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Executive SummaryA "hydroceramic" nuclear waste form, developed especially to address the immobilization of the reprocessing wastes from the Idaho National Engineering and Environmental Laboratory, has been demonstrated to possess superior chemical and mechanincal properties. Furthermore, the processing requirements of hydroceramic waste forms are simple, less costly and offer greater safety to INEEL personnel than other waste form preparation systems.The objective of this research was two fold. The initial phase of the study was to systematically survey the suitability of readily available pozzolanic additions as raw materials for hydroceramic formulations in order to identify a source material that would be compatible with the established processing requirements for the waste form i.e., no excessive water demand, proper mineralogical composition of the waste form, low leachability, waste loadings greater than 20 weight percent calcine and also readily available to INEEL in large quantities once the pozzolan(s) selection was made. Pozzolanic materials are normally finely divided substances that contain either glassy or crystalline sources of silica that are chemically reactive enough to combine with lime and water at room temperature to form cementitious material. The primary objective of the research program was to establish the final processing parameters for the preparation of hydroceramic waste forms form INEEL wastes i.e., the rate at which hydroceramic is formed, the phases that formed and the optimum temperature needed to minimize leachability.A total of 20 pozzolanic materials were surveyed. These included a number of different fly ash sample, natural and thermally altered clays, reactive aluminas and even finely ground bottle glass. The survey resulted in the selection of a natural, thermally altered clay (metakaolinite) that has found extensive use in the manufacture of blended Portland cement and currently mined in Troy Idaho.A "host" matix formulation was initially developed using Troy metakaolinite and all processing parameters and chemical and mineralogical characterization was conducted on these samples. Once developed, the host matrix was used to subsequently prepare waste forms based on fluorinel and zirconia simulated calcines supplied by INEEL. A waste loading study was conducted in order to determine the maximum loading that could be sustained and still exibit the leaching characteristics and mechanical properties of the laboratory specimens. The "host" matrix samples and the two waste forms were processed at 75, 85, 95, 125, 150, 175 and 200 o C at 100% relative humidity for times often exceeding 500 hours. Two sets of mineralogy were observed for the "host" samples and "waste loaded" samples. The waste loading study optimized the hydroceramic waste form at 30% by weight for both fluorinel and zirconia waste calcines.The hydration rate studies conducted as a function of time and temperature determined that both the "host" matrix formulation and the fluorinel and zirconia waste loaded...