Early Projects

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Two of Creative Engineers’ early projects were:

Enrico Fermi (EF-1), Breeder Reactor, Primary and Secondary Systems Cleanout (1997-2008)

CEI supported Detroit Edison Company in reacting sodium and NaK residues and other un-drainable pools and accumulations throughout the whole of the Enrico Fermi 1(EF-1) breeder reactor system. EF-1, a 400 MW demonstration breeder reactor, was shut down in the early 1970s and the bulk of the primary and secondary sodium and NaK was removed in the 1970s and 1980s and taken to other sites for future potential re-use. Components of the primary and secondary systems included the defueled nuclear reactor vessel, primary and secondary reactor pumps, intermediate heat exchangers, steam generators, two large secondary cold traps, six large bulk sodium storage tanks plus a myriad of auxiliary support systems containing sodium and NaK pools and residues.

All equipment and systems have been cleaned and rendered sodium and NaK free.

The large reactor vessel cleaning was completed in May 2008.

All sodium reaction/passivation work was completed using the superheated steam process except for one small NaK auxiliary system. The NaK system was processed using a water vapor nitrogen (WVN) process.

This project illustrates CEI’s long time experience with sodium and NaK deactivation work in the nuclear industry, and demonstrates the effectiveness of superheated steam for processing a myriad of equipment types. One of the highlights of the extended project was CEI’s processing of two large (700 to 900 gallon) cold traps using melt-drain followed by a heat soak then superheated steam processing and flooding of the vessels with water.

Oak Ridge Explosion NaK Cleanup (2000)

Oak Ridge Y-12 Facility CEI was called in to consult after a violent explosion occurred in the Arc Melt furnace at Oak Ridge’s Y-12 facility in Oak Ridge, Tennessee. The explosion resulted when a force was applied to an accumulation of spilled sodium-potassium alloy (NaK), mineral oil and potassium superoxide lying at the bottom of the furnace. Several serious injuries occurred and a DOE Type “A” investigation was completed by DOE. After the Type “A” accident investigation was completed, CEI was contracted to,
Stabilize the existing situation after the explosion, to assure that no further explosions could occur. This included remediating existing shock-sensitive mixtures. Completion of this activity allowed portions of the area to be re-opened to resume critical production operations which had been suspended for over a year.

Safely react all remaining NaK liquid (approximately 1,400 pounds) at the Oak Ridge site. The NaK had been used for two different systems in the Y-12 Arc Melt area.

Safely react all remaining NaK residues in the existing tanks, piping, cold traps, vessels, pumps, heat exchangers, and other equipment from the two systems.
Chemically decontaminate the Arc Melt area (floors, walls ceiling, overhead cranes, etc.) that were splashed with debris from the explosion. Suspected chemicals in the debris included caustic (sodium and potassium hydroxides), un-reacted NaK, mineral oil, and possibly potassium superoxide.

Included in the equipment was a small (15 to 20 gallon) cold trap which was also cleaned. The project work was completed safely and thoroughly to the customer’s satisfaction.

CEI was nominated for “Small Business Contractor of the Year,” and received the “Administrator’s Award of Excellence” for this project.

The project illustrates CEI’s unique experience with NaK and potassium superoxide. CEI founders were previously responsible for all NaK, potassium, and potassium superoxide manufacturing and design work while working for Callery Chemical Company (now BASF), the world’s largest manufacturer of all of these products. One of the reasons CEI was selected for this project was because of their extensive experience with NaK and potassium superoxide.

All NaK processing activities were accomplished using superheated steam.