HIGH ASSAY, LOW ENRICHED URANIUM DECONVERSION PROCESS
20230368933 · 2023-11-16
Inventors
Cpc classification
International classification
Abstract
A novel semi-batch process for deconverting high assay low enriched uranium (HALEU) from its uranium hexafluoride state to uranium dioxide and other chemical states useful as feeds for nuclear fuel in a nuclear reactor is provided. The semi-batch process enables the use of equipment that is small enough, and production rates that are low enough, to meet nuclear criticality safety restraints for HALEU, while enabling the safe, dependable, and economical production of HALEU feed for nuclear fuel at a nominal capacity of up to about 20 MTU (metric tons of uranium metal) per year per deconversion reactor.
Claims
1. A semi-batch process for deconversion of fluorinated HALEU material to produce HALEU feed for nuclear fuel, comprising the following steps: a) providing a seed bed of uranium dioxide (UO.sub.2) powder in a fluidized bed reactor vessel, wherein the UO.sub.2 powder comprises uranium that includes greater than 5% by weight U-235 isotope; b) fluidizing the UO.sub.2 powder in the reactor vessel using an upflow stream comprising an inert gas, while heating the reactor vessel; c) feeding a stream of hydrogen and steam to the upflow stream of inert gas; d) feeding vaporized uranium hexafluoride (UF.sub.6) and additional steam to the fluidized bed reactor vessel, wherein the UF.sub.6 comprises uranium that includes greater than 5% by weight U-235 isotope; e) reacting the UF.sub.6 with some of the steam to yield uranyl fluoride (UO.sub.2F.sub.2); f) reacting the UO.sub.2F.sub.2 with the hydrogen in the upflow stream to yield additional UO.sub.2 powder which accumulates in the fluidized bed; g) stopping, when the UO.sub.2 in the fluidized bed reaches a target mass, the feeding of UF.sub.6 and additional steam and allowing any residual UF.sub.6 in the reactor vessel to react with the stream of hydrogen and steam to yield additional UO.sub.2 powder which accumulates in the fluidized bed; and h) stopping the stream of hydrogen and steam to enable discharge of a quantity of the UO.sub.2 powder from the reactor vessel.
2. The process of claim 1, further comprising the steps of discharging enough of the UO.sub.2 powder from the reactor vessel to leave behind a seed bed of UO.sub.2 powder as in step a), and repeating steps b) to h).
3. The process of claim 1, wherein the target mass in step g) is at least about three times a mass of the seed bed in step a).
4. The process of claim 1, wherein the target mass in step c) is at least about five times a mass of the seed bed in step a).
5. The process of claim 1, wherein the uranium in steps a) and d) includes greater than about 10% by weight U-235 isotope.
6. The process of claim 1, wherein the uranium in steps a) and d) includes greater than about 15% by weight U-235 isotope.
7. The process of claim 1, wherein the inert gas in step b) comprises nitrogen.
8. The process of claim 1, wherein the heating in step b) is sufficient to enable performing step e) at a temperature of at least about 450° C.
9. The process of claim 1, wherein the heating in step b) is sufficient to enable performing step f) at a temperature of at least about 600° C.
10. The process of claim 1, further comprising the steps of discharging the quantity of UO.sub.2 powder from the reactor vessel and reacting the discharged UO.sub.2 powder with oxygen to yield triuranium octoxide (U.sub.3O.sub.8).
11. The process of claim 10, wherein the reacting of the discharged UO.sub.2 powder with oxygen to yield U.sub.3O.sub.8 is performed in a second fluidized bed reactor vessel at a temperature of at least about 140° C.
12. The process of claim 1, further comprising the steps of discharging the quantity of UO.sub.2 powder from the reactor vessel and reacting the discharged UO.sub.2 powder with hydrogen fluoride gas to yield uranium tetrafluoride (UF.sub.4).
13. The process of claim 12, wherein the reacting of the discharged UO.sub.2 powder with hydrogen fluoride gas to yield UF.sub.4 is performed in a second fluidized bed reactor vessel at a temperature of about 400° C. to about 500° C.
14. The process of claim 12, further comprising the step of reacting the UF.sub.4 with an alkali metal to yield uranium metal (U).
15. The process of claim 14, wherein the alkali metal comprises calcium (Ca) and the reacting of UF.sub.4 with calcium is performed in in a pressure and temperature-resistant vessel at a temperature of at least about 400° C.
16. A semi-batch process for deconversion of fluorinated HALEU material to produce HALEU feed for nuclear fuel, comprising the following steps: a) providing a seed bed of uranium dioxide (UO.sub.2) powder in a fluidized bed reactor vessel, wherein the UO.sub.2 powder comprises uranium that includes at least about 10% by weight U-235 isotope; b) fluidizing the UO.sub.2 powder in the reactor vessel using an upflow stream comprising nitrogen gas, while heating the reactor vessel to a temperature of at least about 450° C. in a top portion of the reactor vessel and 600° C. in a bottom portion of the reactor vessel c) feeding a stream of hydrogen and steam into the upflow stream of inert gas; d) feeding vaporized uranium hexafluoride (UF.sub.6) and additional steam in the top portion of the fluidized bed reactor vessel, wherein the UF.sub.6 comprises uranium that includes at least about 10% by weight U-235 isotope; e) hydrolyzing the UF.sub.6 in an upper portion of the fluidized bed reactor vessel to yield uranyl fluoride (UO.sub.2F.sub.2); f) reacting the UO.sub.2F.sub.2 with the hydrogen in the upflow stream to yield additional UO.sub.2 powder which accumulates in the fluidized bed; g) stopping, when the UO.sub.2 in the fluidized bed reaches a target mass, the feeding of UF6 and additional steam and allowing any residual UF.sub.6 in the reactor vessel to react with the stream of hydrogen and steam to yield additional UO.sub.2 powder which accumulates in the fluidized bed; and h) stopping the stream of hydrogen and steam to enable discharge of a quantity of the UO.sub.2 powder from the reactor vessel.
17. The process of claim 16, further comprising the steps of collecting the UO.sub.2F.sub.2 formed in step e) using a sintered metal filter located near the top of the reactor vessel, and periodically blowing the UO.sub.2F.sub.2 off of the filter using nitrogen blowback of the filter, causing the UO.sub.2F.sub.2 to drop toward the fluidized bed.
18. The process of claim 17, wherein the step f) of reacting the UO.sub.2F.sub.2 with the hydrogen in the upflow stream occurs in the fluidized bed.
19. The process of claim 16, wherein the uranium in steps a) and d) includes at least about 15% by weight U-235 isotope.
20. A semi-batch process for deconversion of fluorinated HALEU material to produce HALEU feed for nuclear fuel, comprising the following steps: a) providing a seed bed of uranium dioxide (UO.sub.2) powder in a fluidized bed reactor vessel, wherein the UO.sub.2 powder comprises uranium that includes about 19.75% by weight U-235 isotope; b) fluidizing the UO.sub.2 powder in the reactor vessel using an upflow stream comprising an inert gas, while heating the reactor vessel; c) feeding a stream of hydrogen and steam to the upflow stream of inert gas; d) feeding vaporized uranium hexafluoride (UF.sub.6) and additional steam to the fluidized bed reactor vessel, wherein the UF.sub.6 comprises uranium that includes about 19.75% by weight U-235 isotope; e) reacting the UF.sub.6 with some of the steam to yield uranyl fluoride (UO.sub.2F.sub.2); f) reacting the UO.sub.2F.sub.2 with the hydrogen in the upflow stream to yield additional UO.sub.2 powder which accumulates in the fluidized bed; g) stopping, when the UO.sub.2 in the fluidized bed reaches a target mass, the feeding of UF.sub.6 and additional steam and allowing any residual UF.sub.6 in the reactor vessel to react with the stream of hydrogen and steam to yield additional UO.sub.2 powder which accumulates in the fluidized bed; and h) stopping the stream of hydrogen and steam to enable discharge of a quantity of the UO.sub.2 powder from the reactor vessel.
21. The process of claim 20, further comprising the steps of discharging enough of the UO.sub.2 powder from the reactor vessel to leave behind a seed bed of UO.sub.2 powder as in step a), and repeating steps b) to h).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0024]
[0025]
[0026]
[0027]
DETAILED DESCRIPTION
[0028] Referring to
[0029] In some examples, the fluidized bed reactor 10 includes a gas distributor plate 12, which can be a sintered metal plate having a central opening 30, and is used to inject evenly distributed fluidizing gas near the bottom of the fluidized bed reactor 10. In the first step a), a seed bed 14 of HALEU uranium dioxide powder (described above) is provided on top of the gas distributor plate 12. This can be accomplished, for example, using a vertical pipe (not shown) extending upward through the central opening 30. As a non-limiting example, for a 10 kg batch, the seed bed can have a mass of about 0.5 kg to about 2 kg, or about 1 kg to about 1.5 kg. In the second step b), a fluidizing stream of an inert gas, suitably nitrogen, is fed to the gas distribution plate 12 at an injection point 16 below the gas distributor plate, at a sufficient velocity and volumetric flow rate to fluidize the seed bed 14. The fluidizing stream provides an upflow stream that flows from the bottom to the top of the fluidized bed reactor 10.
[0030] The reactor vessel is heated, suitably by heating both the inert gas stream and the fluidized bed reactor 10, to a temperature sufficient to cause the defluorination reactions to take place in the desired temperature ranges of at least about 400-450° C. for the conversion of UF.sub.6 to uranyl fluoride and at least about 600° C. for the conversion of uranyl fluoride to UO.sub.2 powder. Initially, this may require different amounts of heat to be applied in a bottom portion of the fluidized bed reactor 10, which can be initially heated to at least about 600° C., and in a top portion of the reactor 10, which can be initially heated to at least about 400° C. Because the reactions taking place can be a combination of exothermic and endothermic, steady state operation may require an ongoing removal of heat near the top and an ongoing addition of heat near the bottom of the fluidized bed reactor 10. In the third step c), as the upflow stream is being heated, steam and hydrogen gas can be added to the upflow stream at the same injection point 16 as the inert gas or close to it.
[0031] When the reactor vessel has reached a suitable reaction temperature, in the fourth step d), separate streams of vaporized UF.sub.6 and steam are added at a second injection point 18 (or two injection points at about the same location), whereupon the injection point(s) 18 are significantly higher in the reactor vessel that the first injection point 16. The injection point(s) 18 can be located above the top of the fluidized bed 14. The amount of hydrogen gas added at the first injection point 16 and the collective amounts of steam added at the first and second injection points 16 and 18 should be sufficient to carry out the following deconversion reactions. First, the UF.sub.6 is converted to UO.sub.2F.sub.2 at about 450° C. in the fifth step e) according to the following reaction.
UF.sub.6(g)+2H.sub.2O(g).fwdarw.UO.sub.2F.sub.2(s)+4HF(g) Step e):
[0032] Second, the UO.sub.2F.sub.2 is converted to UO.sub.2 powder at a temperature of about 600° C. in the sixth step f) according to the following reaction.
UO.sub.2F.sub.2(s)+2H.sub.2(g).fwdarw.UO.sub.2(s)+4HF(g) Step f):
[0033] While there can be some overlap in the performance of steps e) and f), the two reactions commence at different temperatures and can initiate at different locations in the reactor vessel. The reaction that yields uranyl fluoride (step e)) commences at about 450° C. when the UF.sub.6 is combined with steam in the entrance nozzle and added to the reactor, while the reaction that converts uranyl fluoride to uranium dioxide (step f)) commences at about 600° C. as the UO.sub.2F.sub.2 is being formed and is contacted with hydrogen. As the uranyl fluoride is being formed, it initially accumulates on a plurality of sintered metal filters 28 located at the top of the fluidized bed reactor 10, forming a cake on the filter surfaces. The cake is periodically discharged from the filters 28 using a nitrogen blowback which dislodges the uranyl fluoride and drops it back into the fluidized bed. As the process cycle continues, the dislodged uranyl fluoride becomes incorporated into the fluidized bed and reacts with the hydrogen gas to form the uranium dioxide (step f)) as the temperature in the upflow stream approaches 600° C.
[0034] The collective amounts of steam added to the fluidized bed reactor vessel in both injection points 16 and 18 can exceed the stoichiometric amount required to achieve hydrolysis of the uranium hexafluoride as explained above. The inert gas such as nitrogen serves as a fluidizing gas and acts as a diluent for the steam. The amount of hydrogen added should be as close as possible to what is needed to complete the conversion of uranyl fluoride to uranium dioxide and can be increased as necessary if the defluorination is less than complete, or is less than a desired target amount. Each of the two reactions generates hydrogen fluoride (HF) by-product which exits the off-gas outlet 20 along with the nitrogen and any excess steam and hydrogen. The hydrogen fluoride mixes with the excess steam to form hydrofluoric acid which condenses and separates from the nitrogen and hydrogen gas, resulting in separate streams 22 and 24. The nitrogen and hydrogen gas can be disposed of or recycled, while the hydrofluoric acid can be sold for other industrial uses.
[0035] As the uranium dioxide product is formed in step f), it accumulates as a powder and becomes part of the fluidized bed. The mass of the fluidized bed therefore increases until it reaches a target mas which can be at least about three times, or at least about five times, or at least about seven times or more, compared to the mass of the initial seed bed. For example, the fluidized bed reactor 10 can be sized to operate with a seed bed of about 1-2 kg of uranium dioxide powder and a target mass of about 10 kg. When the fluidized bed reaches the target mass, step g) is performed which includes stopping the inlet feed of UF.sub.6 into the fluidized bed reactor 10 and allowing all remaining UF.sub.6 in the reactor 10 to react with the stream of hydrogen and steam to first form uranyl fluoride (UO.sub.2F.sub.2) and then uranium dioxide (UO.sub.2) powder, which accumulates in the fluidized bed. Step g) can be allowed to continue until the fluidized bed contains essentially pure UO.sub.2 powder and is essentially devoid of fluorinated intermediate products, at which point the initial batch of UF.sub.6 feed has been completely defluorinated or has been defluorinated to a desired level.
[0036] When the batch of UF.sub.6 has been completely defluorinated or defluorinated to a desired level in the fluidized bed reactor 10, the seventh step g) is performed, which includes stopping the feed stream of hydrogen and steam in the first inlet 16 to enable discharge of a quantity of UO.sub.2 powder through the center opening 30 in the gas distribution plate 12 and through the discharge outlet 32 at the bottom of the fluidized bed reactor 10. The inlet flow of nitrogen can be increased as needed to maintain enough fluidization to facilitate the discharge. The quantity of UO.sub.2 powder that is discharged can be just enough to leave behind a seed bed of UO.sub.2 powder to aid in processing the next batch of UF.sub.6 feed and can be about 80% to about 95% of the accumulated or target mass in the fluidized bed reactor 10. The UO.sub.2 powder that is discharged through the outlet 32 can be fed to either or both of two streams 34 and 36. The illustrated stream 34 leads to a storage container whereupon the UO.sub.2 powder can be used directly as feed for nuclear fuel in some applications. The illustrated stream 36 leads to a second fluidized bed reactor whereupon the UO.sub.2 powder can be converted to other feeds for nuclear fuels useful for some applications, including without limitation U.sub.3O.sub.8, UF.sub.4, and (following the conversion to UF.sub.4) to uranium metal.
[0037] When step g) has been completed, leaving behind enough UO.sub.2 powder to replenish the seed bed, steps b)-h) can be repeated using a new batch of UF.sub.6 feed. The process can be repeated as many times as needed to produce enough UO.sub.2 powder to meet ongoing needs. The nominal capacity of a single fluidized bed reactor as described above, operating with a target mass of 10 kg UO.sub.2 powder, is estimated to be about 20 MTU per year. The production rate can be increased by arranging several of the fluidized bed reactor vessels 10 in parallel, whereupon each one can contribute an annual production capacity of about 20 MTU per year.
[0038]
3UO.sub.2(s)+O.sub.2(g).fwdarw.U.sub.3O.sub.8(s)
[0039] Any U.sub.3O.sub.8 powder that accumulates on the sintered filters 28 can be blown off using air or nitrogen. When the reaction is complete, the source of heat can be shut off and, after cooling, the U.sub.3O.sub.8 powder can be discharged from the second fluidized bed reactor through the opening 30, outlet 32 and stream 46 leading to a storage container.
[0040]
UO.sub.2(s)+4HF(g).fwdarw.UF.sub.4(s)+2H.sub.2O(g)
[0041] The off-gas including nitrogen, steam from the reaction and residual HF exits the reactor through outlet 20. The exit stream then splits into a gas stream 22 of nitrogen gas and a liquid stream 24 of hydrofluoric acid formed by the mixing of HF gas with condensing steam. The UF.sub.4 product exists as a green salt which is discharged from the fluidized bed reactor vessel 50 via opening 30 and discharge outlet 32. The discharge stream of UF.sub.4 that is discharged through the outlet 32 can be fed to either or both of two streams 54 and 56. The illustrated stream 54 leads to a storage container whereupon the UF.sub.4 salt can be used directly as feed for nuclear fuel in some applications. The illustrated stream 56 leads to a closed vessel “bomb reactor” where the UF.sub.4 salt can be reacted with calcium metal to yield uranium metal. The bomb reactor can be lined with an inert material such as magnesium oxide. The reaction can be initiated at a temperature of about 400° C. until the exothermic reaction is initiated, after which the following exothermic reaction can drive the temperature up to about 1400° C. as the reaction proceeds to completion:
UF4(s)+2Ca(m).fwdarw.U(m)+2CaF.sub.2(s)
[0042] Assuming a starting batch of about 10 kg UF.sub.4 salt, the reaction in the bomb reactor typically yields about 8 kg of uranium metal and about 2 kg of calcium fluoride slag which can be separated from the uranium. The uranium metal can then be used as feed for nuclear fuel in some applications.
[0043] The illustrated fluidized bed reactor vessel 10 provides a highly effective and efficient small reactor that meets nuclear safety standards for the deconversion of fluorinated HALEU feed material into a variety of useful HALEU feeds for nuclear fuels. In one example, the reactor vessel 10 may have a diameter of only about 4-5 inches with a somewhat expanded vapor space at the top to aid in disengagement of the fluidized powder from the sintered metal filters. Two virtually identical reactor vessels of the same size and construction can be provided in series to convert the UO.sub.2 powder to a variety of alternative HALEU feeds for nuclear fuels. Because the fluidized bed reactor vessel is an order of magnitude (about 90%) smaller than conventional continuous dry process deconversion reactors, it is especially suited for the deconversion of fluorinated HALEU feed material.
[0044]
[0045] The foregoing description of specific embodiments will so fully reveal the general nature of embodiments of the disclosure that others can, by applying knowledge of those of ordinary skill in the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of embodiments of the disclosure. Therefore, such adaptation and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. The phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the specification is to be interpreted by persons of ordinary skill in the relevant art in light of the teachings and guidance presented herein.
[0046] The breadth and scope of embodiments of the disclosure should not be limited by any of the above-described example embodiments but should be defined only in accordance with the following claims and their equivalents.
[0047] Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain implementations could include, while other implementations do not include, certain features, elements, and/or operations. Thus, such conditional language generally is not intended to imply that features, elements, and/or operations are in any way required for one or more implementations or that one or more implementations necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or operations are included or are to be performed in any particular implementation.
[0048] A person of ordinary skill in the art will recognize that any process or method disclosed herein can be modified in many ways. The process parameters and sequence of the steps described and/or illustrated herein are given by way of example only and can be varied as desired. For example, while the steps illustrated and/or described herein may be shown or discussed in a particular order, these steps do not necessarily need to be performed in the order illustrated or discussed.
[0049] The various exemplary methods described and/or illustrated herein may also omit one or more of the steps described or illustrated herein or comprise additional steps in addition to those disclosed. Further, a step of any method as disclosed herein can be combined with any one or more steps of any other method as disclosed herein.
[0050] The various exemplary methods described and/or illustrated herein may also omit one or more of the steps described or illustrated herein or comprise additional steps in addition to those disclosed. Further, a step of any method as disclosed herein can be combined with any one or more steps of any other method as disclosed herein.
[0051] It is, of course, not possible to describe every conceivable combination of elements and/or methods for purposes of describing the various features of the disclosure, but those of ordinary skill in the art recognize that many further combinations and permutations of the disclosed features are possible. Accordingly, various modifications may be made to the disclosure without departing from the scope or spirit thereof. Further, other embodiments of the disclosure may be apparent from consideration of the specification and annexed drawings, and practice of disclosed embodiments as presented herein. Examples put forward in the specification and annexed drawings should be considered, in all respects, as illustrative and not restrictive. Although specific terms are employed herein, they are used in a generic and descriptive sense only, and not used for purposes of limitation.
[0052] Unless otherwise noted, the terms “a” or “an,” as used in the specification, are to be construed as meaning “at least one of” Finally, for ease of use, the terms “including” and “having” (and their derivatives), as used in the specification, are interchangeable with and have the same meaning as the word “comprising.”
[0053] From the foregoing, and the accompanying drawings, it will be appreciated that, although specific implementations have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the appended claims and the elements recited therein. In addition, while certain aspects are presented below in certain claim forms, the inventors contemplate the various aspects in any available claim form. For example, while only some aspects may currently be recited as being embodied in a particular configuration, other aspects may likewise be so embodied. Various modifications and changes may be made as would be obvious to a person skilled in the art having the benefit of this disclosure. It is intended to embrace all such modifications and changes and, accordingly, the above description is to be regarded in an illustrative rather than a restrictive sense.