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DOE OSTI2025

Application of Advanced Materials Processing to Enable Direct Production of Fast Reactor Fuel Alloys

Argonne National Laboratory (the Contractor), located in Lemont, IL, and Oklo, Inc. (the Participant), headquartered in Sunnyvale, CA, entered into a Cooperative Research and Development Agreement (CRADA) to integrate advanced electrorefining co-deposition and molten-salt monitoring technologies to produce a uranium-transuranic (U/TRU) alloy within a controlled composition range that can be used as fast reactor fuel for Oklo, Inc.’s advanced reactor technology. Argonne performed the integration of electrorefining and process monitoring technologies, determined operating parameters for producing U/TRU alloys, and developed optimized design and operating parameters for co-deposition of U/TRU alloys. Oklo, Inc. worked with Argonne and the Nuclear Regulatory Commission (NRC) to provide the necessary process documentation to begin implementing pyroprocessing technology in the fast reactor fuel production process. Outcomes of this project included a pilot-scale co-deposition cathode design and technical basis for the operation of the co-deposition electrorefiner to produce U/TRU alloys with controlled composition.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Bonding Environments and Radiation Stabilities of Phosphate Glasses

This report is a summary of some key take-aways presented during the Phosphate Round Table Workshop held in 2020, which was led by PNNL and ANL and funded by DOE-NE. Phosphate glasses have a wide range of commercial and industrial uses due to their unique optical, chemical, and physical properties. They are a candidate material for use as an advanced waste form matrix for immobilizing radioactive waste due to their unique ability to immobilize high fractions of alkali- and sulfur-rich streams in chemically durable glasses. This literature review provides an overview of the structure of phosphate glasses, waste-form related properties of interest (e.g., chemical durability and radiation stability), a summary of how specific composition ratios affect chemical durability (e.g., [Fe]/[P] ratio, [O]/[P] ratio, Fe 2+ /Fe 3+ ratio), as well different ways that phosphate glasses can be affected by radiation. All of these are of interest to the waste form community as phosphate glasses, primarily Fe-P-O glasses, are investigated for usage in immobilizing various types of nuclear waste including U.S. legacy wastes as well as a method for treating salt-based high-level wastes from molten salt reactors and pyroprocessing of used nuclear fuels.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Effect of moisture ingression on material performance and particle generation in molten salts

This report summarizes activities conducted to understand and mitigate the negative consequences that moisture ingressions have upon the operations of pyroprocessing equipment. The objectives of the work conducted in FY25 were to characterize (1) the physicochemical properties of particles generated as a result of moisture ingressions, and (2) the corrosion of relevant structural materials with the introduction of moisture. Compositional and morphological analyses of the generated particles were conducted through a suite of characterization technologies, including X-ray diffraction, microscopy, and particle size analysis. The results gathered this year were compared to those obtained in FY24 when studies with oxygen ingressions were conducted on CeCl 3 -LiCl-KCl and UCl 3 -LiCl-KCl systems. Investigations involving performance evaluations of industrially relevant structural alloys were also conducted under moisture ingress conditions. In-line electrochemical monitoring of the bulk salt was augmented with microscopy of alloy samples to quantify the concentration and accumulation of corrosion products in the bulk salt. The results reported in this work provide a more holistic understanding of the effects of atmospheric ingressions on molten chloride salt chemistry such that effective redox control strategies may be implemented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Finding ways to reduce nuclear waste: searching for the unknown one step at a time

In my home country, Venezuela, research has been stagnant. Due to the political turmoil and the crisis, many educated people have left the country in search for a better life. This has caused a deficit in any technological and scientific advances, making Venezuela one of the first South American countries to have its rate of publications decline by 29% in 2013. Currently, Venezuela lacks the infrastructure and the means to keep up with the research progress as compared to other countries in South America, such as Brazil. Since coming to the United States (US), and currently working for a national laboratory, the active research environment endorses a wide range of careers and engineering programs that allow researchers to thrive at any given field. Researchers have access to funds and tools to succeed in developing materials for the future. There are 17 national laboratories in the US, and all of these have a different research focus/objective. As examples, Los Alamos National Laboratory and Sandia National Laboratory focus is on national homeland security, weapon science, radiation effects, among others. Argonne National Laboratory focuses on nuclear energy, energy storage, high performance computing, etc. At Idaho National Laboratory (INL) the research focuses on innovating nuclear energy and clean energy resources, critical infrastructure materials, along with fuel cycle solutions to manage, dispose and find ways to recycle current and future radiological waste. Compared to other national laboratories, INL focuses slightly more on applied processes and how nuclear energy can be innovated to next reactor design and technologies. The research being conducted at INL made me apply for a Seaborg distinguished postdoctoral position. For the position itself, the researcher must submit a proposal related to actinide chemistry on a research field area. In this position, 50% of my time will be focused on my own proposal. The proposal that I am working on is focused on the innovation of nuclear energy and fuel cycle recycling, which is why I was mainly interested on working at this national laboratory. To give a bit more context of what my proposal is about, a little bit of background is necessary: After the nuclear fuel (UO2) is used in a reactor, the fuel matrix is then characterized by various fission products (FP). Among these FP (including rare earth elements, alkali/alkaline earths, and actinides), many can potentially be recovered through nuclear reprocessing technologies. In pyroprocessing, the used nuclear fuel undergoes electrochemical dissolution into a molten chloride salt mixture in an electrorefiner. Initially, uranium is reduced onto an inert cathode by applied potentials. However, numerous remaining FPs accumulate in the melt and pose challenges for recovery by an inert electrode, particularly the rare earth elements (e.g., Nd, Gd, Pr, Sm) due to their multivalent oxidation states and tendencies toward side reactions, leading to their dissolution in the electrolyte. These recovery challenges result in inefficiencies and necessitate the continual discarding of the molten chloride salt, thereby generating additional waste. Furthermore, the presence of rare earth elements and other fission products in the molten salt electrolyte alters its physical and chemical properties, affecting both uranium recovery efficiency and the longevity of the molten chloride salt. To improve the recovery efficiency of the FP, specifically rare earth elements, I am investigating the fundamental interactions between rare earth elements in the molten chloride salt and their metallic form. The kinetic pathways and the chemical reactions of these elements will give insights on how the recovery efficiency can be improved. The interactions and speciation of these elements are being studied by spectro-electrochemistry at high temperature environments in quartz and other ceramic materials (e.g., alumina crucibles). Some of the challenges I am facing specifically relates the reactivity of some of these elements with different glass and crucible materials. Although my research focuses on fundamental science, it will benefit the applied process by generating new scientific knowledge and closing the gap for an efficient recycling of the waste: one step at a time.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Imaging and Analysis of Insoluble Electrorefiner Material

Throughout pyroprocessing efforts at the Hot Fuel Examination Facility (HFEF), insoluble material has accumulated in the Electrorefiner (ER) vessel. The objective of this effort was to analyze the accumulated material to determine its origin. Material was removed from the ER salt bath and distilled to remove excess salt prior to performing analysis. Three samples were sent for chemical and isotopic analysis and underwent an ethyl acetate-bromine dissolution to segregate the oxide fraction from the metal fraction. Actinide concentrations were determined using a quadrupole–inductively coupled plasma–mass spectrometer (Q-ICP-MS). Three additional samples were sent for morphologic and elemental analysis by scanning electron microscopy (SEM) with Energy Dispersive X-ray (EDX) analysis at the Irradiated Materials Characterization Laboratory (IMCL). Analyses suggest that the material is primarily composed of UO2. with a small fraction of metal. This study draws no single conclusion as to the origin of the insoluble material in the ER. The particle sizes and morphologies observed in SEM micrographs indicate that the larger particles observed may be a result of introducing material to the ER that has not been completely reduced in Oxide Reduction (OR) operations, which precede electrorefining. Smaller particles may be due to reactions with oxygen and moisture present in HFEF. This research suggests that microscopic analysis of fuel particles before and after OR operations (including after distillation) as well as the uranium product collected on the cathode in the ER would increase understanding about particle morphology within the pyrochemical process.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Direct Processing of Lithium Chloride Based Waste Salt in a Ceramic Waste Form

Ceramic waste form materials were fabricated with a LiCl based salt mixture to demonstrate the suitability of direct processing of waste salt from an all LiCl pyroprocessing flow sheet on the formation, microstructure, and durability of ceramic waste forms. Materials were successfully synthesized by using the simplified direct processing technique with salt loadings of 5, 7.5, and 10 wt% at the laboratory scale. Materials fabricated with LiCl based salt indicated full conversion of zeolite to sodalite occurred to form products with low open porosity. This indicates that the Na 2 O content of NBS4 glass is suitable for processing salt chemistries which do not contain NaCl. Generated sodalite was microencapsulated by the glass binder, halite occlusions were detected within sodalite domains at all salt loadings, and a Cs-rich phase believed to be Cs-pollucite was detected in the material made with the lowest salt loading (5 wt%). Salt inclusions were encapsulated within the binder glass at all loadings, and found to consist primarily of NaCl with Cs present. A small amount of salt was found at the surface of the wasteform made with the highest salt loading of 10 wt%, which may indicate an upper limit to the amount of salt that can be accommodated or incomplete mechanical mixing of the reagents. Durability testing by using the ASTM C1308 method indicated that initial rapid dissolution of exposed halite inclusion phases was directly correlated to salt loading. Wasteform degradation during all tests occurred primarily due to dissolution of the sodalite phase. Durability of the binder glass was found to increase as the waste salt loading increased. Results for the release of cations from the salt indicate the changes in wasteform durability and halite inclusion chemistry are strongly influenced by ion exchange phenomena between the salt and the glass. This appears to be the result of the relatively stronger affinity for the glass phase of Li, compared to that of other cations such as Na and Cs. The effects from cation exchange were diminished at lower salt loadings.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Crossroads of Nonproliferation and Safeguarding Technologies for Implementation in Molten Salt Reactors

Idaho National Laboratory (INL) recently conducted a workshop endorsed by the National Nuclear Security Administration (NNSA) under the auspices of the Defense Nuclear Nonproliferation R&D (DNN R&D) Office's Safeguards Portfolio. The workshop's primary objective was to foster an engaging dialogue among researchers, with a specialized emphasis on the safeguards pertaining to molten salt reactors. At INL, the installation of the state-of-the-art Molten Salt Thermophysical Examination Capability (MSTEC) is underway. This shielded argon glovebox facility, designed for both irradiated and non-irradiated actinide materials, represents the cutting edge of research infrastructure. MSTEC is poised to serve as a pivotal research platform in the realm of molten salt technology, with significant implications for safeguards applications. Participants of the workshop had the opportunity to tour the facilities, including the site where MSTEC is being installed, as well as to observe the INL's molten salt and pyroprocessing research hot cells. The event featured insightful presentations delving into molten salt chemistry and the MSTEC project. Each participating laboratory contributed to the discourse with presentations on their respective research efforts addressing safeguards in relation to molten salt reactors. The workshop culminated with a generative brainstorming session, where participants shared their thoughts on strategic integration with partner agencies, aiming to synergize efforts in advancing the field of nuclear safeguards.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Advanced Facility Design and AI/ML Enabled Safeguards to Establish Secure, Economical Recycling of Fast Reactor Fuels (Final Scientific/Technical Report)

The project, "Advanced Facility Design and AI/ML Enabled Safeguards to Establish Secure, Economical Recycling of Fast Reactor Fuels," represents a significant advancement in nuclear fuel recycling technology. It integrates cutting-edge multimodal sensor fusion, machine learning (ML), and digital twin (DT) technologies to address challenges in material safeguarding, process optimization, and regulatory compliance for pyroprocessing facilities. This research has significantly enhanced the understanding of pyrochemical fuel recycling processes by developing innovative tools and methodologies. The Multimodal Safeguards Monitoring Unit (MSMU) combines electroanalytical techniques, Raman spectroscopy, and differential thermal analysis (DTA) to enable high-fidelity, near-real-time material accountancy measurements. Machine learning techniques, such as Long Short-Term Memory (LSTM) autoencoders, are utilized to detect anomalies in material balances and sensor data, improving the reliability of safeguards monitoring. Additionally, digital twin technology has been established to provide real-time system-level monitoring and diagnostics, integrating physics-based models with sensor data to optimize process safety and efficiency.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

The Role of Low-Carbon Fuels and Carbon Capture in Decarbonizing the U.S. Clinker Manufacturing for Cement Production: CO2 Emissions Reduction Potentials

Low-carbon fuels, feedstocks, and energy sources can play a vital role in the decarbonization of clinker production in cement manufacturing. Fuel switching with renewable natural gas, green hydrogen, and biomass can provide a low-carbon energy source for the high-temperature process heat during the pyroprocessing steps of clinker production. However, up to 60% of CO2 emissions from clinker production are attributable to process-related CO2 emissions, which will need the simultaneous implementation of other decarbonization technologies, such as carbon capture. To evaluate the potential of fuel switching and carbon capture technologies in decarbonizing the cement industry, a study of the facility-level CO2 emissions is necessary. This study evaluates the potential for using a single low-carbon fuel as an energy source in clinker production for cement manufacturing compared to conventional clinker production (which uses a range of fuel mixes). In addition, conventional carbon capture (operated with natural gas-based steam for solvent regeneration) and electrified carbon capture configurations were designed and assessed for net-zero emission targets. Carbon emissions reductions with and without biogenic emissions credits were analyzed to ascertain their impact on the overall carbon accounting. Results show that carbon emissions intensity of cement can vary from 571 to 784 kgCO2eq/metric ton of cement without carbon capture and from 166.33 to 438.66 kgCO2eq/metric ton of cement with carbon capture. We find that when biogenic carbon credits are considered, cement production with a sustainably grown biomass as fuel source coupled with conventional carbon capture can lead to a net-negative emission cement (−271 kgCO2eq/metric ton of cement), outperforming an electrified capture design (35 kgCO2eq/metric ton of cement). The carbon accounting for the Scope 1, 2, and biogenic emissions conducted in this study is aimed at helping researchers and industry partners in the cement and concrete sector make an informed decision on the choice of fuel and decarbonization strategy to adopt.

42 ENGINEERING↗
DOE OSTI2024

Role of Hydrogen as Fuel in Decarbonizing US Clinker Manufacturing for Cement Production: Costs and CO2 Emissions Reduction Potentials

As a low-carbon fuel, feedstock, and energy source, hydrogen is expected to play a vital role in the decarbonization of high-temperature process heat during the pyroprocessing steps of clinker production in cement manufacturing. However, to accurately assess its potential for reducing CO2 emissions and the associated costs in clinker production applications, a techno-economic analysis and a study of facility-level CO2 emissions are necessary. Assuming that up to 20% hydrogen can be blended in clinker fuel mix without significant changes in equipment configuration, this study evaluates the potential reduction in CO2 emissions (scopes 1 and 2) and cost implications when replacing current carbon-intensive fuels with hydrogen. Using the direct energy substitution method, we developed an Excel-based model of clinker production, considering different hydrogen–blend scenarios. Hydrogen from steam methane reformer (gray) and renewable-based electrolysis (green) are considered as sources of hydrogen fuel for blend scenarios of 5%–20%. Metrics such as the cost of cement production, facility-level CO2 emissions, and cost of CO2 avoided were computed. Results show that for hydrogen blends (gray or green) between 5% and 20%, the cost of cement increases by 0.6% to 16%, with only a 0.4% to 6% reduction in CO2 emissions. When the cost of CO2 avoided was computed, the extra cost required to reduce CO2 emissions is $229 to $358/ metric ton CO2. In summary, although green hydrogen shows promise as a low-carbon fuel, its adoption for decarbonizing clinker production is currently impeded by costs.

Okeke, Ikenna J.↗
DOE OSTI2023

Integration of Nuclear Material Accounting Data and Process Monitoring Data for Improvement on Detection Probability in Safeguarding Electrochemical Processing Facilities (Final Technical Report)

The KAERI advanced spent fuel conditioning process (ACP) process is a critical component of the US- South Korean nuclear cooperation and the following “123 Agreement.” Its development has received considerable attention in both countries. The ACP is an electrochemical processing (pyroprocessing) that recycles over 96% of the used nuclear fuel (UNF). It is also intrinsically proliferation-resistant in theory. In normal operation, the U/TRU product is very hot radiologically. In addition, the Cm provides a high level of spontaneous neutrons, making the product unsuitable for weapon use. However, as pointed in some study, “the need for safeguards to protect against the diversion and misuse of separated plutonium applies essentially equally to all grades of plutonium.” As pointed by many studies, the well-established traditional Nuclear Material Accounting (NMA) approach cannot be directly applied to electrochemical processing because of the lack of an input accountability tank, the non-continuous material flow, and the unsatisfactory level of confidence in sampling methods. Therefore, nuclear safeguards remain a grand challenge in the developing of commercial electrochemical separations facilities, especially around the heart of such facilities, the electrorefiner (ER) systems. In contrast to NMA data, process monitoring (PM) data is normally an indirect measurement of the SNM and is acquired much more frequently. In a broad sense, PM includes monitoring by various types of equipment, e.g. radiation detectors, cameras, voltage, current sensors. Because it is already being collected by the operator, the additional cost to safeguards is low. It has long been believed that PM data can supplement NMA data and help improve safeguards, although the benefits are hard to quantify. The U.S. DOE’s Material Protection, Accounting, and Control Technology (MPACT) campaign has made substantial investments into innovative PM sensor technology and predictive model development for real- or near real-time measurement and prediction of molten salt density and level, salt composition and actinide concentration especially Pu, the cell voltage, and the cell current to supplement traditional NMA. For aqueous-based reprocessing facilities, it is reported that PM, integrated with traditional NMA, have a high detection probability for specific diversions. For electrochemical reprocessing, preliminary studies have shown that PM data can support traditional NMA in various ways by providing a basis to estimate some of the in-processing nuclear material inventories. Despite early success, further studies on fusion of PM data and NMA data are still needed, which is the goal of this proposed work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Molten Salt Sampling Techniques and Analytical Approaches

Recent global interest in pyroprocessing and molten salt reactors has brought salt sampling methods and techniques back to the forefront of nuclear safeguards concerns. Issues with uranium supplies have also encouraged various countries to pursue advanced nuclear fuel cycles. Tracking nuclear material in molten salt has proven to be a challenge and updating molten salt sampling will greatly help in this endeavor. Molten salt is problematic to sample due to salt stratification, lack of homogeneity, solids, and difficulty with hot cell adaptations. Various salt sampling techniques have been used since before the 1960s including surface, spoon/spatula, and bar solidification. Since then, new types of sampling techniques have been developed to improve sampling results. These include rod/dip, pipet, suction, filtered sampling along with devices such as the Valve Core Sampler and the Multi-Level Sampler. These different approaches are being analyzed and improved upon along with developing requirements for an improved salt sampling device. Work continues to develop salt samplers that are more robust, easier to segment, collect at a specific depth, can work with filters, and can collect fines. Sampling parameters are also being narrowed in terms of stirring, settling time, filtration, depth, etc. In the future, we hope to address deficiencies for process control and nuclear material accountancy control by determining the best way to collect samples that minimizes contaminants and is representative. A compilation of salt sampling approaches, analyses techniques, and an evaluation of findings will be presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Electrochemical Characterization of Molten Salt Chemistry During Atmospheric Ingressions

This report describes the salt chemistry and sedimentation studies that were completed in FY23 as part of the Pyrochemical Fuel Cycles – ANL project. The primary objective of these activities was to employ electrochemical methods in order to quantify and gain insights into the reaction mechanisms associated with the interaction of O2 and moisture impurities with the molten chloride salts used for the pyrochemical processing of nuclear materials. If not monitored and controlled, the ingression of these atmospheric impurities can lead to changes in the salt redox conditions and initiate the formation of oxide particles, potentially resulting in operational and safeguards challenges. By elucidating the mechanisms underlying the formation of oxide particles, we can effectively monitor the conditions of the salt and design systems to mitigate the influence of atmospheric O2 and H2O. To achieve these goals, we designed a test system that allowed for precisely controlled gas ingressions into the molten salt vessel. This system included on-line monitoring provided by electrochemical probes that enable near real-time measurements of the salt conditions throughout the course of the experiment. Using this system, we systematically varied experimental conditions, including O2/Ar flow rates and O2 concentrations, to comprehensively understand their impact on solid particle formation. We also used a particle size and shape analyzer to characterize the particles that were generated. Tests in FY23 concentrated on the formation of CeO2 particles, but we also prepared a separate apparatus targeting UO2 particles for use in FY24. We additionally conducted extensive modeling activities in support of this work. This included multiphysics simulations of the gas ingressions along with the development of a machine learning workflow to enable accelerated molecular dynamics modeling of the molten salt chemistry of LiCl-KCl-UCl3. The combination of experimental and modeling tools has allowed us to begin to get a more complete understanding of the reactions that occur when atmospheric ingressions occur in pyroprocessing systems.

Guo, Jicheng↗
DOE OSTI2024

Nuclear waste reduction: Exploring new pathways one step at a time

In my home country of Venezuela, nuclear energy is not a topic that attracts much attention. The government briefly oversaw some nuclear energy programs during the 1950s, but currently there are no active nuclear power facilities in the country. In fact, the Venezuelan government signed and ratified the treaty of the prohibition of nuclear weapons in 2021, which states that Venezuela has never owned, possessed or controlled nuclear weapons or programs of any kind. When I moved to the United States, however, nuclear energy became an extremely relevant topic. In the 1940s, the U.S. government established and oversaw the Manhattan Project to build atomic bombs for use in World War II. After the war, the government encouraged scientists to use this information on nuclear reactions to develop nuclear energy for peaceful civilian purposes instead.1 During these early days of nuclear research, there were no formal regulatory standards for nuclear waste management. Policies usually were self-regulated and often created based on existing policies of disposal for non-nuclear waste.2 As a result, there were instances of nuclear waste leaching into the environment and affecting local communities. So, much research has been conducted since then to characterize and store nuclear waste safely and securely.3 I first became interested in nuclear energy during my undergraduate studies when I worked on a project involving ligand synthesis to help extract actinides from nuclear waste. I then studied electrochemistry in molten salt systems for nuclear energy applications during my Ph.D. As I approached graduation, I started looking into national laboratories that have programs involving nuclear energy and waste management. At Idaho National Laboratory (INL), the focus is more on applied processes and how nuclear energy can be innovated to realize next-generation reactor design and technologies. This focus led me to apply for a Seaborg distinguished postdoctoral position at INL, for which I was chosen based on my proposal of a way to improve nuclear waste recycling. To understand my proposal, we must familiarize ourselves with the makeup of nuclear waste. After uranium dioxide is used as nuclear fuel in a reactor, the fuel matrix is then characterized by various fission products, including rare earth elements, alkali and alkaline earths, and actinides. Some of these fission products can potentially be recovered through pyroprocessing, 4 which involves the electrochemical dissolution of the used nuclear fuel in a molten chloride salt mixture at high temperatures. Though some of the fission products can be easily recovered—for example, uranium is reduced onto an inert cathode by applied potentials—numerous other fission products such as rare earth elements are difficult to recover due to their multivalent oxidation states and side reactions.5 To improve the recovery efficiency of rare earth elements specifically, I proposed investigating the fundamental interactions between rare earth elements in the molten chloride salt and their metallic form (Figure 1). The kinetic pathways and the chemical reactions of these elements, which will be elucidated through spectro-electrochemistry at high temperatures, will give insights on how the recovery efficiency can be improved. Although my research focuses on fundamental science, it will benefit the applied process by generating new scientific knowledge and closing the gap for efficient recycling of the waste: one step at a time.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Bubbler Design Updates for Nuclear Safeguards Applications

The accurate monitoring of molten salt compositions is crucial for nuclear safeguards, particularly in the context of mixtures used in molten salt reactors as well as pyroprocessing. However, for nuclear material accountancy in actinide bearing molten salts, the solution volume is also needed to determine the total mass of material in the salt. This study explores the effectiveness of two bubbler configurations, triple and single, for density and level measurements within these molten salts for salt volume determinations. The triple bubbler system utilizes three gas dip-tubes strategically positioned at different heights within the molten salt. With this design, the molten salt level, density, and surface tension can be determined simultaneously. The single bubbler configuration, on the other hand, relies on a dynamic single dip-tube to determine the density and level. Both configurations will be tested in aqueous solutions as well as in LiCl-KCl and NaCl-MgCl2 molten salts between 450°C and 750°C. Dip-tube diameters and bubbler inferences will also be explored. A new bubbler is being designed based on results. The findings of this study will provide valuable insights into the optimal bubbler design and configuration for ensuring representative sampling of molten salt compositions in nuclear safeguards applications. This will contribute to enhanced accountability and transparency in the monitoring of actinide bearing molten salts, promoting nuclear safeguards objectives.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Undercooling minimization in ultrasound coupled DTA measurements of molten salts

Molten salts are ionic liquids that are used for the electrolytic pyroprocessing of metals and as heat transfer fluids in very high temperature processes. Recently, halide-based molten salt reactors (MSR) have gained momentum for high density and environmentally responsible electricity generation. The function of these reactors and their fuel cycle depend on a knowledge of the halide salt’s thermodynamic properties [1]. Therefore, high accuracy phase equilibria of MSR relevant base halide and actinide containing salts are needed. Modern thermal analysis of the phase transitions of halide salts is usually done during heating at relatively high scan rates with commercial devices. Normally such measurements are adequate for pure or pseudo-binary salts. However, as the number of components in the mixture increases, accurately resolving the liquidus becomes increasingly difficult. Reversing the scanning mode greatly increases the sensitivity of phase transition measurements but can decrease accuracy due to undercooling [2] — a common occurrence in molten halide systems [3]. This work presents the development of a differential thermal analysis (DTA) cell intended for use in radiological gloveboxes. Non-contact ultrasonic agitation of the halide salt is implemented to limit kinetic limitations on crystallization during cooling to minimize undercooling [4]. Measurements on halide salts are also presented to elucidate the effect of non-contact mixing on undercooling. Reference [1] S. Boyd and C. Taylor, “3 - Chemical fundamentals and applications of molten salts,” in Molten Salt Reactors and Thorium Energy, T. J. Dolan, Ed., Woodhead Publishing, 2017, pp. 29–91. doi: 10.1016/B978-0-08-101126-3.00003-8. [2] K. Nitsch, A. Cihlár, and M. Rodová, “Molten state and supercooling of lead halides,” J. Cryst. Growth, vol. 264, no. 1, pp. 492–498, Mar. 2004, doi: 10.1016/j.jcrysgro.2004.01.011. [3] L. Rycerz, “Practical remarks concerning phase diagrams determination on the basis of differential scanning calorimetry measurements,” J. Therm. Anal. Calorim., vol. 113, no. 1, pp. 231–238, Jul. 2013, doi: 10.1007/s10973-013-3097-0. [4] Md. H. Zahir, S. A. Mohamed, R. Saidur, and F. A. Al-Sulaiman, “Supercooling of phase-change materials and the techniques used to mitigate the phenomenon,” Appl. Energy, vol. 240, pp. 793–817, Apr. 2019, doi: 10.1016/j.apenergy.2019.02.045.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Time dependent chlorination of CeO 2 , La 2 O 3 and Nd 2 O 3 by ZrCl 4 dissolved in eutectic LiCl–KCl

Partial chlorination of CeO 2 , La 2 O 3 , and Nd 2 O 3 was achieved using ZrCl 4 dissolved in molten LiCl-KCl at 450°C over a period of 4-5 hr. ZrCl 4 was pre-volatilized into an argon stream to maintain a constant vapor pressure for equilibration with the salt. This approach was effective at maintaining the ZrCl 4 concentration at the solubility limit of 1.3 mol% in the molten salt throughout the duration of two of the chlorination experiments and within about 60% of the solubility limit in the third experiment. Based on the analysis of salt samples, fractional conversion after four hours of reaction for CeO 2 , and five hours for La 2 O 3 , and Nd 2 O 3 were calculated to be 0.97, 0.28, and 0.65 respectively. Assuming a shrinking core diffusion-limited model, the diffusivity of ZrCl 4 through the hypothesized ZrO 2 layer was calculated for the chlorination of CeO 2 , La 2 O 3 , and Nd 2 O 3 were 1.76 x 10 -10 cm 2 /sec, 7.85 x 10 -12 cm 2 /sec, and 7.42 x 10 -12 cm 2 /sec, respectively. Given the extremely low values calculated for diffusivity, it was concluded that the process is chemical reaction rate limited and that a complete reaction of each rare earth oxide could be achieved. Furthermore, a chemically controlled shrinking core model was shown to also fit the experimental data closely.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Experimental determination of the electrochemical properties of bismuth chloride in eutectic LiCl–KCl and LiCl–KCl–CaCl 2 molten salts

Bismuth has been investigated as a potential liquid electrode for molten salt electrorefining, but the electrochemical behavior of Bi 3+ /Bi redox couple has received scant attention in LiCl–KCl and LiCl–KCl–CaCl 2 eutectics. Electroanalytical techniques were used to determine properties of Bi 3+ /Bi. Diffusivities of 6.71 and 8.93 × 10 –6 cm 2 s –1 and standard apparent potentials of 0.1166 and 0.1187 V versus Ag/AgCl (4.75 mol%) were recommended for BiCl 3 in LiCl–KCl and LiCl–KCl–CaCl 2 eutectics, respectively, at 680 ± 3.1 K. The ICP-MS analysis of BiCl 3 content limited the accuracy of the results. Furthermore, the reliability of the results improved with a more thorough drying procedure for CaCl 2 .

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗