1. PLASMA TECHNOLOGY An Optimal Solution for Radioactive Waste Minimization PLASMA TECHNOLOGY An Optimal Solution for Radioactive Waste Minimization UKRAINIAN NUCLEAR FORUM 2012 27-28 March - KIEV

2. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 2 INDEX 1. BACKGROUND 2.1 Introduction to the Technology 3. PLASMA TREATMENT PLANTS 2.2 Applicable Waste Types 2.3 Advantages and Disadvantages 3.2 Plasmatek Pilot Plant 3.3 Plasma Melting Facility – KNPP Bulgaria 2.5 Main Equipment 3.1 Operational Experience - ZWILAG 2. PLASMA TECHNOLOGY

3. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 3 1. BACKGROUND 2.1 Introduction to the Technology 3. PLASMA TREATMENT PLANTS 2.2 Applicable Waste Types 2.3 Advantages and Disadvantages 3.2 Plasmatek Pilot Plant 3.3 Plasma Melting Facility – KNPP Bulgaria 2.5 Main Equipment 3.1 Operational Experience - ZWILAG 2. PLASMA TECHNOLOGY

4. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 4 1 Background The main purpose of treatment, conditioning and packaging is volume reduction and physical-chemical and mechanical stabilisation of the waste in view of its confinement in the final repository. The reduction in disposal costs is often the main reason to promote volume reduction Volume reduction technologies such as supercompaction and incineration are widely applied Plasma technology offer higher volume reduction and is applicable for organic and inorganic waste. High efficiency volume reduction technologies typically require a large input volume to operate economically The largest potential benefit from waste reduction efforts can be expected for new nuclear plants and for decommissioning.

5. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 5 INDEX 1. BACKGROUND 2.1 Introduction to the Technology 3. PLASMA TREATMENT PLANTS 2.2 Applicable Waste Types 2.3 Advantages and Disadvantages 3.2 Plasmatek Pilot Plant 3.3 Plasma Melting Facility – KNPP Bulgaria 2.5 Main Equipment 3.1 Operational Experience - ZWILAG 2. PLASMA TECHNOLOGY

6. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 6 2.1 Introduction to the technology Plasma treatment uses an electric arc to generate temperatures in the gas stream that can achieve several thousand degrees centigrade causing the rupture of molecular structures of materials into their constituent atoms. In a temperature range of 7.000 – 1.0000 °C, the organic material is vaporised in volatile hydrocarbons, carbonmoxide, etc. while non-combustible and other inorganic constituents are melted and transformed into glassy slag o The treatment of solid radioactive waste using plasma heating sources occurs in primary chambers. o The resulting vapour phase is passed through an afterburner followed by appropriate treatment in the off-gas. o The molten residues (slag), which contain most of the radioactivity, are transferred into an external vessel and cooled. 2 Plasma Technology

7. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 7 Developed into the sixties for testing heat shields for the space industry. After more than 4 decades, plasma technology is being utilised worldwide in many industrial processes (e.g. metal cutting, metallurgical application, vitrification of fly ash from municipal incinerators, treatment of problematic chemical wastes, etc). 2.1 Introduction to the technology 2 Plasma Technology First application for Radioactive waste treatment was taken into operation in 2004 in ZWILAG. Having completed testing for the regulators, in 2004 ZWILAG was granted permission to process low level radioactive waste. From 2004, ZWILAG has had many successful campaigns processing radioactive waste.

8. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 8 Due to the higher temperature range of the plasma compared to conventional methods of incineration, the range of applicable waste types is much greater The waste feed can include organic waste and also inorganic and mixed materials 2.2 Applicable Waste Types 2 Plasma Technology TECDOC 1527

9. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 9 Advantages Applicable to solid organic and inorganic waste and also to other waste type such as drummed spent resins and liquid waste One single process can treat the waste as generated (no prior treatment). This implies less dose uptake and risk for contamination The final waste form is robust, free of organic material, and suitable for long term storage and disposal. High volume reduction  lower disposal cost VRF~ 6waste containing mostly metals and debris VRF~10mixed waste VRF~100 primarily organic waste. The heat source is a plasma  less production of certain flue gasses and the greenhouse gas CO 2 2.3 Advantages and Disadvantages 2 Plasma Technology

10. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 10 Disadvantages Gaseous effluent restrictions - EC Directive 2000/76/EC (off-gas design) Cost (justifiable when volume of waste to be treated is large) There is limited full-scale plant experience with radioactive waste: o ZWILAG is the only plasma facility for the treatment of radioactive waste in the world with a wide experience in industrial operation. o PMF (Plasma Melting Facility) in Kozloduy (Bulgaria) – On going project 2.3 Advantages and Disadvantages 2 Plasma Technology

11. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION Feeding system options: –Continuous feed system Continuous by shredder  more constant flow rate and able to homogenize all types of wastes –Batch feed system Batch feed by drum feeder  high instantenuous flow rate so off gas must have higher dimensions 2.5 Main equipment 2 Plasma Technology

12. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 12 PLASMA TORCH Transferrable torch Non transferrable torch: most used and less complex (anode and cathode are in the torch) Typical temp: 5.000°C  organic material is gasified and iron, concrete, glass and other inorganic material are melted to form a slag Power 100 kW to 2.000 kW 2.5 Main equipment 2 Plasma Technology

13. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 13 OFF-GAS SYSTEM 2.5 Main equipment 2 Plasma Technology Afterburner  the syngas, hydrocarbons containing Cl and S are oxidized to primary components such as CO 2, H 2 0, SO 2 and HCl After complete oxidation, the flue gases are routed to an off-gas treatment system: o Boiler: Gases are cooled down (recovery can be used for heating) o Scrubber: Gases are washed to absorb remaining portions of acids, inorganic contaminants and sulphur dioxide (SO 2 ). o Filters: Trap radioactive dust particles o DENOX: N0 x concentration is reduced by means of selective catalytic reduction

14. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 14 EMISSION CONTROL 2.5 Main equipment 2 Plasma Technology There are two different emission control systems: Radiological emission control To monitor the off-gas system exhaust air in terms of radioactivity The system has to ensure that the measured data never exceed the maximum permissible values. Conventional emission control. To monitor that the complete off-gas stream flowing out of the plant stack The measurement system covers the following categories: CO, SO 2, HCI, NOx, NH 3, Hg, dust, moisture and flow rate.

15. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 15 1. BACKGROUND 2.1 Introduction to the Technology 3. PLASMA TREATMENT PLANTS 2.2 Applicable Waste Types 2.3 Advantages and Disadvantages 3.2 Plasmatek Pilot Plant 3.3 Plasma Melting Facility – KNPP Bulgaria 2.5 Main Equipment 3.1 Operational Experience - ZWILAG 2. PLASMA TECHNOLOGY

16. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION ZWILAG is the only plasma facility for the treatment of radioactive waste in the world with a wide experience in industrial operation Nuclear start up: 2004 Run on a commercial base 100 ton per campaign (500 drums) o 200 kg/h for burnable waste o 300 kg/h for meltable waste. About 140 pours per campaign Nowadays: 2 campaigns of 10 weeks per year End 2009: Total 4000 drums or 690 ton 3.1 ZWILAG 3 Plasma Treatment Plants

17. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 3.1 ZWILAG 3 Plasma Treatment Plants

18. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION Plasmatek is a pilot plant of plasma technology to treat low and intermediate level wastes From 1995, IBERDROLA INGENIERÍA has participated in the design and commissioning of Plasmatek. 3.2 PLASMATEK PILOT PLANT 3 Plasma Treatment Plants

19. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION In 2009 the Joint Venture formed by IBERDROLA Ingeniería and BELGOPROCESS was awarded with a contract to “Supply of a facility for treatment and conditioning of solid and liquid radioactive wastes with a high volume reduction factor at Kozloduy NPP” Turnkey project co-funded by EBRD and KNPP. Joint Venture formed by IBERDROLA Ingeniería and Belgoprocess. 3.3 PMF – KNPP BULGARIA 3 Plasma Treatment Plants

20. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION Capacity: 65kg solid waste per hour and 5 to 10kg liquid waste per hour. Primary Treatment Chamber temperature: 1100 – 1500 ºC Non tranferrable Plasma Torch power: 500KW Gas residence time in Secondary Chamber: > 2 sec Secondary Chamber outlet temperature: 950 – 1200 ºC Off gas nominal flow:1.200Nm³/h Effective operation hours per year: 4000h Volume Reduction Factors (VRFs): o Bags VRF ~80 o 220 l drums VRF ~20 o Pellets VRF ~2 3.3 PMF – KNPP BULGARIA 3 Plasma Treatment Plants

21. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 3.3 PMF – KNPP BULGARIA 3 Plasma Treatment Plants Category 2a waste delivered in bags, 200 l drums and super-compacted drums.

22. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 22 Most significant equipments in KNPP PMF: Plasma treatment chamber  fix furnace with tilt design Torch  500 kW non-transferred arc plasma torch Feeding system  continuos through a shredder Off-gas system  based on Cilva facility (Belgoprocess) SCC (Slag collection chamber)  based on Zwilag design Plasma treatment chamber Plasma torchShredderSCC 3.3 PMF – KNPP BULGARIA 3 Plasma Treatment Plants

23. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION Plasma furnace Slag collection and cooling chamber 23 Conveyor & Lift Shredder Feeder Afterburner Ash collection system Off-gas PMF FLOW DIAGRAM 3.3 PMF – KNPP BULGARIA 3 Plasma Treatment Plants Plasma torch

24. UNF International Conference27-28 March 2012 KIEV PLASMA TECHNOLOGY - AN OPTIMAL SOLUTION FOR WASTE MINIMIZATION 3.3 PMF – KNPP BULGARIA 3 Plasma Treatment Plants (Furnace w/Plasma Torch) – France (Civil Works + Utilities + Construction) – Bulgaria (STC + Off-gas) – Netherlands (Feeding System + Shredder) – Belgium (Slag Collection Chamber) – Spain (SCADA + C.E.M.) – Spain (Technological consultant – Switzerland

25. THANK YOU Susana Gutiérrez Waste Management and Decommissioning Department