# Patent

## Title
Low temperature route to uranium nitride

## Abstract

A method of preparing an actinide nitride fuel for nuclear reactors is provided. The method comprises the steps of a) providing at least one actinide oxide and optionally zirconium oxide; b) mixing the oxide with a source of hydrogen fluoride for a period of time and at a temperature sufficient to convert the oxide to a fluoride salt; c) heating the fluoride salt to remove water; d) heating the fluoride salt in a nitrogen atmosphere for a period of time and at a temperature sufficient to convert the fluorides to nitrides; and e) heating the nitrides under vacuum and/or inert atmosphere for a period of time sufficient to convert the nitrides to mononitrides.

## Background
GOVERNMENT INTEREST
The United States Government, as represented by the Department of Energy, has a paid-up license in the invention described and may manufacture and/or use this invention for governmental purposes in accordance with the terms of Contract No. DE-AC52-06NA25396.


FIELD OF THE INVENTION
This invention relates to a low temperature process for preparing actinide nitrides, for use as fuel in nuclear reactors.
BACKGROUND OF THE INVENTION
With the increasing demand for energy and the pressing issues associated with CO2 emissions, nuclear power is once again becoming an attractive alternative for electrical production. The generation-IV reactors which are under development will run at much higher temperatures and with a much greater burn-up of the fuel than the current generation of nuclear reactors. A consequence of this higher working temperature and greater burn-up is a need for new fuel formulations.
There are many materials that may fit the requirements of the generation-IV reactors. Oxides are relatively simple to produce and are the current materials of choice for conventional reactors. Unfortunately, oxide fuels have several inherent limitations, which include a relatively low fissile density that reduces the breeding ratio and poor thermal conductivity that restricts the linear heating rate. Of the alternatives, nitrides represent the best combination of properties with the potential to solve these problems.
Uranium nitride has many favorable fuel properties, such as a high fissile density, a high melting point similar to that of oxide fuel and high thermal conductivity similar to that of metal fuel. While uranium nitride (UN) has many of the properties that would make it an excellent reactor fuel, it has failed to make the leap to practical systems due to the difficulty in its synthesis. In particular, the inclusion of carbon from the currently favored carbothermic reduction routes to UN is a major issue in the production of nitride fuels. The carbothermic synthesis relies on the conversion of the uranium carbide to the nitride at high temperatures. The high temperatures required for the UN production have unfortunate side effects in that the low vapor-pressure actinides, particularly americium, become volatile leading to serious contamination issues.
GB 1,186,630 discloses a process for the production of uranium nitride, plutonium nitride, or mixtures thereof, by reaction of uranium or plutonium tetrafluorides or trifluorides by high-temperature ammonolysis into the corresponding higher nitride or mixture of higher nitrides, which is then dissociated in vacuo into the corresponding mononitride or mixture of mononitrides. Optionally, zirconium nitride can be included in the admixture.
U.S. Pat. No. 3,953,355 discloses a process for the preparation of actinide nitrides from massive actinide metal, massive being a single piece of metal having a mass of 0.1 kg or more. The process involves partially hydriding the massive metal and simultaneously dehydriding and nitriding the dehydrided portion. The process is repeated until all of the massive metal is converted to a nitride.
U.S. Pat. No. 5,128,112 discloses a process of preparing an actinide nitride, phosphide, sulfide or oxide, by admixing an actinide organometallic precursor with a suitable solvent and a protic Lewis base selected from ammonia, phosphine, hydrogen sulfide and water, and heating the mixture until the actinide compound is formed.
B. N. Wani et al. report in Fluorination of Oxides of Uranium and Thorium by Ammonium Hydrogen Fluoride. J. Fluorine Chem. 44 (1989) 177-185, that UO2, U3O8 and ThO2 were fluorinated by NH4HF2 at room temperature to produce (NH4)4UF8·2H2O, (NH4)3UO2F5·H2O and (NH4)4ThF8·2H2O, respectively.
There remains a need to provide low temperature methods of preparing actinide nitrides for use as nuclear fuels.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a method of preparing an actinide nitride fuel for nuclear reactors comprising the steps of: a) providing at least one actinide oxide and optionally zirconium oxide; b) mixing the oxide or oxides with a source of hydrogen fluoride for a period of time and at a temperature sufficient to convert the oxide to a fluoride salt; c) heating the fluoride salt to remove water; d) further heating the fluoride salt in a nitrogen atmosphere for a period of time and at a temperature sufficient to convert the fluoride salt to nitride; and e) heating the nitride under vacuum and/or inert atmosphere for a period of time and at a temperature sufficient to convert the nitride to mononitride.
The present invention provides a process for producing actinide nitrides such as uranium nitride at temperatures of 1100° C. or less without carbon contamination. The method utilizes the simple conversion of oxides to fluorides and their subsequent conversion to nitrides. The process does not rely on any significant change in oxidation state of the uranium and hence does not employ carbothermic reduction.



BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further illustrated by the following drawing in which:
FIG. 1 is a line graph of x-ray diffraction data for UN2.



DETAILED DESCRIPTION OF THE INVENTION
As used herein, unless otherwise expressly specified, all numbers such as those expressing values, ranges, amounts or percentages may be read as if prefaced by the word “about,” even if the term does not expressly appear. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. Plural encompasses singular and vice versa.
Actinide series elements are the fifteen chemical elements that lie between actinium and lawrencium on the periodic table, with atomic numbers 89-103. Suitable actinides for use in nuclear fuels include, for example, thorium, uranium, plutonium, neptunium, americium and curium. Mixtures of two or more actinide oxides are preferred, such as mixtures of plutonium and uranium. Mixtures of three or more actinides can also be used, such as mixtures of plutonium, uranium and thorium. Especially preferred are mixtures of oxides of thorium, uranium, plutonium, neptunium, americium and curium; plutonium, neptunium, americium and curium; and uranium, plutonium, neptunium, americium and curium. In any of the above mixtures, the relative amount of each actinide may vary from 0.01-100% in the mixture.
Optionally, zirconium oxide can be added to the actinide oxide in amounts known in the art. Zirconium oxide is a well known stabilizer for nuclear fuels and is also used for cladding the fuel pellets. As used throughout the specification and claims, “oxide” or “oxides” refers to the at least one actinide oxide, which is optionally mixed with zirconium oxide. The process of the present invention thus produces at least one actinide mononitride, which is optionally mixed with zirconium mononitride.
The actinide oxide or oxides are mixed with a source of hydrogen fluoride for a period of time and at a temperature sufficient to convert the oxide to a fluoride salt, according to the following reaction (where “Act” denotes actinide):

ActO2+4NH4HF2→(NH4)4ActF8·2 H2O  (1)

Suitable sources of hydrogen fluoride include, for example, ammonium bifluoride, ammonium fluoride and combinations of these. Preferably, the ammonium bifluoride and/or ammonium fluoride is enriched to at least 50% 15N, with higher levels more preferred. The reaction of the oxide with hydrogen fluoride can be carried out at ambient temperature, at temperatures between 20°-30° C. As the temperature is increased to about 50° C. the salt is dried and water is driven off:

(NH4)4ActF8·2 H2O→(NH4)4ActF8+2 H2O  (2)

Following removal of water, fluoride salt is further heated in a nitrogen atmosphere for a period of time and at a temperature sufficient to convert the fluoride salt to nitride:

(NH4)4ActF8+2NH3→ActN2+4NH4F+H2  (3)

Preferably, the nitrogen atmosphere is ammonia. 100% ammonia is preferable for rate optimization, however ammonia as a percentage in any inert carrier gas will work. The temperature used in this step of the process is between 600°-1000° C., more preferably 750°-850° C., and the period of time sufficient to complete the reaction is between 15 minutes to 3 hours, more preferably 30 minutes to 2 hours.
After conversion to the nitride, the at least one actinide nitride (and optionally zirconium nitride) is heated under vacuum and/or inert atmosphere for a period of time and at a temperature sufficient to convert the actinide nitride to a mononitride:

ActN2→ActN+1⁄2N2+H2+2H2O  (4)

This is accomplished at temperatures between 1000°-1300° C., more preferably at temperatures between 1050°-1200° C. Complete 100% conversion to the mononitride occurs within ten hours, usually within 3-5 hours.
EXAMPLE
UO2 was reacted with NH4HF2 to give (NH4)4UF8 on a 50 g scale with a 10% excess of NH4HF2. Analysis of the bright green material indicates that it was mainly (NH4)4UF8 with small amounts of α-(NH4)2UF6 and γ-(NH4)2UF6.
By washing the green material with large amounts of water, the reaction was completed and (NH4)4UF8·2H2O was obtained as the exclusive product, with no impurities detected. The hydrate was dried at 50° C. to give (NH4)4UF8 in quantitative yield (100% yield).
When the (NH4)4UF8 was heated to 800° C. under NH3, a quantitative conversion from (NH4)4UF8 to a uranium nitride, which analyzed as UN2, occurred.
For the UN2, x-ray diffraction patterns (shown in FIG. 1) can be indexed as cubic, with a=5.305034(30) Å. The Rietveld Refinement (see Table 3, below) confirmed the product as UN2 with a small impurity (0.7%) consisting of UO2. While UN2 has been previously characterized, it is one of the rarer uranium nitrides with very few reports describing its preparation or properties.
The EXAFS spectrum also confirmed the known UN2 structure and lattice parameters and are presented in Table 2.
An examination of the thermal stability of UN2 using thermogravimetric analysis (TGA) indicated that a significant weight loss occurs at 1000° C. Heating the UN2 to 1100° C. resulted in the complete conversion to UN within 2 hours. The materials obtained for the thermal decomposition of UN2 was cubic UN. The EXAFS spectrum fits the x-ray data and confirms the presence of the simple UN.







TABLE 1







Experimental Powder X-ray Diffraction Pattern of Uranium Dinitride














calculated
experimental


hkl
d(A)
20
intensity
intensity














111
3.06379(2)
29.12313
100
100


002
2.65332
33.75363
37.2
44.68


022
1.87618
48.48097
38.2
40.16


311
1.60001
57.55807
34.2
27.57


222
1.53189
60.37619
7.8
6.92


004
1.32666
70.98974
4.7
4.75


331
1.21743
78.50319
11.1
10.22


042
1.1866
80.95721
8.4
8.59
















TABLE 2







Comparison of XRD and EXAFS Spectroscopy


Results on Uranium Dinitride














EXAFS

XRD*




Bond
R ± 0.02 Å
C.N ± 20%
R ± 0.002 Å
C.N.

















U-N1
2.28
7.5
2.299
8



U-U1
3.73
12
3.754
12



U-N2
4.38
24
4.402
24

















TABLE 3





Rietveld Refinement, Experimental versus Calculated Fit















R-Values










Rexp: 0.83
Rwp: 9.19
Rp: 7.10
GOF: 11.07


Rexp′: 1.41
Rwp′: 15.58
Rp′: 16.25
DW: 0.45










Quantitative Analysis—Rietveld








Phase 1: “LaB6 SRM 660a”
50.231(91)%


Phase 2: “UN2 Fm-3m”
49.380(91)%


Phase 3: “Uraninite C”
0.389(78)%





Background


Chebychev polynomial,
9884(14)


Coefficient 0


1
−6544(24)


2
3848(21)


3
−1595(21)


4
710(17)


5
−179(16)





Instrument








Primary radius (mm)
240


Secondary radius (mm)
240


Receiving slit width (mm)
0.0809(99)


Divergence angle (°)
1.000(16)


Full Axial Convolution


 Filament Length (mm)
10


 Sample Length (mm)
20(11)


 Receiving Slit Length (mm)
30(15)


 Primary Sollers (°)
2.3


 Secondary Sollers (°)
2.3


Tube_Tails








 Source Width (mm)
0.092(55)


 Z1 (mm)
−0.04(38)


 Z2 (mm)
0.345(31)


 Fraction
0.121(43)





Corrections








Zero Error
0.0516(20)


Specimen displacement
0.0690(45)


LP Factor
0





Structure 1








Phase name
LaB6 SRM 660a


R-Bragg
2.240


Spacegroup
Pm-3m


Scale
0.07313(20)


Cell Mass
203.778


Cell Volume (A{circumflex over ( )}3)
71.83047


Wt %—Rietveld
50.231(91)


Crystallie Size


 Cry Size Lorentzian (nm)
307.8(34)


Crystal Linear Absorption Coeff. (1/cm)
1124.705


Crystal Density (g/cm{circumflex over ( )}3)
4.711





PVII peak type







FWHM = a + b/Cos(Th) + c Tan(Th)








  a
0.0013(86)


  b
0.0009(91)


  c
0.0068(33)







Exponent m = 0.6 + ma + mb/Cos(Th) + mc/Tan(Th)








  ma
20(570)


  mb
0(430)


  mc
5(79)





Lattice parameters


 a(Å)
4.1569000







Site  Np  x    y      z  Atom Occ  Beq





La1  1  0.00000  0.00000  0.00000  La 1  0.7038


B1   6  0.19587  0.50000  0.50000  B 1  0.65(13)





Structure 2








Phase name
UN2 Fm-3m


R-Bragg,
6.256


Spacegroup
Fm-3m


Scale
0.006623(12)


Cell Mass
1064.164


Cell Volume (Å{circumflex over ( )}3)
149.3016(26)


Wt %—Rietveld
49.380(91)





Crystallite Size


 Cry Size Lorentzian (nm)
207.1(16)


Crystal Linear Absorption Coeff. (1/cm)
3267.166(56)


Crystal Density (g/cm{circumflex over ( )}3)
11.83568(20)










PVII peak type


FWHM = a + b/Cos(Th) + c Tan(Th)








  a
0.0001(60)


  b
0.0001(66)


  c
0.0299(38)







Exponent m = 0.6 + ma + mb/Cos(Th) + mc/Tan(Th)








  ma
0.0(17)


  mb
0.05(59)


  mc
1.70(96)


Lattice parameters


  a (Å)
5.305034(30)







Site  Np  x    y      z  Atom Occ  Beq





U1  4  0.00000  0.00000  0.00000   U + 6 1  1


N1  8  0.25000  0.25000  0.25000 N 1  3.52(21)


Structure 3








Phase name
Uraninte C


R-Bragg
2.184


Spacegroup
Fm-3m


Scale
0.0000472(95)


Cell Mass
1080.105


Cell Volume (Å{circumflex over ( )}3)
162.38(24)


Wt %—Rietveld
0.389(78)


Crystallite Size


 Cry Size Lorentzian (nm)
0(3600000)


Crystal Linear Absorption Coeff. (1/cm)
3010.5(45)


Crystal Density (g/cm{circumflex over ( )}3)
11.045(16)





PV_TCHZ peak type


 U
1.2(39)


 V
0.4(26)


 W
−0.09(45)


 Z
0


 X
0.0(12)


 Y
0





Lattice parameters


 a (Å)
5.4556(27)







Site  Np  x    y      z  Atom Occ  Beq





U1  4  0.00000  0.00000  0.00000   U + 4 1  1


O1  8  0.25000  0.25000  0.25000  O−2 1  1





Very weak unknown peaks at dhkl × 4.403 Å, 5.486 Å, 2.496 Å.






Very weak unknown peaks at dhkl=4.403 Å, 5.486 Å, 2.496 Å.

Whereas particular embodiments of this invention have been described above for purpose of illustration, it will be evident to those skilled in the art the numerous variations of the details of the present invention may be made without departing from the invention as defined in the appended claims.

## Claims

1. A method of preparing a nitride fuel for nuclear reactors comprising:
a) providing at least one actinide oxide;
b) mixing the oxide or oxides with a source of hydrogen fluoride that is enriched to at least 50% 15N for a period of time and at a temperature sufficient to convert the oxide to a fluoride salt;
c) heating the fluoride salt to remove water;
d) further heating the fluoride salt in a nitrogen atmosphere for a period of time and at a temperature sufficient to convert the fluoride salt to nitride; and
e) heating the nitride under vacuum and/or inert atmosphere for a period of time and at a temperature sufficient to convert the nitride to mononitride.

2. The method of claim 1, wherein the hydrogen fluoride source is selected from the group consisting of ammonium bifluoride, ammonium fluoride and combinations thereof.

3. The method of claim 2, wherein the actinide oxide is optionally mixed with zirconium oxide.

4. The method of claim 1, wherein the at least one actinide oxide is selected from the group consisting of thorium, uranium, plutonium, neptunium, americium, and curium.

5. The method of claim 4, wherein the at least one actinide oxide is a mixture of oxides of plutonium and uranium.

6. The method of claim 4, wherein the at least one actinide oxide is a mixture of oxides of plutonium, uranium and thorium.

7. The method of claim 4, wherein the at least one actinide oxide is a mixture comprising oxides of thorium, uranium, plutonium, neptunium, americium and curium.

8. The method of claim 4, wherein the at least one actinide oxide is a mixture comprising oxides of uranium, plutonium, neptunium, americium and curium.

9. The method of claim 4, wherein the at least one actinide oxide is a mixture comprising oxides of plutonium, neptunium, americium and curium.

10. The method of claim 1, wherein the period of time in step b) is at least 20 minutes.

11. The method of claim 1, wherein the period of time in step c) is at least 10 minutes.

12. The method of claim 1, wherein the period of time in step d) is at least 15 minutes.

13. The method of claim 1, wherein the period of time in step e) is at least 1 hour.

14. The method of claim 1, wherein the temperature in step b) is at least 0° C.

15. The method of claim 1, wherein the temperature in step c) is at least 20° C.

16. The method of claim 1, wherein the temperature in step d) is at least 300° C.

17. The method of claim 1, wherein the temperature in step e) is at least 500° C.

18. The method of claim 1, wherein the produced actinide mononitride is optionally mixed with zirconium mononitride.