kg hoppers.

The hoppers are filled from the vertical, cylindrical blender vessels in the oxide building.

Granules processed in new building 254 bypass the existing storage silos and milling in the oxide building and are stored in the blender vessels.

The filled hoppers move on a wheeled transporter through the existing pellet building 255 and into the adjoining'new pelletizing building 254.

There, the granules flow by gravity from the hopper to the mill (micronizer) and the resulting powder is pneumatically transferred by negative pressure into a blender capable of handling up to 3000 kg of powder.

The blended powder is pneumatically transferred by negative pressure to a new dry powder preparation process that includes addition of a pore-former and lubricant, slugging and granulating.

The granulated powder is pressed on new rotary 3-3

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presses.

(See Section 4.2 for further description.)

Finished pellets from the new line are p.whaged for shipping and loaded through an isolating transfer port between buildings 254 and 256 directly into drums on shipping skids in the new warehouse building 256.

This transfer port separates the production area from the clean warehouse area.

Building 254 also has the capability for recycle of green scrap and hard scrap.

The process employed is the same as the existing process in building 240 for recovery of clean dry scrap from the existing pellet building 255.

The clean scrap is oxidized in a furnace, milled and reduced to UO in a second furnace.

Recycled powder is added to the cubrent powder run or stored for later use.

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3.2.4 Buildina 256 - New Warehouse Buildino Utilization The new warehouse serves as a storage and shipping facility for finished pellets and as a receiving warehouse for site supplies.

l Truck access to the warehouse is via a new, unrestricted roadway l

corridor that runs from the main gate to the warehouse between an I

existing fence line and the new fence line.

The outdoor truck ramp and adjacent surfaces drain to a sump that is lower in elevation than the site storm drain.

A pump in the sump transfers drainage to the site storm drain system via a manhole located outside the south wall of building 256 opposite to building 255.

l The warehouse and the adjacent truck ramp access areas are maintained as radiologically clear areas.

3.2.5 Euildina 253 - New Storace/ Utilities /Cffice Buildina Utilization The existing boiler room is incorporated into the new storage / utilities / office building and the existing pump house adjoins the north end of the new building as it did the existing building.

Filtrate evaporation is performed south of building 240 and solidification is performed in the south end of new building 253.

The center area provides storage for UO, powder, chemicals and' maintenance items.

New process engineering offices and a change room occupy the bi-level north end of building 253.

The center storage area receives bulk recycle oxide in containers from building 240.

After analysis and release, the oxide is transferred into wheeled hoppers and the hoppers serve as storage within building 253.

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TABLE 3-1 BUILDINGS AND FACILITIES Existina Buildinas and Facilities Building.

No. and Name Utilization 101 Tile Barn Emergency-Center and Equipment Storage Pucp House Site Water Supply 110 Office Building Guard Station, Offices 120 Wood Barn Equipment Storage Oxide Building & Dock UF to UO Conversion 235 West Vault Nakural a$d Depleted Uranium Storage 240 240-1 Offices, Cafeteria, Locker Room Laundry 240-2 & 240-3 Recycle and Recovery Area 240-4 Laboratory, Maintenance Shop 250 Boiler Room / Warehouse Steam Supply, Storage 251 Warehouse Shipping / Receiving, Storage 252 South Vault Radioactive Waste Storage 255 Pellet Plant Fuel Pellet Fabrication, UO2 Storage Chances and Additions After Revitalization (See Fiaure 2-3) 250 Partially Demolished 251 Demolished 253 Utility Building (new)

Steam Supply, Storage, Offices, Liquid ~ Waste I

solidification 1

254 Pelletizing Building (new)

Pellet Fabrication, Packaging 256 Warehouse (new)

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4.0 CHANGES TO HEMATITE PELLETIRl[{G This section describes two -hanges to the existing pelletizing process employed at Hematite.

They are the addition of erbia to the UO in the existing pellet line and changes to the mechanical 7

preparation of the UO2 p wder for the pellet presses in the new pellet lines.

4.1 Erbia - UO Pellets 2

Erbia is the oxide of the rare carth erbium.

It is employed in concentrations up to a maximum of about two percent by weight in UO as a burnable neutron absorber.

In a nuclear reactor fully cokmitted to the use of erbia, up to about twenty percent of the fuel rods might contain erbia.

The existing pellet line in building 255 at Hematite is used as the orbia line.

Erbia is received in powdered oxide form and is added to the UO This concentrated erbia mixture is diluted with UOpowder at the powder milling step (micronizers).

and blended 2

to achieve the desired concentration.

There is no other change from the existing pelletizing process.

The first nuclear reactor irradiation of erbia in fuel produced by C-E is scheduled for 1989 on a developmental scale.

Over a number of years the use of erbia may increase, but is limited to about twenty percent of all pellet production.

Thus, pellet production in the existing pellet line at Hematite is greatly reduced after the new pellet line is initially started up and thereafter orbia pellet production in the existing pellet line might increase to approximately twenty percent of total pellet production.

Erbia is an inert, non-toxic mineral that receives no off-site environmental considerations.

Since it is processed in the existing UO pelletizing equipment, the existing provisions for UO, powder $ solation and filtration are adequate for personnel safety.

4.2 Chances to Powder Preparation Changes occur in the powder preparation process, between the withdrawal of oxide and the pressing of green pellets in the new pelletizing building.

Table 4-1 summarizes the steps in this process, and shows the differences between the existing and the new pelletizing processes.

In the new process, Uo withdrawn from the oxide building in larger batche$ granules are and are milled and blended in larger blenders, but the milling and blending processes are essentially the same.

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After blending, the new process omits addition of the organic binder (Cranko brand) and its trichloromethane (TCE) solvent.

The existing pellet line employs the binder to agglomerate the milled and blended powder to make it flow freely in the final pellet.

i press operation.

Instead of adding a binder, a slugging press forms slugs from the dry. milled and blended powde".

The slugs are then granulated.

The product is powder that flows freely in the final pellet press.

New presses are multiple die rotary presses instead of the existing dual die press.

Other chemical changes may be made to the new pellet lines.

First, ammonium oxalate may be substituted for starch as a 1

pore-former.

It is added to the blended powder and mixed in a conical mechanical mixer ahead of the slugging press.

Then a lubricant is added for the final pellet press operation.

In the existing pellet line, the organic binder serves also as the lubricant.

Both the pore-former and the lubricant volatize and burn off in the pellet furnaces.

6 4-2

l L

E pLE 4-1 COMPARISON OF PELLETIZING PROCESS STEPS Process Step Existing Process New Process 1.

Store Cooled U0 Granules In In U0 Sil s Bypass Silos & Store 2

2 Oxide Bldg.

In Hoppers 2.

Transfer to Mill Gravity Feed From Load 1000 kg hopper,

)

l Silos Wheel to Bldg. 254.

I Gravity Feed 3.

Mill Powder Micronizer at Silos Micronizer in Bldg 254

)

4.

Transfer to Blender Closed, Pneumatic Closed, Pneumatic 5.

Blend Powder Blender in Oxide Bldg 3000 kg Blender in Bldg. 254

)

6.

Transfer Blended Powder 5 gal pails Closed, Pneumatic 7.

Agglomerate Add Organic Binder Add Poreformers Add Pore-former Conical Mixer Mix (V tumbler)

Slugging Press I

Dry Granulate Granulate Add Lubricant Rotary, Inclined Mixer 8.

Transfer to Presses Pails Closed, Gravity Feed i

l 9.

Final Pellet Press Dual die Multiple Rotary Die 10., Load into Furnace Hand Load Corrugated

. Random Filled Boats Trays

11. Dewax and Decarburize 1st and 2nd furnaces 1st furnace

12. Sinter 3rd furnace (reducing) 2nd furnace (reuucing)

13. Grind Pellets Wet Grinder Wet Grinder

14. Dry Air dry on carts Air dry on carts

15. Package and Ship Stack Pans Into Stack Trays Into Drums Drums l

l 4-3

d 5.0 SITE WATER SUPPLY, UTILIZATION AND DISCHARGE 5.1 Water Sunniv The site water source for daily use is unchanged after revitalization.

It is a well, located northeast of building 240.

The city water line from the town of Hematite will be extended to the site.

A hydrant will be located near the east end of the wood barn (see Figure 5-1).

The hydrant is for emergency use such as ammonia leak suppression and fire fighting.

5.2 Water Utilization Water is used for three main purposes:

1.) sanitary, laundry, showers and drinking, 2.) processes related to oxide and pellet production and 3.) equipment cooling.

Table 5-1 lists the water usage previously reported as 71,000 gallons per day.

About sixty percent of this was allocated for once-through equipment cooling.

Prior to the revitalization program, a circulating water cooling system including a forced convection evaporative cooling tower was installed.

Cooling water utilization is reduced to between 400 and 1000 gallons per day of cooling tower makeup water, depending on the weather.

The total allocated daily usage is reduced by about 43,000 gal / day with the cooling tower.

A recent measurement of the total water drawn from the site well extending over a one week period of full production yields an estimate of the existing total daily average water usage at 11,300 gal / day.

Table 5-1 shows the existing distribution of water usage.

After revitalization, water usage increases mostly because the number of personnel increases.

Table 5-1 shows the estimate for water usage after revitalization.

That estimate is substantially lower than previous water usage before the cooling tower i

installation.

l 5.3 Water Discharce 1

There are thre'e means of water discharge from the site:

1.)

)

sanitary system, 2.) storm drains and 3.) evaporation to the 4

atmosphere.

The sanitary system takes the water from sinks,

}

toilets, showers and drinking fountains.

The routing of the l

sanitary drains is unchanged except for the additional hookup to i

new buildings 253 and 254 (see Figure 5-1).

The previous septic tank and sand filter was replaced in 1978 with an extended aeration sewage treatment plant (Reference 6) equipped with a hypo-chlorinator and chlorine contact tank.

Design capacity is s

l 5-1 1

/

i I

3000 gal / day whereas estimated usage after revitalization is 2400 gal / day.

The location of the discharge point for the sanitary system effluent is unchanged.

It flows into the site creek below the dam on the site pond.

j

)

The second means of water discharge is to the storm drain.

This

]

drain takes rainwater runoff from roof and ground surface drains, filtered laundry water, laboratory sink water from cleaning glassware, and steam condensate from the UF Vaporizer.

6 Relocation and extension of two branches of the storm drain located adjacent to existing building 255 and between existing buildings 250 and 251 is necessary to stay away from the footings for the new buildings and to pick up pumped sump water from the new warehouse loading dock area.

Figure 5-1 shows the storm drain routing and its unchanged discharge location into the site pond.

Because the prior addition of the cooling tower practically eliminated the discharge of once-through equipment cooling water to the storm drain, the discharge is much smaller than previously stated.

There may be a fractional increase in the existing storm drain flow after revitalization as a result of increased laundry water because of a slight increase in employment.

The third means of water discharge is by evaporation of the final filtrate from the recycle / recovery processes.

Evaporation occurs by steam heating as part of the solidification process that is relocated to the south end of building 240.

Concentrated liquid waste is solidified for transport to a commercial licensed disposal facility or is recycled for uranium recovery.

Previously used on-site evaporation ponds are no longer in use (See Reference 6).

After revitalization, no increase is expected in the recovery / recycle filtrate evaporation and solidification I

since the total amount of scrap processed will be the same.

More will be generated at Hematite, but less will be returned from the Windsor facility for recovery.

1 4

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TABLE 5-1 WATER UTILIZATION AND EFFLUENTS WATER UTILIZATION Mjil DAILY FLOW (aal/ day)

Eteviousiv Existina After Revitalization Plant Processes 25,600 9,000 11,400 Equipment Cooling 44,000 1,000 1,200 Sanitary System 1.400 2.000

_2dDD TOTAL 71,000 12,000 15,000 WATER EFFLUENTS Effluent Path and Oriain DAILY FLOW (aal/ day)

Existina After Revitalization d

Storm Drains

{

Deionized (Lab and Process) 5,800 7,000 l

i Boiler Makeup (Condensate) 300 300 l

Other Process 2,500 3,820 l

Laundry 200*

240*

j SU8 TOTAL 8,800 11,360 Sanitary System Showers, Sinks, Toilets 2.000*

2.400*

SUBTOTAL 2,000 2,400 Evaporation Concentration and Solidification 200 240 1

Cooling Tower 1.000 1,200 SUBTOTAL 1,200 1,240 TOTAL 12,000 15,000

• These effluents may contain trace quantities of radioactivity.

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6.0 RADIOLOGICAL EFFLUENTS 6.1 Radiological Waste Water Effluent There are no changes to the methods of treatment of the various radiological water effluent streams as a result of revitalization and only a small fractional potential increase in the volume of radiological water effluent.

Table 5-1 lists the radiological waste water effluent paths.

The volumes from these paths after revitalization are described in the following.

The industrial waste water system (storm drain) receives trace amounts of radioactivity from the existing site laundry in building 240.

The laundry water is filtered, held in a storage tank and sampled prior to release.

After revitalization the volume of laundry water effluent increases in proportion to the increase in the number of production personnel for the new pellet lines.

Existing production personnel number about 55, and after revitalization they may increase by up to about 20 percent.

The second radiological water effluent path is the sanitary water system.

It receives trace amounts of radioactivity from existing sinks and showers in buildings 240 and 255 and new showers in building 254.

After revitalization the volume of water effluent also increases in proportion to the number of production personnel.

I 6.2 Radiological Airborne Effluent Figure 6-1 shows the existing stack locations on the oxide building, on the existing pellet building 255 and on the existing recycle / recovery building 240.

These are the existing sources of airborne radiological effluents.

After revitalization, these stacks remain.

Effluent from the oxide building is unchanged.

Effluent from the existing pellet building substantially decreases as pellet production is shifted to the new building 254.

Effluent from the recycle / recovery building is not expected to increase.

Figure 6-2 sh'6Ws the five new additional stacks on the new pellet building 254 and one new additional stack on the new utility building 253.

The pellet building stacks each have an exhaust flow rate of approximately 12,000 cfm.

The utility stack has an exhaust flow rate of 1,500 cfm.

All new exhausts are filtered through a double bank of HEPA filters.

Thus, even with the increase in pellet production after revitalization, there is no anticipated increase in the total airborne radiological effluents from the pellet buildings.

6-l

v 6.3 Radioloalcal Solid Effluents The primary source of radioactive solid waste resulting from routine oxide and pellet production is the solidification process.

In this process, the liquid waste end product from the existing recovery / recycle processes and mop water is heated and concentrated.

The concentrate is solidified and put.into drums for transport to a commercial licensed disposal facility.

It is anticipated that improved powder confinement provided by the new pellet lines will allow increased pellet production with no significant increase in mop and cleanup water.

Although some additional solid wastes will be generated as a result of operating the new pellet lines, volume reduction by incineration and elimination of the potential for contamination through use of the new clear warehouse will minimize the quantity of these wastes.

Therefore, there is at most a small fractional increase in the radiological solid waste effluent after revitalization.

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i 7.0 CHANGES TO NON-RADIOLOGICAL CHEMICALS AND EFFLUENTS 7.1 Ammonia - (NH )

]

3 Increased pellet production increases the ammonia _used to produce I

a reducing atmosphere in the pellet sintering furnaces by 200,000 lbs per year.

Existing ammonia usage is 420,000 lbs per year in oxide and pellet production and in the recycle and recovery processes.

A new 8000 gallon ammonia storage tank is located above ground near the existing 10,000 gallon tank (see Figure 2-3).

It is l

connected in parallel with the existing tank and includes 1

associated plumbing and excess flow limit valves in the discharge lines.

I Excess hydrogen from the ammonia used in the pellet furnaces I

burns off and is exhausted to the atmosphere along with the

{

nitrogen.

No significant change to existing environmental I

discharge occurs as a result of increased ammonia usage.

Consequences from potential ammonia leaks are reduced by the addition of a hydrant connected to the Hematite city water supply.

The hydrant will be located on site near the east end of the wood barn.

It provides an increased fire hose water supply to reduce accidental ammonia dispersion off-site.

7.2 Cranko Existing Cranko usage is approximately 9000 lbs per year.

It is a binder added during pellet powder preparation and it also l

serves as the pellet die lubricant.

Cranko burns off during the pellet dewaxing operation.

It is a proprietary' formulation of Imperial Chemical Industries that contains butyl methacrylate.,

i methyl methacrylate and methyl acrylic acid.

After revitalization, the amount of Cranko used decreases in proportion to the decrease in pellet production from the existing pellet line in building 255.

The new pellet lines in building 254 do not employ a binder.

7.3 Trichloro' ethane (TCE)

Existing TCE usage is approximately 9,500 lbs per year.

It is the solvent for the Cranko binder and volatizes during the powder drying operation and is discharged.

After' revitalization, TCE usage decreases in proportion to the reduction in Cranko usage previously discussed.

7-1

~

e i

7.4 Ammonium Oxalate ((NH )2 C02 4.H O) 4 2

Ammonium oxalate may be employed in the new pellet lines in building 254 to control porosity of the sintered pellet.

It burns off cleanly in the pellet furnaces.

Approximately 1500 lbs per year are used.

Ammonium oxalate is an alternative to hydrophobic starch (C H 0

that is used in the existing pellet line for the same purpod8.5) Alternate compounds may also be used g

l as pore-formers.

7.5 Zinc Stearate (Zn(Cyg 35 2)2)

H 0

Zinc stearate may be employed as a pellet die lubricant.

It is mixed with the powder prior to the final pellet press in the new pellet lines and burns off in the pellet furnaces.

Approximately 1,500 lbs per year may be used, but alternate lubricants are being investigated.

The existing pellet line does not employ a separate lubricant.

7-2 i

4 8.0 ENVIRONMENTAL MONITORING There are no changes to the existing environmental monitoring locations, monitoring procedures or monitoring frequencies after revitalization.

There are additional monitoring locations for radioactive gaseous effluents on the five new stacks on the new pellet building 254 and on the new stack on the new utility building 253.

These new stacks (See Figure 6-2) are continuously monitored when stacks are in operation by the same extractive sample and counting method in use on all existing stacks.

1 j

j 8-1

I 9.0 DOSE COMMITMENT This evaluation of dose commitment to off site population after revitalization is based upon the 1979 NRC calculations and action limits imposed by the NRC in compliance with the EPA regulations in 40 CFR 190 and issued in Reference 11.

Two pathways, liquid releases and airborne releases, were considered.

The NRC concluded "that the liquid effluent is not a significant pathway to man."

This conclusion was reached, based upon the measured six month average liquid release of 1.65 x 10 Ci for the period I

1975 through 1978.

The measured liquid release from the site l

pond reported to the NRC for the mosg recent 6 month period from July to Deconber, 1988 is 1.58 x 10 Ci.

After revitalization the radioactive liquid release may show a small fractional increase.

Therefore, the liquid release after revitalization is less than the release previously employed in the NRC calculations.

1 In Reference 11, the NRC calculated that the total annual airborne release required in order to deliver a dose of 25 l

mrem /yr to an infant continuously exposed at the nearest site boundary is 733 C1/yr.

The annual average measured release through 1978 was 319 pCi.

To acknowledge the ALARA principle and based upon monitoring data through 1978, the NRC imposed an action limit below the 25 mrem /yr limit specified in 40CFR190.

The action limit in the existing license is 150 Ci per calendar quarter, or 600 pCi/yr.

Monitoring data for the years from 1978 through 1988 yield a maximum total annual airborne release of 348 pCi.

Given the design objective for the revitalization program that the total airborne radiological release does not significantly increase, the existing license action limit based upon the site boundary dose continues to be satisfied.

l l

In Reference 11, the NRC also calculated the dose to the nearest resident as of 1978, located about one-half mile southeast of the plant site.

Based upon a total annual release of 319 pCi, the lung dose to an infant was 0.12 mrem /yr.

The location of the defined nearest resident is the same after revitalization as in 1978.

Even assuming the total annual release were to increase to the existing license action limit of 600 pCi, the nearest critical resident dose is 0.9 percent of the 25 mrem annual limit as specified in 40CRF190.

The integral dose to the population surrounding the plant depends upon the population.

Table 9-1 shows historical data from the U.S. Census and from the local school district to evaluate the population trends.

The plant site lies about in the middle of Jefferson County and about 35 miles southwest of the city of St.

Louis.

County-wide population trends probably represent growth 1

l 9-1

l l

1 of the suburbs near St. Louis more than the growth of the rural l

area surrounding the unincorporated town of Hematite.

The l

nearest large towns to the Hemetite plant site are Festus and Crystal City, located 3-1/2 miles east.

Data in Table 9-1 show a population trend for these towns that is generally below the county growth rate.

In order to estimate population trends in the rural areas and unincorporated towns surrounding the plant site, the student population in the local county school district is listed in Table 1

9-1.

The Festus school district includes Festus and Crystal City on the east, extends to the boundary of Hillsboro on the west and extends to the boundary of DeSoto on the south (see Figure 9-1).

l The district approximates the area within a 5 mile radius of the plant site.

The average annual growth in the student population s

of the Festus district over the past 5 years is less than 2%.

j l

Considering the low dose to the nearest resident, the low l

surrounding population density and the low population growth H

rate, one concludes that changes to the total radiological dose commitment to the population are not significant.

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9-2 1_------.___

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TABLE 9-1 POPULATION TRENDS i

U.S.

Census Data for County and City Populations Population I

Year Jefferson County-Festus/ Crystal City I

i 1940 32,023 8,037 1950 38,007 8,698 1960 66,377 10,699 1970 105,647 11,428-1980 146,183 11,192 1986 (Est.)

163,800 12,670 4

Festus School District Student Pooulation

]

Year Student PoDulation 1984 - 85 2078 1985 - 86 2151 1986 - 87 2137 1987 - 88 2152 September, 1988 2235 1

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10.0 REFERENCES

1.

" Environmental Impact Information, Combustion Engineering, Inc., Hematite, Missouri Plant Site," for NRC License No.

SNM-33, Docket No. 70-36, June, 1975.

2.

Responses to " Questions and Comments on Environasntal Impact Information, Hematite Facility," enclosed with letters:

H.E. Eskridge (C-E) to R.B. Chitwood (NRC), February 19, 1976, March 23, 1976 and June 30, 1976 and H.E. Eskridge (C-E) to R.E. Cunningham (NRC), July 30, 197'5.

3.

" Environmental Impact Information Related to Installation and Operation of a Wet Scrap Recovery Process," August, 1976.

Enclosed with letter from H.E.

Eskridge (C-E) to L.C.

Rouse (NRC), August 23, 1976.

4.

" Supplemental Environmental Impact Information Related to Installation and Operation of a Wet Scrap Recovery Process,"

June, 1977.

Enclosed with letter from H.E. Eskridge (C-E) i to L.C.

Rouse (NRC), June 3, 1977.

I 5.

" Environmental Impact Information Related to Use of Spent Scrubber Rock as Onsite Fill Material," enclosure to letter from H.E. Eskridge (C-E) to L.C. Rouse (NRC), September 9, 1977.

6.

" Supplemental Environmental Impact Information Related to Installation and OI 7 tion of Additional Uranium l

Hexafluoride Conve>#

n Capability," for License No. SNM-33 l

on Docket No. 70-?6, harch, 1978, and associated answers to

)

questions.

7.

" Transmittal of Radiological Survey Results," letter from A. E. Scherer (C-E) to L.

C.

Rouse (NRC), LD-88-114, dated October 12, 1988.

8.

Letter, L. C. Rouse (NRC) to Dr.

P.

L. McGill (C-E), dated Octo'oer 31, 1988.

9.

"Hr;matite Construction Program Soil Sampling Results,"

letter from A. E. Scherer (C-E) to L.

C.

Rouse (NRC),

L'J-88-162, dated December 20, 1988.

1 10-1 L_______________

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10.

Letter, L.

C. Rouse (NRC) to A.

E. Scherer (C-E), dated February 24, 1989.

11.

" Radiological Assessment of Individual Dose Resulting from Routino Operation - Demonstration of Compliance with 40CFR190,", Enclosure to Amendment No. 5 to Materials License-No. SNM-33 on Docket No. 70-36, signed by R. E. Cunningham (NRC), January, 1980.

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