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DOE OSTI2020

Separation of thorium, uranium, and rare earths from a strip solution generated from coarse coal refuse

This work systematically evaluated the separation performance of thorium, uranium, and rare earths when coal and coal byproduct were utilized as a non-traditional feedstock for rare earth production. A synthetic solution was prepared following the elemental composition of a strip solution generated from coarse coal refuse and used throughout the study. Various separation techniques including selective precipitation, solvent extraction, and a modified experimental protocol incorporating the two were applied to extract rare earths while minimizing the non-selective recovery of thorium and uranium into the product stream. Test results indicate that selective precipitation was effective for the removal of thorium at a pH value approaching 5 while solvent extraction preferentially removed uranium from rare earths. Therefore, a modified experimental protocol consisting of both selective precipitation and solvent extraction was subsequently developed and implemented. The findings following the modified experimental protocol indicate that extractant concentration, solvent extraction feed pH, and organic to aqueous (O/A) ratio all played a significant role in the removal of uranium. Among all the tests conducted, the best separation performance was achieved using a one-stage precipitation at a pH value of 4.8, 50 v% TBP, solvent extraction feed pH of 3.5, and an O/A ratio of 3, which corresponded to an overall rare earth, thorium, and uranium recovery of 79.6%, 0%, and 3.1%, respectively.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2016

Multistage bioassociation of uranium onto an extremely halophilic archaeon revealed by a unique combination of spectroscopic and microscopic techniques

The interactions of two extremely halophilic archaea with uranium were investigated in this paper at high ionic strength as a function of time, pH and uranium concentration. Halobacterium noricense DSM-15987 and Halobacterium sp. putatively noricense, isolated from the Waste Isolation Pilot Plant repository, were used for these investigations. The kinetics of U(VI) bioassociation with both strains showed an atypical multistage behavior, meaning that after an initial phase of U(VI) sorption, an unexpected interim period of U(VI) release was observed, followed by a slow reassociation of uranium with the cells. By applying in situ attenuated total reflection Fourier-transform infrared spectroscopy, the involvement of phosphoryl and carboxylate groups in U(VI) complexation during the first biosorption phase was shown. Differences in cell morphology and uranium localization become visible at different stages of the bioassociation process, as shown with scanning electron microscopy in combination with energy dispersive X-ray spectroscopy. Finally, our results demonstrate for the first time that association of uranium with the extremely halophilic archaeon is a multistage process, beginning with sorption and followed by another process, probably biomineralization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Molecular dynamics studies of grain boundary mobility and anisotropy in BCC γ-uranium

Grain morphologies such as grain size and aspect ratio in uranium-based metallic fuels are important microstructural features that can impact various fuel performance properties such as fission-gas-induced swelling, thermal transport, high burnup structure formation, and radiation resistance. Accurate prediction of the fuel grain morphologies requires knowledge of critical grain growth parameters such as grain boundary (GB) mobility and anisotropy. In this work, molecular dynamics simulations were performed to study the GB mobility and its anisotropy in pure body-centered-cubic (BCC) γ uranium. Nine GBs with different combinations of misorientation angles (20°, 30°, 45°) and rotation axes (<100>, <110>, <111>), as well as an additional <111> 38.2° GB were studied using three interatomic potentials. Here, it is found that the GB mobility anisotropy has complex trends, depending on both rotation axis and misorientation. However, in general the <110> rotation axis has the fastest GB mobility at the same misorientation. The results of this work can be used as not only baselines for future studies of GB mobility in uranium-based alloys such as uranium-molybdenum (U-Mo) fuels, but also input for mesoscale modeling of grain growth in uranium-based alloys.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Raman spectroscopy of uranium nitride kernels

Uranium nitride is an advanced fuel candidate for a wide variety of advanced nuclear reactors. This work summarizes the first characterization of UN kernels by Raman spectroscopy. First-principles density functional theory calculations were performed to predict the Raman spectra of uranium sesquinitride (U 2 N 3 ), uranium dinitride (UN 2 ), uranium mononitride (UN), uranium monocarbide (UC), as well as U-N-C (UN 1-x C x ) and a U-N-C-O mixture. Further, a core–shell structure was identified by scanning electron microscopy and Raman spectroscopy imaging. A signal at ~500 cm -1 was identified on the periphery of the core-shell structure, possibly corresponding to U 2 N 3 and/or UN 2 . This signal broadens and shifts to 470 cm -1 because of the formation of UNC, UNCO or U 2 N 3+x structures. The culmination of this work demonstrates the feasibility of using Raman spectroscopy to identify variations in composition and phases in UN kernels.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Investigation of potential polyatomic interferences on uranium isotope ratio measurements for the LS-APGD-Orbitrap MS system

The determination of actinide (e.g., U and Pu) content and isotopics is of importance to the nuclear forensics and safeguards communities. However, in the analysis of environmental samples, such as those collected by the International Atomic Energy Agency, uranium measurements can be complicated by isobaric interferences from polyatomic variants of heavy elements (e.g., Pb). This leads to complex, time-consuming sample manipulations (i.e., separations) before determining isotope ratios. An alternative strategy to sample pretreatment is to use high-resolution mass spectrometric platforms during the analysis to fully resolve the uranium isotopes from potential polyatomic interferences, negating the need for prior chemical separation. The liquid sampling - atmospheric pressure glow discharge (LS-APGD) coupled with an Orbitrap mass spectrometer provides a high-resolution (>70,000 m/Δm at m/z 200) inorganic mass spectrometry platform. Further, as a demonstration of the power of this instrumental platform, and indeed, the high-resolution approach in general, uranium isotope ratios were determined in the presence of elemental impurities (e.g., Pb, Pt, Ta, W) commonly encountered with environmental sample swipe analysis, without any prior treatment. Even at elemental impurity concentrations of 1000–5000× relative to uranium, no interference was observed with the 235 U or 238 U signal. In addition, the 235 U/ 238 U isotope ratio for the samples with the concomitants present are within 2 standard deviations of the values obtained without their addition, indicating that these impurities do not impact the determined uranium isotope ratio. These findings represent a significant first step in leveraging the high resolution of the LS-APGD-Orbitrap-MS to overcome isobaric and molecular interferences instead of relying on chemical separations.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2021

Rapid and automated separation of uranium ore concentrates for trace element analysis by inductively coupled plasma – optical emission spectroscopy/triple quadrupole mass spectrometry

The present study documents an automated approach to performing elemental analysis on a large group uranium ore concentrate (UOC) samples. In this work, 17 UOC samples, 2 quality control samples, and 26 process blanks were purified sequentially through a single 500 μL Uranium and TEtra Valent Actinides (UTEVA®) column. For each sample, the trace elemental impurities were separated from its dissolved uranium matrix on the UTEVA column and collected for analysis by inductively coupled plasma – optical emission spectroscopy / triple quadrupole mass spectrometry (ICP-OES/TQMS). The UTEVA column was subsequently regenerated prior to separation of the following sample. The column was efficiently regenerated, for each UOC, even after processing ~50 mg of uranium, cumulatively. The validity of the method was established by determining the trace impurities of two quality control uranium reference samples (CRM 124–1 and CUP-2). The current trace element measurements from the 17 UOC samples were compared to previously reported values from an interlaboratory comparison exercise, when available. The methodology employed here produces trace elemental analysis with excellent correlation to the previously reported data for many of the elements / samples, particularly when viewed through the context of existing geochemical comparisons tools (e.g. chondrite normalized variation plots).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2015

Uranium Removal from Seawater by Means of Polyamide 6 Fibers Directly Grafted with Diallyl Oxalate through a Single-Step, Solvent-Free Irradiation Process

In order to test the effectiveness of oxalate-based polymeric adsorbents in the recovery of uranium from seawater, diallyl oxalate (DAOx) was grafted onto nylon 6 fabrics by exposing the fabric, immersed in pure liquid DAOx or in a surfactant-stabilized dispersion of DAOx in water, to electron beam or gamma radiation. Following drying and weighing to determine the degree of grafting (DoG), the presence of oxalate in the fabrics was verified using XPS. Zeta potential measurements showed the fabric surfaces to be negatively charged. The fabrics were tested by rotating them for 7 days in a rotary agitator with actual seawater spiked with 0.2 or 1.0 mg∙L -1 uranium. The fraction of uranium in the solution which was removed due to uptake on the fabrics was found to rise with increasing DoG at both uranium concentrations. EDS measurements were used to map the distribution of adsorbed uranium on the polymeric fibers.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Uranium isotopes fingerprint biotic reduction

Knowledge of paleo-redox conditions in the Earth’s history provides a window into events that shaped the evolution of life on our planet. The role of microbial activity in paleo-redox processes remains unexplored due to the inability to discriminate biotic from abiotic redox transformations in the rock record. The ability to deconvolute these two processes would provide a means to identify environmental niches in which microbial activity was prevalent at a specific time in paleo-history and to correlate specific biogeochemical events with the corresponding microbial metabolism. Here, we demonstrate that the isotopic signature associated with microbial reduction of hexavalent uranium (U), i.e., the accumulation of the heavy isotope in the U(IV) phase, is readily distinguishable from that generated by abiotic uranium reduction in laboratory experiments. Thus, isotope signatures preserved in the geologic record through the reductive precipitation of uranium may provide the sought-after tool to probe for biotic processes. Because uranium is a common element in the Earth’s crust and a wide variety of metabolic groups of microorganisms catalyze the biological reduction of U(VI), this tool is applicable to a multiplicity of geological epochs and terrestrial environments. The findings of this study indicate that biological activity contributed to the formation of many authigenic U deposits, including sandstone U deposits of various ages, as well as modern, Cretaceous, and Archean black shales. In addition, engineered bioremediation activities also exhibit a biotic signature, suggesting that, although multiple pathways may be involved in the reduction, direct enzymatic reduction contributes substantially to the immobilization of uranium.

58 GEOSCIENCES↗

DOE OSTI2019

Prompt Neutron Decay Constant Measurements on a Copper Reflected Intermediate Enrichment Uranium System with Lead Intersitial

This work examines a set of prompt neutron decay constant measurements performed on the Zeus critical experiment. The Zeus experiment was designed to measure the lead void reactivity coefficient associated with an intermediate enrichment uranium system. The initial goal was to perform the measurements on a low enriched uranium system, but weight limitations on the Comet critical assembly only allowed for a system with 21%-22% effective uranium enrichment to be built. The Zeus critical experiment was performed on the Comet critical assembly machine located at the National Criticality Experiments Research Center (NCERC). The Comet critical assembly machine is a vertical lift assembly capable of supporting general large size critical experiments. This critical experiment consists of a copper reflector set most notably used in other configurations of the Zeus experiment series. The fuel used during the Zeus experiments consists of cylindrical highly enriched uranium (HEU) plates with a nominal 1/8-in. (0.318-cm) thickness. These plates were collocated with natural uranium plates to reduce the effective enrichment of the system to 21%-22%. Lead plates are interleaved between each fuel set.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2016

Subsurface Conditions Controlling Uranium Incorporation in Iron Oxides: A Redox Stable Sink

Toxic metals and radionuclides throughout the U.S. Department of Energy Complex pose a serious threat to ecosystems and to human health. Of particular concern is the redox-sensitive radionuclide uranium, which is classified as a priority pollutant in soils and groundwaters at most DOE sites owing to its large inventory, its health risks, and its mobility with respect to primary waste sources. The goal of this research was to contribute to the long-term mission of the Subsurface Biogeochemistry Program by determining reactions of uranium with iron (hydr)oxides that lead to long-term stabilization of this pervasive contaminant. The research objectives of this project were thus to (1) identify the (bio)geochemical conditions, including those of the solid-phase, promoting uranium incorporation in Fe (hydr)oxides, (2) determine the magnitude of uranium incorporation under a variety of relevant subsurface conditions in order to quantify the importance of this pathway when in competition with reduction or adsorption; (3) identify the mechanism(s) of U(VI/V) incorporation in Fe (hydr)oxides; and (4) determine the stability of these phases under different biogeochemical (inclusive of redox) conditions. Our research demonstrates that redox transformations are capable of achieving U incorporation into goethite at ambient temperatures, and that this transformation occurs within days at U and Fe(II) concentrations that are common in subsurface geochemical environments with natural ferrihydrites—inclusive of those with natural impurities. Increasing Fe(II) or U concentration, or initial pH, made U(VI) reduction to U(IV) a more competitive sequestration pathway in this system, presumably by increasing the relative rate of U reduction. Uranium concentrations commonly found in contaminated subsurface environments are often on the order of 1-10 μM, and groundwater Fe(II) concentrations can reach exceed 1 mM in reduced zones of the subsurface. The redox-driven U(V) incorporation mechanism may help to explain U retention in some geologic materials, improving our understanding of U-based geochronology and the redox status of ancient geochemical environments. Additionally, U(VI) may be incorporated within silicate minerals though encapsulation of U-bearing iron oxides, leading to a redox stable solid. Our research detailing previously unrecognized mechanism of U incorporation within sediment minerals may even lead to new approaches for in situ contamination remediation techniques, and will help refine models of U fate and transport in reduced subsurface zones.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2018

Advances in the Recovery of Uranium from Seawater: Studies Under Real Ocean Conditions

The objective of this project was to move the testing of uranium adsorbents from the laboratory to the field. We were successfully able to test fibers in both a flume and ocean environment under varying conditions to quantify the adsorptive properties and uranium uptake of adsorbents under coastal ocean conditions. Through this testing we have identified numerous challenges to be overcome prior to large-scale deployment of these fibers This project began in Phase I with laboratory experiments examining the effects of flow rates and water filtration on the absorption of uranium to fibers in flowthrough columns. In this experiment we found that fibers adsorb most efficiently at a flow rate of 250 ml/min, on a per liter basis. However faster flow rates increase exposure volume and allowed for slightly greater total U absorption. Therefore a balance between current speeds that are too fast and potentially break down fibers and those that are slower will be important to consider, alongside bio-fouling and exposure time, when deciding which current regimes are best to place fibers in the ocean. Phase II examined biofouling, comparing exposure of fibers in filtered flume water to that in a coastal ocean environment. Results from the dock and flume parallel experiment indicate a strong effect of biofouling on the capacity of the adsorbent fibers to adsorb uranium towards the very end of the experiment. Dock and flume samples showed comparable adsorption rates with the flume maximum achieved at day 49 with an adsorbance of 3.4 g U/kg-ads while the dock maximum was reached at day 42 with an adsorbance of 2.7 g U/kg-ads. Biofouling mitigation techniques were also examined. A comparison of 5 m and 12 m samples showed less growth at 12 meters where there is less light as well as less growth on the copper cages, which are toxic to many marine organisms. Overall despite biofouling, particles and other elements present, the fibers adsorbed uranium up to 2.7 g U/kg-ads in our open water dock experiments. This is lower than the maximum achieved in the flume of 3.4 g U/kg-ads and much lower than rates observed with synthetic seawater in laboratory experiments. Phase III involved two parts: working at Woods Hole Oceanographic Institution (WHOI) we examined the feasibility of reusing fibers after ocean deployment. Fiber reuse is an important consideration for operational costs associated with deployment. At present our data implies that reuse after open ocean exposure may not be significantly more effective than a single long deployment of fibers. The second part of Phase III involved collaboration with A. Slocum and M. Haji at MIT to examine the effects of various enclosures for fibers. This also involved testing a rotating system, designed to be deployed as part of an offshore wind turbine.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2020

A Rapid and High Throughput MIC Determination Method to Screen Uranium Resistant Microorganisms

The assessment of minimum inhibitory concentration (MIC) is a conventional technique used for the screening of microbial resistance against antibiotics, biocides, and contaminants such as heavy metals. However, as part of our ongoing work, we have observed biases associated with using traditional liquid MIC method to screen microbial heavy metal resistance, including both bacterial and fungal strains. Specifically, the addition of uranium into synthetic media causes immediate precipitation prior to the initiation of microbial growth, thus hampering the optical density measurements, and the obtained MIC values are thus flawed and inaccurate. To address this discrepancy, we report the optimization and development of a serial-dilution-based MIC method conducted on solid growth media supplemented with uranium, which is more accurate, relative to the testing of MICs performed in liquid cultures. Notably, we report on the efficacy of this method to screen not only bacteria that are resistant to uranium but also demonstrate the successful application to yeast and fungal isolates, for their ability to resist uranium, is more accurate and sensitive relative to the liquid method. We believe that this newly developed method to screen heavy metal resistance, such as uranium, is far superior to the existing liquid MIC method and propose replacing the liquid assay with the solid plate MIC reported herein.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Remote Detection of Uranium Using Self-Focusing Intense Femtosecond Laser Pulses

Optical measurement techniques can address certain important challenges associated with nuclear safety and security. Detection of uranium over long distances presents one such challenge that is difficult to realize with traditional ionizing radiation detection, but may benefit from the use of techniques based on intense femtosecond laser pulses. When a high-power laser pulse propagates in air, it experiences collapse and confinement into filaments over an extended distance even without external focusing. In our experiments, we varied the initial pulse chirp to optimize the emission signal from the laser-produced uranium plasma at an extended distance. While the ablation efficiency of filaments formed by self-focusing is known to be significantly lower when compared to filaments produced by external focusing, we show that filaments formed by self-focusing can still generate luminous spectroscopic signatures of uranium detectable within seconds over a 10-m range. The intensity of uranium emission varies periodically with laser chirp, which is attributed to the interplay among self-focusing, defocusing, and multi-filament fragmentation along the beam propagation axis. Grouping of multi-filaments incident on target is found to be correlated with the uranium emission intensity. The results show promise towards long-range detection, advancing the diagnostics and analytical capabilities in ultrafast laser-based spectroscopy of high-Z elements.

42 ENGINEERING↗

DOE OSTI2017

Uranium Bio-Transformations: Chemical or Biological Processes?

Uranium bio-transformations are the many and varying types of interactions that microbes can have with uranium encountered in their environment. In this review, bio-transformations, including reduction, oxidation, respiration, sorption, mineralization, accumulation, precipitation, biomarkers, and sensors are defined and discussed. Consensus and divergences are noted in bioavailability, mechanism of uranium reduction, environment, metabolism and the type of organism. The breadth of organisms with characterized bio-trans formations is also cataloged and discussed. We further debate if uranium biotransformations provide bio-protection or bio-benefit to the microbe and highlight the need for more work in the field to understand if microbes use uranium reduction for energy gain and growth, as having the ability is separate from exercising it. The presentation centers on the fundamental drivers for these processes with an additional exposition of the essential contribution of inorganic chemistry techniques to the molecular characterization of these biological processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2016

Uranium and strontium fate in waste-weathered sediments: Scaling of molecular processes to predict reactive transport

Objectives of the project: 1. Determine the process coupling that occurs between mineral transformation and contaminant (U and Sr) speciation in acid-uranium waste weathered Hanford sediments. 2. Establish linkages between molecular-scale contaminant speciation and meso-scale contaminant lability, release and reactive transport. 3. Make conjunctive use of molecular- to bench-scale data to constrain the development of a mechanistic, reactive transport model that includes coupling of contaminant sorption-desorption and mineral transformation reactions. Hypotheses tested: - Uranium and strontium speciation in legacy sediments from the U-8 and U-12 Crib sites can be reproduced in bench-scale weathering experiments conducted on unimpacted Hanford sediments from the same formations. - Reactive transport modeling of future uranium and strontium releases from the vadose zone of acid-waste weathered sediments can be effectively constrained by combining molecular-scale information on contaminant bonding environment with grain-scale information on contaminant phase partitioning, and meso-scale kinetic data on contaminant release from the waste-weathered porous media. - Although field contamination and laboratory experiments differ in their diagenetic time scales (decades for field vs. months to years for lab), sediment dissolution, neophase nucleation, and crystal growth reactions that occur during the initial disequilibrium induced by waste-sediment interaction leave a strong imprint that persists over subsequent longer-term equilibration time scales and, therefore, give rise to long-term memory effects. Enabling capabilities developed: Our team developed an iterative measure-model approach that is broadly applicable to elucidate the mechanistic underpinnings of reactive contaminant transport in geomedia subject to active weathering. Experimental design: Hypotheses were tested by comparing (with a similar set of techniques) the geochemical transformations and transport behaviors that occured in bench-scale studies of waste-sediment interaction with parallel model systems studies of homogeneous nucleation and neo-phase dissolution. Initial plans were to compare results with core sample extractions from the acid uranium waste impacted U-8 and U-12 Cribs at Hanford (see original proposal and letter of collaboration from J. Zachara). However, this part of the project was impossible because funding for core extractions were eliminated from the DoE budget. Three distinct crib waste aqueous simulants (whose composition is based on the most up-to-date information from field site investigations) were reacted with Hanford sediments in batch and column systems. Coupling of contaminant uptake to mineral weathering was monitored using a suite of methods both during waste-sediment interaction, and after, when waste-weathered sediments were subjected to infusion with circumneutral background pore water solutions. Our research was designed to adapt as needed to maintain a strong dialogue between laboratory and modeling investigations so that model development was increasingly constrained by emergent data and understanding. Potential impact of the project to DOE: Better prediction of contaminant uranium transport was achieved by employing multi-faceted lines of inquiry to build a strong bridge between molecular- and field-scale information. By focusing multiple lines and scales of observation on a common experimental design, our collaborative team revealed non-linear and emergent behavior in contaminated weathering systems. A goal of the current project was to expand our modeling capabilities, originally focused on hyperalkaline legacy waste streams, to include acidic weathering reactions that, as described above, were expected to result in profoundly different products. We were able to achieve this goal, and showed that these products nonetheless undergo analogous silicate and non-silicate transformation, ripening and aging processes. Our prediction that these weathering reactions would vary with waste stimulant chemistry resulted in data that was incorporated directly into a reactive transport model structure.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2017

ADVANCED TEST REACTOR (ATR) CONVERSION TO LOW ENRICHED URANIUM (LEU) FUEL

The United States Department of Energy (DOE), National Nuclear Security Administration (NNSA), Office of Material Management and Minimization (MMM) is working to convert research reactors globally from highly enriched uranium (HEU) fuel to low-enriched uranium (LEU) fuel. MMM and its predecessor programs have converted or verified the shutdown of 88 HEU research reactors and isotope production facilities, using LEU fuel developed in the 1980s. However, there is a small set of high performance research reactors which require a new high density LEU fuel for conversion, including six U.S. high performance research reactors (USHPRRs), which include the Advanced Test Reactor (ATR) and the ATR Critical (ATRC) Facility at the Idaho National Laboratory (INL) near Idaho Falls, ID; University of Missouri Research Reactor (MURR) at Columbia, MO; Massachusetts Institute of Technology Reactor (MITR) at MIT in Cambridge, MA; High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) near Oak Ridge, TN; and National Bureau of Standards Reactor (NBSR) at the National Institute of Standards and Technology (NIST) Center for Neutron Research (NCNR) in Gaithersburg, MA. These reactors will share the same uranium-molybdenum (U-Mo) fuel plate design. The U-Mo fuel meat foil will have a zirconium (Zr) diffusion barrier with aluminum cladding. Three different application methods for the Zr diffusion barrier layer are being pursued – co-rolled, electroplating and plasma spraying. Fabrication of the higher density LEU U-Mo fuel has presented several challenges. Because the U-Mo fuel fabrication process uses the existing stockpile of 93% highly enriched uranium (HEU) to be blended with molybdenum and depleted uranium (DU) to form 19.75% LEU, cost benefits of enriching to 19.75% will not be realized. Homogeneity of the U-235 and molybdenum in the metal foil is a challenge due to U-Mo casting process results in variations between adjacent cast U-Mo plates. LEU will not require less U-235 as previously believed due to self-shielding properties of U-238 requiring additional U-235 to be loaded in each fuel element. Although the overall dimensions of the ATR fuel element remain unchanged, the weight of the LEU ATR fuel element is 72% greater than a HEU ATR fuel element. During waste recovery and recycling efforts, separation of aluminum cladding from the HEU fuel meat is a relatively simple chemical dissolution, however, separation of the Zr diffusion barrier from the U-Mo fuel meat is significantly more challenging.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

URANIUM ACCUMULATIONS IN CASTING OPERATIONS

In December 2017, unexpected accumulations of uranium were discovered in several locations throughout the casting process area at the Y-12 National Security Complex that subsequently placed casting operations on hold. The Y-12 uranium casting process takes place in enclosures and hoods, many of which are open to a large floor surface area that has limited visibility and access. At the time of discovery, there were no Nuclear Criticality Safety (NCS) analyses or limits for material accumulations in the casting processing areas. Due to changes in the operation of the casting process and invalid assumptions in the criticality safety evaluation, significant material accumulations were occurring inside the enclosures. The material accumulations were identified as a result of an extent of condition review from another process, and an occurrence report was filed. The NCS organization worked with Production and Operations personnel to identify additional areas of uranium accumulation in the casting area, which resulted in several iterations of cleaning and material collection. Following material recovery, a causal analysis was performed that identified several contributing factors that allowed the accumulations to go unnoticed. In order to resume operations, the criticality safety evaluation was revised to analyze and control uranium accumulations in the casting area. Additionally, improvements in nuclear material control and accountability (NMC&A) controls were required. Casting operations have since resumed with frequently required material collections, which have limited the amount of uranium material accumulation.

42 ENGINEERING↗

DOE OSTI2019

URANIUM ACCUMULATIONS IN CASTING OPERATIONS

61 RADIATION PROTECTION AND DOSIMETRY↗