This alternative involves those activities required to support the production and maintenance of the secondaries and case components of the nuclear weapons physics package as follows:
Functional capabilities required to perform these activities include
operations to physically and chemically process, machine, inspect,
assemble, certify, disassemble, and store secondary materials.
Management of wastes generated from these operations is also required.
The fabrication of secondaries and cases can be subdivided into
the following major material production processes: uranium, lithium,
and nonnuclear/special materials. The following typical process
descriptions are provided to illustrate the functional activities
and operations associated with each of the major production processes.
These processes are based on traditional secondary and case fabrication
methods and represent upper bounds to the types and number of
processes that would be continued in the downsized and reconfigured
Complex. Alternative sites for performing secondary and case fabrication
are Y-12, LANL, and LLNL. The site-specific descriptions provided
in sections A.3.2.1 to A.3.2.3 are based on more streamlined and
less unit operations than described in this section. When comparing
data between site alternatives, it is important to note that there
are differences in the facility designs. The Y-12 alternative
considers all the necessary support facilities to conduct the
missions, not just the production and storage facilities. The
LANL and LLNL alternatives only consider the incremental changes
for operating the production facilities. The actual production
footprint size of each alternative is almost identical; however,
the production capacities vary between site alternatives. For
example, base case, multiple-shift capacities at Y-12 and LANL
are about 150 units, whereas at LLNL the equivalent production
capability would be about 50 units. This creates significant differences
in some of the data.
Process Descriptions
Uranium. The uranium process provides finished uranium
parts and products. The operations are capable of all uranium
handling and processing functions, from raw materials handling
to finished parts manufacturing. In addition, uranium storage
areas need to be provided for storage of in-process uranium materials
and, at ORR only, for the HEU strategic reserve. In the event
secondary and case fabrication is phased out at ORR and performed
at LANL or LLNL, the storage of the HEU strategic reserve would
be addressed at the weapons A/D site (i.e., Pantex or NTS).
The production of uranium parts and products involves casting
or wrought processing; metal- working; machining, inspection,
and certification; chemical recovery; assembly, disassembly, and
quality evaluation; and in-process storage. The products from
casting or wrought processing are billets and cast parts that
feed directly to machining and metalworking. Billets are cropped
and cast parts are delugged before they are sent to the next operation.
The input to casting consists of retired weapons parts, metal
buttons from storage, and recycled scrap metal from metalworking
and machining. A casting charge is made up and processed in a
critically safe configuration in a vacuum induction furnace. Scrap
metal and machine turnings are degreased, cleaned, and briquetted
before direct recycle.
Metalworking prepares a wrought product as feed for machining.
Cropped billets from casting are preheated in a salt bath, rolled
into a sheet, annealed in a salt bath, blanked, and pressed. The
blanking operations are a major source of recycled metal for casting.
Formed parts are cleaned, debrimmed, and machined.
Both formed and cast blanks are machined to finished dimensions
and inspected. Scrap metal and machine turnings are returned to
casting for cleanup and reuse. Miscellaneous solids are sent to
the chemical recovery systems for treatment to recycle the material
back to metal buttons. Product inspections and certification is
accomplished with coordinate measuring machines, optical gaging,
high-energy x-ray radiography, ultrasonic and dye penetrant flaw-inspection
methodology, plating thickness gaging, and mechanical properties
testing.
Uranium chemical recovery receives feed from virtually all areas
in the process. The major feeds are residuals from casting, impure
metal chips from machining, and a miscellaneous array of combustibles
from all areas. The feeds are incinerated and processed in a head-end
treatment consisting of acid dissolution, leaching, and feed preparation
for solvent extraction. The feed solution is processed through
primary extraction by which it is purified, concentrated by evaporation,
and purified further by secondary extraction. The resulting solution
is converted to oxide, then to uranium tetrafluoride, and then
to uranium metal buttons. Secondary residues are returned to the
head-end treatment. Finished metal is returned to casting for
reuse.
Assembly operations assemble piece parts into subassemblies using
joining techniques such as welding, adhesive bonding, and mechanical
joining. Disassembly takes retired weapons apart and recycles
all materials of value. The quality evaluation function receives
weapons from the stockpile for disassembly, evaluation, and lifecycle
testing. Shipping containers for weapons parts and subassemblies
are certified and refurbished as part of the A/D process.
Uranium storage includes storage vaults for in-process uranium
materials, which includes buttons and other scrap materials directly
recycled, as well as semi-finished and finished components. The
vaults at ORR are also for the strategic reserve, which includes
assembled secondaries and HEU metal castings.
Lithium. The lithium process provides finished lithium
hydride and deuteride parts. Primary functional elements of this
process include powder production and forming, finishing and inspection,
and deuterium production. These systems are briefly described
below.
The lithium hydride and deuteride from storage, recycled weapons
parts, and manufacturing scrap are broken, crushed, and ground
to produce powder. The powder is loaded into molds and cold isostatically
pressed to form solid blanks.
The blanks are unloaded from the molds and placed into vacuum
furnaces where they are outgassed by heating under vacuum. After
cooling, the outgassed blanks are loaded into form-fitting bags,
heated, and then warm pressed. After being warm pressed, the blanks
are cooled to room temperature and removed from the bags. The
fully dense machining blanks that result from forming operations
are radiographed to detect any high-density inclusions. Powder
production, mold loading, and radiography are all performed in
dry glove boxes to minimize reaction of the lithium hydride and
deuteride with moisture in the atmosphere. Mold unloading, furnace
loading and unloading, and bag loading and unloading are all conducted
in an inert glove box. The lithium hydride or deuteride is handled
outside inert-atmosphere glove boxes only when it is sealed in
a mold or bag.
The blanks from forming operations are machined to final shapes
and dimensions on lathes using single-point machining methods
in finishing operations. Most machine dust is collected for direct
recycle salvage operations. The finished part weight and dimensions
are inspected using certified balances and contour measuring machines.
All machining and inspection activities are conducted in dry glove
boxes to minimize any reaction with moisture in the atmosphere.
Certified parts receive a final vacuum outgassing treatment before
final assembly.
Deuterium is required for many of the products and will be stored
for future use. Deuterium oxide, or heavy water, is electrolytically
reduced. The resulting deuterium is compressed and stored for
use. The compressed deuterium gas is used to reconvert the lithium
metal to deuteride in the final step of wet chemistry if needed.
Lithium wet chemistry can be used to pre-produce lithium hydride
and deuteride to meet production requirements for many decades.
The principal function of wet chemistry is to purify lithium hydride
and deuteride by removing oxygen and other trace elements. The
principal feeds to this system are retired weapon components from
the disassembly operation, machine dust, powder, and killed parts
from other operations. Purification is accomplished by transforming
the lithium hydride and deuteride through a chemical dissolution
process; then the solution is evaporated and crystallized. The
crystals are then reduced to lithium metal and impurities are
removed. The lithium metal is then reconverted to lithium hydride
and deuteride by combining it with hydrogen or deuterium gas.
The resulting lithium hydride and deuteride billet, sealed in
a thin stainless-steel can, is transferred to lithium storage.
The production of lithium hydride and deuteride components creates
a considerable amount of scrap that must be recycled to recover
the lithium and deuterium. Much of the machine dust, unacceptable
formed parts, machined parts that fail inspection, and stockpile
returned parts are directly recycled. Salvage operations typically
process material that is too impure to be recycled. Salvage operations
primarily involve washing and chemical recovery. Items that require
washing include machining tools and fixtures, filters used throughout
the processes, and sample bottles. Oil-soaked lithium hydride
and deuteride blanks from the powder-forming operations are also
prepared for storage. Solutions from the purification and wash
operations, including mop and dike water streams, are neutralized,
filtered, crystallized, and sent to storage or waste disposal.
Long-term storage is required for chemicals and pre-produced lithium
hydride and deuteride billets. Interim storage is to be provided
for lithium hydride and deuteride components from disassembly
or retired weapons and rejected components from forming and finishing
operations.
Special Materials. Special materials such as diallyl-phthalate
are required to support the lithium processes. Diallyl-phthalate
based molding compound is formed into near-net-shape blanks that
are later machined to finished parts. The primary forming operation
is compression or transfer molding, which is followed by a drying
and final curing step.
Nonnuclear. The nonnuclear process is responsible for producing
certain weapon components composed of nonnuclear materials and
for providing the uranium and lithium processes with specialized
material and support services. Many types of materials are processed
to provide a diverse product line consisting of both nonnuclear
metal components and tooling and a variety of polymer-based items.
The principal manufacturing technologies employed are hydroforming,
hydrostatic forming, rolling, forging, heat treating, welding,
machining, cold/hot isostatic pressing, grinding, winding, casting,
plating, molding, and coating.
The nonnuclear process handles several product streams, which
are described briefly in the following paragraphs.
Several types of urethane foams are required to be produced. The
urethane components and blowing agents are pumped into molds and
allowed to expand to fill the mold. After curing, the foam moldings
are ejected and trimmed to final shape.
Steel and aluminum are construction materials for both components
and support tooling, making this a relatively high throughput
product line. The usual fabrication route for both materials is
rough machining, heat treatment, and finish machining.
Operations to produce stainless steel cans consist of blanking,
followed by hydroforming and hydrostatic forming with subsequent
machining and heat treatment. Ultrasonic cleaning is required
before heat treatment to ensure cleanliness for welding, which
completes the assembly.
Ceramic finished parts are finished from blanks or procured. Procured
parts are inspected and certified prior to final assembly.
Polyvinyl chloride is formed into bags and castings and also applied
as a coating. Items to be coated are dipped into a tank of curable,
plasticized polyvinyl chloride formulation, whereas castings are
produced by transferring the polyvinyl chloride liquid into a
mold. All items are heat cured.
Y-12 has performed the secondary and case fabrication mission
in the Complex for over 40 years. This mission includes the production
of materials and components for thermonuclear weapons secondary
assemblies and the associated functions such as depleted uranium
for radiation cases and other miscellaneous materials for other
applications. Figure A.3.2.1-1
shows the location of Y-12 at ORR.
The Y-12 secondary and case fabrication mission requires approximately
30 ha (75 acres) of the existing 328-ha (811-acre) Y-12 site.
This, unlike the LANL and LLNL alternatives, includes significant
area for support facilities. There would be no new developed land
outside the currently existing Y-12 boundary. Land for construction
laydown and warehousing would be minimal and would use existing
Y-12 developed areas; construction parking requirements, about
0.8 ha (2 acres), can be satisfied by existing unused parking
facilities.
The Y-12 complex consists of an array of production and support
facilities. The physical configuration for the Y-12 secondary
and case fabrication mission consists of five main production
buildings, one shared production facility, and a number of office,
utility, and changehouse facilities.
During the past 12 years, major restoration projects (such as
Production Capability Restoration, Utility System Restoration,
and the Capability Assurance Program) have brought the infrastructure
supporting this facility up to current standards and should allow
the use of these facilities for up to an additional 40 years.
Figure A.3.2.1-2 is a plot
plan of Y-12 showing these main and shared facilities.
The secondary and case fabrication mission would be located in
the following Y-12 production buildings: 9996, 9212, 9215, 9201-5N,
9204-2E, 9204-2 (isostatic press), 9720-19, and 9998. The secondary
and case fabrication mission footprint comprises 61,800
m 2 (665,000 ft 2 ) of total DP area including a
production footprint of 21,840 m 2 (235,000 ft
2 ). The total proposed footprint includes all DP functions:
production, storage, maintenance, dedicated utilities, and administration.
Buildings 9204-2 and 9201-5W would be placed in cold standby to
enable reactivation in the event of unforeseen additional capacity
demands. Activation of these buildings would require separate
NEPA evaluation.
The following production buildings would be used to support the
Stockpile Stewardship and Management Program.
Building 9212
Building 9998
Building 9215
Building 9996
Building 9204-2
Building 9201-5N
Building 9201-5W
Building 9720-19
Building 9204-2E
No new facilities are required at Y-12 to support the secondary
and case fabrication mission. Table A.3.2.1-1
summarizes key facility data, such as plant functions, nuclear
materials present, building square footage, number of floors in
the building, and type of construction.
Construction. Modification of Y-12 facilities to support
the secondary and case fabrication mission would require 6 years
to complete. The materials and resources that would be consumed
during this period are summarized in table A.3.2.1-2.
Emissions generated during construction are provided in table A.3.2.1-3.
The principal sources of airborne emissions from construction
are fugitive dust, construction activities, and exhaust from construction
equipment and vehicles. Construction employment for the Y-12 Secondary
and Case Fabrication Facility modification is shown in table A.3.2.1-4.
Operations. The secondary and case fabrication mission
processes require the following utilities during operations: electricity,
diesel fuel, natural gas, coal, air (compressed, dehumidified,
and breathing), water (demineralized, fire, potable, plant, and
cooling tower), and steam. Table A.3.2.1-5
presents the estimated utilities consumed during surge operation
of the Y-12 secondary and case fabrication facilities. Chemicals
consumed during secondary and case fabrication surge operations
are summarized in table A.3.2.1-6.
Emissions. The contaminated and potentially contaminated
zones within the plant facilities that handle uranium materials
have high efficiency particulate air (HEPA) filtered ventilation
systems that exhaust to the atmosphere. Some exhausts are provided
with liquid scrubbing prior to HEPA filtration to remove chemical
vapors such as nitric acid. The annual emissions for surge operation
of the Y-12 secondary and case fabrication mission are shown in
table A.3.2.1-7.
|
|
|
|
|
|
|
| 9103 | Communication/support | 10 | 6,780 | 3 | B-1 | |
| 9117 | Communication/support | 10 | 1,810 | 1 | A-5 | |
| 9119 | Administration/support | 100 | 6,660 | 4 | B-5 | |
| 9201-5N | Uranium/nonnuclear | 85 | Uranium | 7,480 | 2 | B-2 |
| 9204-2E | Uranium | 85 | Uranium | 14,050 | 3 | B-1 |
| Lithium | 10 | Lithium | ||||
| Maintenance/support | 5 | |||||
| 9212 2 | Uranium | 40 | Uranium | 28,930 | 3 | B-2 |
| 9215 | Uranium | 90 | Uranium | 14,590 | 3 | B-2 |
| Nonnuclear | 10 | |||||
| 9401-3 | Steam plant support | 10 | 3,130 | 3 | B-4 | |
| 9404-2 | Compressed air/support | 40 | 430 | 1 | B-2 | |
| 9706-2 | Emergency Operations Center | 20 | 2,040 | 2 | A-2 | |
| Medical/support | 20 | |||||
| 9710-2 | Fire station | 10 | 1,760 | 1 | B-2 | |
| 9710-3 | Security/support | 60 | 3,820 | 4 | B-3 | |
| 9711-5 | Cafeteria/support | 10 | 5,360 | 2 | B-1 | |
| 9723-31 | Changehouse/support | 50 | 2,710 | 2 | B-3 | |
| 9995 | Plant laboratory | 7,810 | 2 | B-3 | ||
| Uranium | 6 | Uranium | ||||
| Lithium | 3 | Lithium | ||||
| Nonnuclear | 1 | |||||
| 9996 | Uranium | 100 | Uranium | 3,110 | 2 | B-3 |
| 9998 | Uranium | 70 | Uranium | 12,740 | 2 | B-3 |
| Nonnuclear | 20 |
|
|
|
| Concrete (m3) | 100 | |
| Electricity (MWh) | 2.7 | 0.2 MWe |
| Industrial gases 4 (m 3 ) | 300 | |
| Liquid petrochemicals (L) | 10,000 | |
| Steel (t) | 20 | |
| Water (L) | 2,000,000 |
|
|
| Carbon monoxide | 2.4 |
| Nitrogen oxides | 0.8 |
| Particulate matter | 0.6 |
| Sulfur dioxide | 0.1 |
| Total suspended particles | 1.0 |
| Volatile organic compounds | 1.2 |
OR MMES 1996j . |
|
|
|
|
|
|
|
|
| Craftworkers | |||||||
| Carpenter | 0.4 | 0.4 | 0.4 | 0.4 | 0.4 | 0 | 2 |
| Concrete mason | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 0 | 1 |
| Electrician | 1 | 1 | 1 | 1 | 0.5 | 0.5 | 5 |
| Iron worker | 2 | 2 | 2 | 2 | 2 | 2 | 12 |
| Laborer | 1 | 1 | 2 | 1 | 1 | 1 | 7 |
| Millwright | 0.5 | 0.5 | 0.5 | 0.5 | 2 | ||
| Operator | 0.5 | 0.5 | 0.5 | 0.5 | 0.5 | 0.5 | 3 |
| Other craftworkers | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 1 | |
| Pipe fitter | 0.5 | 0.5 | 0.5 | 0.5 | 0.5 | 0.5 | 3 |
| Sheet metal worker | 0.4 | 0.4 | 0.4 | 0.4 | 0.4 | 2 | |
| Sprinkler fitter | 0 | ||||||
| Teamster | 0.3 | 0.3 | 0.3 | 0.4 | 0.4 | 0.3 | 2 |
| Total Craftworkers | 6.5 | 7.0 | 8.0 | 7.1 | 6.6 | 4.8 | 40 |
| Construction management and support staff | 5.2 | 5.6 | 6.4 | 5.7 | 5.3 | 3.8 | 32 |
| Total Employment | 11.7 | 12.6 | 14.4 | 12.8 | 11.9 | 8.6 | 72 |
|
|
|
| Coal (t) | 500 | |
| Diesel fuel (L) | 250,000 | |
| Electricity | 118,000 MWh | 19.0 MWe |
| Natural gas 7 (m 3 ) | 17,000,000 | |
| Raw water (L) | 1,510,000,000 |
|
(kg) |
| Solid Chemicals | |
| Aluminum trihydride | 3,000 |
| Barium nitrate | 15 |
| Borax | 15 |
| Calcium hydroxide | 30,000 |
| Calcium nitrate | 150 |
| Calcium oxide | 150 |
| Curing agent | 4 |
| Diatomaceous earth | 2,500 |
| Epoxy resin | 10 |
| Erbium oxide | 75 |
| Ferric sulfate | 7,500 |
| Graphite | 2,000 |
| Lithium carbonate | 1,200 |
| Magnesium sulfate | 100 |
| Methylene diphenyl diisocyanate | 100 |
| Nickel compounds | 75 |
| Polycure | 75 |
| Potassium carbonate | 3,000 |
| PVC plastisol | 1,500 |
| Silicon carbide | 40 |
| Sodium bicarbonate | 75 |
| Sodium carbonate | 450 |
| Sodium molybdate dihydrate | 5 |
| Sodium nitrate | 1,500 |
| Sodium potassium | 3 |
| Trisodium phosphate | 250 |
| Tungsten carbide | 1 |
| Yttria | 150 |
| Zirconium oxide | 180 |
| Liquid Chemicals | |
| Acetic acid | 15 |
| Acetone | 8 |
| Acetonitrile | 150 |
| Anisol | 200 |
| Corrosion inhibitor | 800 |
| Diamond paste | 1 |
| Diesel fuel | 75,000 |
| Ethanol | 1,000 |
| Gasoline | 110,000 |
| Hydraulic oil | 3,000 |
| Hydrogen peroxide | 750 |
| M-pyrol | 50 |
| Methanol | 2,500 |
| Micro/oakite detergent | 12 |
| Mineral oil | 1,500 |
| Mold release | 7.5 |
| Nitric acid | 1,000 |
| Nitrogen tetroxide | 150 |
| Oxalic acid | 2 |
| Petroleum oils (lubricants) | 1,500 |
| Potassium chloride | 15 |
| Propylene glycol | 150 |
| Pump oil | 3 |
| PVC primer | 2 |
| Solvent 140 | 750 |
| Toluene 2,4-diisocyanate | 100 |
| 1,1,1-Trichloroethane | 800 |
| Gaseous Chemicals | |
| Ammonia, anhydrous | 7.5 |
| Argon | 1,400,000 |
| Carbon dioxide | 30,000 |
| Chlorine | 75 |
| Freon or equal (cleaning) | 750 |
| Helium | 6,000 |
| Hydrogen | 1,500 |
| Nitrogen | 5,000,000 |
| Oxygen | 50,000 |
| Note: PVC- polyvinyl chloride. Source: OR MMES 1996j; ORR 1995a:4 . | |
Employment. Y-12 generally operates with one shift per
day, 5 days per week, except for some utility systems and security
functions that operate continuously. Surge capacity would be accommodated
by operating multiple shifts. The employment during surge operation
for the secondary and case fabrication mission is summarized in
table A.3.2.1-8. The data presented
includes employees from the management and operating contractor,
support organizations, and DOE.
|
|
| Carbon monoxide | 7.4 |
| Chlorine | 0.15 |
| Hydrogen chloride | 4.8 |
| Methyl alcohol | 14 |
| Nitric acid | 7.1 |
| Nitrogen oxides | 195 |
| Ozone | 0.07 |
| Particulate matter | 0.5 |
| Pressing lubricant | 0.3 |
| Sulfuric acid | 1.8 |
| Sulfur dioxide | 80 |
| Total suspended particles | 10 |
| Volatile organic compounds | 1.2 |
| Radiological Isotope |
Estimated Release |
| Uranium-235 (microcuries) | 420 |
| Uranium-238 (microcuries) | 1,490 |
OR MMES 1996j; ORR 1995a:4. | |
Approximately 20 percent of the dosimeter badged population at Y-12 routinely work inside the radiological area (uranium handling areas). Based on current design definition, 20 percent is also assumed for the Y-12 secondary and case fabrication mission. Therefore, it is estimated that 174 of the badged employees would be at risk of radiological exposure as shown in table A.3.2.1-8. In addition, on a nonroutine basis, a small fraction of badged visitors may enter the radiological area.
|
|
|
| Craftworkers | 131 | 61 |
| Laborers | 8 | -- |
| Officials and managers | 88 | 7 |
| Office and clerical | 95 | -- |
| Operatives | 93 | 43 |
| Professionals | 284 | 35 |
| Service workers | 584 | -- |
| Technicians | 93 | 28 |
Total Employees |
1,376 | 174 |
OR MMES 1996j; ORR 1995a:4. | ||
Waste Management. The solid and liquid nonhazardous wastes
generated during modification activities would include concrete
and steel construction waste materials and sanitary wastewater.
The steel waste would be recycled as scrap material before completing
construction. The remaining nonhazardous wastes generated during
construction would be disposed of by the construction contractor.
Uncontaminated wastewater would be managed per site practice.
Wood, paper, and metal wastes would be shipped offsite to a commercial
contractor for recycling. Hazardous wastes would be packaged in
DOT-approved containers and shipped offsite to commercial RCRA-permitted
treatment, storage, and disposal facilities. A small amount of
solid LLW consisting of contaminated steel and concrete would
be generated. This waste would be placed in an appropriate container
and shipped to an approved LLW disposal facility.
The project design considers and incorporates waste minimization
and pollution prevention. Production processes would be configured
with minimization of waste production given high priority. Future
D&D considerations have also been incorporated into the design.
Table A.3.2.1-9 presents the estimated
annual waste volumes from the secondary and case fabrication facilities
during modifications and surge operations. Solid and liquid waste
streams are routed to the waste management system. Figures A.3.2.1-3
through A.3.2.1-6 [figure A.3.2.1-4]
[figure A.3.2.1-5] depict
the waste management system. Solid wastes would be characterized
and segregated into low-level, hazardous, and mixed wastes, then
treated to a form suitable for disposal or storage within the
facility. Liquid wastes would be treated onsite to reduce hazardous/toxic
and radioactive elements before discharge or transport. All fire-sprinkler
water discharged in process areas would be contained and treated
as process wastewater, when required.
|
|
|
Surge Operations (m 3 ) |
| Low-Level | |||
| Liquid | None | 320 | None |
| Solid | 8 | 1,120 8 | 570 9 |
| Mixed Low-Level | |||
| Liquid | None | 3,400 | 3,400 |
| Solid | 1 | 92 10 | 92 |
| Hazardous | |||
| Liquid | None | Included in mixed | Included in mixed |
| Solid | 2 | Included in mixed | Included in mixed |
| Nonhazardous (Sanitary) | |||
| Liquid | 27 | 320,000 | 319,400 11 |
| Solid | 30 12 | 13,500 13 | 7,670 14 |
| Nonhazardous (Other) | |||
| Liquid | Included in sanitary | Included in sanitary | Included in sanitary |
| Solid | 2 | 10,000 15 | Included in sanitary |
Spent Nuclear Fuel. The Secondary and Case Fabrication
Facility would not generate any spent nuclear fuel.
Transuranic Waste. The Secondary and Case Fabrication Facility
would not generate any TRU wastes.
Low-Level Waste. LLW would be generated by operation of
the Secondary and Case Fabrication Facility and would consist
primarily of depleted uranium oxide in drums and contaminated
scrap metal, air filters, and HEPA filters. Approximately 10 percent
of all LLW generated would currently be suitable for disposal
onsite. The remaining waste would be packaged for offsite treatment
and disposal at the waste feed preparation facility and stored
at K-25, pending disposal at an approved disposal facility. Scrap
metal would be sent offsite for smelting into shielding blocks
for DOE use.
Mixed Low-Level Waste. Mixed LLW would be generated from
operation of the Secondary and Case Fabrication Facility and would
consist primarily of ash and sludge immobilized in grout, compacted
gloves, and wipes. Mixed LLW would be collected in DOT-approved
containers and sent to an onsite hazardous waste accumulation
area. Waste suitable for incineration would be sent to the K-25
TSCA incinerator. After compaction, if appropriate, the remaining
solid wastes would be packaged and stored onsite awaiting disposal
by an offsite commercial vendor.
Hazardous Waste. These materials are included in the mixed
LLW.
Nonhazardous (Sanitary) Waste. Sewage wastewater would
be discharged directly to the Oak Ridge Municipal Wastewater Treatment
System sewer system. Process wastewater would be treated in the
sanitary wastewater treatment facilities and discharged through
permitted NPDES outfalls. Sludge would be stored onsite, pending
treatment by a commercial vendor. Nonhazardous solid wastes including
small amounts of classified nonhazardous waste would be generated
from operation of the Secondary and Case Fabrication Facility
and disposed of in a State of Tennessee permitted Class II landfill.
Nonhazardous (Other) Waste. Nonrecyclable (other) wastes
would be disposed of in a permitted landfill or discharged through
permitted NPDES outfalls.
LANL secondary and case fabrication facilities would include all
of the functional operations required to physically and chemically
process, machine, inspect, assemble, certify, and disassemble
secondary materials to produce canned subassemblies and radiation
case components for the nuclear weapons physics package.
The secondary and case fabrication facilities would occupy 21,739
m2 (234,000 ft2) of floor space inside existing structures within
their current footprint of 1.1 ha (2.7 acres). Additional land
area for the construction of new buildings would not be required.
A nominal area would be required for equipment staging, material
laydown, and parking during the modifications of these facilities.
Facility Description. Secondary and case fabrication would
utilize existing facilities within the boundaries of TAs -3, -8,
-50, -54, and -55 (figure A.3.2.2-1).
Facilities within each of these technical areas include the TA-3
Sigma Complex (SM-35, SM-66, and SM-141), the TA-3 Chemistry and
Metallurgy Research building (SM-29), the TA-3 main machine shop
(SM-39 and SM-102), the TA-8 Nondestructive Evaluation Facility
(Buildings 22 and 23), the TA-55 Nuclear Material Storage Facility
for overflow capacity, the TA-50 Liquid Radioactive Waste Treatment
Facility, and the TA-54 Solid Radioactive Waste Treatment Area.
The flow of fissile material would be contained within the Chemistry
and Metallurgy Research building (SM-29). Manufacturing operations
would take their feeds from both incoming stockpile returns and
the chemical recovery process. Components from manufacturing would
be sent back out for assembly. Low-equity waste (graphite, booties,
and machining fluids) would be sent back to waste management for
processing, storage, and disposal. Recoverable quantities of fissile
material would be reprocessed in chemical recovery and returned
as feed stock to manufacturing.
Figure A.3.2.2-2 shows the
major structures located in TA-3. The buildings shown on this
plot plan for use in stockpile stewardship and management operations
are SM-29, SM-35, SM-39, SM-66, SM-102, and SM-141. Modifications
are required for the following facilities:
Table A.3.2.2-1 summarizes key facility
data for the building and support structures to be utilized in
secondary and case fabrication.
The Chemistry and Metallurgy Research building is a large reinforced
concrete building with a basement, a first floor, and an attic
floor. This building has been classified as a Performance Category
PC-3 Nuclear Facility (per DOE-STD-3009-94). The administration
wing and Wing 1 contain second-floor office areas. The plan of
the building is centered on a spinal corridor oriented in a north-south
direction with an administration wing and seven laboratory wings
(Wings 1, 2, 3, 4, 5, 7, and 9) that extend from the corridor.
Wings 2, 3, 4, 5, and 7 have equipment/change rooms located at
the front of each wing and filter towers located at the end of
the wings, which house the filter plenum and other large mechanical
equipment for the exhaust ventilation system. The building also
contains a waste assay facility located at the loading dock between
Wings 1 and 4 and a Category I special nuclear material vault.
The Chemistry and Metallurgy Research building replaced the World
War II "D" building and was designed to house analytical
chemistry facilities, plutonium metallurgy, uranium chemistry,
engineering design and drafting, electronics, and other support
functions. At the time it was built, the Chemistry and Metallurgy
Research building represented the state-of-the-art instrumentation
and safety controls for a modern chemistry laboratory.
|
|
of Levels |
|
|
| SM-29 Chemistry and Metallurgy Research | 51,097 | 3 | Special nuclear materials | Concrete post and beam with concrete masonry unit in-fill walls |
| SM-66 Sigma | 15,794 | 3 | NA | Concrete post and beam with concrete masonry unit in-fill walls |
| SM-39 Nonnuclear Shops | 14,202 | 3 | NA | Concrete post and beam with concrete masonry unit in-fill walls |
| SM-102 Uranium Shops | 2,090 | 3 | NA | Concrete post and beam with concrete masonry unit in-fill walls |
| SM-141 Rolling Mill | 1,858 | 2 | NA | Concrete post and beam with concrete masonry unit in-fill walls |
| SM-35 Press | 929 | 2 | NA | Concrete foundation with steel pillars and sheet metal walls |
| SM-67 Guard Station Sigma | 22.9 | |||
| SM-127 Cooling Tower | 138 | |||
| SM-145 Switchgear Station | 39 | |||
| SM-147 Air Plenum and Fan | 15.2 | |||
| SM-154 Chemistry and Metallurgy Research Cooling Tower | 37.2 | |||
| SM-159 Forming | 14.9 | |||
| SM-161 Magazine | 1.5 | |||
| SM-169 Warehouse | 581 | |||
| SM-187 Cooling Tower | 37.2 | |||
| SM-317 Graphite Flour Storage | 140.5 | |||
| SM-451 Micro Machining | 160 | |||
| TA-8-22 Nondestructive Evaluation Lab | 843 | |||
TA-8-23 Nondestructive Evaluation Support | 316 | |||
NA - not applicable.LANL 1995e. |
The Sigma Complex comprises three main processing buildings located
in TA-3 just east of the Chemistry and Metallurgy Research building.
The fenced area encompassing the Sigma Facility contains a total
of 16 buildings. The three buildings designated as SM-66, SM-141,
and SM-35 contain the majority of laboratory space. Other structures
house utilities, support functions, and storage areas. The Sigma
Complex has been classified as a low-hazard chemical (PC-1), nonnuclear
facility.
The Press building (SM-35) is the oldest building in this complex.
Construction was completed in 1953. The building was originally
designed to house the 4,536-t (5,000-ton) press for the Materials
Technology Group. Building construction consists of a concrete
foundation and supporting steel pillars with insulated double
sheet metal walls outside. Inside walls (separating various work
areas and offices) are similar or made of concrete block.
The Rolling Mill building (SM-141) has reinforced concrete foundations,
floors, support columns, and beams with concrete block exterior
walls. Interior walls separating various work areas and offices
are made of concrete block and/or metal studs with gypsum board.
The roof is built of tar and gravel over rigid insulation and
is supported by steel joists. The building was designed to house
areas for powder metallurgy and fabrication. Today the Rolling
Mill building continues to house these activities in addition
to work areas for ceramics research, beryllium technology, and
development and rapid solidification research.
The Sigma building (SM-66) was constructed in 1959 and was originally
designed to house activities in physical metallurgy, ceramics,
powder metallurgy, plastics, a metal foundry, electrochemistry,
fabrication, and other support functions. Today the Sigma building
continues to house all these functions except plastics. The building
is built on a reinforced concrete foundation using reinforced
concrete post and beam construction techniques. The exterior walls
are constructed of concrete block fill between the supporting
posts and beams. The mezzanine spaces are constructed of supported
metal decking. Interior walls separating various work areas and
offices are also concrete block or metal studs and gypsum board.
The roof is built of tar and gravel over rigid insulation and
metal decking supported by steel joists. The building has a basement,
a first floor, and a small second floor. The plan of the building
is on a spinal corridor oriented in a north-south direction. SM-66
has 11 major work areas that extend from the corridor.
Building SM-102 is connected to the Main Shops building, SM-39,
by a 38-m (125-ft) long corridor. Constructed in the late 1950s,
it originally housed a foundry, a heat-treating operation, a graphite
machining shop, and a radioactive materials machine shop. Since
that time, the northeast corner of the building, which provided
programmatic support to the Rover Project, has been decommissioned
and now is dedicated to the support of Engineering, Sciences,
and Applications division operations. Currently, the southern
half of the building is occupied primarily by Shop 13, the uranium
and lithium machine shops. The building is constructed of cinder
block and has a concrete floor. Shop 13 contains machines that
are used for machining operations on uranium. The majority of
the building houses pyrophoric, toxic, and radioactive material
machining and a dimensional inspection area. SM-102 has been classified
as a low-hazard chemical (PC-1), nonnuclear facility.
Building SM-39 is of concrete and cinder block construction. The
main bay is aligned from north to south and is 183 m (600 ft)
in length by 37 m (120 ft) in width. Three wings extend eastward
from the north and south ends of the bay, as well as the middle
of the main bay. The south main (high) bay section, the middle
wing, and the south wing contain metal and machining shops owned
by the Mechanical Fabrication Group. SM-39 has been classified
as a low-hazard chemical (PC-1), nonnuclear facility.
The north wing contains offices occupied by the Materials Technology
Polymers & Coatings Group (MST-7) and the Standard and Calibration
Group (ESH-9). It also contains Mechanical Fabrication Group beryllium
machining and inspection, a glass shop operated by MST-7, and
a Standards and Calibration Laboratory operated by ESH-9. Three
transportable equipment storage trailers are located on the south
side of the north wing.
Construction. Modification to the LANL facilities to perform
the stockpile management secondary and case fabrication mission
would require approximately 7 years for design, construction,
mission transfer, and operational startup. With conceptual design
beginning in 1997, operational startup could commence in 2004.
The materials and resources consumed during modification activities
are provided in table A.3.2.2-2.
Emissions generated during modification activities are provided
in table A.3.2.2-3. The principal sources
of airborne emissions during modification are fugitive dust, construction
debris, and exhaust from construction equipment and vehicles.
|
|
|
| Concrete (m 3 ) | 245 | |
| Electricity | 4,130 MWh | 0.75 MWe |
Industrial gases 17 (m 3 ) | 11,500 | |
| Liquid fuel (L) | 22,700 | |
| Steel (t) | 54 | |
| Water (L) | 4,160,000 |
|
(t) |
| Carbon monoxide | <1 18 |
Lead | 0 |
| Nitrogen dioxide | <1 18 |
| Particulate matter | <1 18 |
| Sulfur dioxide | <118 |
| Volatile organic compounds | 0 |
Employment needs during the modification phase are presented in
table A.3.2.2-4.
Operation. The secondary and case fabrication processes
require the following utilities during operation: electricity,
natural gas, diesel fuel, air, water, and steam. Table A.3.2.2-5
presents a listing of the utilities consumed during Secondary
and Case Fabrication Facility surge operations. Chemicals
consumed during operation are summarized in table A.3.2.2-6.
The annual emissions from surge operation required in the Secondary
and Case Fabrication Facility are based on historical emissions
and amounts of materials to be processed as shown in table A.3.2.2-7.
Employment. The employment needs in support of secondary
and case fabrication surge operation activities at LANL are summarized
in table A.3.2.2-8.
|
|
|
|
|
|
| Total craftworkers | 34 | 45 | 45 | 45 | 169 |
| Construction management and support staff | 6 | 10 | 10 | 10 | 36 |
Total Employment |
40 | 55 | 55 | 55 | 205 |
LANL 1995e. | |||||
|
|
|
| Diesel fuel (L) | 100,000 | |
| Electricity | 36,000 MWh | 5 MWe |
| Natural gas 20 (m 3 ) | 0 | |
Water (L) | 55,000,000 |
|
(kg) |
| Solid Chemicals | |
| Aluminum nitrate | 75 |
| Aluminum trihydride | 3,000 |
| Barium nitrate | 15 |
| Borax | 15 |
| Calcium hydroxide | 30,000 |
| Calcium nitrate | 150 |
| Curing agent | 4 |
| Epoxy resin | 10 |
| Ferric sulfate | 7,500 |
| Graphite | 2,000 |
| Lithium chloride | 6,000 |
| Magnesium sulfate | 100 |
| Methylene diphenyl diisocyanate | 100 |
| Nickel compounds | 75 |
| Polycure | 75 |
| Potassium carbonate | 3,000 |
| PVC plastisol | 1,500 |
| Silicon carbide | 40 |
| Sodium bicarbonate | 75 |
| Sodium carbonate | 450 |
| Sodium molybdate dihydrate | 5 |
| Sodium nitrate | 1,500 |
| Trisodium phosphate | 250 |
| Tungsten carbide | 1 |
| Yttria | 300 |
| Liquid Chemicals | |
| Acetic acid | 15 |
| Acetone | 20 |
| Acetonitrile | 150 |
| Anisol | 200 |
| Corrosion inhibitor | 800 |
| Diamond paste | 1 |
| Dibutyl carbitol | 1,000 |
| Ethanol | 1,000 |
| Gasoline and diesel | 100,000 |
| Hydraulic oil | 3,000 |
| Hydrogen peroxide | 750 |
| Kerosene, high grade | 150 |
| M-pyrol | 50 |
| Methanol | 2,500 |
| Micro/oakite detergent | 12 |
| Mineral oil | 1,500 |
| Mold release | 7.5 |
| Nitric acid | 1,000 |
| Nitrogen tetroxide | 150 |
| Oxalic acid | 2 |
| Petroleum oils (lubricants) | 1,500 |
| Potassium chloride | 15 |
| Propylene glycol | 150 |
| Pump oil | 3 |
| PVC primer | 2 |
| Solvent 140 | 750 |
| Toluene 2,4 diisocyanate | 100 |
| Gaseous Chemicals | |
| Ammonia, anhydrous | 7.5 |
| Argon | 1,000,000 |
| Carbon dioxide | 10,000 |
| Chlorine | 75 |
| Freon or equal (cleaning) | 750 |
| Helium | 6,000 |
| Hydrogen | 1,500 |
| Nitrogen | 500,000 |
| Oxygen | 50,000 |
| Note: PVC- polyvinyl chloride. Source: LANL 1995b:4; LANL 1996e:1. | |
|
(t) |
| Carbon monoxide | 4.5 |
| Lead | 0.1 |
| Nitrogen dioxide | 117 |
| Particulate matter | 0.3 |
| Sulfur dioxide | 48 |
| Volatile organic compounds | 0.6 |
| Radiological Isotope | Estimated Release |
| Uranium 235 (microcuries) | 486 |
| Uranium 238 (microcuries) | 1776 |
LANL 1995b:4. | |
|
|
|
| Office and clerical | 26 | 0 |
| Officials and managers | 34 | 4 |
| Professionals | 37 | 13 |
| Service workers | 244 | 61 |
| Technicians | 182 | 73 |
Total Employees |
523 21 | 151 |
Nearly all of the personnel performing operations in the secondary
fabrication facilities would be dosimeter-badged. As shown in
table A.3.2.2-8, it is estimated that approximately 151 workers
would be at risk of radiological exposure. In addition, a small
fraction of badged visitors may nonroutinely enter radiological
areas.
Waste Management. Wastes generated during secondary and
case fabrication operations include radioactive, mixed, hazardous,
and nonhazardous byproducts. Secondary and case fabrication operations
would not generate any high-level or TRU wastes. Low-level radioactive
waste would consist primarily of depleted uranium oxide chips,
contaminated scrap metal, and filter media. Mixed and hazardous
wastes would consist of ash, sludges, filters, rags, and wipes.
Liquid radioactive and inorganic chemical wastes that meet the
LANL waste acceptance criteria are sent either by truck or industrial
drain to be processed at TA-50, Building 1. Mixed wastes are currently
stored at TA-54; liquids in Area L and solids in Area G. Hazardous
and organic chemical (RCRA) wastes are packaged and shipped to
TA-54, Area G, for interim storage and subsequently shipped offsite.
Nonhazardous solid waste is collected in dumpsters and taken to
the landfill operated by Los Alamos County. Sanitary liquids are
disposed of by either sanitary drain or permitted outfall. Sanitary
process and support liquids are sent by drain to the sanitary
wastewater treatment plant, TA-46, and treated similarly to municipal
sewage. Table A.3.2.2-9 provides an
estimate of the annual quantities of these waste categories for
Secondary and Case Fabrication Facility surge operation.
|
Volume Generated from Construction (m 3 ) |
|
|
| Low-Level | |||
| Liquid | None | 192 | None |
| Solid | 134 | 690 | 349 22 |
| Mixed Low-Level | |||
| Liquid | None | 30 | 30 |
| Solid | 10 | 108 | 108 |
| Hazardous | |||
| Liquid | None | 60 | 60 |
| Solid | 37 | 216 | 216 |
| Nonhazardous (Sanitary) | |||
| Liquid | 890 | 20,240 | 20,370 |
| Solid | 120 | 1,160 | 639 23 |
| Nonhazardous (Other) | |||
| Liquid | Included in sanitary | None | None |
| Solid | 10 24 | 3,000 | 3,000 |
The LLNL secondary and case fabrication facilities would be housed
within existing buildings at the Livermore Site (figure A.3.2.3-1).
All of the structures required to house the secondary and case
fabrication functions are in place; finalizing the capability
would require installing some new equipment, moving existing equipment
to other locations, and modifying some facilities to meet production
requirements. A new structure, a 167-m2 (1800-ft2) steel framed,
Butler-type building would be required to provide covered space
within the Superblock protected area in which to house the enriched
uranium inventory. At the Livermore Site, the existing security
system for the fenced Superblock could be used with minor modifications
to include Building 239, the radiographic facility for enriched
uranium fabrication, assembly, disassembly, storage, and surveillance
operations.
Manufacturing and assembly of the canned secondary assemblies
would take place in the buildings indicated on the Livermore Site
plan, figure A.3.2.3-2. The
overall site occupies approximately 332 ha (821 acres) and is
surrounded by security fencing. The individual facilities to be
used for secondary and case fabrication are within protected areas,
limited areas, or exclusion areas as required for security and
safeguards. Support facilities are located both inside and outside
the security areas but inside the overall site perimeter fence,
which is controlled at the entrances to the perimeter fenced area.
The required facilities comprise approximately 19,500 m2 (210,000
ft2) and cover approximately 2 ha (5 acres). The Livermore Site
has sufficient yard area and warehousing space to accommodate
required laydown areas for receipt and staging of equipment and
construction materials. In addition, parking for construction
workers is available onsite.
Facility Description. Uranium parts are fabricated within
a high-security, fenced area of the Livermore Site Superblock.
Building 332 would house casting, machining, chemical recovery,
destructive testing, nondestructive testing, dimensional inspection,
storage, and A/D/surveillance operations. LLNL would use Building
334 as an additional site for A/D/surveillance operations and
for metalworking of uranium parts.
The uranium processing facility is divided into three heating
ventilation and air conditioning zones for radioactive contamination
confinement. Zone 1 comprises areas where radioactive materials
are handled and processed and includes enriched uranium receiving,
processing, and storage areas. Zone 2 consists of areas where
there is normally no radioactive contamination, but where there
is the possibility of contamination. This zone includes the rooms
containing glove boxes, process operating areas, and service corridors
surrounding Zone 1 areas. Building 332 is a reinforced-concrete
structure meeting the requirements of DOE 430.1, Life-Cycle Asset
Management. The existing fire protection; radiation monitoring;
heating, ventilation, and air conditioning; and emergency power
facilities in Building 332 would be used. Building 239 would be
used for radiography. Other buildings used in enriched uranium
operations would include Building 177 for mass spectroscopy and
Buildings 222, 235, and 251. These buildings are existing facilities
that are adequate for this mission, and only minor modifications
and upgrades would be needed.
As in the uranium parts manufacture, Building 239 is used for
radiography, Building 177 for mass spectroscopy, and Buildings
222 and 251 for chemical laboratory analysis. The existing facilities
in Building 235 are used for chemical laboratory analysis and
nondestructive testing. Additional non-destructive testing functions
take place in Building 327. Building 322 is used for some uranium
part plating operations. The existing facilities in Buildings
322 and 327 are adequate for this mission. All of these facilities
have been reviewed and approved for adequacy of building construction
in accordance with applicable design codes and standards for the
planned mission to be performed.
The special materials fabrication operations are performed in
Buildings 231 and 241. Mass spectroscopy will be done in the existing
facilities in Building 177, and chemical laboratory analysis in
Buildings 222 and 235. Dimensional inspection is done in Building
321. Special materials would be fabricated in existing facilities
in Building 231, with finishing operations to take place in Building
241. Again, all of these facilities have been reviewed and, with
the exception of Building 241, approved for adequacy of building
construction in accordance with applicable design codes and standards
for the planned mission to be performed. Building 241 would require
some minor, additional seismic retrofits before operations could
commence.
The nonnuclear component fabrication capabilities would be housed
in the extended Building 321 area complex at the Livermore Site.
This includes the major Buildings 321 (with Wings A, B, C), 327,
329, and 322. Mechanical specimen testing would be performed in
Building 231.
Table A.3.2.3-1 summarizes key facility
data for the buildings and support structure to be utilized in
secondary and case fabrication. While table A.3.2.3-1 summarizes
all the facilities that are proposed for the canned secondary
assemblies mission at LLNL, many of the facilities are used only
for sample tests and are existing facilities that would be used
as is and shared with other LLNL programs. Buildings 177, 222,
235, 251, 322, 327, and 329 fit into this category. The remaining
facilities are discussed because they are the main processing
facilities for the canned secondary assemblies mission.
|
(m2) |
of Levels |
Materials |
|
| B-175 | 734 | 1 | None | Reinforced concrete |
| B-177 | 28 | 1 | SNM | Steel frame |
| B-222 | 113 | 1 | SNM | Steel frame |
| B-231 | 1,661 | 1 | None | Steel frame |
| B-235 | 140 | 2 | SNM | Steel frame |
| B-239, Radiography | 136 | 2 + basement | SNM | Reinforced concrete |
| B-241 | 620 | 1 | None | Steel frame |
| B-251 | 19 | 1 | SNM | Steel frame |
| B-321 | 13,945 | 2 | None | Steel frame |
| B-322 | 149 | 1 | None | Steel frame |
| B-327 | 143 | 1 | None | Steel frame |
| B-329 | 484 | 1 | None | Steel frame |
| B-332 | 738 | 2 | SNM | Reinforced concrete |
| B-334 | 438 | 3 | SNM | Reinforced concrete |
| New, Butler storage building | 167 | 1 | SNM | Steel frame |
SNM - special nuclear materials.LLNL 1995e. | ||||
Construction. Modification to the Livermore Site facilities,
as discussed above, to perform the secondary and case fabrication
mission would require approximately 3 years based on a fiscal
year 1998 start date, with the first production unit scheduled
for the beginning of 2004. To meet this milestone, facilities
would have to be in place several years before that date to provide
for certification of equipment and processes and for training
and certification of personnel. It is anticipated that facilities
would be required to be in place for this activity no later than
2001.
The materials and resources consumed during the modification phase
are provided in table A.3.2.3-2. Information
is based on a 3-year construction schedule.
Resource |
|
Demand |
| Concrete (m3) | 612 | |
| Electricity | 3,500 MWh | 400 kW 25 |
| Gasoline, diesel fuel, and lube oil (L) | 908,000 | |
| Industrial gases 26 (m3) | 142 | |
| Steel (t) | 73 | |
| Water (L) | 8,710,000 |
Estimated emissions generated during modification activities for the secondary and case fabrication mission at LLNL are provided in table A.3.2.3-3. The principal sources of airborne emissions during facility modification would be fugitive dust, construction debris, and exhaust from construction equipment and vehicles. The peak year is defined as the year when modification activities would be the highest and equipment is anticipated to be arriving for installation.
|
(t) |
| Carbon monoxide | 635 |
| Oxides of nitrogen | 63.5 |
Particulate matter | 544 |
| Sulfur dioxide | 5.44 |
| Volatile organic compound | 6.53 |
LLNL 1995e. | |
Employment needs during the modification period are presented in table A.3.2.3-4. The modification activities would include some site work on the secondary fence enclosure of Building 239; seismic upgrades to Buildings 231 and 242; upgrades to building utilities such as electrical distribution systems, heating, ventilation and air conditioning, and security systems; and installation and checkout of equipment.
|
|
|
|
|
| Construction management and support staff | 15 | 15 | 10 | 40 |
| Craftworkers | 115 | 115 | 60 | 290 |
Total Employment |
130 | 130 | 70 | 330 |
LLNL 1995e. | ||||
During modification activities, some support personnel and crafts
would be at risk of radiological exposure. Approximately 20 personnel
involved in decontamination of the 5 rooms in Building 332 would
be at risk during the first year of construction. However, since
the building is a certified plutonium handling facility, all construction
personnel working in this building during the modification phase
would be at some risk of radiological exposure.
Operations. The secondary and case fabrication processes
would require consumable materials and resources to maintain facility
operations. Annual utility consumption for surge operations secondary
and case fabrication at the Livermore Site is presented in table A.3.2.3-5.
|
|
|
| Electricity | 15,000 MWh | 2 MWe |
| Liquid fuel (L) | 85,200 | |
| Natural gas 28 (m3) | 566,000 | |
Raw water (L) | 194,000,000 |
Table A.3.2.3-6 lists the estimated annual chemicals consumed during surge operation of the secondary and case fabrication mission at LLNL.
|
(kg) |
| Solid Chemicals | |
| Aluminum trihydride | 875 |
| Barium nitrate | 4 |
| Borax | 4 |
| Calcium hydroxide | 8,730 |
| Calcium nitrate | 45 |
| Calcium oxide | 45 |
| Curing agent | 1 |
| Diatomaceous earth | 730 |
| Epoxy resin | 3 |
| Erbium oxide | 25 |
| Ferric sulfate | 2,200 |
| Graphite | 590 |
| Lithium carbonate | 350 |
| Magnesium sulfate | 30 |
| Methylene diphenyl diisocyanate | 30 |
| Nickel compounds | 25 |
| Polycure | 25 |
| Potassium carbonate | 875 |
| PVC plastisol | 450 |
| Silicon carbide | 15 |
| Sodium bicarbonate | 25 |
| Sodium carbonate | 135 |
| Sodium molybdate dihydrate | 1 |
| Sodium nitrate | 440 |
| Sodium potassium | 1 |
| Trisodium phosphate | 75 |
| Tungsten carbide | 0.3 |
| Yttria | 45 |
| Zirconium oxide | 55 |
| Liquid Chemicals | |
| Acetic acid | 4 |
| Acetone | 2 |
| Acetonitrile | 45 |
| Anisol | 60 |
| Corrosion inhibitor | 240 |
| Diamond paste | 0.3 |
| Diesel fuel | 21,850 |
| Ethanol | 300 |
| Gasoline | 32,000 |
| Hydraulic oil | 875 |
| Hydrogen peroxide | 220 |
| M-pyrol | 15 |
| Methanol | 730 |
| Micro/oakite detergent | 3 |
| Mineral oil | 440 |
| Mold release | 2 |
| Nitric acid | 300 |
| Nitrogen tetroxide | 45 |
| Oxalic acid | 0.1 |
| Petroleum oils (lubricants) | 440 |
| Potassium chloride | 4 |
| Propylene glycol | 45 |
| Pump oil | 1 |
| PVC primer | 1 |
| Solvent 140 | 220 |
| Toluene 2,4-diisocyanate | 30 |
| 1,1,1-Trichloroethane | 235 |
| Gaseous Chemicals | |
| Ammonia, anhydrous | 2 |
| Argon | 407,300 |
| Carbon dioxide | 8,750 |
| Chlorine | 25 |
| Freon or equal (cleaning) | 220 |
| Helium | 1,750 |
| Hydrogen | 440 |
| Nitrogen | 1,450,000 |
| Oxygen | 14,550 |
Note: PVC- polyvinyl chloride.
LLNL 1995e; LLNL 1995i:3. | |
The estimated annual emissions from surge operation of the Secondary and Case Fabrication Facility are based on historical emissions and amounts of materials to be processed and are shown in table A.3.2.3-7.
|
(t) |
| Carbon dioxide | 3,100 |
| Carbon monoxide | 1.0 |
| Chloride | 1.6 |
| Chlorine | 0.05 |
| Methyl alcohol | 4.5 |
| Nitric acid | 2.3 |
| Nitrogen dioxide | 1.9 |
| Ozone | 0.03 |
| Particulate matter | 0.1 |
| Pressing lubricant | 0.1 |
| Sulfur dioxide | 0.02 |
| Sulfuric acid | 0.6 |
| Total suspended particulates | 3.2 |
| Volatile organic compounds | 0 |
| Water vapor | 1,040 |
| Radiological Isotope | Estimated Release |
| Uranium-235 (microcuries) | 135 |
| Uranium-238 (microcuries) | 480 |
LLNL 1995e; LLNL 1995i:3. | |
Employment. The additional employment needs in support
of secondary fabrication surge activities at LLNL are summarized
in table A.3.2.3-8.
Approximately 250 (33 percent) badged employees would work inside
radiological areas and are considered to be at risk for radiological
exposure. In addition, a small fraction of badged visitors may
nonroutinely enter radiological areas. Table A.3.2.3-8 provides
a breakdown of those employees who may be at risk of radiological
exposure.
|
|
|
| Office and clerical | 120 | 0 |
| Officials and managers | 45 | 10 |
| Operatives | 330 | 150 |
| Professionals | 120 | 50 |
| Technicians | 145 | 40 |
Total Employees |
760 29 | 250 |
Waste Management. Radioactive wastes generated from construction
activities would be from the five rooms in Building 332 which
must be decontaminated before the installation of new equipment.
Included in this waste is some ducting, flooring, equipment that
would need to be disposed of, and building partitioning materials.
Hazardous waste would consist primarily of lubricants and coolants
that would be recycled or disposed of in accordance with RCRA
guidelines. Nonhazardous solids include construction debris, metal,
containers, and packaging materials. Liquid nonhazardous wastes
would be treated locally and discharged to the sanitary sewer
or hauled to an offsite facility for treatment and disposal. Wastes
generated during replacement secondary fabrication operations
include radioactive, mixed, hazardous, and nonhazardous byproducts.
Table A.3.2.3-9 provides an estimate
of the quantities of these waste categories effluent volumes as
a result of secondary fabrication construction and surge operations.
Secondary and case fabrication operations would not generate any
spent nuclear fuel, HLW, or TRU wastes.
LLW generated from fabrication activities includes protective
clothing, abrasive materials, cutting tools, filters, small equipment,
and mop water contaminated with uranium. This waste would be treated
by sorting, separation, concentration, and size reduction processes.
Processed LLW would be surveyed and shipped to an offsite facility
for land disposal.
Mixed wastes would consist of analytical solutions, wipes and
rags with acetronitrile and acetone, and organic wastes contaminated
with uranium. These wastes would be packaged and shipped to a
DOE waste management facility for temporary storage pending treatment
and disposal.
Hazardous wastes would include analytical solutions, rags with
acetonitrile and acetone, coolants, hydraulic fluid, curing agents,
epoxy resins, and plastics. These wastes would be managed and
shipped to a commercial waste facility for treatment and disposal.
Nonhazardous (sanitary) wastes would consist of such solid items
as office waste, paper, spent tools, and scrap materials. These
materials would be hauled to an offsite sanitary landfill for
disposal. Sanitary liquids would include sewage waste, uncontaminated
process fluids, and mop water. These wastes would be discharged
to the local municipal sewage system.
|
Volume Generated from Construction (m3) |
|
|
| Low-Level | |||
| Liquid | None | 105 | None |
| Solid | 5 | 370 | 304 |
| Mixed Low-Level | |||
| Liquid | None | 550 | 550 |
| Solid | None | 12 | 12 |
| Hazardous | |||
| Liquid | 11 | 540 | 540 |
| Solid | 41 | 18 | 18 |
| Nonhazardous (Sanitary) | |||
| Liquid | 5,050 | 102,000 | 102,000 |
| Solid | 2,820 | 4,320 | 4,320 |
| Nonhazardous (Other) | |||
| Liquid | Included in sanitary | Included in sanitary | Included in sanitary |
| Solid | 255 | 3,200 30 | None |
Nonhazardous (other) wastes would be collected and examined before being reclaimed for other recycled use or release to the environment. Examples of this type of waste are paper, glass, and recyclable metals.
1
Building construction key:
Single story building with: A-1 wood frame, A-2 masonry bearing
walls with wood roof framing, A-3 masonry bearing walls with structural
steel roof stem, A-4 masonry bearing walls with precast concrete
roof system, and A-5 prefabricated metal building with metal wall
panels.
Multistory building with: B-1 reinforced concrete structure with
masonry walls, B-2 reinforced concrete and structural steel with
masonry walls, B-3 structural steel skeleton with masonry walls,
B-4 structural steel skeleton with cement-asbestos wall panels,
and B-5 structural steel skeleton with metal wall panels.
2
Not all of Building 9212 is within the DP footprint.
3
Peak demand is the maximum rate expected.
4
Cubic meters measured at standard temperature and pressure.
5
Full-time equivalent.
6
Peak demand is the maximum rate expected during any hour.
7
Cubic meters measured at standard temperature and pressure.
8
Includes 10 m 3 of classified waste, 40 drums depleted
uranium ash from chip oxidation (one 55 gal drum = 0.2 m 3
), and 1,100 m 3 of unclassified waste.
9
Assumes 100:1 wastewater to sludge ratio for the treatment of
liquid LLW followed by 2:1 for solidification. Assumes 2/3 of
LLW is compactible by a factor of 4:1. LLW in drums is not compactible.
10
Includes 2 m 3 of classified waste and 90 m 3 of
unclassified waste.
11
Y-12 only pretreats industrial wastewater prior to discharge to
the city of Oak Ridge Municipal Sanitary Sewer System.
12
Includes 3.4 m 3 of concrete and 4.1 t of steel.
13
Includes 5 m 3 of classified waste.
14
Assumes 2/3 of solid is compactible by a factor of 4:1.
15
Recyclable wastes.
16
Peak demand is the maximum rate expected.
17
Cubic meters measured at standard temperature and pressure.
18
The total of all criteria pollutants is estimated to be less than
1 metric ton.
19
Peak demand is the maximum rate expected during any hour.
20
Cubic meters measured at standard temperature and pressure.
21
Total surge employment. Increment to current employment would
be 321.
Source: LANL 1995b:4.
22
Assumes 2/3 of the solid LLW is compactible by a factor of 4:1.
The wastewater to sludge ratio for liquid LLW treatment is 100:1,
followed by 2:1 solidification ratio.
23
Assumes 2/3 of the solid waste is compactible by a factor of 4:1.
The wastewater to sludge ratio for liquid sanitary treatment is
350:1.
24
Includes 300 t of recyclable steel and 18 t of recyclable copper.
25
Peak demand is the maximum rate expected.
26
Cubic meters measured at standard temperature and pressure.
27
Peak demand is the maximum rate expected during any hour.
28
Cubic meters measured at standard temperature and pressure.
29
Total surge employment. Increase to current employment would be
290.
Source: LLNL 1995e.
30
Recyclable wastes.
