GROUT HOPPER MODELING STUDY

Abstract

The Saltstone facility has a grout hopper tank to provide agitator stirring of the Saltstone feed materials. The tank has about 300 gallon capacity to provide a larger working volume for the grout slurry to be held in case of a process upset, and it is equipped with a mechanical agitator, which is intended to keep the grout in motion and agitated so that it won't start to set up. The dry feeds and the salt solution are already mixed in the mixer prior to being transferred to the hopper tank. The hopper modeling study through this work will focus on fluid stirring and agitation, instead of traditional mixing in the literature, in order to keep the tank contents in motion during their residence time so that they will not be upset or solidified prior to transferring the grout to the Saltstone disposal facility. The primary objective of the work is to evaluate the flow performance for mechanical agitators to prevent vortex pull-through for an adequate stirring of the feed materials and to estimate an agitator speed which provides acceptable flow performance with a 45{sup o} pitched four-blade agitator. In addition, the power consumption required for the agitator operation was estimated. The modeling calculations were performed by taking two steps of the Computational Fluid Dynamics (CFD) modeling approach. As a first step, a simple single-stage agitator model with 45{sup o} pitched propeller blades was developed for the initial scoping analysis of the flow pattern behaviors for a range of different operating conditions. Based on the initial phase-1 results, the phase-2 model with a two-stage agitator was developed for the final performance evaluations. A series of sensitivity calculations for different designs of agitators and operating conditions have been performed to investigate the impact of key parameters on the grout hydraulic performance in a 300-gallon hopper tank. For the analysis, viscous shear was modeled by using the Bingham plastic approximation. Steady state analyses with a two-equation turbulence model were performed with the FLUENT{trademark} codes. All analyses were based on three-dimensional results. Recommended operational guidance was developed by using the basic concept that local shear rate profiles and flow patterns can be used as a measure of hydraulic performance and spatial stirring. Flow patterns were estimated by a Lagrangian integration technique along the flow paths from the material feed inlet. The modeling results show that when the two-stage agitator consisting of a 45{sup o} pitched propeller and radial flat-plate blades is run at 140 rpm speed with 28 in diameter, the agitator provides an adequate stirring of the feed materials for a wide range of yield stresses (1 to 21 Pa) and the vortex system is shed into the remote region of the tank boundary by the blade passage in an efficient way. The results of this modeling study were used to develop the design guidelines for the agitator stirring and dispersion of the Saltstone feed materials in a hopper tank.