Melter Feed Reactions at T ≤ 700°C for Nuclear Waste Vitrification

To understand feed‐to‐glass conversion for the vitrification of nuclear waste, we investigated batch reactions and phase transitions in a simulated nuclear waste glass melter feed heated at 5 K/min up to 700°C using optical microscopy, scanning electron microscopy with energy‐dispersive X‐ray spectroscopy, and X‐ray diffraction. To determine the content and composition of leachable phases, we performed leaching tests; the leachates were analyzed by inductively coupled plasma atomic emission spectroscopy. By 400°C, gibbsite and sodium borates lost water and converted to amorphous phase, whereas other metallic hydroxides dehydrated to oxides. Between 400°C and 700°C, carbonates decomposed before 500°C; amorphous aluminum oxide and calcium oxide reacted with the sodium borate and formed the more durable amorphous borate phase along with intermediate crystalline products; above 500°C, quartz began to dissolve, and hematite started to convert to trevorite.     

Effects of heating rate,quartz particle size,viscosity, and form of glass additives on high‐level waste melter feed volume expansion

Nuclear waste can be vitrified by mixing it with glass‐forming and ‐modifying additives. The resulting feed is charged into an electric glass melter. To comprehend melting behavior of a high‐alumina melter feed, we monitored the volume expansion of pellets in response to heating at different heating rates. The feeds were prepared with different particle sizes of quartz (the major additive component) and with varied silica‐to‐fluxes ratio to investigate the glass melt viscosity effects. Also, we used additional melter feeds with additives premelted into glass frit. The volume of pellets was nearly constant at temperatures <600°C. After a short period of volume shrinkage at ~600°C‐700°C, foam generation produced massive volume expansion. The low heat conductivity of foam hinders the transfer of heat from molten glass to the reacting feed. The extent of foaming increased with faster heating and higher melt viscosity, and decreased with increasing size of quartz particles and fritting of the additives. Volume expansion data are needed for the mathematical modeling of the cold cap.     

X‐ray tomography of feed‐to‐glass transition of simulated borosilicate waste glasses

High‐level waste feed composition affects the overall melting rate by influencing the chemical, thermophysical, and morphological properties of a cold cap layer that floats on the molten glass where most feed‐to‐glass reactions occur. Data from X‐ray computed tomography imaging of melting pellets comprised of a simulated high‐aluminum feed reveal the morphology of bubbles, known as the primary foam, for various feed compositions at temperatures between 600°C and 1040°C. These feeds were formulated to make glasses with viscosities ranging from 0.5 to 9.5 Pa s at 1150°C, which was accomplished by changing the SiO₂/(B₂O₃+Na₂O+Li₂O) ratio in the final glass. Pellet dimensions and profile area, average and maximum bubble areas, bubble diameter, and void fraction were evaluated. The feed viscosity strongly affects the onset of the primary foaming and the foam collapse temperature. Despite the decreasing amount of gas‐evolving components (Li₂CO₃, H₃BO₃, and Na₂CO₃), as the feed viscosity increases, the measured foam expansion rate does not decrease. This suggests that the primary foaming is not only affected by changes in the primary melt viscosity but also by the compositional reaction kinetic effects. The temperature‐dependent foam morphological data will be used to inform cold cap model development for a high‐level radioactive waste glass melter.     

Thermal Expansion of BaO · 2B<Subscript>2</Subscript>O<Subscript>3</Subscript> in the Vitreous and Crystalline States: I. Thermal Expansion and Density of Barium Diborate Prepared from Monolithic Glass of the Same Composition

The thermal expansion and density of vitreous and polycrystalline barium diborates prepared by crystallization of monolithic glasses of stoichiometric composition are investigated in the temperature range 20–700°C. The glass crystallizes in the form of the α and β modifications depending on the heat treatment conditions. The α phase nucleates on the surface of the monolithic sample and grows inward the sample in the form of textured layers. The β phase nucleates in the melt bulk and grows in the form of spherulites. Textured polycrystalline barium diborate in the form of the α phase possesses a pronounced anisotropy of thermal expansion with respect to the direction of crystalline-layer growth. This is associated with the negative expansion along one of the crystallographic axes. The effective temperature coefficients of thermal expansion in the temperature range 20–600°C increase in the order: α phase-glass-β phase. Upon heating above 690°C, the β phase transforms partially into the α phase. This is accompanied by a considerable increase in the volume. The densities of the glass and polycrystalline samples in the temperature range 20–700°C increase in the order: glass-α phase–β phase.     

Determination of Temperature‐Dependent Heat Conductivity and Thermal Diffusivity of Waste Glass Melter Feed

The cold cap is a layer of reacting glass batch floating on the surface of melt in an all‐electric continuous glass melter. The heat needed for the conversion of the melter feed to molten glass must be transferred to and through the cold cap. Since the heat flux into the cold cap influences the rate of melting, the heat conductivity is a key property of the reacting feed. We designed an experimental setup consisting of a large cylindrical crucible with an assembly of thermocouples (TC) that monitors the evolution of the temperature field while the crucible is heated at a constant rate. Then we used two methods to calculate the heat conductivity and thermal diffusivity of the reacting feed: the approximation of the temperature field by polynomial functions and the finite‐volume method (FVM) coupled with least‐squares analysis. Up to 680°C, the heat conductivity of the reacting melter feed was represented by a linear function of temperature.     

Preparation of Porous Glass‐Based Thick Film Using Diffusion‐Induced Phase Separation from Scrap Glass

The porous glass thick film was fabricated by the diffusion‐induced phase separation and the sintering technique from scrap glass, polyvinylidene fluoride, and dimethylacetamide (DMAc). Pores formed due to the dissolution of DMAc in water. As heat treatment temperature increases, densification of porous glass was gradually enhanced while the pore channels were maintained. Porosity data of ~62% and 55% were obtained at 700°C and 800°C, respectively. The pore size diameters were 91.1 μm (700°C) and 90.8 μm (800°C) separately. The porous materials showed acid durability partially because flower‐like crystals were dissolved in 1M HCl solution. The process reported in this paper provided a simple method to prepare porous glass under one‐step calcinations at low temperature and was helpful for the reuse technology of scrap glass.     

Novel Ag–Glass Composite Interconnect Materials for Anode‐Supported Flat‐Tubular Solid Oxide Fuel Cells Operated at an Intermediate Temperature

We developed novel Ag–glass composite interconnect materials for anode‐supported flat‐tubular solid oxide fuel cells (SOFCs) operated at 700 °C by optimization of the glass content. For this purpose, the variations of phase stability, area specific resistance (ASR), microstructure, gas leak rate, cell performance, and open circuit voltage (OCV) were determined for the Ag–glass composite materials with respect to the glass content. The Ag–glass composite materials maintain phase stability without chemical reactions. The ASR increased as the glass content increases due to glass existing as an insulator between the Ag phases. All the composite materials showed dense coating layers on the anode support and had a low gas leak. The cell performance and OCV were measured to identify the optimum composition of the Ag–glass composites. Our results confirm that Ag–glass composites are suitable for high performance interconnects in anode‐supported flat‐tubular fuel cells operated below 700 °C.     

Crystallinity morphology and dynamic mechanical characteristics of PBT polymer and glass fiber‐reinforced composites

The crystalline morphologies of PBT (poly butylene terephthalate) and its glass fiber reinforced composite systems were investigated in a thin‐film form by polarized optical microscopy and wide‐angle X‐ray diffraction. Three different types of PBT morphology were identified in the Maltese cross pattern: 45° cross pattern (usual type) by solvent crystallization, 90° cross pattern (unusual type) by melt crystallization at low crystallization temperature, and mixed type by melt crystallization at crystallization temperatures higher than 160°C. The glass fibers increased the number density of spherulites and decreased the size of crystallites acting as crystallization nucleation sites without exhibiting trans‐crystallinity at the vicinity of the glass fiber surfaces. Finally, the storage modulus was analyzed by using a dual‐phase continuity model describing the modulus by the power‐law sum of the amorphous‐ and crystalline‐phase moduli. The crystalline‐phase modulus was extracted out from the PBT polymer and composite systems containing different amount of crystallinity. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 86: 478–488, 2002     

Melter feed viscosity during conversion to glass: Comparison between low‐activity waste and high‐level waste feeds

During nuclear waste vitrification, a melter feed (a slurry mixture of a nuclear waste and various glass forming and modifying additives) is charged into the melter where undissolved refractory constituents are suspended together with evolved gas bubbles from complex reactions. Knowledge of flow properties of various reacting melter feeds is necessary to understand their unique feed‐to‐glass conversion processes occurring within a floating layer of melter feed called a cold cap. The viscosity of two low‐activity waste (LAW) melter feeds were studied during heating and correlated with volume fractions of undissolved solid phase and gas phase. In contrast to the high‐level waste (HLW) melter feed, the effects of undissolved solid and gas phases play comparable roles and are required to represent the viscosity of LAW melter feeds. This study can help bring physical insights to feed viscosity of reacting melter feeds with different compositions and foaming behavior in nuclear waste vitrification.     

Solid‐state structure of thermally crystallized syndiotactic polystyrene

The solid‐state structure of syndiotactic polystyrene (s‐PS) after crystallization from the melt and the glassy state was examined by differential scanning calorimetry (DSC), density, and X‐ray diffraction analysis. It was possible to prepare semicrystalline s‐PS containing either the pure α‐ or the pure β‐crystalline form by melt crystallizing s‐PS from 280 or 330°C. The measurements confirmed the low density of both crystalline forms, which in the case of α‐crystalline form was smaller and in the case of β‐crystalline form was only slightly larger than the density of the glassy amorphous s‐PS. An endeavor to introduce the crystalline phase in s‐PS through cold crystallization at constant temperature above the glass transition resulted in a complex ordered phase. This ordered phase, depending on the crystallization temperature, contained the planar chain mesomorphic phase and the α‐crystalline phase with a low degree of perfection (cold crystallization in the range 120–175°C) or a mixture of the α‐ and β‐crystalline forms with a high degree of perfection (cold crystallization in the range 210–260°C). The combination of DSC and X‐ray measurements enabled us to resolve the complex ordered structure in semicrystalline s‐PS after cold crystallization. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 83: 2705–2715, 2002     

Influence of Crystallization on the Conversion of Sm3+→Sm2+ in SrO–Bi2O3–K2O–B2O3 Glass‐Ceramics

Sm³⁺‐doped glass 13SrO–2Bi₂O₃–5K₂O–80B₂O₃ was fabricated by the conventional melt‐quenching technique. The glass‐ceramics were obtained by heating the as‐prepared glasses in air atmosphere at selected temperatures 550°C, 600°C, 615°C, and 650°C, respectively. The luminescence spectra of both Sm³⁺ and Sm²⁺ were detected in the ceramic heated at 650°C where crystalline phase is formed. The as‐prepared glass and the ceramics heated at 550°C, 600°C, and 615°C show only the emission due to Sm³⁺. In the sample heated at 650°C in air atmosphere, however, part of Sm³⁺ ions was converted to Sm²⁺, giving rise to sharp emission lines which are characteristic of Sm²⁺ in crystalline state. It is suggested that Sm²⁺ ions are located at Sr²⁺ site in the ceramic while Sm³⁺ ions are located at Bi³⁺ sites. The Sm²⁺‐doped glass‐ceramic has a high optical stability because the fluorescence intensity decreases by only about 8% of its initial value upon excitation at 488 nm Ar⁺ laser.     

Performance of long glass fiber‐reinforced polypropylene composites at different injection temperature

Long glass fiber‐reinforced polypropylene composites were prepared using self‐designed impregnation device. Effects of the different injection temperature on mechanical properties, crystallization, thermal, and dynamic mechanical properties of long glass fiber‐reinforced polypropylene composites were discussed. The differential scanning calorimetry (DSC) results indicate that the melting peak temperature of PP/LGF composites gradually reduced, however, the crystallinity of PP/LGF composites gradually increased with increasing injection temperature. Thermo‐gravimetric analyzer (TGA) results demonstrate that with increasing injection temperature, the temperature of the PP/LGF composites melt increased, the viscosity of the PP/LGF composites melt lowered, the mold filling of the PP/LGF composites melt was easy, the shear force of glass fiber was relatively low, which made the residual length of glass fiber in products increase. Dynamic thermal mechanical analyzer (DMA) results show that the storage modulus of PP/LGF composites is the highest while the injection temperature is at 290°C, and the peak value of tan σ of PP /LGF composites at 290°C is minimal, which indicates that the mechanical properties of PP /LGF composites at 290°C is the best. What' more, the injection temperature at 290°C significantly ameliorated “glass fiber rich skin” of products of glass fiber‐reinforced composites. J. VINYL ADDIT. TECHNOL., 24:233–238, 2018. © 2016 Society of Plastics Engineers     

Formation of Technetium Salts in Hanford Low‐Activity Waste Glass

The distribution and physical form of technetium in a Hanford low‐activity waste (LAW) glass was examined with scanning electron microscopy (SEM) and X‐ray diffraction (XRD). A simulated Hanford LAW glass was spiked with varying amounts of potassium pertechnetate and melted at 1000°C. The glass was melted in a sealed quartz ampoule with the air pumped out, so that volatile material could leave the glass but would not be lost from the system. Previous studies have shown that technetium remains in the glass up to about 2000 ppm, but rises to the top of the melt as a separate salt phase above this concentration. Examination by SEM shows that crystals of technetium compounds appear to grow out of the hot glass, which implies that the hot glass was supersaturated in technetium salts. Some of the technetium compound crystals had apparently melted, but other crystals had obviously not melted and must have formed after the glass had partially cooled. The technetium compounds in the salt layer are KTcO₄ and NaTcO₄, according to SEM and XRD. No TcO₂ was found in the salt phase, even though Tc(IV) has been previously reported in the glass.     

Rheology of simulated radioactive waste slurry and cold cap during vitrification

During the vitrification of radioactive waste in a Joule‐heated melter, aqueous melter feed slurry forms a cold cap, a reacting and melting material, which floats on the surface of the molten glass. The rheological behavior of the feed affects cold cap formation and shape, and is vital for modeling the feed‐to‐melt conversion process. We used slurry feed simulant and fast‐dried slurry solids representing the cold cap to investigate the rheological behavior of the feed as it transforms into glass. Both low‐temperature and high‐temperature rheometry were performed and a new scheme was applied to estimate the feed viscosity. This study shows that the conversion advances in four sequential stages that form distinct regions in the cold cap: (i) a fast‐spreading boiling slurry from which water evaporates, (ii) a porous solid region (viscosity > 10⁸ Pa s) containing reacting solids and molten salts, (iii) a plastic region in which glass‐forming melt connects the refractory solids (~10⁸ to ~10⁶ Pa s), and (iv) a viscous foam layer in which the viscosity drops from ~10⁵ to ~10¹ Pa s. The implications for the mathematical modeling of the cold cap are discussed.     

Design,synthesis, and characterization of a potential flame retardant poly(lactic acid‐co‐pyrimidine‐2,4,5,6‐tetramine) via direct melt polycondensation

Directly starting from d ,l ‐lactic acid (LA) and pyrimidine‐2,4,5,6‐tetramine (PTA), the copolymer P(LA‐co‐PTA) as a novel potential solid compatible polymeric flame retardant is synthesized as designed via melt polycondensation. When the molar feed ratio LA/PTA is 60/1, the optimal synthetic conditions are discussed. After the prepolymerization at 140°C for 8 h, using 0.5 wt % stannous oxide as the catalyst, the melt copolymerization at 160°C for 4 h gives the copolymer with the biggest intrinsic viscosity 0.88 dL g^?1. The structures and properties of P(LA‐co‐PTA)s at different molar feed ratios are characterized by FT‐IR, ¹H‐NMR, ¹³C‐NMR, GPC, XRD, DSC, and TGA. The decomposition temperatures of P(LA‐co‐PTA)s are higher than these of homopolymer poly(d,l ‐lactic acid) (PDLLA). All copolymers have higher char yield than PDLLA, and the more PTA in the feed content, the higher char yield. What's more, there are some residues at 700–800°C, indicating that P(LA‐co‐PTA)s have good charring ability. When the monomer PTA is introduced into polylactic acid by chemical bonding as purine (PU) unit formed during the condensation, both the PTA's relatively higher nitrogen content and the PU's similar structure with flame retardant benzimidazole are beneficial to improve the thermal stability and charring ability, especially the latter. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40275.     

Determination of Heat Conductivity and Thermal Diffusivity of Waste Glass Melter Feed: Extension to High Temperatures

The heat conductivity (λ) and the thermal diffusivity (a) of reacting glass batch, or melter feed, control the heat flux into and within the cold cap, a layer of reacting material floating on the pool of molten glass in an all‐electric continuous waste glass melter. After previously estimating λ of melter feed at temperatures up to 680°C, we focus in this work on the λ(T) function at T > 680°C, at which the feed material becomes foamy. We used a customized experimental setup consisting of a large cylindrical crucible with an assembly of thermocouples, which monitored the evolution of the temperature field while the crucible with feed was heated at a constant rate from room temperature up to 1100°C. Approximating measured temperature profiles by polynomial functions, we used the energy equation to estimate the λ(T) approximation function, which we subsequently optimized using the finite‐volume method combined with least‐squares analysis. The heat conductivity increased as the temperature increased until the feed began to expand into foam, at which point the conductivity dropped. It began to increase again as the foam turned into a bubble‐free glassmelt. We discuss the implications of this behavior for the mathematical modeling of the cold cap.     

Cationic electron‐beam curing of a high‐functionality epoxy: effect of post‐curing on glass transition and conversion

This paper reports on the cationic electron‐beam curing of a high‐functionality SU8 epoxy resin, which is extensively used as a UV‐curing negative photoresist for micro‐electronics machine systems (MEMS) applications. Results show that elevated post‐curing treatment significantly increased both the conversion and the glass transition. The degree of conversion and the glass transition temperature were measured by using Fourier‐transform infrared (FTIR) spectroscopy and modulated differential scanning calorimetry (MDSC^®), respectively. The glass transition temperature (T_g), which has been observed to be dependent on the degree of conversion, reaches a maximum of 162 °C at 50 Mrad and post‐curing at 90 °C. The degradation pattern of the cured resin does not show much variation for exposure at 5 Mrad, but does show significant variation for 50 Mrad exposure at various post‐curing temperatures. A degree of conversion of more than 0.8 was achieved at a dosage of 30 Mrad with post curing at 80 °C, for the epoxy resin with an average functionality of 8 a feature simply not achievable when using UV‐curing. Copyright © 2004 Society of Chemical Industry     

Phase separation and crystallization behavior in extruded polypropylene/ethylene–propylene rubber blends

Liquid–liquid (L–L) phase separation and its effects on crystallization in polypropylene (PP)/ethylene–propylene rubber (EPR) blends obtained by melt extrusion were investigated by time‐resolved light scattering (TRLS) and optical microscopy. L–L phase separation via spinodal decomposition (SD) was confirmed by TRLS data. After L–L phase separation at 250°C for various durations, blend samples were subjected to a temperature drop to 130°C for isothermal crystallization, and the effects of L–L phase separation on crystallization were investigated. Memory of the L–L phase separation via SD remained for crystallization. The crystallization rate decreased with increasing L–L phase‐separated time at 250°C. Slow crystallization for the long L–L phase‐separated time could be ascribed to decreasing chain mobility of PP with a decrease in the EPR component in the PP‐rich region. The propylene‐rich EPR exhibited good affinity with PP, leading to a slow growth of a concentration fluctuation during annealing. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 695–700, 2001     

Influence of the mixing time on the phase structure and glass‐transition behavior of poly(ethylene terephthalate)/poly(ethylene‐2,6‐naphthalate) blends

Blends of poly(ethylene terephthalate) and poly(ethylene‐2,6‐naphthalate) (70 : 30 w/w) were prepared via a melt‐mixing process at 280°C with various mixing times. The melt‐mixed blends were analyzed by magnetic resonance spectroscopy, differential scanning calorimetry, dynamic mechanical measurements, transmission electron microscopy, and tensile tests. The results indicate that the blends mixed for short times had lower extents of transesterification and were miscible to a limited extent. The blends initially show two glass transitions, which approached more closely and merged gradually with increasing mixing time. A mechanical model was used to help understand the glass‐transition behavior. With increasing mixing time, the phase structure of the blends improved, and this led to an increase in the tensile strength. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Phase stability and melting behavior of the α and γ phases of nylon 6

The phase stability and melting behavior of nylon 6 were studied by high‐temperature wide‐angle X‐ray diffraction and differential scanning calorimetry (DSC). The results show that most of the α phase obtained by a solution‐precipitation process [nylon 6 powder (Sol‐Ny6)] was thermodynamically stable and mainly melted at 221°C; the double melting peaks were related to the melt of α crystals with different degrees of perfection. The γ phase formed by liquid nitrogen quenching (sample LN‐Ny6) melted within the range 193–225°C. The amorphous phase converted into the γ phase below 180°C but into the high‐temperature α phase at 180–200°C. Both were stable over 220°C. α‐ and γ*‐crystalline structures were formed by annealing but were not so stable upon heating. Typical double melting peaks were shown on the DSC curve; melt recrystallization happened within the range 100–200°C. The peak at 210°C was mainly due to the melting of the less perfect crystalline structure of the γ phase and a fraction of the α phase; the one at 219°C was due to the high‐temperature α‐ and γ‐phase crystals. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011