# Patent

## Title
Two step dry UO2 production process utilizing a positive sealing valve means between steps

## Abstract

The present invention provides a two-step process for producing nuclear grade, active uranium dioxide (UO2) powder in which the first step comprises reacting uranium hexafluoride (UF6) with steam in a flame reactor to yield uranyl fluoride (UO2F2); and the second step comprises removing fluoride and reducing UO2F2 to uranium dioxide (UO2) in a kiln under a steam/hydrogen atmosphere. The two-step process, each step separated by a positive sealed valve means to prevent gas, particularly H2 flow back, tightly controls the exothermicity of the reaction, which allows for a very tight temperature control which controls the growth of the particles and results in UO2 powder that is active and of consistent morphology.

## Background
This present application is a Continuation-in-Part application that claims priority from U.S. Non-Provisional application Ser. No. 11/741,158, filed Apr. 27, 2007, now abandoned which U.S. Nonprovisional application claims priority to U.S. Provisional Application Ser. No. 60/833,232, filed Jul. 25, 2006, all of which is incorporated herein by reference.


BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods of manufacturing uranium oxide powder for use as nuclear fuel and, more particularly, to a two-step dry process for producing uranium oxide powder that eliminates the need for wet processing, and results in easy to handle UO2 powder and stable pellets.
2. Description of the Prior Art
The preparation of commercial nuclear fuels mainly has been by processes which use enriched and depleted uranium (i.e., enriched or depleted in the uranium-235 isotope compared to the uranium-235 content of naturally occurring uranium ore) feed as UF6. The enriched UF6 is converted to UO2 by processes selected to give the ceramic sinterability needed for the preparation of nuclear fuel pellets.
While procedures for converting UF6 to uranium oxides are known, currently available procedures are not particularly efficient or economical for converting UF6 to UO2. More specifically, the UF6 conversions for nuclear fuels have been developed to prepare UO2 with well controlled ceramic properties. Furthermore, because of the need to control their ceramic properties and because of thermodynamic limitations, the known commercial conversion processes are either complex aqueous-based processes with multiple process stages or a one-stage dry process. While the wet processes are easier to control, they produce large amounts of liquid wastes. The single step dry process produces a minimal waste stream but is difficult to operate.
Early patents issued to Reese et al., U.S. Pat. No. 3,168,369, filed in 1961, and to Blundell et al., U.S. Pat. No. 3,235,327, filed in 1962, described all the basic reactions and general technology required to make uranium dioxide nuclear fuel for nuclear reactors from uranium hexafluoride:




at 1000° F.-1800° F. or 537° C.-982° C. in dry processes. Here an inert gas could be used to promote a gas phase reaction between UF6 and H2O, as steam, to provide a very high surface area, uranyl fluoride (UO2F2) fluffy powder, having a tap density in the range 0.5 to 1.5 gm./cc. and a surface area in the range of 2 to 4 meters2/gm. (Tap density is obtained by putting the UO2 powder in a graduated cylinder and vibrating for a given time. This sets the volume and the graduated cylinder is weighed to obtain the weight of the powder.)
Numerous U.S. patents have been subsequently issued directed towards processes for the conversion of UF6 to uranium oxides. See, for example, U.S. Pat. No. 4,830,841 and the U.S. patents listed therein, which describe procedures for converting UF6 to uranium dioxide in furnaces, rotary kilns, fluidized beds and the like. For example, U.S. Pat. No. 4,830,841 is directed to a process for preparing UO2 from UF6 by reacting UF6 with steam to produce submicron uranyl fluoride powder, fluidizing a bed of uranium oxide material with a mixture of steam, hydrogen and inert gas at about 580° C. to about 700° C., and introducing the submicron uranyl fluoride powder into the fluidized bed of uranium oxide material so that the uranyl fluoride powder is agglomerated, densified, fluidized, defluorinated and reduced to a fluoride-containing uranium oxide material which is removed from the fluidized bed and then contacted with hydrogen and steam at elevated temperature to obtain UO2 essentially free of fluoride. The UO2 product produced from this process tends to be very inactive and requires an intense milling step to produce moderately active powder. In addition, there often is incomplete conversion of UO2F2 to UO3/U3O8, which leads to unacceptable contamination in the final UO2 powder. This likely is due to inadequate residence time and the growth of large particles in the initial phase which cannot complete the fluoride removal reaction. The differences between plural fluid bed reactors and flame reaction via flame plumes as used in this invention are dramatically, fundamentally different and nonequivalent, as discussed later.
Other U.S. patents disclose single-step processes for producing nuclear reactor fuel, such as U.S. Pat. No. 4,397,824 and U.S. Pat. No. 5,875,385. An exemplary single-step process for producing solid uranium oxide powder is disclosed in U.S. Pat. No. 5,752,158, which describes a single-step MDR (Modified Direct Route—this is really a trade name and not a very illustrative name) process for producing solid uranium oxide powder and gaseous HF from UF6 by bringing together two gaseous reactant streams, one of the streams comprising UF6 optionally admixed with oxygen as O2, and the second reactant stream comprising a mixture of hydrogen as H2 or as a hydrogen-containing compound and oxygen as an oxygen-containing compound. The gaseous reactant streams are brought together at a temperature and composition such that the UF6 is converted rapidly by flame reaction into readily separable solid uranium oxide and a gaseous HF product. Another single-step process is disclosed in U.S. Pat. No. 4,112,005, which describes reacting UF6 with steam within a first region of a vessel in which UO2F2 is obtained, which then is subjected to reduction within a second region of the vessel to obtain UO2. The UO2F2 obtained is contacted with a mixture of hydrogen gas and steam in a first zone of the second region of the vessel, in which an oxide having an intermediate composition between U3O8 and UO2 is contacted with the hydrogen gas and steam within a second zone of the second region of said vessel. The problem with these processes is the low feed rate due to the need to produce acceptable ceramic grade UO2 powder that can be made into dense UO2 pellets.
Additional single-step dry processes for obtaining uranium dioxide powder (i.e., by direct reduction of UF6 into UO2) which include the IDR (Intermediate Dry Route—another trade name, not very descriptive) process have been widely used and are described in, for example, U.S. Pat. No. 4,889,663; U.S. Pat. No. 4,397,824 and French No. 2,060,242. The powders obtained by the dry conversion process, including water vapor hydrolysis followed by pyrohydrolysis of the uranyl fluoride UO2F2 obtained, have the advantage of being readily sinterable. The powder produced is very active but hard to handle and produces very weak green pellets. Handling therefore is delicate and rejects are numerous if special care is not exercised. The IDR process converts UF6 to UO2 in a one-step, vapor/solid phase reaction that is hard to control and tends to produce a product with a UO2F2 contaminant. Part of the problem with this process is that two very exothermic processes occur in the same location at the tip of the mixing nozzle: (1) formation of UO2F2; and (2) some UO3/U3O8 from the reaction of steam and entrained hydrogen from the surrounding atmosphere. As the process flow rate is increased, the amount of hydrogen that is intermixed with the steam hydrolysis step becomes variable which produces large variations in the flame temperature and results in large variations in the powder properties.
There are several so-called double step processes, to produce UO2 from UF6, utilizing flame reactors and rotary kilns, connected by scroll/screw type rotatable moving means for the first reaction generated UO2F2 powder. The general problem with these processes is that step 1 production of UO2F2 is not, in fact, protected from H2 gas intrusion from step 2 formation of UO2 in a rotary kiln; and H2 intrusion into step 1 produces the variations in the powder properties described above. These seem not to be true commercial realizations, as H2 seepage through unfilled screw or scroll feeders leads to the reaction:

UO2F2+N2+H2O+H2→UO2+2HF+H2O+N2,

with uncontrolled temperature which produces either unreactive or too reactive powder.

Carter et al., U.S. Pat. No. 5,757,087, utilizes at least two obliquely positioned flame reactor plumes, to produce circulating product UO2F2 product powder, which is “scrolled” to a horizontal kiln for reaction with countercurrent flow of steam and/or H2 to provide UO2 through an outlet chamber. No example is given. Feugier, in U.S. Pat. No. 6,136,285, also utilizes a screw feeder between steps 1 and 2, and teaches concentric introduction of UF6 internally, and N2 in an annular space between UF6 and steam; to provide a reaction at a central nozzle tip injector in a flame reactor to provide UO2F2 and HF gas. The N2 is injected between the UF6 and the steam to keep crystalline UO2F2 from forming on the nozzle tip. All HF, excess steam and N2 gas must be exhausted through filters in the top of the flame rector, as they are the only HF off gas filters shown in the patent. While this patent concentrates on the concentric nozzle in the flame reactor, there seems little realization as to what happens to HF formed, and unreacted H2 and steam, in the second stage rotary pyrohydrolysis furnace which injects countercurrent steam and H2. This rotary furnace requires 5 zones, with its FIG. 8 showing kiln temperatures of over 680° C. in zones 1-4, with maximum temperatures of the interior gas of H2 HF and H2O of 730° C.-800° C., which temperatures should easily translate in a steady state process to the kiln shell. The only HF filters must also exit excess H2 and steam, passing through/bubbling through, under pressure, the screw progressing UO2F2 and exiting through the same set of filters as the off-gas from the flame reactor exits through. Only one set of filters is contemplated in the patent.
All of these processes provide substantial amounts of HF gas and micro entrained particles of UO2, UO2F2, and U3O8, which must be removed in order to make a by-product of HF, uncontaminated with any uranium compounds. One patent in particular, Feugier, U.S. Pat. No. 7,422,626, provides substantial detail in this area. There, again, filters are shown only in the stage 1 flame reactor, which seems to imply that HF and unreacted H2 and steam from the stage 2 rotary kiln pass through the screw transport to exit in the stage 1 flame reactor. Therefore, the flame reactor is not truly hydrogen free and as the flame transitions between laminar and turbulent flow and randomly entrains gases in the flame from the surrounding gas, random fluctuations in temperature occur leading to highly variable UO2F2 powder properties which leads to highly variable UO2 powder properties.
Here, as in all filter systems, filtering radioactive materials formed as fluffy particles must be cleaned by gas, such as N2 blowback. Feugier, U.S. Pat. No. 7,422,626, requires extremely radical sonic ejection of powder, by N2 blowback at speeds of over 300 m/s for less than 1 sec.; this is over about 700 mph (sonic speed=343.14 m/s at 20° C. which=707.58 mph). This is essential to their process. Sintered metal filters are well know, and almost all such filters have gas blowback valve means, as described in Mott Corporation Brochure, “Fiber Metal Gas Filtration” Rev. Feb. 10, 2008, and Union Carbide article by T. Shapiro et al. “Porous Metal Filters, Application to Feed Materials Production”, Jun. 15, 1961 (copy supplied to the British Library) where application of sintered porous metal filters to solid gas systems was operated in fluid bed systems. There, metal filters that have been plugged with dust, were cleaned by gas blowback at about 115 cubic feet/min., at 15 psi which translates to a velocity of about 417 feet/sec or 127 meters/sec which is below sonic speed. The calculation is as follows:
Nozzle openings= 3/16 inch
Number of nozzles=24 (page 15, FIG. 1)
Flow per nozzle=115/24=4.79 cubic feet/minute/nozzle
Velocity=4.79 ft3/(3/16.3/16.3.14/4 in2)*(144 in2/ft2)/(60 sec/min) (where * is equivalent to “times” or x=multiplied by)
Velocity=417 ft/sec or 127 meters/sec.
Ejectors are also shown in FIGS. 1, 4, 6, and 8 of T. Shapiro et al. (the small nubs over the opening of each filter in these figures) and described on page 12, 4th paragraph.
Another process for producing UO2 fuel pellets is disclosed in U.S. Pat. No. 5,091,120, which describes a method for producing fritted UO2 nuclear fuel pellets from metallic uranium. This method uses high value metal and therefore is not economically feasible.
U.S. Pat. No. 6,656,391 discloses the use of a wet ammonium diuranate process (ADU) to produce both UO3/U3O8 from both uranyl nitrate hexahydrate (UNH) and UF6. In particular, the UO3/U3O8 that is produced from this process then is processed in a calciner to produce UO2. The ADU process produces a stable but only moderately active (i.e., only achieves a final pellet density of about 97.5% on a consistent basis) UO2 powder. In addition, this process produces a large amount of liquid waste that must be treated to remove the fluoride. The common way of treatment is to add calcium hydroxide (Ca(OH)2) slurry which then forms a large amount of solids from the final neutralization of the fluoride as CaF2. Disposal of these solids is difficult due to their origin in a nuclear facility. The discharged liquid waste while having a very low residual fluoride, is still regulated and must be monitored for any discharge permits that are obtained. Furthermore, the nitrate-based recycle (UNH) must be spiked with HF in order for it to have reasonable handling properties during the centrifugation and drying steps and produces a significant amount of nitrate that must be handled in the discharge as well as fluoride. The nitrate disrupts the ammonia recovery process due to the required addition of sodium hydroxide to free the ammonia from the nitrate. Another problem is the carryover of NH4F in the dried UO3/U3O8 product to the final calciner. This fluoride tends to agglomerate the UO2 fines which reduces the overall powder activity and produces a semi-volatile NH4F material that plates out and plugs the off-gas vents of the calciner.
A further extended type fluid bed process for producing nuclear reactor fuels is disclosed in U.S. Pat. No. 4,053,559 (Hart et al.), which describes a three-step process using continuous, four stage fluidized beds interconnected in series to provide substantially complete conversion of UF6 to UO2. This process, however, is quite complicated, hard to operate and generates a UO2 product with much residual fluoride.
Notwithstanding the extensive prior efforts referred to above, there remains a substantial need for improved procedures for converting UF6 into solid UO2 that produces a highly active, ceramic grade UO2 powder at high production rates and which is easy to control, and which very importantly completely isolates steps where H2 reactant is completely excluded from initial first stage reactions, where it poses serious UO2 product variability problems. Use of fluid bed processes are not an answer due to the issues with forming un-reactive, large solids and residual fluoride removal.
It is, therefore, a major object of the invention to provide a block to H2 backflow into the first reaction stage, a calcination process that can produce UO2 with low residual fluoride levels and a product that has controlled particle sizes and a powder with good reactivity.
It is an object of the present invention to provide a two-step dry process for making nuclear grade, active UO2 powder which tightly controls the exothermicity of the process steps and thus allows for very tight temperature control of each process step, and allows dual HF gas filtering, and particulate recirculation of entrained particles in the off-gases.
It is a further object of the present invention to provide a two-stage process wherein UF6 first is converted to UO2F2 using steam and then converting the UO2F2 to UO2 using a mixture of steam and hydrogen, which UO2 contains only very small amounts of unconverted UO2F2 (less than about 50 ppm).
It is a further object of the present invention to provide a two-stage process for making nuclear grade, stable, active UO2 powder, in which the two-stage process is carried out in two kilns, calciners or in flame reactors in which significant amounts of solids are retained in the kiln or calciner or are entrained in the flame reactor flame.
SUMMARY OF THE INVENTION
The present invention meets this need and solves the above problems by providing a multi-step process for producing nuclear grade, active uranium dioxide (UO2) powder:
(1) by reacting 1 mole of uranium hexafluoride gas (UF6) steam with a steam to UF6 mole ratio of 2 to 10 moles, plus N2 of steam (H2O), plus N2 or other inert gas or gases, in a first stage flame reactor having at least one flame plume, to yield initial product uranyl fluoride particles (UO2F2) plus less than 0.1 mole of at least one of oxide particles UO3 and U3O8 HF gas and unreacted steam and N2 or other inert gas or gases, at a temperature in the flame plume of from 300° C. to 800° C.;
(2) passing the HF gas, unreacted steam and N2 or other inert gas or gases, as well as fine, gas entrained initial product particles to a filter where all HF, unreacted steam and N2 or other inert gas or gases pass through the filter and entrained particles do not;
(3) recycling filtered entrained solids by means of a steam or nitrogen powered gas ejector back into the steam or nitrogen flow of the flame reactor;
(4) passing the unentrained initial product, uranyl fluoride particles and any UO3 and U3O8 particles through a positive, sealed valve means which passes powder, but prevents significant amounts of gaseous feedback from subsequent reactions in the second stage from entering into step (1);
(5) passing the initial product particles that pass through the positive sealed valve means into a second stage rotary kiln reactor, having a kiln shell and a temperature range ramp up and down at its kiln shell of from an initial 400° C. to 700° C. to a final temperature between 100° C. to 300° C., where uranyl fluoride particles with any UO3 and U3O8 particles, both from step (1), are passed along the rotary kiln countercurrent to 5 moles to 30 moles of steam (H2O), 5 to 50 moles of H2 and inert gas or gases, to reduce uranyl fluoride particles, and remove fluoride as HF gas and to reduce uranyl fluoride particles and any UO3 and U3O8 particles, to form a sinterable outlet, UO2 powder having a particle size from 0.1 micrometers to 100 micrometer, having a surface area from 2 meters2/gm to 8 meters2/gm (gram), preferably 4.5 meters2/gm to 6 meters2/gm;
(6) passing the HF gas, inert gas or gases, and unreacted H2 or steam from the second stage reactor of step (5) through a filter to remove any entrained solids;
(7) passing the particles that do not pass through the filter of steps (2) and (6) back into the flame reactor of step (1) or the kiln of step (5);
(8) condensing HF and steam gas into liquid HF from the filtered off-gases;
(9) collection of UO2 powder from an outlet of step (5); and
(10) pressing the collected UO2 powder to a density greater than 98.5 wt. %.
A separate powder transport, such as an optional screw feeder or the like can be used between the positive sealed valve used in step (4) and the rotary kiln of step (5). These seals are not completely hermetic, however, they allow substantially less gas to flow back (about 94% to 95% less flowback) than a loose bed of particles, such as in a screw feeder. An optional, second, positive sealed valve can also be used between an optional screw feeder used to pass the initial product in step (5) and the actual rotary kiln of step (5). Residual fluoride as UO2F2 is less than 50 ppm and combined residual UO3 and U3O8 is less than 100 ppm total in the final UO2 of step (9). Blowback to clean the HF filters is standard practice and is constituted by short bursts of N2 at below sonic speeds, that is at less than 250 meters/second (m/s). The “active” powder of step (9) is capable of pressing to a density greater than 98.5 wt %. The term “active” as used herein means a UO2 powder that can be readily pressed into a pre-sintered (“green”) pellet that can withstand normal handling without chipping and cracking or end-capping and that when sintered produces a high density (>98% theoretical density) pellet without excessive chips or cracks or other flaws.
In the first step of the process, the steam to UF6 mole ratio can range from between about 2 to 10 moles steam per mole UF6, preferably from 4 to 8 moles steam per mole UF6. Varying the steam/UF6 ratio controls the temperature of the reaction which varies the properties of the UO2F2 powder that is produced as well as the final UO2 powder.
In the second step carried out in a separate kiln, the steam to hydrogen mole ratio can range from between about 1 to 10[?], that is 1 mole steam to 1 mole H2; to 1 mole steam to 10 moles H2. The residence time in the second kiln can range from between about 0.25 to 4.0 hours.
In both steps of the process, the preferred temperature can range from between about 400° C. to 700° C.



BRIEF DESCRIPTION OF THE DRAWINGS
In order to better understand the invention, embodiments of the present invention will now be described, by way of example only, with reference to the following accompanying drawings, in which:
FIG. 1 is a detailed schematic diagram of the method of this invention, showing hermetic gas blocking valve means between the flame reactor and rotary kiln, dual HF and steam gas filters and recirculation of entrained particulates back into the flame reactor;
FIG. 2 is a schematic, partially cross sectional view of the flame reactor nozzle and plume;
FIG. 3 is a schematic view of the hermetic gas blocking valve means in the form of a star valve, shown feeding to a screw feed transport means; and
FIG. 4 is a schematic, partly in section of one embodiment of a type of gas filter with particulate feedback and regular pulse valve inert gas blowback cleaning mechanism.



DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a two-step process for producing nuclear grade, active uranium dioxide (UO2) powder. The first step of the process comprises reacting uranium hexafluoride (UF6) with steam in a flame reactor to yield uranyl fluoride (UO2F2) and small amounts of uranium trioxide/uranium octaoxide (UO3/U3O8). The second step of the process comprises removing fluoride and reducing UO3/U3O8 and/or UO2F2 to uranium dioxide (UO2) in a rotary kiln, such as, for example, a calciner, under a steam/hydrogen atmosphere.
The term “flame reactor” means a reaction vessel operated to form a flame plume by reacting gas, such as uranium hexafluoride in an hydrolysis reaction with an oxidant such as steam, gaseous H2O at over about 300° C. to form a powder product and off gas, such as HF and excess steam. Nitrogen gas can be used as a buffer in a co-axial tubular jet or nozzle where usually steam is the outer reactant and uranium hexafluoride is the central reactant, the N2 being used as a buffer gas so that the reaction occurs and solid particles are formed some distance from the jet or nozzle tip, as also described in U.S. Pat. No. 5,757,087 (Carter et al.) and U.S. Pat. No. 6,136,285 (Feugier). The term “rotary kiln” means a rotating tubular pyrohydrolysis oven provided with heater means, powder feed means at an entry end and injector means near the reaction product exit for injecting a countercurrent flow of at least steam, gaseous H2O and H2 as generally described in U.S. Pat. No. 6,136,285 (Feugier).
Neither the “flame reactor” nor the “rotary kiln” are in any way related to or equivalent to “fluidized bed reactors”, which are described, for example in U.S. Pat. No. 4,053,559 (Hart et al.). The process of this invention is meant to specifically exclude fluidized beds, using instead a combination of flame reactor and rotary kiln. Fluidized beds are tanks that inject process gas at the bottom below the powders. At a high enough gas flow and with the proper gas distributor at the bottom, the powder then resembles a liquid in that it conforms to the vessel geometry and solid objects put on the top surface of the fluidized bed would sink if they were dense enough. The advantage of a fluidized bed is that heat transfer is very good throughout the bed and the bed is therefore essentially a single temperature. The disadvantage is that fluidization occurs over a very narrow particle size range for a given gas flow rate. If the particles are too small, they are blown out of the reactor with the off-gas (called elution). If they are too large, they sink to the bottom. In this reaction where particle sizes would range from very small (small amount of UF6 reacts with steam to form a small particle of UO2F2 to very large (UF6 reacts with steam near an already formed particle of UO2F2 to make that particle bigger) a fluidized bed would be very difficult to control. Large particles must be milled down to produce a sinterable powder.
The flame reactor concept makes and grows particles while they are entrained in a jet. By controlling the residence time in the jet, one can set the maximum sized particle that is produced. Particles that are finer stay entrained in the gas and are re-introduced to the flame reactor to grow to a larger size.
Referring now to FIG. 1 of the drawings, a multi-step process 10 is provided, where 1 mole of uranium hexafluoride gas (UF6) from a storage cylinder or the like 20 heated to between 65° C. and 175° C. by heater 22, and passed through line 24 to a flame reactor 12, through “flame reactor ejector” 14 having at least one nozzle 16, to react with 2 to 10 moles of steam 28 at a temperature of from 300° C. to 800° C. within at least one flame plume 18 to provide initial product uranyl fluoride (UO2F2) that do not agglomerate greater than about 0.01 to 40 micrometers, so there is little trapped fluoride which passes as powder particles 31 into hopper 21. The entrained fines will generally have a particle size of from 0.01 micrometer to 20 micrometers. Off gases HF, N2 and H2O are passed with entrained particles into first gas exit 30 and then as stream 42 to a fines filter 46. Additionally, HF, N2 and H2O with entrained particles are also withdrawn from the bottom of flame reactor 12 as recycle stream 11 by, for example, the passing recycle stream 11 to dry steam 35 through ejector 13 to pull a vacuum. This stream is then recycled with the dry steam back to the flame ejector reactor nozzle 14. The purpose of this recycle is to grow the very fine particles that are entrained into larger particles that will settle out in the hopper 21 by putting them back into the flame reactor. Inert N2 gas 26 can also be passed into nozzle 16, which nozzle preferably passes parallel gas streams in a concentric gas entry configuration, with a central UF6 stream and outer steam streams with a N2 stream therebetween separating the UF6 and steam at the nozzle so particles are not formed directly at the nozzle entry into the flame reactor 12. This is better shown in FIG. 2 of the drawings, where a flame plume 18 is shown. Preferably, in the first step of the process, the steam: UF6 mole ratio can range from between about 4 to 8 mole steam: 1 mole UF6.
Very importantly, to provide truly multi-step process, with no flow-back of gas that could contain hydrogen from subsequent steps, a “positive sealed valve means” 32 is required between the hopper 21 and any further steps, such as optional screw feeder 33. This is preferably in the form of a rotary vane star airlock valve, shown in FIGS. 1 and 3. The star valve rotates, which controls the flow of powder through the valve and prevents any significant amount of the gases from moving from the lower area to the upper area (or visa versa). By “significant amount” is meant less than 0.1 vol. % of gases used in the rotary kiln. The advantage of this type of valve over a screw feeder is that a positive seal is always provided whereas in a screw feeder, if the powder level gets too low, there is a direct path for gases to flow from the high to low pressure area or if the gas pressure in the second reactor is too high, the gas can blow through the powder back into the low pressure area. As shown in FIG. 3, powder particles 31 from the hopper 21 initially fill spaces between the vanes 23, which vanes turn to empty the particles into a subsequent apparatus, such as optional screw feeder 33. The vanes minimize potential backflow of gases harmful to step 1, such as H2 utilizing tight vane contact with the walls of the valve and gas lock spaces 15 references. Some gas can get into the volume between the vanes of the star valve, but this is minor. Another positive sealed approach would be the use of lock hoppers. The term “positive sealed valve means” means any device which minimizes gas backflow into the flame reactor.
Recycle line 34 takes particles from the fines filter 46 back to the flame reactor. The initial process UO2F2 powder as well as the minor amount of UO3 and U3O8 powder are transported by gravity, fall, or as shown in FIGS. 1 and 3 optional screw feeder 33, scroll member or sealed conveyor belt, or the like to a rotary kiln/calciner 36 having a containing kiln shell 28′ with heaters 39 surrounding the kiln. The kiln operates at a shell temperature of 400° C. at the UO2F feed end, to a maximum middle temperature of 700° C. and at a temperature of 100° C. to 300° C. at the UO2 product discharge end. The bed temperature is likely to be higher than the shell temperature due to the exothermic nature of the UO2F2+H2=>UO2+2HF reaction. However, at steady state, the bed temperature will be in equilibrium with the wall temperature wall temperatures. Use of temperatures over 700° C. will pre-sinter the powder and reduce the activity of the final product unless extreme particle size reduction is enforced upon the particles. A second optional positive seal valve 26 can be used at the exit of the screw feeder if desired, before entry into the rotary kiln.
At the UO2 solid exit end of the rotary kiln a parallel countercurrent flow of 5 moles to 30 moles of dry steam 80 and 5 moles to 50 moles H2, 81 plus inert N2, 82 carrier gas, per 1 mole UO2F2 powder is injected to remove fluoride as HF gas to reduce UO2F2 and UO3 and U3O8 to compressible UO2 powder having a particle size from 0.1 micrometers to 100 micrometers having a surface area from 2 meters2/gm to 7 meters2/gm, containing less than about 50 ppm UO2F2 residue and that can be pressed to a final sintered density greater than 98.5 wt. % of theoretical density.
The generated HF and unreacted H2 and steam plus N2 gases are exited preferably at the initial front end through second off-gas exit 38, feeding into second off-gas stream 44, and passing to separate fines filter 70. This second HF, steam, nitrogen and H2 off-gas exit 38 within the calciner is essential to the process as a means of maintaining a steady state pressure in the calciner. Also shown is a fines recirculation line 74 into fines kiln entry 72 back into the rotary kiln/calciner. A condenser 76 is also shown with a line pump 43 to remove HF as a liquid 78 and produce a fluoride free H2 which can then be burned or recycled.
As shown in FIG. 1, as the off gases and entrained particles from stream 42 and 45 pass into fines filter 46, HF and steam and nitrogen passes to stream 50 and into condenser 56 to provide clean HF liquid 58 for storage or sale. The nitrogen is discharged to the atmosphere. Additionally, trapped particulates are recirculated via recycle line 48 to the rotary kiln as the filter is cleaned via standard subsonic pulse valve 54 admitting N2 gas from pulse line 52 in a standard fashion well known in the art.
FIG. 4 shows a standard type fines filter shown as 46 or 70 in FIG. 1, with off-gas inlet stream 45, HF, steam and N2 and other off gas outlet stream 50, fines return recycle line 48 and pores 51 in the filter body 47. The gas passes through top filter portion 49 while particles collect generally on the filter body which utilizes a N2 subsonic blow-back valve 54 for cleaning the filter. Fines filter 70 shows N2 feed pulse gas line 52′ and pulse valve 54′.
Referring back to FIG. 1, a plurality of valves 40 are also shown as well as UO2 stream exit 60 into powder container 62 which can pass to pellet press 64 through line 61 to provide UO2 pellets 66.
EXAMPLE
The following example is intended to illustrate the invention and should not be construed as limiting the invention in any way.
Example
In the first reaction, the steam/UF6 ratio of 0.2 by weight with the temperature in the flame reactor of 400° C.
In the rotary kiln reaction, the steam/H2 ration=20 by weight, with the temperature held at a maximum 600° C. The steam/UO2 ratio is about 0.8 by weight
The UO2 powder surface area is equal to approximately 4 meters2/gm. The final density of pressed and sintered pellets was approximately 98.5%.
A positive valve seal—star valve is used between the first reaction and the rotary kiln.
While specific embodiments have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular embodiments disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.

## Claims

1. A multi-step process for producing nuclear grade, active uranium dioxide (UO2) powder by:
(1) reacting 1 mole of uranium hexafluoride gas (UF6) with 2 to 10 moles of steam, plus inert gas, in a first stage flame reactor having at least one flame, to yield initial product uranyl fluoride particles (UO2F2), HF gas and unreacted steam and inert gas, at a temperature of from 300° C. to 800° C.;
(2) passing HF gas, unreacted steam and inert gas, as well as gas entrained initial product particles to a filter, where all HF, unreacted steam and inert gas pass through the filter and entrained particles do not;
(3) passing the unentrained initial product uranyl fluoride particles through a positive valve means which passes powder, but prevents significant amounts of gaseous feedback from subsequent reactions into step (1);
(4) passing the initial product particles that pass through the positive sealed valve means into a second stage rotary kiln reactor, having a kiln shell and a temperature range at its kiln shell of from an initial 400° C. to 700° C. to a final temperature between 100° C. to 300° C., where uranyl fluoride particles are passed along the rotary kiln countercurrent to steam, hydrogen, and inert gas, to react and remove fluoride as HF gas and to reduce uranyl fluoride particles, to form a sinterable, outlet, UO2 powder;
(5) passing the HF gas, steam, inert gas, and unreacted H2 or steam and any entrained particles to a filter where all HF, steam, inert gas, and H2 gases pass through the filter and entrained particles do not;
(6) passing the particles that do not pass through the filters of steps (2) and (5) back into the flame reactor of step (1) or the kiln of step (4);
(7) condensing HF and steam gas into liquid HF from the filtered off-gases; and
(8) collecting UO2 powder from an outlet of step (4).

2. The method of claim 1, wherein step (1), generates less than 0.1 mole of at least one of oxide particles UO3 and U3O8 which are also formed and pass through the method.

3. The method of claim 1, wherein the inert gas is N2.

4. The method of claim 1, wherein the filtered entrained particles filtered in step (2) are recycled by means of a gas selected from the group consisting of inert gas or gases and steam and mixtures thereof back into the flame reactor of step (1).

5. The method of claim 4, wherein the gas is selected from the group consisting of N2 and steam and mixtures thereof and an ejector is used in the recycle stream.

6. The method of claim 1, wherein, in step 4, the inert gas is N2 and the sinterable UO2 powder formed has a particle size of from 0.1 micrometer to 100 micrometers.

7. The method of claim 1, wherein entrained particles in steps (2) and (5) have particle sizes from 0.001 micrometer to 0.1 micrometer and the inert gas used in step (5) is N2.

8. The method of claim 1, wherein the initial product that passes through the positive sealed valve means of step (3) is passed into the rotary kiln of step (5) by use of a screw feeder.

9. The method of claim 8, wherein a positive valve means is used between the screw feeder and the rotary kiln.

10. The method of claim 1, wherein the positive valve means is a rotary vane airlock valve.

11. The method of claim 9, wherein the positive valve means is a rotary vane airlock valve.

12. The method of claim 1, wherein the UO2 powder of step (8) has residual UO2F2 of less than 50 ppm and has a combined residual UO3 and U3O8 of less than 100 ppm.

13. The method of claim 1, wherein the filters are cleaned by inert gas blowback bursts with a through the nozzle velocity of less than 250 m/s.

14. The method of claim 1, wherein the collected UO2 powder of step (8) is pressed to a density greater than 98.5 wt. %.

15. The method of claim 1, wherein the outlet UO2 powder has a surface area from 2 meters2/gm to 8 meters2/gm.