Dry Process Fluorination of Uranium Dioxide Using Ammonium Bifluoride LIBRARIES SCIENCE
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Dry Process Fluorination of Uranium Dioxide Using Ammonium Bifluoride by Charles Burnett Yeamans B.S., Chemical Engineering and Nuclear Engineering (2001) University of California, Berkeley Submitted to the Department of Nuclear Engineering as One Element of Fulfillment of the Requirements for the Degree of Master of Science in Nuclear Engineering at the MASSACHUSETTS INSTIl UTE Massachusetts Institute of Technology OF TECHNOLOGY 0 5 200 September 2003 DEC 3 LIBRARIES © 2003 Massachusetts Institute of Technology all rights reserved Signature of Author: W Department of Nuclear Engineering June 30, 2003 Certified by: Kenneth R. Czerwinski Associate Professor of Nuclear Engineering Thesis Supervisor Certified by: . John R. FitzPatrick Techn1 '' ' ;al Laboratory Fhesis Reader Accepted by: Jeffery Coderre Chair, Department Committee on Graduate Studies SCIENCE THIS PAGE INTENTIONALLY LEFT BLANK Dry Process Fluorination of Uranium Oxides using Ammonium Bifluoride by Charles Burnett Yeamans Submitted to the Department of Nuclear Engineering as Partial Fulfillment of the Requirements for the Degree of Master of Science in Nuclear Engineering ABSTRACT An experimental study was conducted to determine the practicality of various unit operations for fluorination of uranium dioxide. The objective was to prepare ammonium uranium fluoride double salts from uranium dioxide and ammonium bifluoride, then decompose these salts to uranium tetrafluoride through heating to temperatures near 425 'C in either a fluidized bed or a stirred bed. Fluorination in the stirred bed was attempted without pretreatment of the reagents. For the fluidized bed experiments, reagents were ball-milled prior to being heated in the bed. Experiments were conducted in either argon or 4% hydrogen in argon. The ball mill appeared to be an effective technique for fluorinating uranium dioxide with ammonium bifluoride. Samples changed color from brown to bright green, and no oxides could be detected in the x-ray diffraction pattern of the product. It was found that stainless steel is a suitable material of construction for reaction vessels, whereas mild steel parts corroded quickly. Only a small degree of fluidization provided adequate mixing in fluidized beds, but a paddle mixing the stirred beds left an unmixed region around the bed perimeter. Results from the stirred beds showed the initial fluorination reaction completed only when the reagents were heated to 110 'C for at least three hours under argon. Decomposition took place under argon with a temperature ramp up to 425 'C. The product UF 4 contained less than 1%oxide as an impurity, and the decomposition appeared to be complete. Fluidized beds were run with both argon and 4% hydrogen in argon as carrier gases. Experiments with 4% hydrogen in argon produced uranium tetrafluoride, with ammonium uranium pentafluoride and uranium dioxide as impurties. Experiments in argon produced uranium tetrafluoride, with uranyl difluoride, ammonium diuranyl pentafluoride and triuranium octoxide as impurities. Minimum temperatures and times needed to decompose the double salt in the fluidized beds were 200 minutes at 115 'C, a 500-minute ramp to 425 *C, and 200 minutes at 425 'C. The intermediate double salt produced at 110 'C appeared to be triammonium uranium septafluoride. Thesis Supervisor: Kenneth R. Czerwinski Associate Professor, Department of Nuclear Engineering Thesis Reader: John R. FitzPatrick Technical Staff Member, Los Alamos National Laboratory THIS PAGE INTENTIONALLY LEFT BLANK Dedicated to Steve Yeamans, Bill Burnett, and David Pierce In Los Alamos: Michael Martinez was absolutely indispensable, and without him I'm sure I never would have completed this project. Bobby Gonzalez, Gene Zimmerman, and Toby Romero got me the stuff to keep my equipment running, whether it had to be bought, made, borrowed, or "borrowed." Lorraine Vigil shoveled through the snowstorm of paperwork, and Louis Rivera kept me company, as was required by security regulations. Brad Shake made sure I had the tools and safety glasses I needed. Amy Canstefneda did most of the preliminary work without being able to take much credit. The library staff humored my requests for obscure articles from long-defunct journals and found most of them among dusty storage room shelves. In Cambridge: Karen Noyes, Gini Curran, and Jon Plaue know all the secret doors, cabinets, handshakes, signs, rooms, and forms it takes to navigate through MIT, as well as answering all of my stupid questions about where to find things. Mathieu Salanne translated all of my French and Belgian references, and for that I owe him a hamburger and French fries (which he informs me are actually Belgian). In addition to that, his work on the project I was supposed to be doing was nothing short of phenomenal, thus diverting enough attention from me to work on this one without harassment. Andy Gallant suggested enough changes to my experimental equipment such that it would actually be possible to construct, and then streamlined it through the machine shop ahead of all the undergraduate thesis projects. The University of California, Berkeley Department of Nuclear Engineering will allow me to pursue my dream of cleaning up other people's radioactive garbage now that MIT has given up on it. Per Peterson talked me into being a nuclear engineer because it's important. My advisor Ken Czerwinski, a.k.a. Flipper and a member of the LFHCfS, continues to be the grooviest cat ever to grace the sciences. He has given me the freedom to do this project for no better reason than I wanted to pursue it. As always, he sends his love. John FitzPatrick came up with this whole idea, and then let me take it with me. I'd like to thank any deities and/or godlike entities who may have assisted me in this project, although no such help was solicited nor knowingly accepted. Apologies: Susan KcKinney, I'm sorry I argued so much that you had to kick me out of high school chemistry. All molecular motion does cease at 0 *C and I was wrong to insist that it didn't. To the sociology department at Berkeley, sociology is not a "pseudoscience," nor is its research methodology "systematically and pathologically unscientific." I was wrong to say those things, among others, and I'm sorry I made your Sociology 3 professor cry. Louie Cernicek, sorry about your back yard, man. Next time I'll do a more thorough job of gluing the fins on the rocket. Mrs. Fox, I never should have flipped you off. That was very rude of me, even though you deserved it. Mrs. Dorin, it was petty of me to repeatedly suggest that it was both trivial and pointless to complete ream after ream of long-division practice sheets. I can't imagine where my life would be without long division... oh the long division I have done since then. You were right to give me even more reams of long-division practice sheets to teach me how to be a better human being. Oh, and I'm sorry I flipped you off, even though you deserved it. Principal Paluzcek, elementary school was not "a big fat waste of my time" and you and your teachers were not "glorified babysitters" and I'm sorry about attempting to tamper with your brakes. In addition, I apologize for making you spend so much time talking to me about my behavior. I can't help but think that if I had just been quiet, paid attention, walked on the sidewalk, followed the rules, and done as I was told I could have done something with my life... maybe even gone to college. Oh, and I'm sorry I flipped you off, even though you deserved it. Contents page Abstract 3 Acknowledgements Contents List of Figures List of Tables Chapter 1: Introduction 11 1.1 Motivation 11 1.2 Experimental Overview 12 Chapter 2: Background 13 2.1 Physical and Chemical Properties of Uranium Compounds 13 2.1.1 Oxides 13 2.1.2 Fluorides and Ammonium Fluorides 14 2.2 Chemical Behavior of the Ammonium-Uranium-Fluoride System 14 2.3 Common Methods for Preparation of Uranium Tetrafluoride 17 2.4 Fluidized Bed Technology in Uranium Processing 17 2.5 Fluidized Bed Behavior 17 Chapter 3: Experimental Equipment and Procedure 21 3.1 General Considerations 21 3.2 Experimental Descriptions 21 3.2.1 Ambient Temperature Fluorination 21 3.2.1.1 Unagitated Reactants 21 3.2.1.2 Manually Agitated Reactants 22 3.2.1.3 Mechanically Agitated Reactants 22 3.2.2 Stirred Bed 22 3.2.3 Fluidized Beds 24 3.2.3.1 Small Glass Column 24 3.2.3.2 Large Glass Column 24 3.2.3.3 Full-Scale Stainless Steel Column 26 3.2.3.3.1 Experimental Apparatus 26 3.2.3.3.2 Temperature Monitoring and Control 27 3.2.3.3.3 Temperature Cycles 27 3.2.3.3.4 Feedstock 28 Chapter 4: Analytical Methods 4.1 General Comments 4.2 Uranium Mass Fraction 4.3 Soluble Uranyl Fluoride Content 4.4 Oxygen Content 4.5 Nitrogen Content 4.6 Thermogravametric Analysis 4.7 X-Ray Diffraction page Chapter 5: Results and Discussion 33 5.1 Fluorination of Uranium Dioxide 33 5.1.1 Unagitated Reactants 33 5.1.2 Mechanically Mixed Reactants 33 5.1.2.1 Stirred Bed 33 5.1.2.2 Ball Mill 34 5.1.2.3 Small Fluidized Bed 37 5.2 Decomposition of the Double Salt 39 5.2.1 Stirred Bed Reactor 39 5.2.2 Fluidized Bed 40 5.2.2.1 Intermediate Product 40 5.2.2.2 Final Product: UF4 43 5.3 Materials Durability and Structural Integrity 50 5.4 Bed Fluidization 50 Chapter 6: Conclusion 6.1 Effectiveness of Ball Mill Technique for Fluorination 6.2 Effects of Plateau Temperatures 6.2.1 Lower Plateau Temperature 6.2.2 Upper Plateau Temperature 6.3 Effects of Hold Times 6.3.1 Lower Hold Time 6.3.2 Upper Hold Time 6.4 Effects of carrier gas 6.5 Suitability of Construction