The radioactive material, known as BUTEX liquor, was a byproduct of early reprocessing operations in the 1950s and had been stored in the Highly Active Liquor Evaporation and Storage (HALES) plant for decades. The original plan was to keep the liquor in these tanks until the facility's operations ceased, but challenges arose in finding new storage solutions on the busy site.
Approximately 110m³ of liquor required relocation. Before the transfer could commence, the plant's systems underwent crucial checks and updates, as the oldest tanks had not seen a transfer in nearly 20 years. Concerns were raised about the functionality of the necessary transfer systems.
A collaborative effort involving operations, engineering, and safety case teams developed a safe and practical solution. The ventilation system was modernised, work was meticulously planned, and necessary permissions were obtained from the Office for Nuclear Regulation and the Environment Agency.
The HALES team began by transferring small quantities of liquor from the old tanks to new ones using valves and controls. Insights gained from this initial phase informed improvements to methods, refinement of controls, and preparation for larger-scale operations.
The major task involved 2,250 operating cycles, transferring 40 litres at a time. What was anticipated to take over a year was completed in several months by dedicated shift teams who worked towards clear targets, resolved issues as they emerged, and maintained programme momentum.
By removing this self-heating liquor from the oldest tanks, the team has significantly reduced the heat load on some of HALES’ most aged assets. The liquid will now be stored safely in the new tanks pending its next stage: vitrification, where it will be mixed with glass for long-term storage.
“"A few years ago, there was real uncertainty about whether this could be done. The team’s willingness to think differently and work through those challenges made this success possible. I’d like to thank everyone who played a part in this achievement. The work was carried out alongside day-to-day operational demands, and the commitment shown by our teams has been outstanding. This success belongs to all those who contributed their time, expertise and determination to get the job done safely."
