Quarterly progress report on metallurgy research operations at Hanford Atomic Products Operation in Richland, Washington.

Report presenting research and development activities in the field of radioactive wastes. This particular report is concerned with the fixation of radioactive residues when the failure of a pot liner destroyed the furnace.

This report defines in detail the source of the dose rate of U233 and describes a method by which they may be predicted.

This report summarizes only that portion of the injection-casting experiments in which the castings were made with air pressure.

Startup and testing of the PRTR has been divided into three parts, Design Tests, Critical Tests and Power Tests. This document is the third of the series and describes the performance tests which will be made under nuclear power and the general schedule of operation. Responsibility for the startup of the reactor has been assigned to the PRTR Startup Council. The Power Test Sub-Council, which has done the planning of the initial power operation, was established by the Startup Council. Operation of the reactor will be the responsibility of the PRTR Operation (PRTRO).

Pressurized water nuclear reactors may be designed based upon either of two concepts: (1) pressure vessel, wherein the entire core is placed in a large, high strength fuel channels within a low pressure container. The Plutonium Recycle Test Reactor is a pressure tube type reactor. Selection of this basic type of pressurized water reactor depended to an appreciable extent upon the availability of suitable pressure tubing.

Calcination of liquid radioactive wastes, the process of converting metal nitrates and sulfates to oxides by heat, is under development at Hanford as a means of reducing these liquids to a dry powder or solid which can be stored safely. Radiant-heat spray calcination, one of the methods under study, was first investigated at the Oak Ridge K-25 Plant (1) as a possible method of calcining uranyl nitrate to uranium trioxide. The process has also been under extensive development at the Pulp and Paper Research Institute of Canada (2) and is designated by them as the Atomized Suspension Technique.

Facilities shall be provided in the 221-U Building for storing the metal solution product of the dissolution step in existing tankage from U, T, and B Plants until a reprocessing campaign is scheduled through Redox. This section shall provide a sampling tank for fuel accountability sampling and a pump tank from which the solution will be pumped via a cross-country pipeline to Redox for further processing.

A correlation between the optical densities if the Pb-Sn alloy system and UO2 with respect to Co^60 gamma radiation has been determined. This enables one to fabricate density standards of whatever geometry may be desired for one in the gamma absorptiometer by simply casting a Pb-Sn alloy of the proper composition to correspond to the density required.

The primary purpose of a cleanup system in a recirculating water loop is to maintain the best possible water quality conditions. This is normally accomplished by continuously purifying all or a portion of the coolant. A secondary objective of the cleanup system is to help maintain the system pH at a constant value. A system that will satisfactorily accomplish both of these objectives is at times difficult to obtain. Generally the pH control characteristics are sacrificed in favor of the more important cleanup requirements. A somewhat new approach to the problem pf cleanup system design appears to offer a solution to this problem for high pH systems.

In the past several years the use of neutron monitors for Pu concentration monitoring has been expanded in the Chemical Processing Department. Most of these monitors have been quite successful, and considerable effort is being made to improve the operation of both existing and future monitoring systems. One of the major improvements has been the development and use of a transistorized pre-amplifier or impedance matching circuits. This unit solves several problems associated with the use of boron trifluoride (BF3) neutron detectors in process monitoring; e.g., vacuum tube pre-amp failure because heat is not being conducted away.

Ultrasonic cleaning uses high-frequency sound waves to induce cavitation within a cleaning, medium. During cavitation, millions of small bubbles form and collapse, resulting in agitation proportional to the energy put into the solution. The making and breaking of these bubbles produce the scrubbing action associated with ultrasonic cleaning.

The majority of two-phase flow problems involving equations of state are solved by use of point-wise utilization steam table values. In this manner, problems involving the use of the various flow equations of continuity, momentum and energy are generally forced into iterative solutions. Considerable effort towards the development of an analytical expression for the state equation seems indicated so as to simplify the analysis of two-phase problems, particularly the transient cases. The question of instability of state and mixture condition is particularly apparent in the analysis of systems undergoing phase transformation as demonstrated by the significant difference between simple theory and experimental critical flow determinations. The assumption of homogeneous, equilibrium mixtures is indicated as a first attack upon the problem.

In October 1959, a combination testing station developed at HAPO was reported to the Sheath committee. This testing station consisted of electronic instrumentation and mechanical scanning equipment to check coextruded fuel elements (rod and tube) for clad thickness, clad integrity, bond, and core integrity. The clad tests are performed by eddy current methods and the other are ultrasonic.

The large scale application of Zircaloy-2 pressure tubes for structural use either in or out of reactor service, is without precedent. For more common materials, there normally are adequate data and long operating histories on which to base design and service limits. In the absence of such information for Zr-2, several investigative programs have been devised to provide much of the information from which design and service limits may be defined for Zr-2 pressure tubes. These investigations encompass in-and-out-of-reactor creep and stress-rupture testing, pre-and-post irradiation testing, and bust strength, as well as the effect of flaws or defects (from both fabrication and service origins) on burst strength and fracture characteristics. Already creep and stress rupture testing of unirradiated Zircaloy-2 is well advanced, and some experimental pre-irradiation burst testing has been carried out and will be extended rapidly as improved equipment becomes available. One irradiated KER tube sample has been burst tested and the requirement for post irradiation burst testing equipment have been defined.

Limitations on the service life of a fuel element imposed by degradation of the fissile core during irradiation have been a matter of great concern. Limitations imposed by changes in cladding properties during irradiation should be evaluated with equal care. Zircaloy-2, stainless steel, and aluminum alloys have been irradiated in the form of cladding on metallic and ceramic fuel elements. Several aspects of fuel behavior as influenced by these clad materials will be discussed. All observations related to irradiation behavior in this paper have been made on fuel specimens irradiated in water coolant.

aluminum has been considered as a material for cladding fuel elements to be used in reactors cooled by high-temperature recirculating water. Aluminum is abundant, chap, has a relatively low cross section for thermal neutrons, and is readily fabricated into complex shapes. For these reasons, it appears that the use of aluminum rather than steel, Zircaloy or other candidate materials for fuel element cladding, would result in considerable savings in operating expense. The actual economics will of course depend on specific factors such as core materials and design of the reactor/. Aluminum appears particularly attractive for cladding the cores of aluminum-plutonium alloy proposed for the Plutonium Recycle Test Reactor since, in this case, the physical characteristics of the core and cladding would be practically identical.

This document presents the bases for those PRTR Process Specifications involving considerations of heat transfer and fluid flow. It will be noted that some of the bases incorporate information gained from laboratory experiments with electrically heated test sections simulating PRTR fuel elements. These experiments are described in some detail elsewhere.

The temperature characteristics associated with the handling of self-boiling radioactive wastes from the separations extraction processes in the Chemical Processing Department have necessitated several heat transfer studies. Earlier studies 1,2,3 defined the feasibility of self-concentration in existing waste storage facilities by determining the rate of heat generation from the decay of stored fission products and by defining the rate of heat loss from existing storage tanks to the surrounding soil.

"The PRTR Pressured Gas-Cooled Loop Facility, or Gas Loop, is an experimental facility to be installed in the Plutonium Recycle Test Reactor for use in studies contributing to advancement of the technology of gas-cooled reactors. The facility will provide an in-reactor loop for studying phenomena occurring under conditions likely to exist in gas-cooled reactors.

This report was written to describe briefly several possible variations of such systems along with probable cost estimates. Previous work has been shown that the application of scintillation detectors is the simplest and most reliable means for such monitoring. By proper detector selection and measuring methods, the system can be of an approximate gamma dose-rate with gamma energy independence above about 100 Kev. The same system using detector change only is directly applicable to beta, gamma, slow neutron and fast neutron detection. Any type of alarming device desired can be incorporated.

Several hollow uranium cores of "C" size I & E diameters were fabricated by cold extrusion (550 to 750 F) at Hunter Douglas Aluminum Corporation. Results show diameter control and reproducibility are excellent. Preferred orientation induced by this process is completely removed by a single standard beta heat treatment.

Laboratory studies involving fluid flow through porous media require use of fluids having low dissolved gas content. Water is the major fluid used in various and box model and soil permeability studies carried out by the Geochemical and Geophysical Research group. Tap water supplied to the 222-U Bldg. contains a large amount of dissolved air. Under the reduced pressure encountered during model studies, the air is released from solution and gradually clogs the pores of the sand or other porous material. This, of course. leads to anomalous results and cannot be tolerated in precious studies. A system was required to effectively remove the air and make available a continuous supply of desired water for the model studies.

The build up of contaminated film on the internal surfaces of high temperature in-reactor recirculating water loops has created serious radiation exposure problems to operational and maintenance personnel. A considerable amount of work has been applied to develop an effective decontamination process for the decontamination of these loops and their components.