A small electric melter was developed to implement studies for converting radioactive waste to glass at the Savannah River Laboratory (SRL). The ceramic-lined, joule-heated melter has been in operation for ten months. During this period, simulated, high-level-waste, calcined materials and frit were processed at rates of 2 to 15 g/min. The melt chamber is 7.6-cm wide, 22.9-cm long and 7.6-cm deep. The total power consumption is 3.5 KVA when the glass processing temperature is 1150°C. A similar unit will be in operation in FY-1979 in the SRL high-level cells.
The radioactive waste glass melter used at Savannah River Site (SRS) is a liquid slurry feed joule-heated ceramic melter. The physical nature of a joule-heated meter is complex and involves interactions between electric, thermal, and flow fields. These interactions take place through strongly temperature-dependent glass properties, natural convection, advection, diffusion, and volumetrically distributed joule heating sources. The cold feed on top of heated glass distabilizes the flow field and develops unsteady asymmetric flow motions underneath. Thus waste glass modeling requires solving a full 3-D, unsteady, momentum, energy, and electric equation with temperature-dependent properties. Simulation of noble metal deposit process requires an additional mass diffusion equation that is coupled to the momentum equation through mass advection term. The objective of this paper is to identify critical issues anticipated in the Defense Waste Process Facility (DWPF) melter operation and address how these issues can be resolved with current state-of-the-art mathematical modeling techniques.
The melter feed, slurry, or calcine charged on the top of a pool of molten glass forms a floating layer of reacting material called the cold cap. Between the cold-cap top, which is covered with boiling slurry, and its bottom, where bubbles separate it from molten glass, the temperature changes by up to 1000 K. The processes that occur over this temperature interval within the cold cap include liberation of gases, conduction and consumption of heat, dissolution of quartz particles, formation and dissolution of intermediate crystalline phases, and generation of foam and gas cavities. These processes have been investigated using thermal analyses, optical and electronic microscopies, x-ray diffraction, as well as other techniques. Properties of the reacting feed, such as heat conductivity and density, were measured as functions of temperature. Investigating the structure of quenched cold caps produced in a laboratory-scale melter complemented the crucible studies. The cold cap consists of two main layers. The top layer contains solid particles dissolving in the glass-forming melt and open pores through which gases are escaping. The bottom layer contains bubbly melt or foam where bubbles coalesce into larger cavities that move sideways and release the gas to the atmosphere. The feed-to-glass conversion became sufficiently understood for representing the cold-cap processes via mathematical models. These models, which comprise heat transfer, mass transfer, and reaction kinetics models, have been developed with the final goal to relate feed parameters to the rate of glass melting.
