Saltstone SDU6 Modeling Study

A new disposal unit, designated as Saltstone Disposal Unit 6 (SDU6), is being designed for support of site accelerated closure goals and salt waste projections identified in the new Liquid Waste System Plan. The unit is a cylindrical disposal cell of 375 ft in diameter and 43 ft in height, and it has a minimum 30 million gallons of capacity. SRNL was requested to evaluate the impact of an increased grout placement height on the flow patterns radially spread on the floor and to determine whether grout quality is impacted by the height. The primary goals of the work are to develop the baseline Computational Fluid Dynamics (CFD) model and to perform the evaluations for the flow patterns of grout material in SDU6 as a function of elevation of grout discharge port and grout rheology. Two transient grout models have been developed by taking a three-dimensional multiphase CFD approach to estimate the domain size of the grout materials radially spread on the facility floor and to perform the sensitivity analysis with respect to the baseline design and operating conditions such as elevation height of the discharge port and fresh grout properties. For the CFD modeling calculations, air-grout Volume of Fluid (VOF) method combined with Bingham plastic and time-dependent grout models were used for examining the impact of fluid spread performance for the initial baseline configurations and to evaluate the impact of grout pouring height on grout quality. The grout quality was estimated in terms of the air volume fraction for the grout layer formed on the SDU6 floor, resulting in the change of grout density. The study results should be considered as preliminary scoping analyses since benchmarking analysis is not included in this task scope. Transient analyses with the Bingham plastic model were performed with the FLUENTTM code on the high performance parallel computing platform in SRNL. The analysis coupled with a transient grout aging model was performed by using ANSYS-CFX code in the parallel computing platform in Mercer University. Recommended operational guidance was developed assuming that local shear rates and flow patterns related to radial spread along the SDU floor can be used as a measure of grout performance and spatial dispersion affected by the grout height and viscosity. The 5 ft height baseline results show that when the 150 gpm grout flow with a 5 Pa yield stress and a 60 cp viscosity is poured down through a 3 inch discharge port, the grout is spread radially up to about 64 ft distance from the pouring center after 2 hours' pouring time. The air volume fraction of the grout layer is about 29% at 5 minutes' transient time, and it is reduced by about 9% in 2 hours' pouring time, resulting in the grout density consisting of about 80% grout and 20% air volume fractions. The sensitivity results show that when the discharge port is located at a higher position, a larger amount of air is trapped inside the layer formed below the discharge port at the early transient time of less than 30 minutes because of the higher impinging momentum of the grout flow on the floor, resulting in the formation of less smooth layer. The results clearly indicate that the radial spread for the 43 ft discharge port is about 10% faster than that of the 5 ft discharge port for the early transient period of 5 minutes. However, for the pouring time longer than half an hour, the discharge port height does not affect the radial distance spread on the disposal floor. When grout quality is related to grout volume fraction, the grout volume fraction for the 43 ft discharge port has lower volume fraction than the 5 ft discharge port for the transient period of the first 5 minutes. However, for the pouring time longer than half an hour, the discharge port height does not affect the grout volume fraction for the layer accumulated on the disposal floor. A modified Bingham plastic model coupled with time-dependent viscosity behavior was developed for conducting the initial scoping calculations to assess the impact of fluid residence time on radial spreading and basic flow patterns. The results for the transient viscosity model show that when grout material becomes more viscous, the thickness of the grout layer accumulated on the floor becomes higher, but the radial distance spread on the horizontal floor becomes smaller. The early transient results for the grout density with about 32% air volume fractions are in reasonable agreement with those of the idealized Bingham plastic model. It is recommended that the current models developed here be benchmarked against the experimental results for critical applications of the modeling results