INTRODUCTIONThere exists approximately 100 million gallons of radioactive waste in underground storage tanks (USTs) at Department of Energy (DOE) sites across the United States. Approximately 54 million gallons are stored at the Hanford Site.The DOE is responsible for immobilization and permanent disposal of this tank waste.The Hanford tank waste is currently classified as high-level waste (HLW).While low-level waste (LLW) can generally be disposed of subsurface on-site, HLW must be disposed of in an underground repository such as that planned for Yucca Mountain. Since LLW disposal is obviously much less expensive than HLW, the plan for remediation at Hanford is to separate the UST waste into a small volume of HLW and a large volume of LLW.Of the 54 million gallons of UST waste at Hanford, approximately 20 volume-percent is solids-based, consisting primarily of sludge, and the remaining 80 volume-percent is liquid-based, consisting of supernate, salt cake, and slurry liquid as shown in Exhibit 1.The sludge consists of well over 99 weight-percent nonradionuclides, as indicated by Exhibit 2.Without some type of sludge processing, the nonradionuclides will dictate a very large volume of immobilized HLW for permanent disposal.Therefore, partial separation of some nonradionuclides from the sludge, such as aluminum, chromium, sodium, and phosphorus, is essential prior to disposal.The separation is accomplished using a caustic wash process referred to as enhanced sludge washing (ESW). Even with ESW, radionuclide loading in the final immobilized HLW will be approximately 50-times less than that permitted by radionuclide heat generation alone (Swanson, 1994, p. 155).This is because the nonradionuclides can dictate the final immobilized glass volume due to physical property limitations such as the rate of glass crystallization.The aluminum, chromium, sodium, and phosphorus separated from The DOE's Office of Science and Technology (OST) has been the primary sponsor for the development and deployment of sludge wash testing. Since each of the 177 USTs at Hanford has a unique waste composition, no single set of sludge wash process conditions will minimize the final amount of immobilized HLW.The sludge wash process being developed at Hanford is referred to as ESW because the wash process is being developed beyond a generic process for all waste. Process parameters evaluated and/or optimized include time, temperature, caustic (NaOH) concentration, and additives targeting dissolution of specific species such as chromium.The time and temperature affect both the capital and operating costs. Excess caustic concentrations can produce excessive radionuclide dissolution, which can contaminate the separated aluminum, sodium, phosphorus, and chromium.Therefore, ESW development has been focused on determining the optimum time, temperature, and caustic concentration for multiple waste types.The author has conducted three past ESW cost studies for the Hanford Site.The first study (DeMuth, 1997) was based upon the original Westinghouse tank ...