METHOD FOR PRODUCING URANIUM OXIDE FROM URANIUM TETRAFLUORIDE AND A SOLID OXIDE COMPOUND

Abstract: A method for producing uranium oxide includes combining uranium tetrafluoride and a solid oxidizing agent having a lower thermodynamic stability than the uranium oxide; heating the combination below the vapor point of the uranium tetrafluoride to sufficiently react the uranium tetrafluoride and the oxidizing agent to produce uranium oxide and a non-radioactive fluorine compound; and removing the fluorine compound.

Description: METHOD FOR PRODUCING URANIUM OXIDE FROM URANIUM TETRAFLUORIDE AND A SOLID OXIDE COMPOUND FIELD OF INVENTION This invention relates to a method for producing uranium oxide and more particularly to a method for converting uranium tetrafluoride into uranium oxide and producing a non-radioactive fluorine compound which is free of contaminants. BACKGROUND OF INVENTION Uranium is a naturally occurring element which is comprised of approximately 0.7% ∞ ϋ and 99.3 238 U. ^U is used to produce Nuclear Energy, while S8 U is not. Because of the low percentage of a5 U found in naturally occurring uranium, naturally occurring uranium must be enriched in order to obtain sufficient amounts of S5 U to support nuclear fission. This enrichment process, aside from producing high concentrations of S5 U, produces huge amounts of depleted uranium hexafluoride (UF 6 ) by-product which is a very hazardous compound posing a serious health threat. Since depleted uranium metal is radioactive and expensive to produce, it is used in limited quantities for highly specialized applications. Accordingly, alternative uses are needed in order to avoid having to dispose of the UF 6 at great expense by storing it ^definitely. One solution to reducing the large stores of UF 6 is to convert the UF 6 into uranium oxide, e.g. UO 2 or U 3 O 8 . One use for uranium oxide is to add it to the concrete which is used to build bunkers in which radioactive waste is stored in order to provide high density shielding for the stored high level radioactive waste. Uranium oxide possesses outstanding radioactive shielding properties and when added to concrete in the form of aggregate makes a very effective, low cost shielding material. There are many methods which can be used to convert UF 6 into uranium oxide. Many of these methods also produce potentially valuable by-products. However, methods which are currently used to convert the UF 6 into uranium oxide taint these valuable by-products with radioactive uranium, rendering the by-products commercially unusable, requiring additional processing to remove the radioactivity, as well as additional contaminants, or disposing of the by-products as low level radioactive waste. The most common method for producing uranium oxide includes reacting uranium hexafluoride with steam (H 2 O) and hydrogen (β__). This produces uranium oxide and hydrogen fluoride gas (HF). However, because the products and reactants are mixed in the gas phase, this HF gas, although having economic value, is contaminated by unreacted uranium thus reducing its value as discussed above. Moreover, it is highly diluted with water, due to the steam, further reducing its value. Another method for producing uranium oxide reacts UF 6 with H 2 to produce uranium tetrafluoride (UF 4 ) and HF gas. The UF 4 is then reacted with steam to produce a uranium oxide, UO 2 or U 3 O 8 , and HF gas. However, the reverse reaction is so strong that tremendous amounts of steam must be used to avoid a reverse reaction. This not only requires a large amount of energy to produce the steam, but again produces a highly diluted hydrogen fluoride product that has little commercial value, requiring further processing to obtain a valuable product. Moreover, complete conversion to uranium oxide is nearly impossible thereby degrading the uranium oxide's suitability for making concrete and thus the value of the uranium oxide produced. Accordingly, the major drawbacks of the presently preferred methods are that the HF is diluted and contaminated with some amount of uranium making it commercially unusable. Thus, while HF has some economic value, the uranium contamination reduces this value and further provides yet another storage dilemma, as encountered with all radioactive waste, or additional processing to purify the HF. Moreover, these methods are very expensive. Thus, an economical way to convert UF 6 to uranium oxide is needed in order to make use of the large quantities of UF 6 in storage and produce commercially valuable by-products which are not radioactive and require no additional processing. SUMMARY OF INVENTION It is therefore an object of this invention to provide a method for producing uranium oxide from uranium tetrafluoride; It is a further object of the present invention to provide such a method which produces uranium oxide without radioactive by-products. It is a further object of the present invention to provide such a method which produces a fluorine compound which is free from radioactive contaminants; It is a further object of the present invention to provide such a method which produces a fluorine compound which is undiluted with water; It is a further object of the present invention to provide such a method which completely reacts the uranium tetrafluoride into uranium oxide. It is a further object of the present invention to provide such a method which is cost effective to implement; The invention results from the realization that a truly efficient and cost effective method for producing uranium oxide can be achieved by combining uranium tetrafluoride and a solid oxidizing agent, having a lower thermodynamic stability than any uranium oxide produced, in stoichiometric proportion so that when the combination is heated to a temperature below the vapor or melting point of the uranium tetrafluoride or the solid oxide the uranium tetrafluoride completely reacts with the oxidizing agent to produce uranium oxide and a volatile fluorine compound free from radioactive carryover and other contaminants. This invention features a method for producing uranium oxide including combining uranium tetrafluoride and a solid oxidizing agent having a lower thermodynamic stability than the uranium oxide to be produced, heating the combination below the vapor point of the uranium tetrafluoride to sufficiently react the uranium tetrafluoride and the oxidizing agent to produce uranium oxide and non- radioactive fluorine compound, and removing the fluorine compound. In a preferred embodiment, the uranium tetrafluoride and the oxidizing agent are combined in stoichiometric proportion. The oxidizing agent may include a solid metal oxide that reacts with uranium tetrafluoride to produce a volatile fluorine compound. The oxidizing agent may include a solid metal oxide that reacts with the uranium tetrafluoride to produce a gaseous fluorine compound. The method may further include introducing oxygen to the reaction. Heating may include heating the combination in a temperature range of 400°C to 1000°C. The oxidizing agent may be selected from the group of oxides of phosphorus, germanium, arsenic, thallium, antimony, titanium, zirconium, tungsten and niobium. The uranium oxide produced may include U 3 O 8 . The fluorine compound produced may include PF 5 , AsF 3 , SbF 5 , SbF 3 , WF 6 , or TIF. The uranium oxide produced may include UO 2 . The fluorine compound produced may included GeF 2 , GeF 4 , NbF 5 , TiF 4 , or ZrF 4 . The oxidizing agent may include B^. The uranium oxide produced may include U 3 O 8 and the fluorine compound may include BF 3 . The uranium tetrafluoride may be powdered and the oxidizing agent may be granular or powdered. Heating may include heating the combination below the melting point of the oxidizing agent. Heating may include heating the combination below the melting point of the uranium tetrafluoride. The invention also features uranium oxide produced by the combining uranium tetrafluoride and a solid oxidizing agent having lower thermodynamic stability than the uranium oxide to be produced, heating the combination below the vapor point of the uranium tetrafluoride to sufficiently react the uranium tetrafluoride and the oxidizing agent to produce the uranium oxide and a non-radioactive fluorine compound, and removing the fluorine compound. In a preferred embodiment the uranium oxide may be UO 2 . The uranium oxide may be U 3 O 8 . The invention also features boron trifluoride produced by combining uranium tetrafluoride and boric oxide, heating the combination below the vapor point of the uranium tetrafluoride to sufficiently react the uranium tetrafluoride and the boric oxide to produce a uranium oxide and the boron trifluoride, and removing the boron trifluoride. DISCLOSURE OF PREFERRED EMBODIMENT Other objects, features and advantages will occur to those skilled in the art from the following description of a preferred embodiment and the accompanying drawings, in which: FIG. 1 is a block diagram of the method for producing uranium oxide according to the present invention; FIG. 2 is a flow chart of the method for producing uranium oxide according to the present invention; FIG. 3 is a schematic diagram of the apparatus used to produce the uranium oxide and fluorine product according to the present invention; FIG. 4 is a representation of an x-ray diffraction analysis performed on the uranium oxide produced according to the method of the present invention compared to a standard x-ray diffraction pattern for UO 2 ; FIG. 5 is a representation of an x-ray diffraction analysis performed on the uranium oxide produced according to the method of the present invention compared to a standard x-ray diffraction pattern for U 3 O 8 ; FIG. 6 is a representation of an x-ray diffraction analysis performed on sodium fluoride, obtained from reacting the fluorine compound produced according to the method of the present invention with a scrubbing agent, compared to a standard x-ray diffraction pattern for sodium fluoride to verify the presence of the fluorine compound produced; and FIG. 7 is a representation of an x-ray diffraction analysis, similar to FIG. 5, in which the x-ray diffraction is performed on sodium fluoroborate obtained from reacting the fluorine compound BF 3 with a scrubbing agent. Uranium hexafluoride UF 6 is reacted with hydrogen H 2 to produce uranium tetrafluoride (UF 4 ) 10, FIG. 1. The UF 4 10 is combined with a solid oxidizing agent 12, and the combination is heated 14 below the vapor or melting point of UF 4 10 to produce uranium oxide and a fluorine compound 16 without uranium carryover. The non-radioactive fluorine compound is then removed 18, for example by gas separation, leaving only the completely reacted uranium oxide 20, and collected 22. The UF 4 , or green salt, which may be granular, is combined in stoichiometric proportion to the oxidizing agent, block 24, FIG. 2. This ensures that the UF 4 is completely reacted. The oxidizing agent may be mixed, however, in slight excess of its stoichiometric proportion. The oxidizing agent is chosen such that it has a lower thermodynamic stability than any oxide of uranium, UO 2 or U 3 O 8 , which may be produced. This is done so that when the combination is heated to sufficiently react the oxidizing agent with the uranium tetrafluoride, block 26, the solid oxide compound readily gives up its oxygen and an oxide of uranium and a volatile, or gaseous, fluorine compound are produced, block 28. In some instances oxygen may be added, block 25 shown in phantom, in the form of dry air for example, in order to obtain a desired oxide of uranium. However, the combination is heated, block 26, only to a temperature below the melting point, or at most the vapor point of the uranium tetrafluoride and oxidizing agent, typically within a temperature range of 400°C to 1000°C. Heating the combination below the vapor point or melting point of either component prevents vaporization of the uranium, ensuring that the uranium does not enter the gaseous phase and thus contaminate the fluorine product with radioactive uramum, and that the fluorine compound produced is not contaminated by any other compound, but remains essentially pure. Moreover, heating the stoichiometric combination below either the vapor or melting point of UF 4 further ensures that the UF 4 completely reacts with the oxidizing agent, because no unreacted uranium is lost to the fluorine compound. Producing a volatile or gaseous fluorine compound allows the uranium oxide and fluorine compound to be easily separated so that the nonradioactive fluorine compound may be removed, block 30. Once the fluorine compound has been removed, block 32, for example by scrubbing the fluorine compound using an adsorbent bed or trapping the fluorine compound with a reactive agent to separate out the fluorine compound, the fluorine compound can be collected, block 34. This is not a necessary limitation of the invention, however, as the fluorine compound may be directly collected. The fluorine compound is recovered from the bed material or trap residue through heat decomposition, well known in the art. Thus, by heating the UF 4 below its vapor or melting point ensures not only that the fluorine compound is not contaminated by unreacted uranium, but that all the uranium tetrafluoride is reacted due to the stoichiometric proportions in which the combination was mixed and the elimination of uranium carryover, producing a valuable oxide of uranium. Choosing an oxidizing agent having a lower thermodynamic stability than any oxide of uramum which may be produced, as determined by the enthalpy of formation, further ensures the uranium tetrafluoride is completely reacted. For example, U 3 O 8 has a an enthalpy of formation of 854.1 kcal/mole, as shown in Table 1. TABLE 1 When the oxidizing agent is a metal oxide such as BjO;,, having an enthalpy of formation of 306.1 kcal/mole, the B^ readily gives up its oxygen which is readily accepted by the uranium to produce, UO 2 and U 3 O 8 and BF 3 according to the reactions 3UF 4 (s) + 2BA(s) + O 2 (g) _> U 3 O 8 (s) + 4BF 3 (g) (1) 3UF 4 (s) + 26,0,(8) → 3UO 2 (s) + 4BF 3 (g) (2) Other oxides that may be used and the fluorine compounds that may be produced are shown in Table 2. TABLE 2 However, this is not a necessary limitation of the invention as these oxides exist in multiple oxidation states, well known in the art. Thus, different oxides of phosphorous (P), germanium (Ge), arsenic (As), thallium (Tl), antimony (Sb), titanium (Ti), zirconium (Zr), Tungsten (W), or Niobium (Nb) may be used as an oxidizing agent in addition to those described above. Examples of the reactions which produce the above compounds include: 15UF 4 + 6P 2 O 5 + 5O 2 → 5U 3 O 8 + 12PF 5 (3) UF 4 + GeO 2 _> UO 2 + GeF 4 (4) 3UF 4 + 2A _> U 3 O 8 + 4AsF 3 + O 2 (5) 3UF 4 + 6Tl 2 O 3 → U 3 O 8 + 12T1F + 5O 2 (6) 3UF 4 -f- 2Sb 2 O 3 + 0 2 → U 3 O 8 + 4SbF 3 (7) 2UF 4 + 2TiO + O 2 → 2UO 2 + 2TiF 4 (8) UF 4 + ZrO 2 _> UO 2 + ZrF 4 (9) 3UF 4 + 2WO 3 + O 2 _> U 3 O g + 2WF 6 (10) 5UF 4 + 4NbO 2 + 0 2 → 5UO 2 + 4NbF 5 (11) UF 4 + 2GeO 2 __> UO 2 + 2GeF 2 + O 2 (12) 15UF 4 + 6Sb 2 O 3 + 110 2 _> 5U 3 0 8 + 12SbF 5 (13) Depending on the oxide chosen, additional oxygen, O 2 , may be introduced to the reaction in order to obtain the desired oxide of uranium, UO 2 or U 3 O 8 . EXAMPLE An amount of 9.9 grams of uranium tetrafluoride was combined with 3.0 grams of boric oxide. The combination was vigorously shaken for ten minutes to thoroughly mix the combination. The combination 36, FIG. 3, was transferred to a high density, non-porous, alumina (99.8%) ceramic crucible 38. The crucible was then placed at the bottom of larger vessel 40, made of the same material and sealed with corrosion resistant monel metal cap 42 and ultra high temperature RTV silicon gasket compound 44. Cap 42 has inlet ports 46 and outlet port 48 for allowing the gas to flow through vessel 40. Sealed vessel 40 was placed in a crucible furnace, not shown. For this particular example, inlet ports 46 were capped and second vessel 50, containing sodium hydroxide (NaOH) for scrubbing the reaction effluent, was connected to outlet port 48. Vessel 40 was heated to 600°C in 3°/min. increments and maintained for three hours thereafter. Vessel 40 was cooled to ambient temperature in 3°/min. increments and crucible 38 removed from vessel 40. Post reaction residue 52, shown in phantom, was black color, and flowed easily from crucible 38. Conversion of UF 4 to U 3 O 8 and UO 2 was essentially complete, nearly 100% yield as determined by percent dissolution in nitric acid. Uranium oxides, namely UO 2 and U 3 O 8 , are very soluble in concentrated nitric acid while UF 4 is relatively inert and is slow and difficult to dissolve. This characteristic can be used to test for the presence of unreacted UF 4 in the residue of the reactor chamber. One gram of residue is added to 5ml of concentrated nitric acid followed by the addition of 3 ml of distilled H 2 O. the resultant mixture is then thoroughly stirred for twenty minutes after which the solution is filtered to separate any undissolved solids. The filtered solids are then washed thoroughly with H 2 O, dried and weighed. The percent of unreacted UF 4 is calculated as follows: % Unreacted UF 4 = (weight of filter residue/one gram of initial solid residue) x 100 The overall reaction yield is given by: Yield = 100 - % Unreacted UF 4 Verification of complete reaction of the products to produce oxides of uranium was achieved using x-ray powder diffraction analysis on post reaction residue 52. X- ray diffraction pattern 54, FIG. 4, of the product residue was compared to a standard x-ray diffraction reference pattern 56, for UO 2 . The correlation of peaks 101-115 of reaction pattern 54 with peaks 101'-115' of UO 2 reference pattern 56 indicates the presence of UO 2 in post reaction residue, 52, FIG. 3. Similarly, the correlation of peaks 201-219 of reaction residue pattern 54, FIG. 5, with peaks 201'-219' of U 3 O 8 reference pattem 58 indicates the presence of U 3 O 8 in post reaction residue 52, FIG. 3. The absence of non-correlating peaks, when FIGS. 4 and 5 are taken as a whole, confirms the absense of unreacted uranium. Verification of the fluorine compound may be done in several ways to include collection of the gaseous BF 3 and rjerforming gas analysis, passing the fluorine compound over an adsorbent bed and analyzing the bed material, or chemically reacting the fluorine compound in a trap and analyzing the product using x-ray diffraction as discussed above. The reaction occurring in the trap in this particular example is given by the equations: 6NaOH + 8BF 3 → BA + 6NaBF 4 + 3H 2 O (12) 2BF 3 + 3NaOH → 3NaF + B + HF (13) Verification of BF 3 was done indirectly using x-ray (hTfraction on the sodium fluoride (NaF) and sodium fluoroborate (NaBF 4 ) produced. X-ray diffraction pattern 60, FIG. 6, of the reaction residue was compared to theoretical reference pattern 62 for NaF. The correlation of peaks 301-310 of reaction pattern 60 and peaks 301'-310' of theoretical reference pattern 62 indicates the presence of BF 3 in the residue. Similarly, verification of NaBF 4 was done using x-ray diffraction. X-ray diffraction pattem 60, FIG. 7, of the trap reaction residue was compared to theoretical reference pattem 64 for NaBF 4 . The correlation of peaks 401-412 of reaction pattern 60 and peaks 401'-412' of theoretical reference pattern 64 indicates the presence of NaBF 4 , and thus indicates the presence of BF 3 . Thus, verification of NaF and NaBF 4 indirectly verifies the presence of BF 3 based on the equations (3) and (4) set forth the above. Moreover, the absense of non- correlating peaks confirms the absense of unreacted uranium. The BF 3 may be collected through heat decomposition of NaBF 4 by heating the trap residue to 400°C. Thus, the method according to the present invention not only reacts all of the uranium, but produces a fluorine compound of very high purity by heating the stoichiometric combination below the vapor or melting point of the uranium tetrafluoride and the metal oxide. The uranium tetrafluoride completely reacts to produce uranium oxide without radioactive carryover into the fluorine compound byproduct producing a commercially valuable product without requiring additional processing or low level radioactive storage. Converting uranium oxide from uranium tetrafluoride, rather than directly from uranium hexafiuoride, produces less radioactive and diluted HF than if all the fluorine value in UF 6 was converted to HF. Although specific features of this invention are shown in some drawings and not others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. Other embodiments will occur to those skilled in the art and are within the following claims: What is claimed is:

Claims: CLAIMS 1. A method for producing uranium oxide comprising: combining uranium tetrafluoride and a solid oxidizing agent having lower thermodynamic stability than the uranium oxide to be produced; heating the combination below the vapor point of the uranium tetrafluoride to sufficiently react the uranium tetrafluoride and the oxidizing agent to produce uramum oxide and a non-radioactive fluorine compound; and removing the fluorine compound. 2. The method of claim 1 in which combining includes combining the uranium tetrafluoride and the oxidizing agent in stoichiometric proportion. 3. The method of claim 2 in which the oxidizing agent includes a sohd metal oxide that reacts with the uranium tetrafluoride to produce a volatile fluorine compound. 4. The method of claim 2 in which the oxidizing agent includes a sohd metal oxide that reacts with uranium tetrafluoride to produce a gaseous fluorine compound. 5. The method of claim 1 in which heating further includes introducing oxygen to the reaction. 6. The method of claim 1 in which heating includes heating the combination in the temperature range of 400°C to 1000°C. 7. The method of claim 6 in which the oxidizing agent is selected from the group of oxides of phosphorus, germanium, arsenic, thallium, antimony, titanium, zirconium, tungsten and niobium. 8. The method of claim 7 in which the uranium oxide produced includes U 3 O 8 . 9. The method of claim 8 in which the fluorine compound includes PF 5 . 10. The method of claim 8 in which the fluorine compound includes AsF 3 . 11. The method of claim 8 in which the fluorine compound includes TIF. 12. The method of claim 8 in which the fluorine compound includes a fluoride of antimony. 13. The method of claim 8 in which the fluorine compound includes WF 6 . 14. The method of claim 8 in which the fluorine compound includes NbF s . 15. The method of claim 7 in which the uranium oxide produced includes UO 2 . 16. The method of claim 15 in which the fluorine compound includes a fluoride of germanium. 17. The method of claim 15 in which the fluorine compound includes TiF 4 . 18. The method of claim 15 in which the fluorine compound includes ZrF 4 . 19. The method of claim 1 in which the oxidizing agent includes BA. 20. The method of claim 19 in which the uranium oxide produced includes U 3 O 8 . 21. The method of claim 20 in which the fluorine compound includes BF 3 . 22. The method of claim 1 in which the uranium tetrafluoride includes powdered uranium tetrafluoride. 23. The method of claim 22 in which the oxidizing agent includes a granular oxidizing agent. 24. The method of claim 22 in which the oxidizing agent include a powdered oxidizing agent. 25. The method of claim 1 in which heating further includes heating the combination below the melting point of the oxidizing agent. 26. The method of claim 1 in which heating further includes heating the combination below the melting point of the uranium tetrafluoride. 27. Uranium oxide produced by the process of: combining uranium tetrafluoride and a sohd oxidizing agent having lower thermodynamic stability than the uranium oxide to be produced; heating the combination below the vapor point of the uranium tetrafluoride to sufficiently react the uranium tetrafluoride and the oxidizing agent to produce said uranium oxide and a non-radioactive fluorine compound; and removing the fluorine compound. 28. The product of claim 1 in which said uranium oxide is UO 2 . 29. The product of claim 1 in which said uranium oxide is U 3 O 8 . 30. Boron trifluoride produced by the process of: combining uranium tetrafluoride and boric oxide; heating the combination below the vapor point of the uranium tetrafluoride to sufficiently react the uranium tetrafluoride and the boric oxide to produce a uranium oxide and said boron trifluoride; and removing said boron trifluoride.

Inventors: BULKO JOHN B, NACHTRAB WILLIAM T, BULKO, JOHN, B., NACHTRAB, WILLIAM, T.
Applicants: STARMET CORP, STARMET CORPORATION
Application year: 1999
Main classification: C01G43
IPC codes: C01B9, C01G1, C01G43