METHOD FOR ERECTING AN APPARATUS FOR DISMANTLING AN INDUSTRIAL PLANT The invention relates to a method for erecting an apparatus for dismantling an industrial plant with a large number of disassembly stations for industrial plant elements, in particular a nuclear plant having corresponding nuclear facilities.
When disassembling or dismantling industrial plants or industrial structures, these are disassembled or dismantled, wherein dismantled elements of an industrial plant are recycled as far as possible or fed into a reusable material cycle so that dismantled elements of such an industrial plant are not finally disposed of as far as possible, but are reused or can be reprocessed.
The invention is described below on the basis of a nuclear plant.
The term nuclear plant refers to a technical facility that is used for the processing, utilisation and/or storage of nuclear fuel.
In particular, the term nuclear plant comprises a nuclear power plant, power reactors, prototype reactors, research reactors, plants for nuclide enrichment, plants for the production and/or processing of nuclear fuel, fuel element factories, reprocessing plants, interim storage facilities and the like.
The term nuclear plant is particularly preferably understood to mean a nuclear power plant and/or a nuclear fission reactor.
Compared to the dismantling of a non-nuclear plant, in which typically no increased radioactivity or radiation exposure is to be expected, the dismantling of such a nuclear plant involves the additional problem that plant elements emit radiation, i.e. are "activated" or can be contaminated and therefore special protective measures must be taken and protective regulations must be observed.
Although special regulations have to be observed in such a nuclear plant compared to other non-nuclear plants, the method described below can also be applied to other industrial plants.
The dismantling of a nuclear plant is known from DE26 38 174 A1. This describes a method for dismantling a nuclear power plant, in which auxiliary and treatment systems that are already present in the nuclear power plant continue to be used during dismantling.
Additional necessary treatment systems, which are only required for dismantling, are placed in containers that are placed in a bunker-like building and connected to the reactor building.
An alternative procedure is disclosed in the document Carsten F. et al.: "15 years practical decommissioning experiences at Greifswald NPP"; CEE Decommissioning & Waste Cooperation, 19 June 2008 (2008-06-19), XP055404456, Berlin.
EP2 833 367 A2 discloses a plant and a method for processing residues, in particular activated or contaminated and/or uncontaminated residues, wherein the residues or waste are able to be recycled and residues or waste originate from a nuclear plant. The plant described is designed in such a way that it is not only built for a single nuclear power plant to be dismantled, but can also be designed and modularly adapted for processing residues from a large number of nuclear power plants. These conventional plants and corresponding methods each require an area that must meet the requirements for processing radioactive materials. In particular, the modular plant mentioned above requires that the radioactive material to be processed be transported to the plant in order to be further processed there and, in the case of radioactive contamination, possibly separated into contaminated residual material, i.e. waste material, and reusable material. In total, the dismantling of such an industrial plant produces several 10,000 tonnes of material, which can be mineral, metal or plastic. It is a constant aim that as much of the material from dismantled plants as possible can be fed into a reusable material cycle and thus be reused. The storage or disposal of the material in a storage facility should be prevented as far as possible for reasons of cost and environmental protection. For the dismantling of some industrial plants, however, the problem arises that dismantling can only be carried out in a suitable environment, in particular when dismantled material is chemically contaminated or radioactive, for example; during dismantling, special protective measures for personnel and for the environment must be met. Typically, such industrial plants are dismantled into transportable pieces, which are then transported to a plant suitable for treatment or processing. These disadvantages are reduced with a method and a corresponding apparatus for dismantling an industrial plant according to independent claim 1. Preferred further developments are specified in the dependent claims. The invention is described below with reference to drawings. In the drawings: Figure 1 shows a schematic view of a horizontal section through an industrial plant; Figure 2 steps of a method for erecting an apparatus for dismantling an industrial plant. Figure 1 shows a schematic representation of a floor plan of an industrial plant, in this case a nuclear plant, which is to be dismantled. The nuclear plant 1 comprises at least one building 2 and a large number of industrial plant elements, which are placed in the building 2 or in the immediate vicinity. The industrial plant elements here are in particular elements of the nuclear plant 1 which are to be disassembled or dismantled. The industrial plant, in this case the nuclear plant, includes various plant elements that are known per se and are to be dismantled. In addition to the building, which typically consists of a large proportion of concrete or stone,
i.e. mineral material, there are also the machines (e.g. pumps) and process engineering equipment (e.g. pipes, valves) substantially required to operate the plant and other components made of different materials (e.g. electrical controls) and, depending on the reactor type (boiling water reactor), a machine room with built-in machines. Therefore, different tools and machines are required for dismantling the various plant elements in order to first process the plant elements at the site of their installation, if necessary, and then to uninstall before they can be transported to a corresponding machine or series of machines to be further treated or processed. Typically, elements of the plant to be dismantled are treated and processed in succession at various stations, hereinafter referred to as disassembly stations, after they have been removed from assembly in the plant. For example, large elements such as concrete walls are split into sections, wherein appropriate tools such as concrete cutters or circular saws or core drills are used for the splitting. A section of a split concrete wall is then transported to a further disassembly station, such as a stationary concrete crusher or shot blasting machine, for further cleaning. Dismantled process engineering equipment, such as valves or pumps, can be (pre-)dismantled on site or transported to suitable disassembly stations for further dismantling. They can then be transported to disassembly stations suitable for metalworking for further dismantling and treated and processed further there, for example with a band saw for dismantling into smaller sections. The disassembled plant elements are preferably transported with uniform containers, in particular with so-called solid wall boxes in the usual standardised size of conventional industrial pallets. Each container can be provided with a unique identifier so that the container can also be identified during the entire passage through the disassembly stations, wherein an electronic system for automatically tracking a container is preferably able to be used. A system which is conventional per se can be used for such an identifier of a container, for example with RFID transponders for the automated detection of the containers at a disassembly station. Alternatively, a semi-automated system can be used, for example with a barcode or QR marking of each container. In particular, a container which has once been used for the transport of waste material is then preferably used only for the transport of waste material in order to avoid contamination of recyclable materials by residues in a container previously used for waste material. Furthermore, the containers are monitored with respect to their contamination in order to prevent accumulation of activated or contaminated material.
Depending on the degree of contamination, the containers are automatically cleaned.
After cleaning, the containers can then be used again for waste material or for recyclable materials.
In addition to dismantling, the cleaning of adhering contamination (radioactive and/or chemical) is an essential method step.
The possibly pre-dismantled plant elements are fed to corresponding disassembly stations for cleaning, e.g. by water jets or another abrasive method.
Furthermore, there is a need to measure the degree of radiation activity, particularly when dismantling a nuclear plant.
If the radiation activity of the dismantled element is below the permissible limit value, the material can be released to a reusable material cycle.
Otherwise, i.e. if the so-called clearance measurement shows a radiation activity above the limit value, the material is considered waste and must be prepared or packaged accordingly for a final disposal that is then required.
Consequently, disassembly stations can be provided for filling such dismantled elements into containers and for producing packaging suitable for final disposal (e.g. pressing or drying steps). The disassembly stations themselves and the corresponding methods for dismantling and subsequent treatment and processing of the dismantled plant elements are already known and can be taken into account when planning the dismantling.
Likewise, the properties of the industrial plant to be dismantled can be determined before the dismantling or are already known and can thus be used as a basis during the dismantling planning phase so that a method for erecting an apparatus for dismantling an industrial plant described above is possible on the basis of the information available.
The aim of the planning is to erect the apparatus for dismantling the industrial plant in existing rooms of the industrial plant to be dismantled such that properties of the industrial plant can be used during the dismantling.
Thus, safety devices of the industrial plant which were already necessary in a nuclear plant to be dismantled for the productive operation of the plant can be used during the dismantling until they themselves are dismantled.
A ventilation system that was provided and configured for filtering exhaust air can therefore continue to be used in an advantageous manner, for example to filter out dust residues from the exhaust air which are not permitted to be released into the environment.
The method begins ,see Figure 2, reference sign 7, with the determination of the sequence in which plant elements, here of the nuclear plant, are dismantled.
On the one hand general principles can be used for this, and on the other hand empirical values can be used that have been collected during the dismantling of other industrial plants; it is obvious to a person skilled in the art that stairs and elevators are kept in an operable condition and therefore not dismantled until the stairs or elevator are no longer needed so that they can be used as transport routes during dismantling.
On the other hand, elements of the industrial plant that are only necessary for the intended operation of the plant but not for its dismantling can be disassembled sooner.
In particular, to determine the sequence in which plant elements are disassembled or dismantled, the placement of a plant element can be taken into account with the aim that those plant elements are dismantled first which have space necessary for erecting disassembly stations, such that the space freed up by disassembling plant elements can be used for a disassembly station.
Furthermore, to determine the dismantling sequence, it is advantageously possible to take into account which disassembly stations are necessary for dismantling a plant element, such that those plant elements are dismantled first for which the further treatment and processing only require those disassembly stations which were already present when the disassembly stations had begun to be erected.
In this way, the dismantling of the nuclear plant can be started without disassembly stations having been erected which are only necessary for dismantling some of the plant elements.
In this way, those plant elements are first dismantled for which their dismantling requires as few disassembly stations as possible and from which the space freed up in the rooms of the plant is used for the erection of further disassembly stations.
For example, disassembly stations can first be installed for the mechanical dismantling of removed components and for cleaning their surfaces, for example by water jets.
Almost simultaneously with the determination of the dismantling sequence, it is determined, see reference sign 8 in Figure 2, which disassembly stations are required for the dismantling and in which order they are required with respect to the sequence of the plant elements to be dismantled.
The sequence of the plant elements to be dismantled and the disassembly stations required for this must be determined with mutual consideration being given so that those disassembly stations can be erected and put into operation in the rooms of the plant to be disassembled that can be used for the dismantling of further plant elements, the space then ideally being able to be used for constructing further disassembly stations.
Following the steps of selecting the dismantling sequence and determining the disassembly stations, the rooms in which the disassembly stations are erected must be determined; see reference sign 9 in Figure 2. In this regard, the rooms in the industrial plant to be dismantled in which the disassembly stations are to be erected are there in any case, so the rooms that are already present in the industrial plant are used for erecting the disassembly stations.
A room within a building of an industrial plant can also be created by removing a wall from two adjacent rooms to create a correspondingly larger room.
No new buildings are to be built in which the apparatus for dismantling the industrial plant is then erected, rather a building is to be used which is not built merely for the dismantling process, but which had already been built at the time of productive operation of the plant for same.
When determining the rooms in which the disassembly stations are erected, the dismantling sequence is taken into account so that those disassembly stations that are required for the dismantling of the first plant elements are erected first.
Furthermore, a placement for each disassembly station in a room is identified by taking into account the determined dismantling sequence, the determined disassembly stations and the determined rooms; see reference sign 10 in Figure 2. When selecting the space for a disassembly station in a room, the size of the dismantled plant elements and the size of the transport vehicle with or in which the dismantled plant elements are transported to the next disassembly station are taken into account.
The steps described above for identifying the dismantling sequence, the required disassembly stations and the rooms in which the disassembly stations are erected and the placement of the disassembly stations in the rooms are carried out for the dismantling and the processing of recyclable materials and for the dismantling and processing of waste materials, such that the reusable materials are processed by means of a first group of disassembly stations and the waste materials that are not reusable but are to be ultimately disposed of are processed by means of a second, separate group of disassembly stations.
The processing or treatment of recyclable materials on the one hand and waste materials on the other should be strictly separated and carried out exclusively in a respective group of disassembly stations.
The recyclable materials as well as the waste materials should only be treated or processed once at each disassembly station, so that the treatment or processing of the recyclable materials and of the waste materials is carried out in a respective group of disassembly stations as in a one-way street.
Furthermore, the rooms and the placement of a respective disassembly station in a room are coordinated in such a way that transport routes between the disassembly stations of the first and second group do not cross.
Therefore, waste materials are only processed in a respective group of disassembly stations provided for this purpose, but not in disassembly stations in the recyclable material processing chain.
This prevents waste materials which may be radioactive and from which radioactive residues might remain on the machines of the disassembly stations from contaminating the disassembly stations of the recyclable material processing chain and possibly contaminating recyclable materials such that they can no longer be fed into a reusable material cycle.
Likewise, contamination of the recyclable materials on the transport routes is prevented by the strict separation and the prevention of crossings.
In this way, two groups of disassembly stations are erected in the rooms of the plant to be dismantled.
In this regard, a first subgroup of disassembly stations can first be erected which is then used for the treatment or processing of at least one first dismantled plant element, and only then is a respective second subgroup of disassembly stations of the group erected.
In this way, some disassembly stations can be erected in a first phase and these are then used for treating and processing dismantled plant elements before further disassembly stations of the respective group are erected.
In this way, the disassembly stations erected first can be used for the treatment and processing of plant elements so that further disassembly stations can then be erected in the space obtained by the dismantling.
The construction of disassembly stations for recyclable materials or for waste materials and the dismantling of corresponding plant elements can be carried out in alternating phases and in such a way that firstly the minimum necessary disassembly stations are erected and put into operation, wherein plant elements are preferably dismantled in the process, and the freed-up space therefrom is used for the erection of further disassembly stations.
In this way, some of the disassembly stations are only erected after a first industrial plant element has been dismantled.
In order to be able to find the most favourable dismantling sequence in conjunction with the necessary disassembly stations and to determine rooms and the associated placements of the disassembly stations, wherein respective groups of disassembly stations for the treatment and processing of recyclable materials and waste materials shall be determined, a simulation can preferably be used which can be run as a computer program on a computer.
Existing information, such as maps of buildings and representations of the plant elements to be dismantled, can be entered into the simulation as a database.
Such a simulation of a dismantling process allows quick optimisation of the dismantling sequence, of the necessary disassembly station and of a sequence for erecting the disassembly stations as well as for determining the rooms and installation sites of the disassembly stations in the rooms.
Finally, if the rooms and placements have been determined or identified on the basis of the dismantling sequence and the necessary disassembly stations, at least one disassembly station will be erected in a determined first room and in a determined space;
see reference sign 11 in Figure 2. However, further disassembly stations can be erected in one or more rooms of the industrial plant in particular if the required space can be made available, for example if the space is only created by disassembling plant elements; so this method step, reference sign 11 in Figure 2, is carried out repeatedly and with time delays.
In one embodiment, the group of disassembly stations for recyclable materials can be separated from the group of disassembly stations for waste materials by a structural separation so that inadvertent crossing of paths is precluded.
In one embodiment, such a structural separation can be a continuous wall or at least a barrier that prevents the transport of waste materials into the zone of recyclable materials.
As an alternative or in addition, the routes from one disassembly station to the next can be highlighted by markings on the ground.
Figure 1 shows a first group of disassembly stations which are provided for processing or treating dismantled elements or material, wherein the dismantled elements or the corresponding material are recyclable material and thus reusable.
The material flow for the recyclable material through the plurality of disassembly stations begins with the delivery of the recyclable material to the disassembly station 3a.
After processing in the first disassembly station 3a, the recyclable material is transported to the next disassembly station 3b and then further via possibly further disassembly stations to the last disassembly station 3c.
The disassembly station 3a can be a cleaning station, the disassembly station 3b can be provided for fragmenting the recyclable material, and the disassembly station 3c can be a station for finalising the processing of the recyclable material, wherein the finalising of the recyclable material in one embodiment comprises fragmentation to a size which enables direct further use.
The transport routes 4 between the disassembly stations are shown as arrows.
A group of disassembly stations 5a-c for processing waste materials is placed in other facilities.
The dismantled plant elements are first processed as waste materials in a first disassembly station 5a and then further processed in further disassembly stations 5b-5c, wherein the transport of the disassembled plant elements, i.e. the waste materials, is shown schematically by arrows 6. The last disassembly station 5c in the stream of waste material processing can be a station for introducing the waste materials into containers, for example into final disposal drums or so-called Konrad containers.
The illustrated groups of disassembly stations for recyclable materials or for waste materials can comprise more or fewer disassembly stations than shown in Figure 1.
List of reference signs 1 Industrial plant, here nuclear plant 2 Building 3a-3c Disassembly station for waste materials 4 Transport route between disassembly stations for waste materials 5a-5¢ Disassembly stations for recyclable materials 6 Transport route 7-11 Method steps