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PRIME stands for

Pyrolysis of Resins In a Mobile Electric installation

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PRIME

Across the globe, the pyrolysis waste mountain is growing. In the nuclear sector, spent resins and organic waste streams are piling up, while existing methods often fall short on safety, efficiency, and sustainability.

Belgoprocess and Montair developed the PRIME (Pyrolysis Resins In Mobile Electric) Installation, a compact and mobile installation fully electrically powered, to treat low- and intermediate-level spent resins in one single reactor without pre-treatment and without intermixing of other additives or waste, allowing for easy traceability and isotopic characterization of the end product.

Ion exchange resins are widely used in nuclear power plants to purify the primary cooling water. Once saturated, these resins become radioactive waste and must be treated under strict safety and environmental regulations. Pyrolysis offers a reliable, efficient and sustainable solution to reduce the volume and inertization of the spent resins waste stream. 

Pyrolysis of spent ion exchange resins has a number of clear advantages over other treatment and conditioning techniques and is therefore seen as one of the best available techniques to manage these waste streams:

  • Compact design
  • Safe and easy process and operation
  • Electrically powered
  • LLW and MLW resins
  • VRF between 5 and 10
  • Low temperature = low carry over
  • No swelling of end product
  • Inert end product

Pyrolysis of spent resins

Across the globe, in the nuclear sector, waste storage is filling up and with life expansion plans for power plants waste storage space is becoming critical. Spent resins represent a relatively large portion of the waste that is currently in repository, while no treatment method exists to efficiently, sustainably and economically reduce volume and increase safety. 

The PRIME installation combines evaporation, drying and pyrolysis in one single electric unit. It processes both wet and dry resins directly in the reactor. At temperatures between 300 and 500 °C, organic components break down under inert conditions, forming a dry, inert residue that retains the radioactivity and allows easy traceability and isotopic analysis. Unlike incineration, pyrolysis is a stable and well-controlled thermal process that prevents agglomeration of resin beads and minimizes dust formation, thereby retaining radio nuclides within the solid waste residue.

Spent resins typically yield a volume reduction factor (VRF) between 5 and 10, depending on resin type. The end product is mostly composed of carbon and small amounts of residual metals or sulfur compounds.

The fully electric design eliminates the need for auxiliary fossil fuels, significantly reducing the carbon footprint while offering a compact, safe, and easy-to-operate installation. Designed to fit the main process in a 20-foot ISO container, the PRIME unit is mobile and easily deployable on-site. With its patented technology and robust performance, PRIME is a next-generation answer to one of the nuclear sector’s most pressing waste challenges.

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R&D

Technology

See how PRIME brings advanced waste treatment to life, in both design and operation.

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1. Feeding system: The feeding system is designed to handle wet resins with or without transport water as well as dry resins. Transport water can be separated in the feeding system prior to feeding the resins to the reactor.

 

2. Pyrolysis reactor and ash collection: The pyrolysis reactor has a volume of 100 L, with a design temperature of 600°C and is equipped with a special design mechanical stirrer on a central axis. A resin inlet on the top connects the reactor to the dosing unit and a pyrolysis gases discharge connection on the top of the reactor connects the reactor to the thermal oxidizer. A discharge connection at the bottom of the reactor is connected to a receiver drum for the resins after treatment. Connections on the bottom and the top allow for nitrogen blanketing, to ensure an inert atmosphere. The inlet and discharge for the resins can be closed with pneumatically actuated slide valves. The pyrolysis reactor is heated by ceramic heating elements around the conical part as well as on the lid of the reactor.

3. Thermal oxidizer: In the fully-electrical thermal oxidizer, the pyrolysis gases released during treatment of the ion exchange resins are heated electrically to 850°C at a minimum residence time of 2 seconds, in the presence of at least 6% volume of oxygen. This ensures that over 99.9% of all volatile organic compounds (VOC’s) are combusted.

 

4. Off-gas: The hot off-gases from the thermal oxidizer are passed through an injector-venturi scrubber for further treatment. In the injector-venturi, water is injected in the off-gases at high pressure. The off-gases are then forced through the narrow venturi throat section, greatly increasing flow velocity and atomizing the water to create a finely dispersed mist. At these conditions, particles and pollutants are quickly captured by the water droplets. In addition, the evaporating water cools down the hot off-gases till saturation temperature. After treatment, the cleaned off-gases are released into the atmosphere by use of an induced draft fan.

Key benefits of the PRIME installation

“Safe. Stable.
Compliant.”

The benefits go beyond waste reduction. PRIME delivers a stable, compliant and storage-ready end product that simplifies every step of the waste management process.

  • Compact design
  • Safe and easy process and operation
  • Electrically powered
  • LLW and MLW resins
  • VRF between 5 and 10
  • Low temperature = low carry over
  • No swelling of end product
  • Inert end product

CONTACT

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