PROCESS FOR TREATING NUCLEAR FUEL SCRAP

Abstract: High fluoride or high moisture content nuclear fuel scraps are treated in a pulsed powder bed reactor to remove those impurities and enable recycling of the treated scrap to a nuclear fuel fabrication process. In the removal of fluoride, the scrap is contacted with steam or steam and hydrogen, at a temperature of 500 to 650°C for a time sufficient to lower the fluoride content to a value of preferably below 20 ppm. In the removal of a high moisture content, the scrap is contacted with nitrogen at a temperature of 150 to 300°C for a period of time sufficient to lower the moisture content to a value of below 0.4 percent by weight.

Description: PROCESS FOR TREATING NUCLEAR FUEL SCRAP This invention relates to a process for treating nuclear fuel scrap. In the fabrication of nuclear fuel, nuclear fuel scrap is formed which must be treated and recycled to the fabrication process. During the conversion of uranium hexafluoride to uranium dioxide, for use as a nuclear fuel, uranium dioxide powder is often formed which has an excessive amount of fluoride content or moisture content. In the fabrication of fuel pellets, with formation of green pellets and sintering thereof to produce usable sintered uranium dioxide fuel pellets, scrap, such as rejected pellets, pellet chips, grinder dust and green scrap are also produced. The present invention is directed to a process for the treatment and recycling of high fluoride or high moisture content nuclear fuel scraps by a pulsed powder bed process that enables recycling of these scraps to the fuel pellet production system. As described in copending United States Patent Application Serial No. 340,593, Shuck et al, filed January 10, 1982, scrap treatment of certain scraps can be effected that converts the scrap into a form which can be combined with virgin uranium dioxide in the formation of fuel pellets. In said application, a process and apparatus are described which provide for the treatment of nuclear fuel fabrication scrap such as rejected green pellets, chips from pellets, grinder dust, green (unsintered) scrap, and rejected virgin powder, by fluidizing the scrap, oxidizing the scrap with oxygen at a temperature of less than 400at and then reducing the oxidized scrap with hydrogen at a temperature of between 400-7000C using a pulsed bed fluidizes The pulsed bed fluidizer, as described in said copending application comprises a fluidized bed reactor that consists of a cylindrical column having a conical lower portion and an enlarged upper portion. The fuel scrap is charged to the reactor and air, hydrogen, and inert gas lines pass to a mixer that mixes the gases, as desired, which mixed gases then pass to a surge tank and a pulse valve, which pulses the gas. The pulsed gas then passes to a preheater, and then is fed through gas inlets at a gas inlet assembly of the reactor. In the gas inlet assembly, the gas passes initially through a porous metal nozzle for partial fluidization of the scrap charge, which permits the gas to push up through the column. A conduit from the reactor is used to pneumatically remove the product, while off gases produced in the reactor pass through filters and are discharged from the top of the reactor. While the process as described in said copending application permits recovery of certain fuel scraps by an oxidation and reduction process, the same is not directed to processing and recycling of certain other types of nuclear fuel scraps. For example, in the conversion of uranium hexafluoride to uranium dioxide, for use in forming nuclear fuel pellets, scrap is produced which may be either high in fluoride content (F#), or which may be high in moisture content. These impurity-containing uranium dioxide scraps are not usable in the formation of nuclear fuel pellets and must be treated if they are to be recycled as usable materials. It is an object of the present invention to provide a process for treating nuclear fuel scrap in a pulsed powder bed reactor, which scrap is either high in fluoride content or high in moisture content. Accordingly, the present invention resides in a process for treating nuclear fuel scrap which comprises fluidizing said scrap in a pulsed powder bed reactor, characterized by contacting said scrap with a fluid stream within said pulsed powder fluidized bed for a period of time sufficient to remove from said scrap, impurities of high fluoride or high moisture content. Where the scrap contains a high fluoride content, the fluid conveniently comprises nitrogen gas wherein the scrap contains a high fluoride content and the fluid comprises nitrogen gas containing steam at a temperature of 500- 650 OC . The fluid may also contain hydrogen gas. Where the scrap contains a high moisture content, the fluid conveniently comprises nitrogen gas desirably at a temperature of 150-3000C and preferably about 2000C. The scraps are treated in a batchwise process and after treatment, may be used for formation of uranium dioxide nuclear fuel pellets. The present process provides for the treatment of nuclear fuel scrap which have either a high fluoride content or a high moisture content in a pulsed powder bed treatment step which enables recycling of the treated scrap for mixing with virgin fuel in the formation of nuclear fuel pellets. The nuclear fuel scrap treated according to the present process can come from pellets fabricated for light water reactors, which consist entirely of U021 or it can come from pellets fabricated for fast breeder fuel and consist of a mixture of U02 and Pu02 containing up to 15 percent Pu02. For the purposes of brevity, the following description will refer to U02 fuels, although the U02 and PuO2 mixed fuels are also subject to the present treatment process. In order that the invention can be more clearly understood, convenient embodiments thereof will now be described, by way of example, with reference to the accompanying drawing which is a flow chart illustrating the treatment of nuclear fuel scrap containing impurities of high fluoride or high moisture content. Referring to the drawing, uranium hexafluoride (UF6) is converted by known processes 1, to a uranium dioxide powder product, 2. The uranium dioxide product 2 is homogenized 3, and formed into green pellets 4 for use as a nuclear fuel. These green pellets 4 are sintered in a sintering furnace 5 and then ground to the desired size in a grinding operation 6, for use within cladding tubes, as uranium dioxide pellets. Pellet scraps or chips 7 which are unusable are sent to a pulsed powder bed treatment system 8, as described in aforementioned copending United States Patent Application Serial No. 340,593, where they are oxidized and then reduced and returned to be mixed with virgin uranium dioxide powder in the homogenization step 3, and formation of further fuel pellets. High fluoride content impurity or high moisture content impurity powders 9, which are separated from the uranium dioxide product 2 formed in the uranium hexafluoride conversion process 1, are also treated in a pulsed powder bed treatment system 8, for removal of the unwanted impurities such that these treated powders may also be mixed with virgin uranium dioxide powders for homogenization and formation of fuel pellets. In the conversion of uranium hexafluoride to uranium dioxide, by calcination, portions of uranium dioxide powder containing a high fluoride content are often formed. Such a product should normally contain a fluoride content of less than 50 parts per million. However, some of the product, so produced, may contain a fluoride content of up to 0.5 percent by weight, and as such, is considered as scrap. In the present process, a batchwise treatment of such high fluoride content nuclear fuel scrap may be treated to render it low enough in fluoride content as to be mixable with virgin uranium dioxide for use in fuel pellet production. The high fluoride content powder scrap is charged to a pulsed powder bed reactor and the scrap subjected to pulsed fluidized treatment with steam or a mixture of steam and hydrogen. In such treatment, the steam is charged to a stream of nitrogen gas or nitrogen gas containing a minor amount of hydrogen, and the mixed fluids passed to the preheater of the system and then to the pulsed reactor for contact with the high fluoride content scrap. The fluid stream is heated, for contact with the high fluoride content scrap, to a temperature of 500-6500C, with a temperature between 550-650 C preferred. The steam, or steam and hydrogen fluid, strips the fluoride, primarily as hydrogen fluoride, from the scrap material, with the reaction products formed discharged with the off gas stream from the reactor. The contact time for the fluid stream with the high fluoride content scrap is that sufficient to lower the fluoride content of the scrap to below 50 parts per million (ppm) by weight, and preferably below 29 ppm. Contact times of about 2-3 hours are preferred, using temperatures of 500-6500C. After treatment at said temperature, the low fluoride content material is dried by passage of nitrogen gas therethrough. An especially useful fluid stream for the removal of the high fluoride content of the scrap at temperatures of 500-6500C is a fluid stream comprised of 3.5 percent steam, 0-5 percent hydrogen, and 90-97 percent nitrogen, by weight. In the treatment of high moisture content powder scrap, which can contain up to one percent by weight of moisture, the scrap is charged to the pulsed powder bed reactor and contacted with a stream of heated dry nitrogen. The temperature of the nitrogen should be 150-300 C, with a temperature of about 2000C being preferred. The contact of the high moisture content scrap with heated nitrogen should be for a period of time sufficient to lower the moisture content to below 0.4 percent by weight. Contact times of 1-2 hours, using a temperature of about 2000C is sufficient. With the use of the present process, where a pulsed powder bed reactor is used to treat high fluoride and high moisture content nuclear fuel scraps, such a pulsed powder bed reactor system is usable in the treatment of the fuel waste or scrap materials from a nuclear fuel fabrication system. Thus, this enables the batchwise use of a single pulsed powder bed reactor system in overall treatment of such nuclear fuel scraps. IDENTIFICATION OF REFERENCE NUMERALS USED IN THE DRAWINGS LEGEND REF. NO. FIGURE LF, CONVERSION 1 1 b02 POWDER PRODUCT 2 1 HOMOGENIZATION 3 1 GREEN PELLETS 4 1 SINTERING FURNaCE 5 1 GRINDING OPERATION 6 1 PELLET SCRAPS OR CHIPS 7 1 PULSED POWDER BED TREATMENT 8 1 HIGH F-POWDER OR HIGH MOISTURE POWDER 9 1

Claims: CLAIMS: 1. A process for treating nuclear fuel scrap which comprises fluidizing said scrap in a pulsed powder bed reactor, characterized by contacting said scrap with a fluid stream within said pulsed powder fluidized bed for a period of time sufficient to remove from said scrap impurities of high fluoride or high moisture content. 2. A process according to claim 1, wherein the scrap contains a high fluoride content and the fluid comprises nitrogen gas containing steam at a temperature of 500-6500C. 3. A process according to claim 2, characterized in that the fluid also contains hydrogen gas. 4. A process according to claim 3, characterized in that the fluid comprises 3-5 percent by weight steam, up to 5 percent by weight hydrogen and nitrogen. 5. A process according to claim 2, 3 or 4, characterized in that the temperature is 550-650 C. 6. A process according to any of claims 1 to 5, characterized in that the fluid is in contact with said nuclear fuel scrap for a period of 2-3 hours. 7. A process according to claim 1, characterized in that the nuclear fuel scrap contains a high moisture content and the fluid comprises nitrogen gas. 8. A process according to claim 7, characterized in that the nitrogen gas is at a temperature of l50-3000C. 9. A process according to claim 8, characterized in that the nitrogen gas is at a temperature of about 2000C. 10. A process according to claim 7, 8 or 9, characterized in that the nitrogen gas is in contact with the nuclear fuel scrap for a period of 1-2 hours. 11. A process according to any of claims 1 to 6, characterized in that the nuclear fuel scrap contains in excess of 50 ppm fluoride, while the nuclear fuel end product contains less than 20 ppm fluoride. 12. A process according to any of claims 7 to 10, characterized in that the nuclear fuel scrap contains up to 1 percent by weight moisture while the nuclear fuel end product contains less than 0.4 percent by weight moisture.

Inventors: CHIEH WU, CHRISTOPHER KUO, SHAH, HEMANT HIRALAL
Applicants: WESTINGHOUSE ELECTRIC CORPORATION
Application year: 1985
Main classification: G21C3
IPC codes: G21C3, G21C19