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Weapons of Mass Destruction (WMD)

EIS-0277F; Final Environmental Impact Statement on Management of Certain Plutonium Residues and Scrub Alloy Stored at the Rocky Flats Environmental Technology Site

VOLUME 1 TABLE OF CONTENTS

VOLUME 2 TABLE OF CONTENTS


List of Figures
List of Tables
Acronyms and Abbreviations

APPENDIX A-SUPPLEMENTARY INFORMATION
Notice of Intent
Notice of Availability
Fact Sheet
Public Reading Rooms
Contractor Disclosure Statement

APPENDIX B-PLUTONIUM RESIDUES AND SCRUB ALLOY CHARACTERISTICS
B.1 Summary B-1
B.2 Rocky Flats Residue Generation B-2
B.2.1 Introduction B-2
B.2.2 Programmatic History B-3
B.2.3 Safeguards Termination Limits, Item Description Codes, and Site Integrated
Stabilization Management Plan Groups B-4
B.3 Detailed Discussions of Rocky Flats Residues B-8
B.3.1 Introduction B-8
B.3.2 Ash Residues B-10
B.3.2.1 Incinerator Ash Residues B-10
B.3.2.2 Graphite Fines Residues B-13
B.3.2.3 Sand, Slag, and Crucible Residues B-14
B.3.2.4 Inorganic Ash Residues B-16
B.3.3 Salt Residues B-17
B.3.3.1 Electrorefining Salt Residues B-18
B.3.3.2 Molten Salt Extraction Salt Residues B-19
B.3.3.3 Direct Oxide Reduction Salt Residues B-21
B.3.4 Plutonium Fluoride Residues B-24
B.3.5 Sludge Residues B-26
B.3.6 Filter Media Residues B-28
B.3.7 Combustible Residues B-30
B.3.8 Glass Residues B-31
B.3.9 Graphite Residues B-33
B.3.10 Inorganic (Metals and Others) Residues B-34
B.3.11 Scrub Alloy B-36
B.4 References B-38
Appendix B - Attachment 1: Flow Diagrams B.1-1

APPENDIX C-DESCRIPTION OF PROCESSING TECHNOLOGIES
C.1 Introduction C-1
C.2 Screening and Evaluation Approach C-1
C.3 Processing Technologies for Rocky Flats Plutonium Residues and Scrub Alloy C-2
C.4 Detailed Process Descriptions for No Action Processing Technologies C-5
C.4.1 Calcination and Cementation of Ash Residues C-5
C.4.2 Pyro-Oxidation of Pyrochemical Salts C-8
C.4.3 Neutralization and Drying of Aqueous-Contaminated Combustibles C-10
C.4.4 Thermal Desorption and Steam Passivation of Organic-Contaminated Combustibles C-12
C.4.5 Repackaging of Dry Combustibles C-13
C.4.6 Acid Dissolution and Plutonium Oxide Recovery of Plutonium Fluorides C-15
C.4.7 Neutralization and Drying of Filter Media C-17
C.4.8 Filtration and Drying of Sludge Residues C-19
C.4.9 Neutralization and Drying of Glass Residues C-21
C.4.10 Repackaging of Graphite Residues, Inorganic Residues, and Scrub Alloy C-22
C.5 Detailed Process Descriptions for Processing Technologies without Plutonium Separation C-24
C.5.1 Immobilization (Vitrification) C-24
C.5.2 Immobilization (Cementation) of Graphite Residues C-28
C.5.3 Blend Down C-30
C.5.4 Pyro-Oxidation and Blend Down of Pyrochemical Salts C-32
C.5.5 Sonic Wash C-34
C.5.6 Catalytic Chemical Oxidation of Combustible Residues C-37
C.5.7 Cold Ceramification for Ash Residues C-40
C.6 Detailed Process Descriptions for Processing Technologies with Plutonium Separation C-42
C.6.1 Purex Process with Plutonium Metal or Oxide Recovery at the Savannah River Site with Preprocessing at Rocky Flats C-42
C.6.2 Mediated Electrochemical Oxidation C-46
C.6.2.1 Mediated Electrochemical Oxidation at Rocky Flats C-46
C.6.2.2 Mediated Electrochemical Oxidation at Savannah River Site with
Preprocessing at Rocky Flats C-49
C.6.3 Salt Distillation C-53
C.6.3.1 Salt Distillation at Rocky Flats C-53
C.6.3.2 Salt Distillation at Los Alamos National Laboratory with Preprocessing
at Rocky Flats C-55
C.6.4 Water Leach with Plutonium Oxide Recovery C-58
C.6.4.1 Water Leach with Plutonium Oxide Recovery at Rocky Flats C-58
C.6.4.2 Water Leach with Plutonium Oxide Recovery at Los Alamos National
Laboratory with Preprocessing at Rocky Flats C-61
C.6.5 Salt Scrub with Purex Processing of Newly Created Scrub Alloy C-64
C.6.6 Acid Dissolution with Plutonium Oxide Recovery of Fluoride and Sludge Residues C-67
C.6.7 Acid Dissolution with Plutonium Oxide Recovery at Los Alamos National Laboratory
with Preprocessing at Rocky Flats for Direct Oxide Reduction Salts C-71
C.7 Detailed Process Descriptions for Combination of Processing Technologies C-73
C.7.1 Combination Process for the Calcination/Cementation of Ash Residues C-74
C.7.2 Combination Process for the Repackaging of Ash Residues C-74
C.7.3 Combination Process for the Pyro-Oxidation of Molten Salt Extraction/
Electrorefining Salts C-75
C.7.4 Combination Process for the Repackaging of Molten Salt Extraction/
Electrorefining Salts C-76
C.7.5 Combination Process for the Pyro-Oxidation of Direct Oxide Reduction Salts C-76
C.7.6 Combination Process for the Repackaging of Direct Oxide Reduction Salts C-77
C.7.7 Combination Process for the Neutralization and Drying of Aqueous-Contaminated Combustibles C-78
C.7.8 Combination Process for the Thermal Desorption and Steam Passivation of Organic-Contaminated Combustibles C-79
C.7.9 Combination Process for the Repackaging of Dry Combustibles C-79
C.7.10 Combination Process for the Neutralization and Drying of Filter Media C-80
C.7.11 Combination Process for the Repackaging of Filter Media C-80
C.7.12 Combination Process for the Filtration and Drying of Sludge Residues C-80
C.7.13 Combination Process for the Repackaging of Sludge Residues C-81
C.7.14 Combination Process for the Neutralization and Drying of Glass Residues C-82
C.7.15 Combination Process for the Repackaging of Graphite Residues and Inorganic
Residues C-82
C.8 References C-84
Appendix C - Attachment 1: Relevant Memos and Letters in the Development of the Safeguards
Termination Limits

APPENDIX D-EVALUATION OF HUMAN HEALTH EFFECTS FROM ROUTINE PROCESSING/ STORAGE OPERATIONS AND ACCIDENTS
D.1 Radiological Impacts to Human Health D-2
D.1.1 Background D-2
D.1.1.1 Nature of Radiation and Its Effects on Humans D-2
D.1.1.2 Health Effects D-6
D.1.2 Methodology for Estimating Radiological Impacts D-9
D.1.2.1 GENII Computer Code D-9
D.1.2.2 Data and General Assumptions for Normal Operations and Postulated
Accidents D-10
D.1.2.3 Health Effects Calculations D-14
D.1.2.4 Uncertainties D-14
D.1.3 Radiological Impact Assessment Data D-15
D.1.3.1 Radiological Impact Assessments at Rocky Flats D-15
D.1.3.2 Radiological Impact Assessments at the Savannah River Site D-21
D.1.3.3 Radiological Impact Assessments at Los Alamos National Laboratory D-30
D.1.4 Sample Batch Flow Diagrams and Supplemental Data D-35
D.2 Normal Operational Radiological Releases and Impacts to the Environment D-41
D.3 Accident and Risk Analysis Methodology, Assumptions, and Results D-53
D.3.1 Exposure Impacts To Be Evaluated D-53
D.3.2 Selection of Facility Accidents for Detailed Evaluations D-54
D.3.3 Accident Evaluation D-57
D.3.3.1 Basic Assumptions D-57
D.3.3.2 Source Term D-57
D.3.3.3 Process Accident Scenario Description and Source Terms D-58
D.3.3.3.1 Accident Scenarios Description and Source Terms at
Rocky Flats D-59
D.3.3.3.2 Accident Scenarios Description and Source Terms at the
Savannah River Site D-69
D.3.3.3.3 Accident Scenarios Description and Source Term at
Los Alamos National Laboratory D-73
D.3.3.4 Storage Accident Scenario Descriptions and Source Terms D-74
D.3.3.4.1 Alternative 1 - No Action D-74
D.3.3.4.2 Alternative 2 - Processing Without Plutonium Separation D-81
D.3.3.4.3 Alternative 3 - Processing With Plutonium Separation D-85
D.3.3.4.4 Alternative 4 - Combination of Processing Technologies D-99
D.3.3.5 Consequences and Risk Calculations D-102
D.3.3.6 Analysis Conservatism and Uncertainty D-108
D.3.3.7 Comparison of Analysis Results with Site Documents D-109
D.3.4 Accident Analyses Consequences and Risks Results D-111
D.3.4.1 Ash Residues D-112
D.3.4.1.1 Alternative 1 - No Action D-112
D.3.4.1.2 Alternative 2 - Processing without Plutonium Separation D-115
D.3.4.1.3 Alternative 3 - Processing with Plutonium Separation D-120
D.3.4.1.4 Alternative 4 - Combination of Processing Technologies D-128
D.3.4.2 Pyrochemical Salt Residues D-131
D.3.4.2.1 Alternative 1 - No Action D-131
D.3.4.2.2 Alternative 2 - Processing without Plutonium Separation D-133
D.3.4.2.3 Alternative 3 - Processing with Plutonium Separation D-136
D.3.4.2.4 Alternative 4 - Combination of Processing Technologies D-157
D.3.4.3 Combustible Residues D-157
D.3.4.3.1 Alternative 1 - No Action D-157
D.3.4.3.2 Alternative 2 - Processing without Plutonium Separation D-160
D.3.4.3.3 Alternative 3 - Processing with Plutonium Separation D-164
D.3.4.3.4 Alternative 4 - Combination of Processing Technologies D-167
D.3.4.4 Fluoride Residues D-168
D.3.4.4.1 Alternative 1 - No Action D-168
D.3.4.4.2 Alternative 2 - Processing without Plutonium Separation D-171
D.3.4.4.3 Alternative 3 - Processing with Plutonium Separation D-173
D.3.4.4.4 Alternative 4 - Combination of Processing Technologies D-181
D.3.4.5 Filter Media Residues D-181
D.3.4.5.1 Alternative 1 - No Action D-181
D.3.4.5.2 Alternative 2 - Processing without Plutonium Separation D-183
D.3.4.5.3 Alternative 3 - Processing with Plutonium Separation D-187
D.3.4.5.4 Alternative 4 - Combination of Processing Technologies D-190
D.3.4.6 Sludge Residues D-192
D.3.4.6.1 Alternative 1 - No Action D-192
D.3.4.6.2 Alternative 2 - Processing without Plutonium Separation D-195
D.3.4.6.3 Alternative 3 - Processing with Plutonium Separation D-199
D.3.4.6.4 Alternative 4 - Combination of Processing Technologies D-202
D.3.4.7 Glass Residues D-204
D.3.4.7.1 Alternative 1 - No Action D-204
D.3.4.7.2 Alternative 2 - Processing without Plutonium Separation D-206
D.3.4.7.3 Alternative 3 - Processing with Plutonium Separation D-210
D.3.4.7.4 Alternative 4 - Combination of Processing Technologies D-213
D.3.4.8 Graphite Residues D-213
D.3.4.8.1 Alternative 1 - No Action D-213
D.3.4.8.2 Alternative 2 - Processing without Plutonium Separation D-215
D.3.4.8.3 Alternative 3 - Processing with Plutonium Separation D-220
D.3.4.8.4 Alternative 4 - Combination of Processing Technologies D-227
D.3.4.9 Inorganic Residues D-228
D.3.4.9.1 Alternative 1 - No Action D-228
D.3.4.9.2 Alternative 2 - Processing without Plutonium Separation D-229
D.3.4.9.3 Alternative 3 - Processing with Plutonium Separation D-232
D.3.4.9.4 Alternative 4 - Combination of Processing Technologies D-239
D.3.4.10 Scrub Alloy D-240
D.3.4.10.1 Alternative 1 - No Action D-240
D.3.4.10.2 Alternative 2 - Processing without Plutonium Separation D-241
D.3.4.10.3 Alternative 3 - Processing with Plutonium Separation D-243
D.3.4.10.4 Alternative 4 - Combination of Processing Technologies D-248
D.3.4.11 Storage Following Processing and Packaging D-248
D.3.4.11.1 Alternative 1 - No Action D-248
D.3.4.11.2 Alternative 2 - Processing Without Plutonium Separation D-250
D.3.4.11.3 Alternative 3 - Processing With Plutonium Separation D-252
D.3.4.11.4 Alternative 4 - Combination of Processing Technologies D-258
D.3.5 Secondary Impacts of Accidents D-259
D.4 Impacts of Exposures to Hazardous Chemicals on Human Health D-260
D.4.1 Methodology D-260
D.4.2 Assumptions D-261
D.4.3 Hazardous Chemical Source Terms D-263
D.4.4 Health Risks from Routine Operation Chemical Exposures D-263
D.4.5 Facility Accident Chemical Exposure Impacts D-263
D.5 References D-268

APPENDIX E-EVALUATION OF HUMAN HEALTH EFFECTS OF OVERLAND TRANSPORTATION
E.1 Introduction E-1
E.2 Scope of Assessment E-1
E.3 Packaging and Representative Shipment Configurations E-3
E.3.1 Packaging Overview E-3
E.3.1.1 Type 6M Packaging E-4
E.3.1.2 Type 9975 Packaging E-8
E.3.1.3 DOE Standard 3013 Storage and Transportation Container E-12
E.3.2 Shipment Overview E-13
E.3.2.1 Safe Secure Transportation E-13
E.3.3 Ground Transportation Route Selection Process E-13
E.4 Methods for Calculating Transportation Risks E-14
E.5 Parameters and Assumptions E-17
E.5.1 Material Inventory E-17
E.5.2 Shipment External Dose Rates E-17
E.5.3 Material Characterization Data E-18
E.5.4 Representative Routes and Population E-19
E.5.5 Health Risk Conversion Factors E-19
E.5.6 Accident Involvement Rates E-19
E.5.7 Container Accident Response Characteristics and Release Fractions E-21
E.6 Risk Results E-21
E.6.1 Per-Shipment Risk Factors E-21
E.6.2 Evaluation of Shipment Risks E-22
E.6.3 Maximally Exposed Individuals E-23
E.6.4 Analysis of Dispersal Risk Occurring in Transport Analysis E-25
E.6.5 Shipment of Transuranic Waste and Separated Plutonium E-26
E.6.5.1 Shipment of Transuranic Waste to the Waste Isolation Pilot Plant E-26
E.6.5.2 Separated Plutonium E-27
E.7 Conclusions and Long-Term Impacts of Transportation E-27
E.7.1 Conclusions E-27
E.7.2 Long-Term Impacts of Transportation E-28
E.8 Uncertainty and Conservatism in Estimated Impacts E-28
E.8.1 Uncertainties in Plutonium Residue and Scrub Alloy Inventory and Characterization E-29
E.8.2 Uncertainties in Containers, Shipment Capacities, and Number of Shipments E-29
E.8.3 Uncertainties in Route Determination E-29
E.8.4 Uncertainties in the Calculation of Radiation Doses E-30
E.9 References E-32

APPENDIX F-ANALYSIS OF ENVIRONMENTAL JUSTICE
F.1 Introduction F-1
F.2 Definitions and Approach F-1
F.3 Uncertainties and Spatial Resolution F-2
F.4 Results for Department of Energy (DOE) Sites F-2
F.5 Results for Transportation Routes F-6
F.6 References F-11

APPENDIX G-COST ANALYSES
G.1 Cost Estimating Bases G-1
G.1.1 Facilities and Equipment Costs G-1
G.1.2 Labor and Site Overhead Costs G-2
G.1.3 Transuranic Waste Costs G-10
G.1.4 Low-Level Waste Costs G-16
G.1.5 Other Materials, Storage, Shipping, and Disposal Costs G-17
G.1.6 Costs Related to Interim Storage of Stabilized Residues and Transuranic Waste at
Rocky Flats G-18
G.2 Processing Durations and Schedules G-18
G.3 Major Schedule Uncertainties G-25
G.4 Availability and Capability of DOE facilities G-26
G.4.1 Availability and Capability of Rocky Flats G-26
G.4.2 Availability and Capability of the Savannah River Site G-27
G.4.3 Availability and Capability of the Los Alamos National Laboratory G-28
G.4.4 Resource Conservation and Recovery Act Designation G-28
G.5 Estimated Absolute and Incremental Costs for Each Processing Option G-29
G.6 References G-37



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