Compaction of

Radioactive Waste

www.nukemgroup.com
COMPACTION
OF RADIOACTIVE WASTE
Introduction
Low level dry active waste is one of
the main waste streams generated
from the operation of nuclear power
plants or other nuclear facilities.
Waste of this type is usually
collected in drums or other
containers. In order to save storage
space and costs, it has to be treated
prior to disposal.
Compaction can reduce the overall
volume of drums containing solid
radioactive material and the
technology is well proven.
NUKEM designs and supplies
compactors for the nuclear industry
that meet all the client’s needs to
achieve efficient and economic
volume reduction.
The advantages that can be gained
by using the NUKEM compaction
technology directly influence the
costs of storage and disposal.
The NUKEM compaction technology
presents the following main features:
Pre-treatment of Waste and Waste Characteristics
The bulk of waste produced in
nuclear facilities is low level, dry and
either combustible or non-
combustible. All of these waste
streams can be treated by the
NUKEM compaction technology. A
pre-sorting stage is advisable and for
combustible wastes, NUKEM
recommends incineration as a pre-
treatment, since this can bring
additional benefits in terms of safety
and economy in subsequent
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• high volume reduction ratios,
small envelope dimensions
• up to 20000 kN pressing force
• special designs to match different
drum dimensions and materials
• compaction inside, an enclosed
volume of the compactor avoids
contamination of the environment
• good maintainability and easy
decontamination
• mobile design possible
• well proven equipment
A special advantage of the NUKEM
design is that the upper external
surfaces of the units are not
encumbered by moving components.
This feature greatly simplifies
attaching an alpha containment and
also ensures that a minimal portion
of the press is installed within the
contaminated zone. It also makes it
possible to design a mobile unit.
storage or disposal. Within limits, wet
wastes can also be compacted.
The following wastes can be
compacted:
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 • Scrap metal • Combustion residue (ash, slag)
• Construction materials • Mixed waste such as glass,
• Paper, wood, plastics worn parts, filters
• Elastic materials, such as • Residue from waste water
small amounts of rubber mixed cleaning processes
with other waste • Dry filter residue

Examples of typical volume reduction ratios obtained by employing a high

force compactor

Waste type Ratio Pellet

volume

Mixed scrap metal 6-7 ~15 %

Chips from metal cutting operations 6-7 ~15 %
Ashes from an incinerator 2-3 ~40 %
Insulation material (glass wool) 16 6.3 %
Rubble (bricks, cement) 2.2 45 %
Sand 1.3 77 %
Glass bottles 5.2 28 %

The ratio achieved can be purposes only. For safe operation,

influenced considerably by the certain limits, specific to the material
nature of the waste and the figures to be compacted, should be
above are given for guidance followed.

The NUKEM High Force Compactor Technology

The NUKEM High Force Compactor (HFC) unit consists of the following
systems:

• Main compactor body • Liquids handling system

• Drum in-feed system • Switchgear for electrical and
• Pellet delivery system control equipment
• Hydraulic power pack • Control desk
• Air, gas and particulate handling
system

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The design of the main compactor
body
The principal component of the com-
pactor is a forged steel structure with
two openings, one for charging
drums and one for discharging
compacted pellets. The top section
forms the main high-pressure
cylinder. The lid is fastened to the
steel structure and rigidly supports
the guiding rod. The main piston
provides the high pressure/low
speed capability while the guiding
rod provides the low pressure/high
speed characteristics. The four
external hydraulic cylinders serve to
return the main piston to the upper
position. The heavy bolster, or
mould, is employed to absorb the
high radial loads generated during
the drum compaction process and
avoids transmitting these radial loads
Fig. 1 High Force Compactor – Main Compactor Body
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2007
into the steel structure, where the
two openings are located. The
bolster is guided at all times within
the structure by replaceable
bearings.
The two doors are part of the
standard press and are used to
isolate the compaction operation,
thus restricting the spread of
airborne particles. They are not used
if the unit is located in an area
without direct man access.
Certain components, e.g. the bolster
liner, and the platens (top, bottom)
are designed to be replaced in the
event that they wear during the
lifetime of the system.
An exhaust opening is provided in
one door for the safe release of
gases and particulate, produced
during the process. In the other door,
an air inlet damper is provided.
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Drum infeed system
The drums are loaded into the press
via the infeed system, which is
directly attached to the main
compactor body. The main
components are the base unit, the
loading plate, the drum centering
device, and the perforating device.
The loading plate provides the trans-
portation capabilities while the
perforating device performs a pre
compaction treatment.
The operating sequences of the high
force compactor are coordinated
from and with the control equipment
of the high force compactor.
Pellet delivery system
The pellets are ejected from the
compactor by the loading plate. The
pellet delivery system provides the
platform for additional steps e.g.
measuring of height and weight.
These are optional. The pellet
delivery system consists of the base
frame and the transfer plate.
Hydraulic power pack
The hydraulic power pack unit was
especially designed for ease of main-
tainance and low space requirement.
Generally it is located in a separate
room.
The main components are:
• Cubical steel tank with a welded
lid
• Immersed hydraulic pump in "on
line" design with regulated high
pressure stage
• Switchgear
• Oil cooler with cooling water
connections
• Immersed heater
• Oil filter
• Tank vent with filter
• Oil filling flange with filter.
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All components are fitted into or onto
the steel tank, except for the
hydraulic pump. The unit is installed
on anti-vibration mountings.
Gas and particulates handling
system
In our standard design, the air or gas
with particulates displaced during the
compaction process is directed to the
compactor chamber outlet, via a
class S particle filter which is located
in one of the doors. If required, a
direct connection to an existing
ventilation system is possible, if
necessary with supporting ventilation
equipment (e.g. fan, filter). For clean
air, an air inlet damper is located in
the door on the opposite side.
Liquids handling system
Bulk liquids should be removed from
the debris prior to compaction.
However, any residual liquids
extracted from the drum are
collected by a ring-shaped drain in
the lower part of the system, that
feeds to a tank for temporary
storage.
Control and electrical equipment
The switchgear system consists of
• a cubicle for the electrical and
control equipment and
• a control desk.
In order to satisfy the different
requirements of the compactor, a
programmable control system (SPS)
coordinates the process. The
individual steps are monitored from
the control desk. The operating
conditions are displayed on the
control panel of the desk. Any
deviation from the correct operating
conditions triggers an alarm.
Depending on the type of deviation, it
is corrected manually or
automatically.
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Two modes of operation are
possible:
• Automatic operation
This is the standard mode. The
compaction process is performed
automatically.
• Manual operation
Manual operation is possible and
is provided only for setting-up,
maintenance and repair purposes
and the repeating tests.
The Operational Steps of
Compaction
Step 1: Loading the drum
The drum is transferred to the drum
infeed system with a crane. The
drum centering device positions and
aligns the drum on the loading plate.
The HFC is at the start position: The
bell-shaped bolster and the main
piston are at the upper position. The
doors are open.
Step 2: Preparation before
compaction
The drum is perforated and is moved
to the center of the main compactor
body below the bolster. Both steps
are again performed by the drum
infeed system.
Step 3: Positioning for
compaction
The bolster is lowered with the four
external hydraulic cylinders. Before
reaching its end position, the loading
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plate is retracted. The drum placed
on the bottom platen and held in
position by the bolster.
Step 4: Compacting process
The bolster and the doors are
closed. This lowest end position
ensures a complete enclosure of the
drum. The guiding rod is pressurized
and the main piston moves down
rapidly onto the drum and starts the
first part of the compacting process.
At the same time, the main piston is
filled with hydraulic fluid. When
completed, the pressure in the main
piston chamber and in the guiding
rod chamber is increased,
compacting the drum into a pellet.
After reaching a pre-set value, this
pressure is maintained for a defined
period of time in order to maximize
the compaction ratio.
Step 5: Pellet removal
After the pressure is reduced, the
compacted drum (i.e. the pellet), is
ejected from the bell shaped bolster.
During this removal stage, the main
piston remains at its lower stop
position, while the bolster is raised to
its upper stop position. Next, the
doors open and the main piston
returns to its upper stop position.
When inserting a new drum, the
loading plate of the drum infeed
system ejects the pellet from the
bottom platen onto the transfer plate
of the pellet delivery system.
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High Force Compactor: Technical Data
The figures below can be varied according to the waste streams

High force compactor body

Pressing force: variable, up to 20000 kN
Throughput: from 6 - 10 drums per hour
(depending on the handling)
Bolster: 1050 mm diameter
Main piston: matched with the drum diameter
Bolster liner: variable for different drum diameters
Material: ferrite steel

Dimensions
Height: approx. 4000 mm
Width: approx. 1600/2100* mm * with perforating
device
Length: approx. 4600 mm

Weights
Main compactor body 250 kN
Drum infeed system (with drum) max. 16 kN
Pellet delivery system (with pellet) max. 16 kN
Hydraulic power pack (filled) 50 kN

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 Fig. 2 High Force Compactor
Limits for materials to be compacted
Stress limit: Rp 0.2 = 400 N/mm² (e.g. pipe with a
nominal diameter of DN 250, 15 mm thick)
Hardness limit: 35 HRC
Drums
Diameter: max. 615 mm, min. 500 mm
Height: max. 900 mm
Weight: max. 12 kN
Control system
Type: Siemens S7 or similar
Hydraulic system
Operating pressures: compacting: up to 50 MPa ,
average 26 - 28 MPa
filling: 10 MPa
Operating temperature: 30 - 50 °C
Auxiliaries
Power consumption: 400 V, 50 Hz, 48 kW
Cooling water: approx. 0,070 m³/min at 5°C and 0.4 - 0.6
MPa

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 Fig. 3 Drummed mixed metal Scrap for compaction HFC 2000

Fig. 4 Drum with mixed metal scrap after compaction (1500 t)

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 Fig. 5 Cross section cut: Drums with mixed metal scrap after compaction

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The NUKEM In Drum Compactor Technology
The NUKEM In Drum Compactor structure with an opening for
(IDC) unit consists of the following inserting 200 litre drums. The upper
systems: section forms the base for the
compression plunger. Additionally, a
• Main compactor body drum retainer can be lowered from
• Drum protection sleeve
• Feed gate
• Plunger its upper position to hold the drum in
• Switchgear for electrical and the correct position. After filling
control equipment manually to a predetermined limit,
• Control desk the compression plunger is lowered.
Depending on the design, individual
Design and operation of the unit maximum forces are achievable.
One or two hydraulic cylinders are
used to deliver the compaction force.
The design is highly flexible and can
The maximum volume reduction ratio
be readily adapted to meet individual
is a function of the waste
requirements. The following
constituents and the applied force
description is given as an example to
and can therefore vary over a wide
illustrate the overall concept.
range.
Generally, In Drum Compaction
In order to protect the surrounding
Technology combines the
area from the spread of conta-
advantages of minimization the
mination during this operation, a
number of drums required together
drum protection sleeve is utilized.
with the ability to fill and document
The displaced air or gas, together
the contents to meet the
with particulates or aerosols, is
requirements of the regulations. The
vented through the filling chamber.
system can be readily integrated into
After retrieving of the plunger to its
a sorting system; indeed, NUKEM In
upper position, additional waste can
Drum Compactors are usually
be added. These steps can be
employed within such an
repeated as often as necessary to fill
environment.
up the drum completely.
In this type of compactor, the main
compactor body is a welded steel

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IDC-160 and IDC-500 - Technical Data
Delivery part
Hydraulic unit and control panel:
The IDC-160 / 500 is equipped with a
supply unit which consists of:
- Pumps
- Switches
- Level indicators
- Oil tank
- Control panel which is equipped with
operating and control devices, control
lights.

Connections
Hydraulic: all couplings which are mounted at the
compactor unit
Electric: The same as above, additional the
necessary cables
Hydraulic fluid: The first filling in the scope of supply
Ventilation: The system for IDC-160 has to be
connected to existing ventilation system
The system for IDC-500 consists of
blowers, pre-filter, absolute filter and
dumper
Functional: all functional steps are interlocked by limit
switches
Safety: all necessary safety devices and interlocks
are installed to protect the operating
personnel

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Fig. 6 In Drum Compactor IDC-160

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In Drum Compactor IDC-160: Technical Data
In Drum compactor body
Pressing force: variable, up to 160 kN
Main piston: matched with the drum diameter
Distance of piston movement: approx. 1200 mm
Pressing time: depending on the loading speed
Material: mild steel, painted with decontaminable
paint

Dimension
Height: approx.3700 mm
Width: approx.2300 mm
Length: approx.1300 mm

Weights
Total weight: approx. 40 kN

Material to be compacted
Paper, laundry waste, filter material, etc.

Drums
Volume: approx. 200 litre
Diameter: approx. 600 mm
Height: approx. 900 mm

Control system
Type: Siemens S7 or similar
Hydraulic system
Hydraulic fluid: fire resistant
Operating temperature: 30 - 50°C

Auxiliaries
Power consumption: 380 V / 50 Hz / power approx. 4 kW
Ventilation exhaust power: approx. 0.5 m³/min

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In Drum Compactor IDC-500: Technical Data
In Drum compactor body
Pressing force: variable, up to 500 kN
Main piston: matched with the drum diameter
Distance of piston movement: approx. 1000 mm
Pressing time: depending on the loading speed
Material: mild steel, painted with decontaminable
paint

Dimension
Height: approx.3800 mm
Width: approx.1200 mm
Length: approx.1700 mm

Weights
Total weight approx. 55 kN

Material to be compacted
Metal, paper, laundry waste, wood, filter material, etc.

Drums
Volume: approx. 200 l
Diameter: approx. 600 mm
Height: approx. 900 mm

Control system
Type: Siemens S7 or similar

Hydraulic system
Hydraulic fluid: fire resistant
Operating temperature: 30 - 50°C

Auxiliaries
Power consumption: 380 V / 50 Hz / power approx. 7.5 kW
Ventilation exhaust power: approx. 7 m³/min

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References
Scope of supply Client Putting in
operation
1 High Force Compactor Ignalina NPP (Lithuia) anticipated
(20000 kN) as part of the 2008
Ignalina Waste Treatment Centre

2 High Force Compactor Chernobyl NPP (Ukraine) anticipated

(20000 kN) as part of the ICSRM 2007
Project

3 High Force Compactor Leningrad NPP (Russia) anticipated

(20000 kN) as Part of the 2007
Leningrad NNP Waste
Treatment Centre

4 High Force Compactor Atomenergoexport / 2002

(20000 kN) as a part of the Balakovo NPP (Russia)
Balakovo NPP Waste Treatment
Centre

5 High Force Compactor China Institute of Atomic 2001

(20000 kN) for various solid Energy CIAE, Beijing (China)
waste

6 High Force Compactor SE a. s. / Bohunice NPP 2000

(20000 kN) as a part of the BSC- (Slovak Republic)
RAO Waste Treatment Centre

7 Design of High Force Compactor South-Ukraine NPP 1997

(20000 kN) as a part of the (Ukraine)
South-Ukraine NPP Waste
Treatment Centre

8 Design of High Force Compactor Chmelnitzki NPP (Ukraine) 1996

(20000 kN) as a part of the
Chmelnitzki NPP Waste
Treatment Centre

9 High Force Compactor (3000 kN) Kernforschungszentrum 1993

for Spent Fuel Scrap Karlsruhe GmbH (Germany)

10 Technical Support to design High BNFL (UK) 1992

Force Compactoer for PCM
Waste
11 Karlstein High Force Compaction Siemens (Germany) 1988
Unit (16000 kN)

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12 In Drum Compactor IDC–160 Uranium Enrichment Plant 1986
(160 kN) Gronau (Germany)

13 In Drum Compactor IDC–160 Uranium Enrichment Plant, 1985

(160 kN) Almelo (NL)

14 High Force Compaction Plant Kernforschungszentrum 1984

(16000 kN) Karlsruhe GmbH (Germany)

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 NUKEM Technologies GmbH
Industriestr. 13
63755 Alzenau
Germany
T +49 (0) 6023 9104
F +49 (0) 6023 911188
E info@nukem.de

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 Compaction of
Radioactive Waste

www.nukemgroup.com