Progress in stabilization of plutonium and residues since DNFSB recommendation 94-1

There are approximately 100 metric tons of residues at the Rocky Flats Environmental Technology Site containing approximately 3 metric tons of plutonium. The residues are byproducts of past plutonium operations incinerator ash; pyrochemical salts; graphite; sand, slag, and crucible; and miscellaneous forms of combustibles, glass, metal, and sludges. In September 1993, a report was released (Reference 1) which identified concerns with the chemical stability of the residues and with the integrity of packaging. In May 1997, the Defense Nuclear Facility Safety Board published recommendation 94-1 citing a concern for the residue stability and requiring that the possibly unstable residues be processed within 3 years and all others within 5 years. A risk categorization scheme was developed which assigned a numerical risk to each residue type based on the probability and consequence of occurrence of failures associated with the hazards identified. The residues were ranked for priority of stabilization actions. Urgent concerns were resolved. All residue drums were vented to eliminate the potential for hydrogen and other explosive gas accumulation. Leaded rubber gloves and ion exchange resins were washed to eliminate the explosion potential. An aggressive characterization program was implemented to search for any additional safety or environmental concerns and to gain more definitive information concerning the choice of processes for stabilization and disposition of the residues. This paper provides background on the safety issues and summarizes recent characterization data. The residue processing and disposition plans, including schedule and cost, are also summarized in the paper. Finally, the paper addresses initiatives undertaken by Safe Sites of Colorado to accelerate the residue program