2. ENGINEERING PROCESS DIAGRAMS AND CALCULATIONS · PDF fileENGINEERING PROCESS DIAGRAMS AND...

43 1.02 06/29/2000 Rev. 07

ENGINEERING DESIGN FILE Functional File No. 020996 EDF No. 1547 0 of 38

2. ENGINEERING PROCESS DIAGRAMS AND CALCULATIONS

The SSSTF T&FR document contains a block flow diagram (Figure 2-l) to show the requirements for the SSSTF. This diagram was used as the basis for the engineering process diagrams presented in this Engineering Design File (EDF). The purpose of the engineering diagrams (a high-level block flow diagram [BFD], decision diagrams, and process flow diagrams [PFDs]) is to initiate and document the engineering design and form a basis for the detailed design documents, such as piping and instrumentation diagrams and facility layout drawings. The legend for the process diagrams is given in Figure 2- 1.

The Staging and Storage Annex (SSA), the ICDF landfill, and the ICDF evaporation pond are shown in half tone on the BFD and PFDs. These facilities are outside the scope of the design phase of this project and are shown only to provide clearer definition of the SSSTF processes within the overall ICDF processes. The SSA will become a part of the SSSTF during operations.

2.1 Block Flow Diagram

The engineering BFD, Figure 2-2 (BFD-1) shows the major activities involving the flow of waste through the SSSTF facility. Each block shows an activity, such as storage or treatment, performed on the primary waste streams only. The amount of waste from the transport vehicle decontamination structure is expected to be significant enough to be included on the BFD with incoming waste streams. Items such as secondary waste, empty containers, and raw processing materials are not shown on the BFD.

The flags and lines show each waste stream and its progression through the facility. The waste inputs to the facility are categorized into streams according to processing method instead of waste generator codes to simplify the diagrams and to more easily provide for documenting future changes to waste streams.

2.2 .Decision Diagram

A decision diagram provides documentation of activities involved in processing waste in the SSSTF/ICDF that cannot be shown on the BFD or PFDs. The decision diagram for the SSSTFKDF waste processes is shown in Figure 2-3. Note, there is not a possibility of getting into an infinite loop of treatment/fail TCLP in the decision matrix. Based on experience at other sites, it is anticipated that treating waste will require at most 2 - 3 times through the process.

2.3 Process Flow Diagrams

In completed form, PFDs provide detailed engineering process design information upon which the physical facility design is based. At the current phase of the SSSTF project, PFDs are approximately 60% complete. These preliminary PFDs (Figures 2-4 through 2-7) expand upon the process shown in the BFD (Figure 2-2), translating activity blocks into facilities and equipment and showing alternate waste stream paths, secondary waste, and raw processing materials as they are currently understood.

Further development of the PFDs will follow approval of the processes documented in this and other EDFs. The diagrams will be continuously updated as part of the engineering design process.

2.4 Process Calculations

The following calculations support the unknowns identified in the T&FR document and the PFDs. Calculations included are incoming waste rates, design processing rates, and manloading estimates.

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ENGINEERING DESIGN FILE

-sue II 8 7 6 5 4 4 3 2 1

LOGIC DIAGRAMS

MAJOR mlwY-nE TO OTHER LOGIC

OECLSlON BLOCK

EQUIPMENT

-ET cENTRmGAL PUMP

CONE BOTTOM TM

cl

CLOSED TOP TANK

SUMP

BELT CMVEYOR

0 LlWlD STORACE OR EVAPOl?NlCf4 POND

ABBREVIATIONS

BFD BLOCK FLOW DlAGRM4 DEC DEClSlON D&GRAM GPH GMLONS PER HOUR HEPA HlGH-EFFICIENCY PARTlCULATE AIR lCDF INEEL CERCIA DISPOSAL FAClLllY wffl IOAHO NATlOM ENGINEERING AND ENVIRONMENTAL PFD PROCESS FLOW DLAGRAM SSA STORAGE & STAGING ANNEX SSSTF STDRACE. STAGING. SIZING & TREATMENT FACILI-IY WAG WASTE ACCEPTANCE CRITERIA

UBORATORY

BLOCK FLOW DIAGRAM

Figure 2-1. SSSTF Process Diagram Legend.

D

Functional File No. 020996 EDF No. 1547 Page 11 of38

43 1.02 06/29/2000 Rev. 07

ENGINEERING DESIGN FILE Functional File No. 020996 EDF No. 1547 Page 12 of 38

REAGENTS AND RAW MATERW FOR TREATMENT PROCESS

MATERAL

STATION

I I c------------y

\ TANK FARM A \ 4 )ScIiL UMPLES - ‘>--------

/ ORPHAN WASTE L------------4 ,’ T -----------------I /-T----jEt ---------- i ------------ ~---------- I--------------------------- ---------------- ------ -----ijiiw+

WASTE MEflING ICDF

NON-WUID WASTE REQUIRING TREATMENT IN SSSTF

(LUCHATE)

. , \ I _

/ , , - RECElPT. STAGI tG VERFlCATlON. (SUMP)

STALG \ \ \ I I / 1-I

I

!

STORAGE r (SW

A

SPEUAL CASE WASTE IS ANY WASTE THAT CAN’T BE

2 mwmatRr AND REPUIRES SPECIAL

DEVELOPMENT WATER THE SSS ANNEX, ICDF lANDflU. EVAPORATlON POND AND ALL ASSOClATED EQUIPMENT ARE OUTSlDE THE

CI

9

SCOPEOFTHlSPROJECT,ANOARESHOWNFOR

f REFERENCE ONLY.

3. THE !3SS ANNEX WlLL STORE ALL NON-UOUID WASTE

SWING UNTlL OPENING OF THE SS!5TF IN 2005. AN0 LlOUID

SSSTF STOf?M WATER - wm . \ WASTE THROUGH THE UFE OF THE SSSTF AS NEEDED. / I

!i gg

TANK FARM SOIL SAMPLES ARE NOT YET bERIFlE FOR INCLUS0N IN WASl’E INvINTORY.

- “3 ORCbNlC TREATMENT PROCESS IS NOT REQUIRED BY

STAGING-TREA ENT \ \ CURRENT WASTE INVENTORY. PROCESS IS UNDER

/ (SUMP) ;FlLTl?iNC) ’ EVALUATION AND INCLUDED BY CUSTOMER REQUEST.

I , ,

(SWDS)

SAMPLES TO OTHER INEEL FACILITY FOR

INEEL- SSSTF

fa tun/mwM YOUNILS SE 011 m

8 7 6 5 t 4 3 2 1

Figure 2-2. SSSTF Engineering Block Flow Diagram.

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ENGINEERING DESIGN FILE Functional File No. 020996 EDF No. I547 Page 13 of 38

C

E

i

WASTE PROFILE

NOTES Q DIAGRAM ASSUMES MAT ONLY WASTES MEETING

THE lCDF/SSSTF WAC WILL BE SHIPPED TO THE FACILllY.

BASED ON EXPERIENCE AT OTHER SITES. IT IS ANTICIPATED THAT TREATING WASTE WILL REOUIRE AT MOST 2-3 TIMES THROUGH THE PROCESS.

c

Figure 2-3. SSSTF Decision Diagram.

43 1.02 06/29/2000 Rev. 07


r-w- 11 8 7 6 5 4 4 3 2 1 Pf WSIONS

: fmcn~o*iz

T-------\ > WELL l’IJRGE/

OEVELOPMEElT WATER ;* --

i------’

f

r4 SPECIAL

is% REPACKAGING

STOkkGE

I :,-q A ’ rWE iil?&iiLi%E~’

r--------- ------ -T- - -- -)wATER TO D,APGRATION ‘>

r-------.-------’ s- ----- _I

L- PflD_IPyT-” _ i

I 1

:’ f TO UNDFLL (m-5)

STABILlZATK)N (PFD-3)

WASTE

4-l CONTUNER

STAGING

PROCESS STREAM

DESCRIPTION

. . xow faz ixska (C~NTUNERS/HR) 1.0

IOLUUE, TOT @OS) 35.765 0 35.765 VU3 VAR VAR VAR 446,035 - VAR VAR

r ROLL-OFF CONTMJERS 2.750 2.750 VAR VU? VAR VAR 34,464 VAR

IOLUME. TOT (CAL) 262.450 - I

NOTES

A 1 SPECIAL CASE WASTE IS ANY WASTE THAT CAN”T BE PROCESSED IN THE SSSTF AND REQUIRES SPECIAL HANDUNG PROCEDURES

THE SSA. ICDF LANDFILL, EVAPORATION POND AND ALL ASSOCIATE0 EWIWENT ME OUlSlDE THE SCOPEOFTl iESSSlFDESGN.ANDbJ?ESHOWN FOR REFERENCE ONLY.

A 3 PURGE/DEVELOPUENT WATER ACCEPTED AT THE ss!sTF MUST COUPLY WITH THE EP WAC

smcc+lRTl m INEEL-

i Figure 2-4. SSSTF Waste Receipt Process Flow Diagram.

43 1.02 06/29/2000 Rev. 07


1

C

E

‘4411 u 8 7 6 5 4 4 3 2 1

EilSlOWS

POWDER ADDITIVE POWDER BIN

STABIUZING REAGENTS REMENT

oao+rr~~noN WATER FROM DECDN PAD (PFD-5)

dONTAMlNATED (FAILED EVAP POND WbC)

I

(FAILED EVAP PONO WAC) 1

FROM SUMP (PFD-5) I 1

I I aw

MAKEUP WATER

PRE-MIX BIN I I

NOTES

A 1 BTABIUZED WASTE OUTPUT!3 ASSUME AVERSE 75X WASTE LOADING.

DESIGN FLDW RATES ARE BA!SED ON 13 WI3 ROLL-OFF CONTAIMRS.

I s I”

VALUES WILL BE FILLEO IN AS THEI BECOME AVAILABLE.

RAW WATER FOR rmzow~puTIoN 1 r I !5

cvwomnob4 POND DREDGIW (PFD-6)

INEEL FACIUlY FOR

Figure 2-5. SSSTF Stabilization Process Flow Diagram.

431.02 06/29/2000 Rev. 07


j 1

LANDflU WASTE

/‘\ I SUMP I

(MEETS EVAP POND WAC) lANoFlLL LEACHATE TO EVAPORATlON PONO (PFD-6)

DECOMAMINATION STATION

RAW WATER FOR DECONTAMINATION

EMPTY CONTUNERS TO WEIGH STATION (PFD-1)

mnJ=9 DECONTMlNATlON FlLTER

(FAlLS EVAP PONO WAC) WATER TO STAelUZAl lON IPFD-Sj

SOLIDS FROM OECONTAMlNATlON WATER TO STABlUZATlON (PFD-3)

A 2 .

I DESCRlPTlON 3

%jEE ygD =$gm %izF

L nowRATE.~(yDs/yR) 14,613 TBD TBD

now rtm. DESIGN (C~NTAINERS/HR) 1.0 VAR

VOLUME. TOT (d) 448,035 47.687 VAR TBD

1 rr------------- I n

z 28 8 I 7 6 I 5 t 4

I

NOTES

A 1 THE !33A. ICOF LANDFILL. EVAPORATION F’CNO AND ALL ASSOCIATED EOUIPMENT ARE OUTSIDE THE SCOPE OF THE SSSTF DESIGN. AND ARE SHOWN FOR REFERENCE ONLY.

A 2 VALUES WILL AVAILABLE.

BE FtLLED IN AS THEY

Figure 2-6. SSSTFACDF Landfill Process Flow Diagram.

431.02 06/29/2000 Rev. 07


-ml- I, a 7 6 5 4 4 3 2 1 REMSKNS

I

T;-PELL 77 JK% T - -- c,G / ~DEVEL!?PMElrT WkTER >-I------------ ---- --- ---------------- ~FRJM~EL.J’A&;- -_, -/

WATER FROM DECON (MEETS ww POND WAC) /’

\/

I

I

RAW WATER FOR \

‘\ \

\ \ \ I

I PONO DREDGING TO

I

OESCRlPTlON ZF ?GF-ElF wEll STATION WE& ii.%& c%i

.OW RATE. OESICN (CPM) 6 Tw TBO -

ILUUE. ml (YD ) lm )LUUE. TOT (GA&) 162.450

5000 GM WATER TANKS, TOT 53

I - I - * I

n / 1

/ /

,/ POND IXEOCING TO ./ IANoFlu (PFO-5)

, -.._ - - .--

NOTES THE SS4, ICOF UNOFlLL, EVAPORAllON PONO AN0 ML ASSOCIATED EQUIPMEM ARE OUTSlDE THE SCOPE OF THE SSI’F OESIGN, AND ARE SHOWN FOR REFERENCE ONLY.

VALUES WILL AVAILABLE.

BE FILLED IN As THEY BECOME

6 I / I 6 I 5 T 4 I 3 I 2 I 1

2 Figure 2-7. SSSTFACDF Evaporation Pond Support Process Flow Diagram.

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