Application of 'Six Sigma{sup TM}' and 'Design of Experiment' for Cementation - Recipe Development for Evaporator Concentrate for NPP Ling AO, Phase II (China) - 12555

Cementation of radioactive waste is a common technology. The waste is mixed with cement and water and forms a stable, solid block. The physical properties like compression strength or low leach ability depends strongly on the cement recipe. Due to the fact that this waste cement mixture has to fulfill special requirements, a recipe development is necessary. The Six Sigma{sup TM}' DMAIC methodology, together with the Design of experiment (DoE) approach, was employed to optimize the process of a recipe development for cementation at the Ling Ao nuclear power plant (NPP) in China. The DMAIC offers a structured, systematical and traceable process to derive test parameters. The DoE test plans and statistical analysis is efficient regarding the amount of test runs and the benefit gain by getting a transfer function. A transfer function enables simulation which is useful to optimize the later process and being responsive to changes. The DoE method was successfully applied for developing a cementation recipe for both evaporator concentrate and resin waste in the plant. The key input parameters were determined, evaluated and the control of these parameters were included into the design. The applied Six Sigma{sup TM} tools can help to organize the thinking duringmore » the engineering process. Data are organized and clearly presented. Various variables can be limited to the most important ones. The Six Sigma{sup TM} tools help to make the thinking and decision process trace able. The tools can help to make data driven decisions (e.g. C and E Matrix). But the tools are not the only golden way. Results from scoring tools like the C and E Matrix need close review before using them. The DoE is an effective tool for generating test plans. DoE can be used with a small number of tests runs, but gives a valuable result from an engineering perspective in terms of a transfer function. The DoE prediction results, however, are only valid in the tested area. So a careful selection of input parameter and their limits for setting up a DoE is very important. An extrapolation of results is not recommended because the results are not reliable out of the tested area. (authors)« less