Publications

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The primary purpose of the preclosure radiological safety assessment (that this document supports) is to identify risk factors for disposal operations, to aid in design for the deep borehole field test (DBFT) engineering demonstration.

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This paper considers concepts for disposal of canistered high-level (radioactive) waste (HLW) in large diameter deep boreholes. Vitrified HLW pour canisters are limited in diameter to promote glass cooling, and constitute a large potential application for borehole disposal where diameter is constrained. The objective for disposal would be waste packages with diameter of 22 to 29 inches, which could encompass all existing and projected HLW glass inventory in the United States. Deep, large diameter boreholes of the sizes needed have been successfully drilled, and we identify other potentially effective designs. The depth of disposal boreholes would be site-specific, and need not be as deep as the 5 km being investigated in the Deep Borehole Field Test. For example, a 0.91 m (36 inch) diameter borehole drilled to 3 km could be used for disposal from 2.5 to 3 km (8, 200 to 9, 840 ft). The engineering feasibility of such boreholes is greater today than was concluded by earlier studies done in Sweden and the United States. Moreover, the disposal concept and generic safety case have evolved to a point where borehole construction need not be as elaborate as previously assumed. Each borehole in the example could accommodate approximately 100 waste packages containing canisters of vitrified HLW. Emplacement of the packages would be through a 32-inch (0.81 m) guidance casing, installed in two sections to reduce hoisting loads, and forming a continuous pathway from the surface to total depth. Above the disposal zone would be a nominal 1 km (3, 280-ft) seal interval, similar to previously published concepts. Following those concept studies, the seal system would consist of alternating lifts of swelling clay, backfill and cement. Above the seal zone the borehole would be plugged with cement in the conventional manner for oil-and-gas wells. The function of seals in deep borehole disposal is to maintain the pre-drilling hydrologic regime in the crystalline basement, where groundwater is increasingly saline, stagnant, and ancient. Seals would resist fluid movement and radionuclide transport during an early period of waste heating, but after cooling little fluid movement is expected. Thus, the function of seals could be less important with HLW that has low heat output, and sealing requirements could be limited. The safety case for deep borehole disposal relies on the prevalence of groundwater that is increasingly saline with depth, stagnant, and ancient, in crystalline basement rock that has low bulk permeability and is isolated from surface processes. The minimum depth for disposal depends on sitespecific factors, and may be less than the 2.5 km example. Rough-order-of-magnitude cost estimates show that deep borehole disposal of HLW would be cost-competitive with the lowest cost mine repository options. Thinner overburden, and shallower development of conditions favorable to waste isolation, could make drilling of large-diameter disposal boreholes even more cost effective. The dimensions of the disposal zone and seal zone would be site specific, and would be adjusted to ensure that both are situated in unaltered crystalline basement rock.

Percussive hammers are a promising advance in drilling technology for geothermal since they rely upon rock reduction mechanisms that are well-suited for use in the hard, brittle rock characteristic of geothermal formations. Also known as down-the-hole (DTH) hammers, they are also compatible with low-density fluids that are often used for geothermal drilling. Experience in mining and oil and gas drilling has demonstrated their utility for penetrating hard rock. One limitation to more wide-scale deployment is the ability of the tools to operate at high temperatures (∼300°C) due to elastomers used in the construction and the lubrication required for operation. As part of a United States Department of Energy Funding Opportunity Announcement award, Atlas Copco was tasked with developing a high-temperature DTH capable of being used in geothermal environments. A full-scale development effort including design, build, and testing was pursued for the project. This report summarizes the results of the percussive hammer development efforts between Atlas-Copco Secoroc and Sandia National Labs as part of DE-FOA-EE0005502. Certain design details have been omitted due to the proprietary nature of the information.

The Deep Borehole Field Test will include demonstration of the emplacement and retrieval of test waste packages (containing no waste) in a 5 km deep borehole drilled into the crystalline basement. A conceptual design for packaging, surface handling and transfer equipment, and borehole emplacement was developed in anticipation of the demonstration project. Test packages are designed to withstand external pressure greater than 65 MPa, at temperature up to 170°C. Two packaging concepts were developed: 1) flasktype for granular waste, and 2) internal semi-flush type for waste that is pre-canistered in cylindrical containers. Oilfield casing materials and sealing connections would be selected giving a safety factor of 2.0 against yield. Packages would have threaded fittings top and bottom for attachment of impact limiters and latch fittings. Packages would be lowered one-at-a-time into the borehole on electric wireline. This offers important safety advantages over using drill pipe or coiled tubing to lower waste packages, because it avoids the possibility of dropping a heavy assembly in the borehole. An electromechanical latch would release each package, or reconnect for retrieval. Frequency of waste package delivery to a disposal site could be the effective limit on emplacement throughput. Packages would be delivered in a shielded Type B transportation cask and transferred to a shielded, doubleended transfer cask on site. The transfer cask would be upended over the borehole and secured to the wellhead. The transfer cask would become an integral part of the pressure control envelope for well pressure control. Blowout preventers can be incorporated as needed for regulatory compliance. Operational safety has been assessed with respect to normal operations, and off-normal events that could cause package breach in the borehole. Worker exposures can be limited by using standard industry practices for nuclear material handling. The waste packages would effectively be robust pressure vessels that will not breach if dropped during surface handling. The possibility of package breach in the borehole during emplacement can be effectively eliminated using impact limiters on every package.

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Sandia National Laboratories has begun research on the potential use of deep boreholes for the dis¬posal of radioactive waste. Characterization activities will focus on measurements and samples that are important for evaluating the long-term iso¬lation capability of the deep borehole disposal (DBD) concept. Engineering demonstration activities will focus on providing data to evaluate the concept’s operational safety and practicality. Procurement of a scientifically acceptable deep borehole field test (DBFT) site and a site management contractor is now under way.

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The dynamic stability of deep drillstrings is challenged by an inability to impart controllability with ever-changing conditions introduced by geology, depth, structural dynamic properties and operating conditions. A multi-organizational LDRD project team at Sandia National Laboratories successfully demonstrated advanced technologies for mitigating drillstring vibrations to improve the reliability of drilling systems used for construction of deep, high-value wells. Using computational modeling and dynamic substructuring techniques, the benefit of controllable actuators at discrete locations in the drillstring is determined. Prototype downhole tools were developed and evaluated in laboratory test fixtures simulating the structural dynamic response of a deep drillstring. A laboratory-based drilling applicability demonstration was conducted to demonstrate the benefit available from deployment of an autonomous, downhole tool with self-actuation capabilities in response to the dynamic response of the host drillstring. A concept is presented for a prototype drilling tool based upon the technical advances. The technology described herein is the subject of U.S. Patent Application No. 62219481, entitled "DRILLING SYSTEM VIBRATION SUPPRESSION SYSTEMS AND METHODS", filed September 16, 2015.

This report presents four concepts for packaging of radioactive waste for disposal in deep boreholes. Two of these are reference-size packages (11 inch outer diameter) and two are smaller (5 inch) for disposal of Cs/Sr capsules. All four have an assumed length of approximately 18.5 feet, which allows the internal length of the waste volume to be 16.4 feet. However, package length and volume can be scaled by changing the length of the middle, tubular section. The materials proposed for use are low-alloy steels, commonly used in the oil-and-gas industry. Threaded connections between packages, and internal threads used to seal the waste cavity, are common oilfield types. Two types of fill ports are proposed: flask-type and internal-flush. All four package design concepts would withstand hydrostatic pressure of 9,600 psi, with factor safety 2.0. The combined loading condition includes axial tension and compression from the weight of a string or stack of packages in the disposal borehole, either during lower and emplacement of a string, or after stacking of multiple packages emplaced singly. Combined loading also includes bending that may occur during emplacement, particularly for a string of packages threaded together. Flask-type packages would be fabricated and heat-treated, if necessary, before loading waste. The fill port would be narrower than the waste cavity inner diameter, so the flask type is suitable for directly loading bulk granular waste, or loading slim waste canisters (e.g., containing Cs/Sr capsules) that fit through the port. The fill port would be sealed with a tapered, threaded plug, with a welded cover plate (welded after loading). Threaded connections between packages and between packages and a drill string, would be standard drill pipe threads. The internal flush packaging concepts would use semi-flush oilfield tubing, which is internally flush but has a slight external upset at the joints. This type of tubing can be obtained with premium, low-profile threaded connections at each end. The internal-flush design would be suitable for loading waste that arrives from the originating site in weld-sealed, cylindrical canisters. Internal, tapered plugs with sealing filet welds would seal the tubing at each end. The taper would be precisely machined onto both the tubing and the plug, producing a metal-metal sealing surface that is compressed as the package is subjected to hydrostatic pressure. The lower plug would be welded in place before loading, while the upper plug would be placed and welded after loading. Conceptual Waste Packaging Options for Deep Borehole Disposal July 30, 2015 iv Threaded connections between packages would allow emplacement singly or in strings screwed together at the disposal site. For emplacement on a drill string the drill pipe would be connected directly into the top package of a string (using an adapter sub to mate with premium semi-flush tubing threads). Alternatively, for wireline emplacement the same package designs could be emplaced singly using a sub with wireline latch, on the upper end. Threaded connections on the bottom of the lowermost package would allow attachment of a crush box, instrumentation, etc.

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Sandia National Laboratories (Sandia) has a long history in developing compact, mobile, very high-speed drilling systems and this technology could be applied to increasing the rate at which boreholes are drilled during a mine accident response. The present study reviews current technical approaches, primarily based on technology developed under other programs, analyzes mine rescue specific requirements to develop a conceptual mine rescue drilling approach, and finally, proposes development of a phased mine rescue drilling system (MRDS) that accomplishes (1) development of rapid drilling MRDS equipment; (2) structuring improved web communication through the Mine Safety & Health Administration (MSHA) web site; (3) development of an improved protocol for employment of existing drilling technology in emergencies; (4) deployment of advanced technologies to complement mine rescue drilling operations during emergency events; and (5) preliminary discussion of potential future technology development of specialized MRDS equipment. This phased approach allows for rapid fielding of a basic system for improved rescue drilling, with the ability to improve the system over time at a reasonable cost.

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