NRC Pre-application Meeting for the Model No. 9979 USA/9979/AF-96 (DOE) Package

Paul S. Blanton Program Manager, Design Authority for 9979

NRC One White Flint North 11555 Rockville Pike, 09-B-04, Rockville, MD

Outline

• Introduction of Attendees • History of 9979 Development

– Program Overview – Design Overview – Patents and License Agreements – Comparison with DOT UN1A2 Specification Packaging

• Basis for Request of NRC License • Content Description and Envelope Limits • Structural Design Evaluation (Testing, Overview, Weights, Insulation Bag) • Thermal Evaluation Results • Shielding / Criticality Evaluation Results • Package Operations • Procurement and Fabrication History • Program History • Closing Discussion

2

History of 9979 Development

• Program Overview – Replacement for DOT UN1A2 Specification Packaging (see comparison)

• Title 49 of the Code of Federal Regulations, Part 173.417 (2004) – Joint EM and NNSA program to develop the 9979

• rulemaking specifying UN1A2 packagings removed from service by September 30, 2008

• Design Overview – Performance Packaging Compliant with 10CFR71.71 and 10CFR71.73 – Design features:

• Steel construction • Standard, removable 30-gallon Drum with Silicone Gasket • Reusable 55-gallon Overpack with integral Liner • Overpack reinforced with polyurethane foam • 55-gallon and 30-gallon Split-Ring Closure Rings • Insulation Bag

• Patents and License Agreements – Split-Ring Closures for the 55-gallon and 30-gallon drums (SRNL); used on Type B packaging

• Design presented to DOT – 55-Gallon Drum Stepped Integral Liner Drum Assembly (SILDA) SRNL/Paragon D&E – NucFil Industries; Split-Ring Closures

3

9979 Design: Overview

4

5

Model 9979 USA/9979/AF-96 (DOE)

9979 Design: Overview

Drum Steel Liner

DOW Polyurethane BETAFOAM

TID

Comparison with DOT UN1A2 Specification Packaging

• Configuration Similarities and Comparison – Content Envelope is maximized

(30-gallon drum, 18-1/4” Ø by 27-1/2 ” high) – Carbon Steel Construction – Standard 30-gal and 55-gal Drums – Fabrication: utilizes commercial parts – Operation: standard tools & handling – Compatible with Nevada Test Site

• Disposal Waste Acceptance Criteria

6

Typical UN1A2 Specification Packaging 9979 Type AF Packaging

• Package gross weight - 350 lbs

• Standard commercial C-Ring closure

• Miscellaneous packing securing inner drum; 30-gallon or less

• < 350 grams 235U

• Package gross weight - 415 lbs • Reinforced split-ring closures

• Engineered liner securing inner

drum; 30-gallon

• < 350 grams 235U; specified contents

Basis for Request of NRC License

• SRNL Contacted by ReNuke Services regarding use of 9979 (May 2015) – DOE Certificate, Package ID Number: USA/9979/AF-96 (DOE)

• Purpose: Relocate Material from Texas A&M University’s AGN Reactor to the TRIGA Reactor Site

• AGN Content Description: – Fuel Disks (~Ø10.25” x up to 2”thick) and Control Rods – Material: <20% enriched uranium fuel embedded in polyethylene matrix – Resembles new fuel: reactor does not operate full time and operates at < 5 MW; low Effective

Full Power Hours (EFPH) – Disks (Qty. 9): The highest U-235 mass is just under 100 grams. – Control Rods: <20 grams Uranium each. Estimate 5 drums in 2-3 shipments. – The fuel (disks and rods) will be transported on public roadways for about 3-5 miles from one

Texas A&M site to another over non-university (public) land.

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9979 Content Description

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Payload Categories Material Form General Description

COM

BUST

IBLE

Filters Roughing, sock, demister, HEPA and other uranium filters

Rubber, Plastics, Cellulose Products Clothing, gaskets, bottles, filter frames, paper, wood, mop heads etc.

Floor Sweepings Miscellaneous materials collected from cleaning activities

Process Solids Furnace residues. (pan filter cloth and scrapings, wipes/sponges, etc.)

NO

N-C

OM

BUST

IBLE

Graphite/Carbon Carbon and graphite scrap molds

Slag and Liner Residue that contains magnesium oxide, calcium fluoride and/or lithium fluoride

Ceramics/Glass Crucibles, glassware and borosilicate rings

Borax Pellets From analytical x-ray operations.

Reduction Sand granular magnesium oxide (MgO)

Asbestos/Firebrick Insulation, floor tiles, etc.

Solid Compounds

Uranyl Fluoride, UO4, ammonium diuranate and residues and solid mixtures, scrapped unirradiated fuel rods and pellets,; e.g., size reduced Light Water Breeder Reactor (LWBR) fuel rods.

Standards and Sources

Encapsulated calibration standards, LEU Plates/Cube

9979 Content Envelope Limits

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• Highly Enriched Uranium (HEU) • Low Enriched Uranium (LEU)

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9979 Structural Evaluation (Testing and Analysis)

Structural Design Features

Summary of Structural Evaluation

NCT / HAC Evaluation

11

Model 9979 Shipping Package – Structural Design Features

DOW Polyurethane closed cell Foam 24 lb/ft3; Drum Body and Lid

12 vent holes (9 in drum wall; 1 in lid; 2 in drum bottom;

prevent over pressurization during HAC Fire

55-Gallon Drum Lid Liner 16-gauge

12-gauge carbon steel with ½- 13UNC-2A ASTM A574

Socket Head Screw

55-gallon drum 12-gauge carbon steel clamshell closure

with 5/8-11UNC-2A ASTM A320-L7 Bolts with jam nut

55-Gallon Drum Liner Cylinder 18-gauge; all other components 16-gauge.

4-¼” carbon steel rods welded between lid and liner

30-gallon drum; 18-gauge carbon steel, DOT 7A drum

55-gallon drum: 16-gauge; DOT 7A drum

9979 Design: Weights

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• 55-Gallon Overpack Assembly Weights – Drum Only 139 lbs

• Drum 84 lbs • Drum Foam 55 lbs

– Lid Only 25 lbs • Lid 15 lbs • Lid Foam 10 lbs

– Closure Ring 10 lbs – Total 55-gallon Assembly 174 lbs

• Maximum Payload 250 lbs (Includes 30-gallon Drum Assembly, ~53 lbs) • Maximum Package Weight 415 lbs

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9979 Structural Evaluations • Chemical, Galvanic, or other Reactions

– No galvanic cell interactions between packaging components and contents; CS, BETAFAOM, Silicone, Epoxy Paint, Insulation Materials, Plastics, etc.

• Effects of Radiation – No effect. Dose is much less than 10^6 rads/year

• Lifting and Tie-Down Devices – No structural features have been included to lift the package or tie-down the package

• Heat and Cold – Heat under NCT and HAC was evaluated by analysis; package performance was determined to be

acceptable – Cold; Package were tested to -40°F with no effect on safety – Differential thermal expansion based on material differences has no effect on safety

• Reduced/ Increased External Pressure – Analysis of reduced 3.5 psia pressure and increased external pressure does not effect package

safety • Vibration

– Shipping and Vibration loads were evaluated by analysis and comparison to similar designed packages. Fatigue and bolt torque evaluations found acceptable. Testing of 9977, AT-400 and BTSP showed no indications of package degradation due to shock and vibration testing.

9979 NCT Evaluation (Testing and Analysis)

• Structural, NCT – Pressure, Thermal gradients, Stresses: by Analysis – Vibration and Shock: by Analysis and Comparison – Water Spray: by Test – Free Drop (4-ft), Corner Drop (1-ft): by Test – Compression, Penetration: by Test

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Water Spray 1-ft drop 4-ft drop Compression Penetration (1-hr) (8 quadrants) (2,165 lbs)

9979 HAC Structural Evaluation (Testing)

• Structural, HAC – Free Drop (30-ft) : by Test – Crush (30-ft, 1,100-lb) : by Test – Puncture (40-in): by Test

15

30-ft top down 30-ft horizontal Horizontal Crush

Puncture

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9979 Evaluation (Testing) – Destructive Examination

SN-02 (Center of Gravity 30-ft Drop - Crush SN-01 (Center of Gravity 30-ft Drop - Horizontal Crush)

Max weight

Min weight

Some damage to 55-gallon drums (resulting from crush); minimal damage to 30-gallon drums; No material loss

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9979 Structural Evaluation

• Conclusions • 1-Hr water spray has no affect; no ingress of water into drum • 24-hr compression test; no observable effect • 1-ft (8); 4-ft drops; minimal damage, scuffed paint • 30-ft drop tests (center of gravity, horizontal, top down, etc.); very minor

damage to packages; • dented hoops, • closure lugs bent inward, • scuffed paint, etc.

• Crush test (center of gravity, horizontal, top down, etc.); greater damage but does not significantly change the bulk configuration of the drum

• hoops dented further • CG impact damage just at location of impact. No gross buckling observed • Horizontal impact damage some flattening of package; No gross buckling • Top down impact some flattening of package extensions; No gross buckling

• Puncture • No effect; slight indication at impact location.

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9979 Thermal Evaluation (Analysis)

Thermal Design Features

Summary of Thermal Evaluation

NCT / HAC Thermal Evaluation

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Model 9979 Shipping Package – Thermal Features

Drum Steel Liner

DOW Polyurethane BETAFOAM in 55-gallon drum Lid and between drum wall and Liner

Insulation Cover

Vent holes; 9 in drum (3 vertical 120º apart)

Polyurethane fill hole for Lid (vent)

Polyurethane fill hole (vent) 2 places on drum bottom

Insulation Bag and Cover in 30-gallon drum (only used for

combustible content) not shown

Pressure Relieving Plug

Drum Lid Steel Liner

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9979 Thermal Evaluation (Analysis)

Thermal Design Features

– Polyurethane foam and Insulation Cover for fire protection

– Insulation Bag for combustible contents

– 30-Gallon Drum high temperature silicone gasket for increased thermal performance

– Drum and Lid vent holes to prevent overpack pressurization during thermal event

– Drum and Lid Liners for foam pour

– Pressure relieving plug (not continuous venting)

9979 Design: Insulation Bag

Keep going for information on SRNL family colors.

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• Used with Combustible Contents • Superwool® Fiber Blanket stitched closed with E-glass • ~1800°F operating temperature

Insulation Bag (cinched closed)

Insulation Bag - Top

30-Gallon Drum

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9979 Summary of Thermal Evaluation

Condition Method

55-Gallon Overpack (ºF)

30-Gallon Drum (ºF)

Drum BETAFOAM™ Insulation

Drum Liner Body Gasket Contents

NCT in Shade Calculated 110 111 104 105 103 152

NCT w/ Insolation Calculated 154 154 144 149 143 189

HAC 30-Minute Fire

Calculated < 1475 n/a 1450 523 326 152

HAC Post-Fire Cool-down w/ Insolation

Calculated (Maximum) < 1475 n/a < 1450 523 501 326

HAC Post-Fire Cool-down w/Insolation

Calculated (Steady State)

196 n/a 177 180 170 211

9979 Component Temperatures

Temperature limits: • BETAFOAM 24 lb/ft3 ; maximum continuous operating temp 200°F • Silicone gasket 500°F (short periods) • Contents 400°F threshold temperature • Insulation blanket material 1,800°F

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Models developed vis MSC.PATRAN/THERMAL Model Parameters – Upright orientation both transportation and storage, – Axisymmetric geometry including all the gaps; excludes drum rolling hoops – Fill gas air – Temperature dependent material properties – Surface to surface radiation and conduction in gaps; convection not modeled – 3.5 watts of heat generation and – Insolation all around except at the bottom – Pre-fire; ambient at 100°F; 3.5 Watts

Boundary Conditions – Bottom adiabatic – Natural convection and radiation heat losses from the drum surface – Solar heat flux all around except at the bottom

9979 Thermal Evaluation General Parameters and Conditions

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9979 HAC Thermal Evaluation

• Methodology • Benchmarked computational model against AT-400A, 9977, and BTSP • AT-400A, 9977 and BTSP are polyurethane foamed packages • Each Fire Tested; 9977 also tested without foam; insulation blanket material present

around drum liner • Parameters

– Forced convection 20 m/s air velocity – Thermal radiation from fire to all drum surfaces – Fire temperature 1475°F (800°C) , 3.5 watts – Post fire solar heat fluxes of 245.77 Btu/ft2-hr on the top of the package and 122.88 Btu/ft2-hr on the side of the package are applied continuously. These values are based on drum surfaces covered with black residue after the fire and solar absorptivity of 1.0.

• Conclusions • HAC analysis results show that the temperatures of the contents are safely below the

threshold temperature of 400°F. Temperatures are well below auto-ignition and pyrolysis temperatures of packing materials such as plastic bagging.

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Maximum Pressures (psia)

1. HAC pressure from temperature increase 20.25 psia; moisture evaporation 41.89 psia 2. NCT pressure from temperature increase 17.03 psia; moisture evaporation 4.13 psia 3. Water assumed to be 1% of payload weight of 200 lb.

Drum 30 55 Comments

NCT 21.16 NA Pressure plug relieves at 12-15 psig

HAC 62.14 NA 55-gallon gasket material degraded; Pressure plug controls 30-gallon overpressure

Design Limit NCT NA NCT – within UN pressure rating

9979 Pressure Evaluation

26

9979 Shielding Evaluation – Dose Rate

Isotopic Masses for Spectra Determination for Dose Rate Calculations

Isotope Mass (g)

Tc-99 1,430

Th-232 90,000

U-232 5.00E-05

U-233 16.7

U-234 26.1

U-235 3,500

U-236 2,500

U-238 90,000

Np-237 76.9

Pu-238 1.59E-03

Pu-239 4.35E-01

Pu-240 1.19E-01

Pu-241 1.58E-02

Am-241 7.69E-03

The Model 9979 Type AF shipping package design does not include any features intended to shield the material within the packaging

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9979 Shielding Evaluation – Dose Rate

Summary Table of External Radiation Levels (Non-Exclusive Use)

Normal Conditions of Transport

Package Surface mSv/h (mrem/h)

1 Meter from Package Surface

mSv/h (mrem/h) Radiation

Gamma 1.365 (136.5) 0.0040 (0.40) Neutron 0.364 (36.4) 0.0011 (0.11)

Total 1.729 (172.9) 0.0051 (0.51) 10 CFR 71.47(a) Limit 10 CFR 71.43(f)

2 (200) 0.1 (10)*

* Transport index may not exceed 10.

• The Transport Index is the maximum dose rate at 1 meter from the package surface in units of mrem/hr.

• The calculated Transport Index is 0.6.

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– Analyze 100 wt. % U-235 metal • Single Unit

– Optimally Moderated • Normal Conditions of Transport Array

– Optimally Moderated • Hypothetical Accident Conditions Array

– Optimally Moderated

9979 Criticality Evaluation

29

9979 Criticality Evaluation

• LEU - 19.192 kg of uranium enriched to <19.9 wt.% U-235 • HEU grams of U-235equivalent mass

• Evaluation demonstrates compliance with the performance requirements for each content envelope as specified in: a) 10 CFR 71.55 – General requirements for fissile material packages b) 10 CFR 71.59 – Standards for arrays of fissile material packages

Hydrocarbon Mass Limit

Carbon+ Beryllium Mass Limit

Fissile Material Fixed on Graphite Pieces

U-235 (eq) Mass Limit **

≤ 1 kg ≤ 1 kg No 350 g ≤ 1 kg No beryllium Yes 350 g > 1 kg ≤ 1 kg No 300 g ≤ 1 kg ≤ 90 kg carbon No 150 g

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9979 Criticality Evaluation – Single Unit Results

Single Package Water surrounding package

Hydro-carbon Mass

Carbon* + Beryllium

Mass

Fissile Material Fixed on Graphite Pieces

U-235 Mass **

Internal Moderation

H/X Case Name Maximum

keff ksafe

≤ 1 kg ≤ 1 kg No 350 g

Not analyzed, bounded by NCT and HAC

≤ 1 kg No beryllium Yes 350 g

> 1 kg ≤ 1 kg No 300 g

≤ 1 kg ≤ 90 kg carbon No 150 g 700 sp700 0.9283 0.931

LEU Cube 3,79161 g† - sp_c_poly 0.593 0.912

LEU Plates 3,0337 g† - sp_hpl_poly.103 0.683 0.912

• Single Unit model • 30 cm of water on all sides • LEU Cube; bottom and center of package; dry and filled with water/poly • LEU Plates; stacked vert/horiz; varied water/poly spacing

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9979 Criticality Evaluation – NCT Results

NCT Array 512 packages (8x8x8), no interstitial moderation, water surrounding array

Hydro-carbon Mass

Carbon* + Beryllium

Mass

Fissile Material Fixed on Graphite Pieces

U-235 Mass **

Internal Moderation

H/X Case Name Maximum

keff ksafe

≤ 1 kg ≤ 1 kg No 350 g 700 nct700be 0.9083 0.931

≤ 1 kg No beryllium Yes 350 g Bounded by nct700be where fissile can be

homogeneously mixed with water

> 1 kg ≤ 1 kg No 300 g 700 nct700p300 0.9166 0.931

≤ 1 kg ≤ 90 kg carbon No 150 g 500 nct500carbon 0.7972 0.931

3375 packages (15x15x15) inner and outer drum flooded, water surrounding array LEU Cube LEU Cube LEU

Cube 3,7916 g† - nct_poly 0.591 0.912

LEU Plates LEU Plates LEU

Plates 3,0337 g† - nct_hpltb_poly 0.675 0.912

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9979 Criticality Evaluation – HAC Results

HAC Array 108 packages (6x6x3), no interstitial moderation, water surrounding array

Hydro-carbon Mass

Carbon* + Beryllium

Mass

Fissile Material Fixed on Graphite Pieces

U-235 Mass **

Internal Moderation

H/X Case Name Maximum

keff ksafe

≤ 1 kg ≤ 1 kg No 350 g 600 hac600dsbe 0.9175 0.931

≤ 1 kg No beryllium Yes 350 g Bounded by hac600dsbe where fissile can be

homogeneously mixed with water > 1 kg ≤ 1 kg No 300 g 700 hac700p300 0.9253 0.931

≤ 1 kg ≤ 90 kg carbon No 150 g 500 hac500c150a 0.9305 0.931

3375 packages (15x15x15) inner drum flooded, no outer drum, water surrounding array LEU Cube LEU Cube LEU

Cube 3,7916 g† - hac_poly 0.768 0.912

LEU Plates LEU Plates LEU

Plates 3,0337 g† - hac_vpltb_poly 0.859 0.912

• Model assumptions • Only 30-gallon drum

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9979 Criticality Evaluation – CSI Results

– Criticality Safety Index • The analysis demonstrates that the package is subcritical for all single package and

array configurations consistent with the package CSI of 1.0.

Normal Conditions of Transport (N = 0.5) Number of undamaged packages that remain subcritical in array

8x8x8

Most reactive credible physical and chemical form of fissile material

100 wt. % U-235 metal

Most reactive interspersed hydrogenous moderation No interstitial moderation, water surrounding array

Most reactive reflecting material Carbon Reflection surrounding the array Water surrounding array

Hypothetical Accident Conditions (N = 1.0) Number of damaged packages to remain subcritical 6x6x3 Most reactive credible physical and chemical form of fissile material

100 wt. % U-235 metal

Most reactive interspersed hydrogenous moderation No interstitial moderation, water surrounding array

Most reactive reflecting material Carbon Reflection surrounding the array Water surrounding array

9979 Package Operations

34

Prototype 1 Prototype 2 SRNL Lift Device

9979 Procurement and Fabrication

35

• Primary Supplier – Paragon D&E – NQA-1

• Sub Suppliers – Skolnik Industries – Drum Parts Midwest – Parker – Morgan Thermal Ceramics – DOW Automotive – Reike Packaging Systems

9979 Procurement and Fabrication History

36

Year User/Customer Quantity

2011 Y-12 Purdue

SNL INL

350 96 35 6

2012 Y-12 145

2013 KAPL LANL Y-12

6 42

320

2014 KAPL INL Y-12 SNL

Portsmouth

14 25

420 45 75

2015/2016 LANL Y12

180 575

9979 Program History

• April 2008: Project Start / Design Requirements Document • April/August 2008: Conceptual Design/Analysis • August/October 2008: Pre-prototype Testing (5-separate designs evaluated) • November/January 2009: Prototype Fabrication • January 2009: Prototype Regulatory Testing • February 2009: SARP Submitted to Argonne National Laboratory (ANL) for

Regulatory Review • March/April 2009/2010: ANL Review • April 2010: Procurement Request for Quote (RFQ) Issued • June 2010: RFQ Return • June 2010: DOE Certificate of Compliance (CoC) Issued • September 2010: SRNL Issue Procurement

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Closing Discussion

• ???

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