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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Kinetics of Dechlorination of Molten Chloride Salt Using Protonated Ultrastable Y Zeolite

Investigation of the kinetics of the ion exchange between protonated ultrastable Y-type (USHY) and surrogate electrorefiner (ER) waste salt was performed to optimize the dechlorination process. The kinetics of the ion exchange reaction was investigated by measuring the amount of unreacted Cl. In theory, the kinetics of the ion exchange reaction in porous media will be limited by diffusion- or reaction-controlled mechanisms. Therefore, second order kinetics and diffusion-limited rate models have been derived and compared to experimental data to elucidate the rate-limiting step and develop a predictive model for the apparent rate of reaction. Ion exchange experiments were performed with varying zeolite particle sizes (up to 600 μm) at 625 °C. The experiments were performed with both unfluidized and continuously fluidized zeolite particles in static and rotating tube furnaces. Finally, it was concluded that the process is limited by reaction kinetics inside the zeolite crystals, and a second order kinetic model best fits the experimental data. Given that the zeolite is not stable at higher temperatures, further increase in the extent of dechlorination for a given batch reaction time requires an increase of the zeolite-to-salt ratio, which has the undesirable effect of increasing the volume of generated waste per amount of salt.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Ambient Rare Earth Metal Electrodeposition in Nitrogen-Coordinated Silylamide Electrolyte

The transition to a sustainable, low-carbon economy demands energy-efficient and environmentally benign methods for rare earth metal (REM) production. Furthermore, while high-temperature molten salt electrolysis remains energy-intensive, corrosive, and environmentally unfriendly, emerging room-temperature processes based on conventional ionic liquids are also hindered by high viscosity and chemical instability. In this study, a nitrogen-coordinated, water-, oxygen-, and fluorine-free silylamide-based electrolyte is presented as a promising system for room-temperature REM electrodeposition. Derived from commercially available lithium silylamide precursors, the system enables facile synthesis, broad electrochemical stability, and tunable metal–ligand interactions. Electrochemical analysis reveals high voltammetric stripping reversibility, stable cathodic and anodic potentials, and selective neodymium (Nd) deposition at appreciable current densities (>1 mA/cm 2 ), with minimal parasitic reactions. Bulk experiments produced high-purity Nd with reproducible performance across multiple batches. Scaled deposition yielded over 1 g of Nd with near-theoretical mass efficiency (0.40 mg/C) and >90% purity. Using sacrificial dysprosium (Dy) and Nd metal anodes, the system maintained constant Nd loading during extended deposition and enabled cathodic codeposition of stripped anode material, demonstrating the electrolyte’s dual functionality for REM electrorefining. Collectively, this silylamide platform offers a compelling combination of electrochemical robustness, chemical resilience, and process scalability for sustainable ambient REM recovery.

36 - MATERIALS SCIENCE↗
DOE OSTI2021

Deliquescence of Eutectic LiCl-KCl Diluted with NaCl for Interim Waste Salt Storage

Molten eutectic LiCl-KCl salt is a widely used electrolyte for electrorefining uranium from spent nuclear fuel. Due to the hygroscopic nature of this salt, such operations must be performed under controlled atmospheric conditions, and waste salts require careful storage to avoid deliquescence and corrosion of container materials. This study investigated a potential processing path for reducing the degree of deliquescence through dilution to varying extents with NaCl. Here, the hydration behavior of LiCl-KCl salts diluted with NaCl was evaluated in terms of mass gain due to water absorption, degree of deliquescence (including first appearances of standing water), and evidence of corrosion to stainless steel containers in a humid air environment (40°C, 20% relative humidity). In this humid air environment, pure eutectic LiCl-KCl exhibited a 50 mass % increase due to water absorption and showed evidence of standing water after 24 h. Waste salt diluted with NaCl required loadings of 89 mass % NaCl in order to prevent deliquescence and exhibited a 3 mass % increase due to water absorption. After periodic observation for 48 h, standing water was observed near all ingots with the exception of the 89 mass % NaCl samples. Dilution with 89% NaCl was also found to reduce evidence of corrosion when stored in stainless steel crucibles. While dilution with NaCl greatly decreases steady-state hydration, the storage volume is increased ~10× through this procedure.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

DIissolution of low enriched uranium from the experimental breeder reactor-II fuel stored at the Idaho National Laboratory

The Idaho National Laboratory (INL) is actively engaged in the development of electrochemical processing technology for the treatment of fast reactor fuels using irradiated fuel from the Experimental Breeder Reactor-II (EBR-II) as the primary test material. The research and development (R&D) activities generate a low enriched uranium (LEU) metal product from the electrorefining of the EBR-II fuel and the subsequent consolidation and removal of chloride salts by the cathode processor. The LEU metal ingots from past R&D activities are currently stored at INL awaiting disposition. One potential disposition pathway is the shipment of the ingots to the Savannah River Site (SRS) for dissolution in H-Canyon. Carbon steel cans containing the LEU metal would be loaded into reusable charging bundles in the H-Canyon Crane Maintenance Area and charged to the 6.4D or 6.1D dissolver. The LEU dissolution would be accomplished as the final charge in a dissolver batch (following the dissolution of multiple charges of spent nuclear fuel (SNF)). The solution would then be purified and the 235 U enrichment downblended to allow use of the U in commercial reactor fuel. To support this potential disposition path, the Savannah River National Laboratory (SRNL) developed a dissolution flowsheet for the LEU using samples of the material received from INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Modernization at the Y-12 National Security Complex: A Case for Additional Experimental Benchmarks

Efforts are underway at the Y-12 National Security Complex (Y-12) to modernize the recovery, purification, and consolidation of un-irradiated, highly enriched uranium metal. Successful integration of advanced technology such as Electrorefining (ER) eliminates many of the intermediate chemistry systems and processes that are the current and historical basis of the nuclear fuel cycle at Y-12. The cost of operations, the inventory of hazardous chemicals, and the volume of waste are significantly reduced by ER. It also introduces unique material forms and compositions related to the chemistry of chloride salts for further consideration in safety analysis and engineering. The work herein briefly describes recent investigations of nuclear criticality for 235UO2Cl2 (uranyl chloride) and 6LiCl (lithium chloride) in aqueous solution. Of particular interest is the minimum critical mass of highly enriched uranium as a function of the molar ratio of 6Li to 235U. The work herein also briefly describes recent investigations of nuclear criticality for 235U metal reflected by salt mixtures of 6LiCl or 7LiCl (lithium chloride), KCl (potassium chloride), and 235UCl3 or 238UCl3 (uranium tri-chloride). Computational methods for analysis of nuclear criticality safety and published nuclear data are employed in the absence of directly relevant experimental criticality benchmarks.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Crediting a Soluble Neutron Absorber at Y-12 under ANSI/ANS-8.14-2004

The Y-12 National Security Complex (Y-12) is performing work to modernize the recovery, purification, and consolidation of un-irradiated, highly enriched uranium metal. The development of advanced technology such as Electrorefining (ER) eliminates many of the intermediate chemistry systems and processes that are the current and historical basis of uranium processing at Y-12. The ER system processes impure broken uranium metal pieces into a high-purity uranium metal disk. The overall system consists of an ER cell, salt vaporization furnace (SVF), and uranium consolidation furnace (UCF).

36 MATERIALS SCIENCE↗
DOE OSTI2018

Electrochemical behavior of Nd and its co-reduction with Bi in molten LiCl-KCl salts - 18360

A molten salt phase is used as the solvent in pyrochemical reprocessing. The molten salt waste generated in pyro-processes contains the residual lanthanides and actinides as various compounds. Various methods have been proposed for recovering and recycling these useful elements. The separation of actinides from lanthanides is performed by electrolysis or reductive extraction. Herein we have studied PyroRedSox-based co-reduction of Nd and Bi via electrolysis in a molten chloride salt. The redox behavior of Nd and the formation potential of intermetallic compounds of Nd and Bi were determined using cyclic voltammetry (CV). Electrorefining was performed under a constant reductive potential at 773 K in LiCl-KCl eutectic mixture; the co-reduction potential was -1.37 V. Lastly, the co-reduction potential of the intermetallic compound was applied to reduce the amount of Nd and Bi. Scanning electron microscopy (SEM) revealed that various kinds of intermetallic compounds were formed in Bi and Nd, and were deposed in the lower part of the molten salt, allowing purification of the contaminated molten salt. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Multi-species Modeling of Molten-Salt Electrochemical Process

Spent nuclear fuel has been produced and stored in over 30 different countries which are operating commercial nuclear power plants. Molten-salt pyroprocessing has been developed for treating both oxide and metal spent nuclear fuels. This process separates long-lived actinide isotopes together as a group from fission products for burning the long-lived isotopes in fast reactors. Main processes of pyroprocessing such as oxide reduction, electrorefining, and electrowinning are based on a concept of electrolytic cell consuming energy to proceed electrochemical reactions. To scale-up the electrochemical processes, the design optimization of the key steps is required to reach high throughput that improves economic competitiveness and reduces an environmental impact. For the optimization, it is significant to compare different unit process designs and find optimum designs and operating conditions. However, this optimization process is very costly if we need to conduct experiments on every case with spent nuclear fuel. Instead, a validated simulation model can help to rapidly calculate and evaluate different case at significantly reduced costs. This paper presents recent development of multi-physics simulation of molten salt electrochemistry for partitioning spent nuclear fuel with limiting factors. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Effect of Concentration, Temperature, and Interelectrode Gap on the Voltage Drop in an Electrochemical System of GdCl{sub 3}-LiCl-KCl

One of the most common conversations for those in the nuclear field and the public when discussing nuclear power is the issue of nuclear waste. When used nuclear fuel (UNF) is removed from a reactor, it contains fission products, some of which are long lived isotopes that will continue to irradiate for hundreds of years. One of several solutions to this issue is reprocessing, a process where minor actinides and other fission products are separated from still fissile and fertile materials. In the United States, there is no reprocessing of UNF at an industrial scale; however, one of the methods that universities and national labs are currently researching is known as pyro-processing. Pyro-processing utilizes electrochemistry in a molten salt environment to treat UNF and remove uranium and plutonium. The heart of the pyro-processing system is an electrorefining process, where most of the U in the UNF is selectively collected on a solid cathode in molten lithium-potassium chloride (LiCl-KCl) at high temperatures (723 K - 773 K). To model the behavior of materials in the electro-refiner, small bench-scale electrochemical experiments are being performed at many research universities and national labs to better understand material behavior. Within the electrochemical cell, there is a small resistance to current between the cathode and anode. This results in a voltage drop, which can affect the results of the experiments. This voltage drop varies based upon concentration of the salt, the temperature, the distance between the anode and cathode, and the scan rate. For this study, cyclic voltammetry will be performed on GdCl{sub 3}-LiCl-KCl at various temperatures (723 K - 798 K), various sample concentrations (1, 5, and 10 wt%), various scan rates (50, 100, 200, and 300 mV/s), and two different electrode spacing configurations. The resulting cyclic voltammograms will be compared for both electrode configurations to see the impact of interelectrode gap on the voltage drop.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Salt Sample Statistical Study

Historically there has, at times, been large variability in measured uranium concentration amongst salt samples taken at the same time from the electrorefiner with relative standard deviations ranging from 0.59% up to a high of 114%. This has led to uncertainty in the actual uranium content of the salt. A series of surrogate experiments were performed with gadolinium to study the effects of Li2O, Gd2O3, and Gd metal additions to an LiCl-KCl-GdCl3 salt on the gadolinium content of the salt. These experiments showed no increase in salt sample variability following the additions of the mentioned species, indicating that the carryover of these species from the oxide reduction process may not lead to the historic variability issues.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

All-LiCl Flowsheet Development

Annual report on the LiCl Pyro project. The objectives of this project are to begin work to determine the feasibility of transitioning to LiCl-only electrorefining for reprocessing nuclear fuel.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

In-situ Synthesis of PuCl 3 and Corresponding Raman and Density Functional Theory Vibrational Modes

The experimental and calculated Raman spectrum of PuCl 3 has been reported for the first time. PuCl 3 is a primary species found in plutonium metal refinement, specifically in pyrochemical salt processes including multicycle direct oxide reduction, metal chlorination, and electrorefining. As such, Raman signatures of PuCl 3 could serve as potential forensic indicators of material process history. A novel technique for synthesizing PuCl 3 from the in situ chlorination of plutonium metal with HCl was developed to establish these signatures. Cerium metal surrogates were utilized to ensure optimization of the plutonium experiments and to minimize personnel exposure, and all experiments were carried out in a Raman reaction chamber designed for air-tight, high vacuum environments. In situ Raman spectroscopy was employed in conjunction with density functional theory (DFT) to investigate the vibrational modes of PuCl 3 . Associated mixed oxy and hydroxyl phases are also reported. The combined Raman and DFT results have eliminated inconsistencies in Raman mode assignments for the MX 3 family of metal chlorides having P6 3 /m symmetry, and IR modes derived from the DFT calculations are additionally presented. The data observed in this study are of potential interest to nuclear forensic analyses, nuclear sample aging, nuclear energy, plutonium processing, and stockpile stewardship.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Gamma-ray spectra analyses of molten salts in spent nuclear fuels pyroprocessing facilities for mass measurement

To evaluate radioactive tracer dilution and gamma spectroscopy as a safeguards technique for monitoring the mass of liquid salt in molten salt systems, the gamma spectroscopy data of salt samples from the pyroprocessing facilities in Idaho National Laboratory were acquired and analyzed. The primary focus is the uncertainty analysis of the gamma radioactivity of 154 Eu isotope in the molten salts. The facilities include an electrorefiner for pyroprocessing spent oxide fuels (SOF-ER) and Mark-IV ER for processing the metallic fuels from Experimental Breeder Reactor-II (EBR-II). The relative gamma radioactivity uncertainty was consistently at 3% for 137 Cs for both Mark-IV ER and SOF-ER salts. However, for 154 Eu, it was 8% for SOF-ER salt and 7% for Mark-IV ER salt. Here, the main reason for the higher uncertainty for 154 Eu is believed to be the lower counting statistics in gamma spectroscopy. To improve the gamma radioactivity uncertainty of isotope 154 Eu, a longer data acquisition time (12 h instead of 4 h) and a higher count rate gamma detector for gamma spectroscopy were tested and it was found that the uncertainty for 154 Eu was significantly improved from 7% or 8–3%.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Uncertainty improvement of 22 Na based radioactive tracer dilution for determining total mass of pyroprocessing molten salt systems by 154 Eu removal

To determine the total salt mass of the molten salt systems for pyroprocessing spent nuclear fuels, a 22 Na based radioactive tracer dilution was studied in Idaho National Laboratory in recent years. This 22 Na based RTD technique was deemed feasible, but due to the gamma energy peak of 22 Na coinciding with one of the energy peaks of 154 Eu radioisotope in the molten salt, the uncertainty of the 22 Na radioactivity in the 22 Na-spiked salt samples was quite high. To improve the uncertainty of the 22 Na based RTD technique, we proposed to chemically remove the 154 Eu of the salt samples by DGA resin for gamma spectroscopy. The effectiveness of removing 154 Eu on uncertainty improvement was evaluated. Furthermore, it was found that (1) the 154 Eu fission product effect on the uncertainty and detection limit can be effectively eliminated by chemically removing the 154 Eu during the salt sample preparation and (2) the uncertainty of 22 Na radioactivity in the salt samples for electrorefining was significantly improved from 13% to 2%, showing the potential of practical engineering application of 22 Na based RTD as a safeguards technique for molten salt systems for pyroprocessing spent nuclear fuels.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Effects of composition and canister centerline cooling on microstructure, phase distribution, and chemical durability of dehalogenated iron phosphate waste forms

This paper discusses the effects of composition and canister centerline cooling (CCC) on the microstructures, phase distribution, and chemical durability of dehalogenated iron phosphate waste forms starting from chloride-based salt simulants including KCl (Simple-1), NdCl3 (Simple-2), SrCl2 (Simple-3), LaCl3 (Simple-4), LiCl (Simple-5), CsCl (Simple-6), as well as a complex simulant containing LiCl, KCl, NaCl, CsI, SrCl2, CeCl3, and NdCl3 called ERV2. The simulants represent salt constituents present in salt wastes from electrorefiners used for electrochemical reprocessing. These salts are reacted with ammonium dihydrogen phosphate (ADP) resulting in a NH4Cl (dechlorination) byproduct that is captured and phosphate product containing oxides of the salt cations. This product is further stabilized using Fe2O3 through vitrification at higher temperatures. The results presented herein describe the properties of CCC-treated materials following dechlorination and vitrification including phase identification and quantification, elemental distributions, and chemical durabilities. The chemical durability in the CCC-cooled samples are lower durability than quenched materials for the ERV2 samples. The phases formed upon CCC cooling are very complex compositionally and microstructurally.

iron phosphate glass, iron phosphate waste forms, ↗
DOE OSTI2019

Liquid cadmium cathode performance model based on the equilibrium behaviors of U and Pu in molten LiCl–KCl/Cd system at 500°C

The liquid cadmium cathode is a pyroprocessing technology used for the recovery of group actinide metals from the molten chloride salts that support uranium electrorefining. This article presents a model for the performance of a liquid cadmium cathode based on considerations of salt/alloy equilibrium thermodynamics, Cd-U-Pu phase diagram behaviors, and mass balance constraints. In conclusion, the model demonstrates how the salt/cadmium system responds as incremental additions of uranium are made to the liquid cadmium cathode.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗