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DOE OSTI2013

Nuclear Fuel Reprocessing

Reprocessing is essential to closing nuclear fuel cycle. Natural uranium contains only 0.7 percent 235U, the fissile (see glossary for technical terms) isotope that produces most of the fission energy in a nuclear power plant. Prior to being used in commercial nuclear fuel, uranium is typically enriched to 3–5% in 235U. If the enrichment process discards depleted uranium at 0.2 percent 235U, it takes more than seven tonnes of uranium feed to produce one tonne of 4%-enriched uranium. Nuclear fuel discharged at the end of its economic lifetime contains less one percent 235U, but still more than the natural ore. Less than one percent of the uranium that enters the fuel cycle is actually used in a single pass through the reactor. The other naturally occurring isotope, 238U, directly contributes in a minor way to power generation. However, its main role is to transmute into plutoniumby neutron capture and subsequent radioactive decay of unstable uraniumand neptuniumisotopes. 239Pu and 241Pu are fissile isotopes that produce more than 40% of the fission energy in commercially deployed reactors. It is recovery of the plutonium (and to a lesser extent the uranium) for use in recycled nuclear fuel that has been the primary focus of commercial reprocessing. Uraniumtargets irradiated in special purpose reactors are also reprocessed to obtain the fission product 99Mo, the parent isotope of technetium, which is widely used inmedical procedures. Among the fission products, recovery of such expensive metals as platinum and rhodium is technically achievable, but not economically viable in current market and regulatory conditions. During the past 60 years, many different techniques for reprocessing used nuclear fuel have been proposed and tested in the laboratory. However, commercial reprocessing has been implemented along a single line of aqueous solvent extraction technology called plutonium uranium reduction extraction process (PUREX). Similarly, hundreds of types of reactor fuels have been irradiated for different purposes, but the vast majority of commercial fuel is uranium oxide clad in zirconium alloy tubing. As a result, commercial reprocessing plants have relatively narrow technical requirements for used nuclear that is accepted for processing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

ON-LINE MONITORING FOR PROCESS CONTROL AND SAFEGUARDING OF RADIOCHEMICAL STREAMS AT SPENT FUEL REPROCESSING PLANTS

The International Atomic Energy Agency (IAEA) has established international safeguards standards for fissionable material at spent nuclear fuel reprocessing plants to ensure that significant quantities of weapons-grade nuclear material are not diverted from these facilities. Currently, methods to verify material control and accountancy (MC&A) at these facilities require time-consuming and resource-intensive destructive assay (DA). Leveraging new on-line non-destructive assay (NDA) techniques in conjunction with the traditional and highly precise DA methods may provide a more timely, cost-effective and resource-efficient means for MC&A verification at such facilities. Pacific Northwest National Laboratory (PNNL) is developing on-line NDA process monitoring technologies, including a spectroscopy-based monitoring system, to potentially reduce the time and resource burden associated with current techniques. The spectroscopic monitor continuously measures chemical compositions of the process streams including actinide metal ions (U, Pu, Np), selected fission products, and major non-radioactive flowsheet chemicals using UV-vis-near infrared and Raman spectroscopy. This paper provides an overview of the methods and reports our on-going efforts to develop and demonstrate the technologies. Our ability to identify material intentionally diverted from a liquid-liquid extraction contactor system was successfully tested using on-line process monitoring as a means to detect the amount of material diverted. A chemical diversion and detection of that diversion, from a solvent extraction scheme was demonstrated using a centrifugal contactor system operating a tributyl phosphate based extraction. A portion of the feed from a counter-current extraction system was diverted while a continuous extraction experiment was underway; the spectroscopic on-line process monitoring system was simultaneously measuring the feed, raffinate and organic products streams. The amount observed to be diverted by on-line spectroscopic process monitoring was in excellent agreement with values based from the known mass of sample directly diverted from system feed solution.

Np↗

DOE OSTI2021

Radiolytic evaluation of acetohydroxamic acid (AHA) under biphasic (n-dodecane and TBP/DEHBA/DEHiBA) used nuclear fuel reprocessing conditions

Acetohydroxamic acid (AHA) has been proposed as a substitute for uranium(IV) and hydrazine as a plutonium complexant and neptunium reductant for simplified, single-cycle used nuclear fuel reprocessing flowsheets. However, the chemical behavior of AHA in an intense multi-component radiation field is poorly understood, especially under representative biphasic reprocessing solvent system conditions. In response to this critical knowledge gap, this study has investigated the gamma radiolytic integrity of AHA in aqueous nitric solutions in contact with an organic phase, comprising current and future reprocessing ligands (TBP, DEHBA, and DEHiBA) dissolved in n-dodecane diluent. Our data show negligible effect of the organic phase on the radiolytic behavior of AHA compared to complementary single-phase experiments.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2022

Multiscale Evaluation of Acetohydroxamic Acid (AHA) Radiolysis Under Used Nuclear Fuel Reprocessing Solvent System Conditions

Acetohydroxamic acid (AHA) has been proposed as an alternative agent for the selective separation of plutonium and neptunium from co-extracted uranium during the reprocessing of used nuclear fuel. However, the fundamental radiolytic behavior of this molecule under envisioned process conditions – i.e., acidic biphasic solvent systems – is not sufficiently understood to support process applications. Here we present a systematic irradiation study (steady-state gamma and time-resolved pulsed electron) into the radiolytic integrity of AHA and formation of degradation products in aqueous nitric acid (HNO3) solutions (0.2 M) in presence and absence of an organic phase, comprising current (tri-butyl phosphate - TBP) and future (N,N-di-(2-ethylhexyl)butyramide - DEHBA and di-2-ethylhexylisobutyramide - DEHiBA) reprocessing ligands dissolved in n-dodecane diluent. Experimental data are complimented by predictive multiscale model calculations for the elucidation of underpinning mechanisms.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2014

DEVELOPMENT OF A HYDROGEN MORDENITE SORBENT FOR THE CAPTURE OF KRYPTON FROM USED NUCLEAR FUEL REPROCESSING OFF-GAS STREAMS

A novel new sorbent for the separation of krypton from off-gas streams resulting from the reprocessing of used nuclear fuel has been developed and evaluated. A hydrogen mordenite powder was successfully incorporated into a macroporous polymer binder and formed into spherical beads. The engineered form sorbent retained the characteristic surface area and microporosity indicative of mordenite powder. The sorbent was evaluated for krypton adsorption capacities utilizing thermal swing operations achieving capacities of 100 mmol of krypton per kilogram of sorbent at a temperature of 191 K. A krypton adsorption isotherm was also obtained at 191 K with varying krypton feed gas concentrations. Adsorption/desorption cycling effects were also evaluated with results indicating that the sorbent experienced no decrease in krypton capacity throughout testing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Classic Nuclear Fuel Reprocessing Flowsheet

This is a flowsheet as well as a series of subsheets to be used for discussion on the standard design of a reprocessing plant. This flowsheet consists of four main sections: offgas handling, separations, solvent wash, and acid recycle. As well as having the main flowsheet, subsections have been broken off into their own sheets to provide for larger font and ease of printing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Radiation Effects in Used Next Generation Nuclear Fuel Reprocessing Strategies

Given global commitments to significantly increase nuclear energy capacity, it is now more important than ever to develop efficient used nuclear fuel (UNF) management strategies to encourage widespread adoption of closed fuel cycles. To achieve this ambitious goal, a comprehensive understanding of radiation effects is essential for these next generation technologies, as radiolysis often limits longevity and performance. Here, we present new findings on: (i) the radiation robustness and performance of advanced sulfur chloride-based chlorination processes in the presence of nuclear materials (Fig. 1A); and (ii) the impacts of voloxidized uranium and rhenium complexation on monoamide-based UNF direct dissolution strategies (Fig 1B). These studies employed a combination of time-resolved electron pulse and dose accumulation gamma and electron beam irradiation techniques.

38 - RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCL↗

DOE OSTI2020

Integrating Data Sources for Improved Safeguards and Accountancy of Electrochemical Fuel Reprocessing Systems. Final Report

Electrochemical reprocessing (also commonly known as “pyroprocessing”) of used nuclear fuel is an alternative to aqueous reprocessing that confers a number of advantages, including the ability to process more recently-discharged fuel, smaller resultant waste volumes, and the lack of isolation of plutonium in the product stream. While electrochemical reprocessing systems have seen a significant research and development effort, nuclear safeguards and security of these systems remains under-developed, particularly given the significant differences in operating environment and process flowsheet compared with established aqueous methods. Objective 4 of DOE’s nuclear energy research and development activities in Nuclear Energy Research and Development Roadmap is: “Understand and minimize the risks of nuclear proliferation and terrorism.” Material Control & Accountancy (MC&A) programs at nuclear processing plants deter and detect theft and diversion of nuclear material by both outside and inside adversaries. Empirical modeling and data analytics of online measurements and state indicators can improve the timeliness of detection and reduce the uncertainty in accountancy measures. To support the development and demonstration of such methods, data are needed that capture expected measurement values collected throughout electrochemical reprocessing facilities. A review of the available literature of current research in measurements for electrochemical reprocessing systems identified twenty-two candidate measurement methodologies, which characterize fuel/salt composition, concentrations of various isotopes and elements, and operational parameters throughout the reprocessing facility. Four primary measurement methodologies have been simulated based on either physical simulations or empirical correlations: gamma emissions, neutron emissions, hybrid k-edge densitometry (HKED), and cyclic voltammetry. Initial investigation into the use of these measures for process monitoring and detection suggests the approach is viable and worthy of further investigation. This report summarizes efforts to generate signatures of key measurements during operation of electrochemical reprocessing facilities and initial investigation of data analytics to support process monitoring, diversion detection, and accountancy.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Impact of Molten Gallium on the Microstructure and Corrosion Behavior of Aluminum and Uranium-Aluminum Alloys for Used Nuclear Fuel Reprocessing

Test reactors around the world utilize highly enriched uranium fuel to achieve high neutron fluxes for materials testing. Once spent, the remaining uranium is a valuable resource for subsequent fuel fabrication. However, some of these test reactor cores consist of curved plate-type fuel elements, fabricated using aluminum alloy 6061 (AA6061) cladding to encapsulate a uranium-aluminum alloy (UAlx) fuel matrix. These assemblies require non-standard reprocessing approaches for uranium recovery, as aluminum dissolves readily in acidic solutions, generating large volumes of waste and complicating downstream chemical separations. In this work, we investigate a novel chemical decladding strategy based on the interaction between AA6061/UAlx and molten gallium (Ga). Ga is known to induce severe degradation of aluminum metal through liquid metal embrittlement (LME), even at relatively low Ga concentrations. By penetrating the aluminum crystal lattice, Ga disrupts grain cohesion and facilitates fracture or dissolution of the aluminum matrix. Thermodynamic analysis of the Al–Ga binary phase diagram suggests that Ga may offer a viable pathway to selectively weaken or dissolve the AA6061 cladding, and potentially the aluminum component of the UAlx fuel matrix within. To this end, parametric experiments were performed at 50 °C and 100 °C across a range of Al–Ga atomic fractions. At lower Al fractions, the AA6061 was completely molten after 2 hours of exposure to the Ga metal. In contrast, samples with higher Al fractions (0.9 Al, 0.1 Ga) contained residual solids after 2 hours, which were characterized by microstructural examination using electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM). These Al-Ga compositions were also evaluated using FactSage thermodynamic modeling to further elucidate the relationship between phase diagram behavior and LME.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Zurückgezogen: Glutarimidedioxime: A Complexing and Reducing Reagent for Plutonium Recovery from Spent Nuclear Fuel Reprocessing

Abstract Efficient separation processes for recovering uranium and plutonium from spent nuclear fuel are essential to the development of advanced nuclear fuel cycles. The performance characteristics of a new salt‐free complexing and reducing reagent, glutarimidedioxime (H 2 A), are reported for recovering plutonium in a PUREX process. With a phase ratio of organic to aqueous of up to 10:1, plutonium can be effectively stripped from 30 % tributyl phosphate (TBP) in kerosene into 1 m HNO 3 with H 2 A. The complexation‐reduction mechanism is illustrated with the combination of UV/Vis absorption spectra and the crystal structure of a Pu IV complex with the reagent. The fast stripping rate and the high efficiency for stripping Pu IV , through the complexation‐reduction mechanism, is suitable for use in centrifugal contactors with very short contact/resident times, thereby offering significant advantages over conventional processes.

Xian, Liang↗

DOE OSTI2016

Glutarimidedioxime: A Complexing and Reducing Reagent for Plutonium Recovery from Spent Nuclear Fuel Reprocessing

Xian, Liang↗

DOE OSTI2026

Radiation Effects in Next Generation Used Nuclear Fuel Reprocessing Strategies

With the global community committed to significantly expanding nuclear energy capacity, the development of efficient used nuclear fuel (UNF) management strategies has become more critical than ever. These strategies are vital to fostering the widespread adoption of closed fuel cycles, which are essential for sustainable nuclear energy production and security. Achieving this ambitious goal necessitates a comprehensive understanding of radiation effects on next-generation technologies, as radiolysis can often limit the longevity and performance of these systems. This seminar will provide an overview of next-generation UNF reprocessing strategies, highlighting the latest advancements and innovative approaches in the field. Particular attention will be given to two key areas of recent research: 1. Radiation robustness and performance of advanced sulfur chloride-based chlorination technologies. We will explore the efficacy of sulfur chloride-based chlorination processes in the presence of surrogate cladding materials, specifically aluminum. These processes have shown promise in the dissolution, decontamination, and recovery of cladding materials for reuse. Detailed findings on how the composition and performance of these sulfur chloride solvents respond to radiation exposure will be discussed. 2. Impacts of metal ion complexation and direct dissolution conditions on monoamide-based reprocessing strategies. We will delve into the time-resolved and dose accumulation effects of irradiation on the direct dissolution of voloxidized uranium and rhenium using N,N-di-(2-ethylhexyl) butyramide (DEHBA) or N,N-di-(2-ethylhexyl)isobutyramide (DEHiBA) in pre-equilibrated n-dodecane solvent. The implications of these interactions on dissolution efficiency, radiolytic stability, and overall process performance will be examined. These studies aim to underscore the importance of understanding radiation effects in the development of next-generation UNF reprocessing technologies and the global transition towards more sustainable and efficient nuclear energy systems.

38 - RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCL↗

DOE OSTI2018

Final Project Report (Oct 2014-Dec 2017): Zeolite Membranes for Krypton/Xenon Separation from Spent Nuclear Fuel Reprocessing Off-Gas

The overall focus of this project is to develop and understand SAPO-34 zeolitic membranes that can separate mixtures of radioisotope krypton-85 and xenon released as off-gases during used nuclear fuel recycling. The primary advantage of separating 85 Kr from Xe is to reduce the volume of radioactive waste for storage. The second advantage is the revenue generated from the sale of high-purity Xe. Zeolite membranes are attractive because of their much lower energy requirements relative to cryogenic distillation, and their high resistance to radiation degradation. We report the detailed study of silicoaluminophosphate zeolite SAPO-34 materials and membranes for this application, due to hypothesized favorable molecular sieving properties. In the 3-year Mission Support project, we developed a novel, high-performance, low-energy intensity, lower-cost zeolite membrane process for Kr/Xe separation during SNF processing; and investigated the underlying molecular adsorption and transport processes in both ‘idealized’ and ‘realistic’ operating conditions to develop reliable synthesis-structure-property relationships for such membranes. Adsorption and diffusion measurements on SAPO-34 crystals indicate their potential for use in Kr-Xe separation membranes, but also highlight competing effects of adsorption and diffusion selectivity. SAPO-34 membranes synthesized on α-alumina substrates via steam-assisted conversion seeding and hydrothermal growth are characterized in detail, with Kr permeances 26 GPU and ideal Kr/Xe selectivities >20 at 298 K after thickness reduction. Post-synthesis cation exchange shows large (>50%) increases in selectivity at ambient or slight sub-ambient conditions. In addition, we confirm that SAPO-34 membrane is stable under radiation exposure and the impact of radiation exposure on membrane performance would not be substantial. We also successfully synthesized hollow-fiber SAPO-34 membranes with the same performance levels as the disk-type and tubular membranes. This important development will allow a very compact and low-cost Kr/Xe separation system. Finally, a detailed process calculation for techno-economic analysis was performed by integrating Maxwell-Stefan model into cross-flow membrane system, in order to estimate the required number of membrane stages and the total cost.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025