In 2005, the THOR steam reforming fluidized-bed reactor technology was selected by the U.S. Department of Energy for treatment of sodium-bearing waste at the INL. The initial commissioning was typical, until June of 2012 when an over-pressurization event resulted in a significant release of solids. Recovery and subsequent testing systematically dealt with challenges associated with operation of three primary vessels: the denitration and mineralization reformer, the process gas filter, and the carbon reduction reformer. Additional challenges with the following ancillary systems surfaced during testing: the auger/grinder, sample system, and the approach to decontamination of the process vessels prior to outages. The major operational challenges covered fluidization issues, premature refractory failure, high-temperature gaseous filter element blinding, cementitious material formation in solids handling equipment, sampling reliability, and vessel decontamination. The purpose of this paper is to share the lessons learned during the extended commissioning of the Integrated Waste Treatment Unit.
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