Sellafield Ltd operates a Waste Vitrification Plant (WVP) to immobilise the arisings from the reprocessing of spent nuclear fuel. Washout of solids from the base of waste storage tanks in preparation for decommissioning is likely to produce feeds enriched in molybdenum to the WVP. Vitrification of such feeds in the borosilicate glass formulation currently used by the WVP for vitrification of reprocessing waste has been investigated to determine the maximum achievable loading of MoO3.The vitrification of molybdenum in the absence and presence of reprocessing waste was studied. A number of glasses were manufactured in the laboratory containing various waste loadings. The resultant glasses were examined both visually and under the scanning electron microscope for the presence of any phase separation. Additional aluminium was added to the glasses manufactured in the absence of reprocessing waste to improve the durability of the glass. In borosilicate glass containing 3.5 wt% Al2O3 the onset of a molybdenum phase separation was observed in glasses containing 2.6 wt% MoO3. In the presence of Magnox reprocessing waste, phase separation was observed when the product contained >3.8 wt% MoO3. Soxhlet durability testing of a selection of the glasses manufactured was carried out. The Soxhlet durability of glasses in the absence of phase separation was good.

The Sellafield Waste Vitrification Plant (WVP) immobilises highly active liquid waste (HAL) arising from the reprocessing of spent nuclear fuel in the UK. In order to optimise WVP operations a full scale working replica of a WVP processing line, the Vitrification Test Rig (VTR), was constructed to processes non-active HAL simulants. Recently the VTR has been used to determine an operational envelope for the vitrification of HAL from Magnox reprocessing at a waste oxide incorporation rate in glass of up to 35wt% (compared to a “standard” incorporation rate of 25wt%). This paper discusses the differences in operating conditions necessary to achieve acceptable waste throughput at the increased incorporation rate. The chemical durability of the resulting vitrified product is also discussed, along with the formation of secondary phases, and a comparison is drawn between 35wt% incorporation glasses and products made at the standard 25wt% incorporation.

The Sellafield Waste Vitrification Plant (WVP) immobilises highly active liquors produced during reprocessing of spent nuclear fuel by bonding the fission products as metal oxides into a borosilicate glass matrix. This provides a stable and durable waste form suitable for safe long term storage and ultimate disposal.WVP was commissioned with feed from reprocessing of Magnox reactor fuel. This material is relatively low in fission product content per tonne of fuel, but contains significant Al and Mg from fuel cladding. WVP also routinely treats a blended feed made from a mixture of Magnox and Oxide reprocessing products. The Oxide fuel from Light Water Reactor (LWR) and Advanced Gas Cooled (AGR) power stations is of higher burnup and contains more fission products per tonne of fuel, also Gd and other process additives. Blending allows 25% incorporation of waste oxides by weight in glass to be achieved routinely.Recent programmes of development work in WVP have been aimed at increasing incorporation rates for these feeds, to reduce the number of waste containers produced for disposal. Work has also focussed on increasing the throughput of WVP, to more rapidly treat current stocks of liquid reprocessing waste, both by increasing the feed rate and by improving the lifetime of key components to improve plant availability.Future challenges for WVP include flowsheet changes to treat historic stocks of reprocessing wastes containing high U, Fe and Cr. Washout of solids from the base of waste storage tanks in preparation for decommissioning is also likely to give high Mo feeds. Development of flowsheet and glass formulation to accept these changes in feed composition will be a key objective of future work.