1. Current DOE Efforts in Nuclear Materials Management Patrice M. Bubar Associate Deputy Assistant Secretary, Office of Integration and Disposition (EM-20) National Governors Association April 2001

2. Topics “At-risk” nuclear materials EM efforts to identify and plan for disposition of surplus nuclear materials DOE corporate nuclear materials stewardship initiatives Current EM nuclear materials stewardship efforts

3. “At-Risk” Nuclear Materials DNFSB Recommendation 00-1/94-1, Remediation of Nuclear Materials at the Defense Nuclear Facilities Complex DNFSB Recommendation 97-1, Safe Storage of Uranium-233

4. Materials Stabilization Status All plutonium in contact with plastic has been repackaged; solution and residue drums have been vented pending stabilization or repackaging  Mitigated risk of hydrogen explosion Over 90% of all plutonium solutions have been stabilized to a solid form Over 50% of plutonium residues have been stabilized and repackaged All highly-enriched uranium solids have been stabilized All SNF at Idaho is in the process of being moved to improved storage

5. Scope of Recommendation 97-1 (issued 05/97) concerns safe storage of Department’s 233 U inventory Inventory is primarily at ORNL and INEEL (~400kg each) with minor amounts at other sites 233 U is a legacy material from past nuclear development programs and presence of certain decay isotopes in the inventory creates a radiological hazard which makes handling difficult It is weapons usable but its promise was primarily as a reactor fuel DNFSB Recommendation 97-1

6. DNFSB Recommendation 97-1 Implementation Status Department completed all commitments at LANL, INEEL and in process of consolidate small holdings Major issue concerns integrity of 233 U packages in storage at ORNL Department’s plan is to begin package sample inspection program in late summer of FY01; remote handling system for packages to be used Department considering making 233 U inventory available for commercial processing of beneficial isotopes –would disposition inventory and resolve storage problems at ORNL –provide greater supply of much needed isotopes to medical community for cancer research an potential treatment

7. NUCLEAR MATERIALS DISPOSITION National Security Materials Non-National Security Programmatic Materials Nuclear Materials Inventory Assessment Surplus Materials Nuclear Materials Stewardship Program National TRU Program LLW Program NSNFP MD (NN-60) WIPP LLW Disposal Sites Geologic Repository Characterization/ Inventory/ Disposition Planning Disposition/Interface Management Disposal National Resource

8. EM Nuclear Material Disposition Path Analysis Materials # of Paths Green TBD Yellow Red Not Assessed Am-241 13 4 7 2 0 0 Np-237/Pu-238 43 2 29 4 8 0 Pu-239 101 9 21 1456 1 Pu-242 13 6 3 0 4 0 HEU 157 129 1 20 2 5 U-233 29 0 29 0 0 0 Th-232 37 1 35 0 0 1  emitters * 47 20 24 3 0 0 Sealed Sources 222 100 55 67 0 0 DU 139 5 130 0 0 4 LEU 113 7 103 2 0 1 NU 70 4 66 0 0 0 Heavy Isotopes 27 5 12 _ 0 10 0 1011 292 515 112 80 12 * Includes Cs/Sr

9. NMI PROJECT (1998) IDENTIFIED AND ASSESSED 1011 DISPOSITION PATHS 515 TBD 112 Yellow 80 Red 292 Green

10. Highlights of Activities to Focus on Identifying Disposition Paths for Nuclear Materials Performed Options Analysis and Trade Studies for High Return Nuclear Materials Assisting Individual Sites with Analysis of “TBD” Material Streams Made Decisions on 3 Major Categories of Materials – 233 U oxides, metals, and fluorides at Oak Ridge –Mark 18 A Targets at Savannah River –Am/Cm tank solutions at Savannah River

11. 3 Recent Decisions on Nuclear Materials - 233 U, Mark 18A targets, and Am/Cm solutions - all considered as potential “National Resources” 233 U at OR - decision was made to make available to private sector, via a current draft Request-for-Proposals, to extract 229 Th decay daughter for use in medical research/cancer therapy Mark 18A Targets at SR contain 244 Pu and other heavy isotopes - decision was made keep for several years while DOE programs (esp. Office of Security and Emergency Operations & Office of Nonproliferation and National Security) seek $ to extract 244 Pu 241 Am/ 244 Cm in tank 17.1 solutions at SR - recovery for reuse/commercial sales not deemed economical; will proceed to vitrify and dispose unless a viable use is identified in near term

12. Tackle High-Return Nuclear Materials Perform Options Analysis: Pu Storage Study (11/00) SRS Canyon Materials Identification Study (2/01) Off-Spec HEU Study Classified Parts Disposition * “Special Item” Disposition DU/NU/LEU Trade Study * Cs-137/Sr-90 Trade Study * = discussed next in greater detail

13. Classified Parts Disposition Complex-wide Inventory of Classified Parts Completed Disposition Options Identified. Options Include –Sanitization with Disposal as TRU waste –Disposal as Classified TRU waste Rocky Flats has a Critical Need to Disposition their Classified Waste. No centralized or on-site sanitization capability exists. DOE is Exploring Disposal of Rocky Flats Classified Waste at WIPP

14. DU/NU/LEU Trade Study Complex-wide Assessment of Inventory shows ~300 TBDs Study Considers Disposition Options: –Relatively Pure Material can be kept for future blending/reuse –Contaminated Material is too costly to process and cheaper to dispose of Study Considers Relative Costs for Storage, Reuse, or Direct Discard Likely Result is a set of “Threshold for Discard” Criteria –based on future uses –to be used by programmatic owners to make informed decisions about disposition pathways for their materials Draft Trade Study is being finalized

15. “TBD” Analysis and Support Provide recommendations to Fernald and Rocky Flats on disposition paths for “TBDs” Providing assistance to Richland and INEEL in FY01 on TBDs Performed analysis with recommendation for off-site storage location for uranium from Fernald & Hanford to Portsmouth Assisted Mound with de-inventorying all surplus nuclear materials

16. Continued Activities in FY01 Consider use of Nuclear Materials Management Groups –Pu –U –Heavy (i.e., transplutonium) Isotopes –Nonactinide Isotopes and Sealed Sources Ensure Packaging and Transportation Infrastructure Exists to Transport Nuclear Materials Continue Interfaces with other DOE Programs

17. Backup Slides

18. Assisted Mound to COMPLETELY de-inventory major holdings of surplus nuclear material in October 2000 Assistance to Fernald includes –technology development automation to facilitate U repackaging, and –consolidation of some U to Portsmouth for storage –recommendations to resolve remaining TBD’s Assistance to Rocky Flats includes: –classified parts disposition –disposition of sealed sources –recommendations to resolve remaining TBD’s Deinventory of Closure Sites (Mound, Fernald, Rocky Flats)

19. Uranium from Fernald in safe storage at Portsmouth

20. Chemically reactive plutonium scrap/residues in PFP gloveboxes at Hanford are hazardous to workers and must be inspected daily.

21. (SRS) Can containing plutonium metal button showing oxide produced during storage; Metal remaining after removal from can

22. Plastic bottles with plutonium solutions in Building 771 gloveboxes at Rocky Flats

23. Corroding MK-31 targets at Savannah River, stabilized under DNFSB 94-1 in 1997.

24. 3013 Container

25. U Materials at Fernald Up to 1000 metric tons of uranium at Fernald will require processing to dispose as low level waste. Tubes Flat Billets Crucible Charge Slag Fines Large Rods Thin Rods Billet In Water

26. Hanford Material Project T-Hoppers ~ 700 MTU Average enrichment 0.84% UO 3 Powder Uranium Billets ~ 200 MTU Enrichment 0.20 - 1.25% Metal Fuel Assemblies ~ 800 MTU Enrichment 0.71 - 1.25% Finished/Unfinished/Clad Metal Stable materials being moved from Hanford to Portsmouth by the Uranium Management Group with coordination from EM-20.

27. Integrated Nuclear Materials Management Plan Action Categories 1 Nuclear Materials Stewardship Infrastructure. Sustain Nuclear Materials Stewardship processes, capabilities, and decision-making infrastructure. 2 Integrated Planning for Facilities and Infrastructure. Develop integrated strategy and plan for modernizing nuclear materials complex. 3 Budgeting and Financial Accounting. Build a budget and financial accounting system to facilitate corporate nuclear materials management budgeting and decision making

28. Integrated Nuclear Materials Management Plan Action Categories 4 Excess Nuclear Materials Disposition. Complete disposition decisions for excess nuclear materials. 5 Research and Development Coordination. Identify and implement opportunities for nuclear materials technology information exchanges and R&D coordination. 6 Information Management System Reengineering. Undertake corporate nuclear materials information management system reengineering and process improvements. 7 Transportation and Packaging Process Improvements. Secure transportation and packaging integration and process improvement opportunities.

29. Recommendation 2000-1 Board’s Recommendation issued January 14, 2000 Re-emphasized the remaining 94-1 stabilization actions Department’s Implementation Plan issued June 8, 2000; addressed the nine technical sub-recommendations from 2000-1 related to stabilization Revision 1 of 2000-1 Implementation Plan issued January 19, 2001; incorporated several individual milestone changes as well as a new baseline for LANL stabilization

30. DNFSB Recommendation 97-1 Recent Developments Secretarial public commitment to ensure availability of 233 U material for cancer treatment clinical trials (6/00) ORNL EOI (6/00) DOE Decision to issue RFP at ORNL(9/00) Draft RFP issued for ORNL Inventory (1/01); comments are being evaluated INEEL began trade studies to examine and validate potential beneficial uses of 233 U and infrastructure to support prospective uses

31. EM Policy Cross-Program Issues AL Technology Transportation NISS MG SR Facility Data Pu MG ID Integration Support OR U MG HI MG EM Nuclear Materials Stewardship Program Participants:

32. Phases of Surplus Nuclear Materials Disposition Define Problem Identify Issues Inventory Nuclear Materials Resolve Policy Issues Develop Tools to Assist Sites Tackle High-Return Nuclear Materials Implementation

33. Achievements of the 1997-99 “Nuclear Materials Initiative” Project “Material Evaluation Teams” were formed to identify inventories and develop disposition plans for... –transuranics (plutonium and heavy isotopes) –uranium –non-actinide isotopes and sealed sources These teams canvassed DOE sites Products : –Draft “Material Management Plans” = summary reports of teams –Inventory of Nuclear Materials by Sites –>1,000 Disposition Maps for Surplus Nuclear Materials Streams These maps are (unclassified) HQ rep’n of disposition plans & a major decision support tool - example shown next –Identified some ways to resolve “TBDs” shown on maps

34. Motivation for Corporate Action 8 programs with divergent objectives manage nuclear materials at or through 36 locations Deinventory and close high mortgage, low value facilities to facilitate infrastructure modernization Improve reporting accuracy and completeness of nuclear materials inventory data Avoid premature shutdown of facilities required to disposition excess nuclear materials Need to save valuable or unique materials or dispose of surplus materials that are expensive to maintain Improve cross-program cooperation Be responsive to external oversight [e.g., DNFSB 94-1 & 97-1; Congress]

35. FY00 Accomplishments Developed two DOE Storage Standards –DOE-STD-3013 - for surplus Pu materials packaged and stored in a “3013” can - this standard jointly developed and owned by DP/MD/EM –DOE-STD-3028 - long-term storage standard for 233 U Assistance to Closure Sites (Mound, Fernald, Rocky Flats) on specific TBD issues. Report on Consolidated Storage Options for Surplus Non-Pit 239 Pu –which sites ship just-in-time to MD/SR, which ship in advance Contributions to other corporate (NMSI) and EM initiatives –NMSI-SIM business case for data

36. Planned Plutonium Flow [result of Plutonium Storage Study]

37. Major Challenges with Sites and Other Programs Improve coordination with EM program offices and sites to plan and facilitate implementation of nuclear material disposition Interface with NN for disposition of weapons-usable nuclear materials Interface with RW to dispose of DOE spent fuel/ “orphans”, decide on transport system, and integrate repository receipt schedule Interface with DP on transfer of surplus nuclear materials and responding to DNFSB Recommendations (00-1/94-1, 97-1 & 97-2) Interface with NE on 233 U procurement at ORNL (97-1), National Resource related issues Support corporate level “Nuclear Materials Stewardship Initiatives” –Determine cost/benefit of Nuclear Material Management Groups –Decide on discard criteria for DU/NU & LEU Integrate site SNF stabilization activities to share lessons learned, improve efficiency, and prepare DOE SNF for repository

38. Pu Dispositioning via Can-In- Canister Immobilization Can of Pu-Ceramic Pucks ~ 20 in. high by 3 in. OD 20 pucks per can 1.02 kg Pu per can Glass “17” MT case: 635 (77 extra) “50” MT case: 1744 (210 extra) No. of Pu Can-in-Cansiter Forms Ceramic Form Titanate mineral phases Fraction of key elements: 10 wt% Pu (~ 50 g) 20 wt% U Pu/Hf ~ 1; Pu/Gd ~ 1 Puck Dimensions: ~2.6 in D x 1 in H Primary phase is pyrochlor: A B (Ti 2 O 7 ) where A = Ca & Gd; B = Pu, U, & Hf