CA2213758C - Process to remove rare earths from spent nuclear fuel - Google Patents

Abstract

The present invention relates to a process for removing rare earth elements (RE) from spent nuclear fuel. The spent nuclear fuel is subjected to an oxidation step at a temperature of between about 200.degree. to about 800 .degree.C and a heating step at a temperature of between about 1000 .degree.C to about 1600 .degree.C. The process results in the segregation of the spent fuel into a rare earth-rich fluorite-type phase and a rare earth-poor U3O8 phase. The RE-rich fluorite type phase is separated from the RE-poor U3O8 phase by conventional separation techniques such as sieving, air classification, sedimentation and the like.

Description

PROCESS TO REMOVE RARE EARTHS FROM SPENT NUCLEAR FUEL
Field of the Invention The present invention relates to a method for removing rare earth elements (for example, neodymium and samarium, which are strong neutron absorbers) from spent nuclear fuel and more particularly, a dry processing technique for so doing.

Background of the Invention Rare earth (RE) elements (La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, and others) are produced in nuclear fuel by uranium fission and by the decay of other fission products. Many of the rare earths have a large neutron cross section so that they make a large contribution (approximately 50%) to the neutron burden of spent nuclear fuel. When the neutron burden becomes too high, nuclear fuel must be removed from the reactor for disposal. An effective method for removing the RE would allow spent fuel to be reused, and thus provide more energy per kilogram of starting material.

Several dry processing techniques, based on air oxidation and thermal treatment of spent nuclear fuel, are available; none of these effect the removal of any significant amounts of rare earths.
Two of the known dry processing techniques are the AIROX and OREOX processes. In the AIROX process, fuel decladding can be accomplished oxidatively or by conventional mechanical means. In oxidative decladding, the fuel pin is punctured and then heated in air (400 to 600 C) so that the oxidation of UOZ to U30$ causes the cladding to rupture. The resulting U30$ powder can then be easily separated from the cladding. The U30$ is then reduced in hydrogen at 600 to 1100 C to regenerate U02. The oxidation/reduction steps are performed at high enough temperatures to cause the release of volatile fission products. By using oxidation/reduction cycling, the AIROX process can achieve almost complete removal of Xe, Kr, Cs and I.

The OREOX process is an improvement on the AIROX process..
Oxidation is performed at a higher temperature (1200 C) than in the AIROX
process resulting in a more effective removal of the volatile fission products.

Wet reprocessing techniques (based on fuel dissolution and subsequent chemical separation) can be used to remove rare earth elements from spent fuel but are not commercially viable because of the large volumes of liquid waste generated and also because of the need to maintain strict plutonium diversion safeguards. For example, Canadian Patent 589,122 discloses a method of re-processing irradiated nuclear reactor fuel. The patent discloses removal of 99%
of some rare earth elements and comprises contacting the uranium in a molten state with a refractory oxide under non-oxidizing conditions and separating the decontaminated uranium from the fission products-containing oxides.

U.S. Patent No. 2,822,260 discloses a process for the separation of rare earths and other fission product metal values from neutron bombarded uranium.
The patent discloses melting uranium with a metal oxide at a temperature from about 1150 to 1400 C in an inert atmosphere to produce a scale of uranium dioxide on the uranium which is strongly concentrated with most of the fission products.

The present invention relates to a dry processing technique which enables the removal of a significant portion of rare earth elements from irradiated uranium dioxide fuels.
Summary of the Invention The invention relates to a method of removing rare earths from spent nuclear fuel. The method comprises the steps of oxidizing the spent nuclear fuel at a temperature of between about 200 to about 800 C thereby oxidizing U02 to U308. The spent nuclear fuel is then heated at a temperature of between about 1000 to about 1600 C thereby causing said U3O$ to segregate into a RE-rich fluorite phase and RE-poor U308 phase. The RE-rich fluorite phase is then separated from the RE-poor U308 phase.
Brief Description of the Drawings ' Figure 1 is the UO-(RE)O-O portion of the ternary U-RE-O phase diagram for a typical rare-earth element for a temperature range from 1000 to 1500 C;
Figure 2 is the UO-(RE)O-O portion of the ternary U-RE-O phase diagram illustrating the behaviour of a U02 sample doped with 1.7 mol. % of a rare-earth element;
Figure 3 is the Differential Thermal Analysis (DTA) trace of the oxidation of U02 in air;
Figure 4 is the DTA trace for the oxidation of 2%Nd-doped U02 in air;
Figure 5 is the X-ray diffraction pattern for powders generated by subjecting neodymium-doped U02 powders to a two stage air oxidation (580 C, 2 hours) and heat treatment (1400 C, 1 hour);
Figure 6 depicts Fraction F of the fluorite-phase material segregated from the U308 versus the at.% Nd for neodymium-doped U02 oxidized to U30a and then annealed in air for 8 h at 1400 C;
Figure 7 depicts Fraction F of the fluorite-phase material segregated from the U308 versus the at.% Ce for cerium-doped U02 oxidized to U308 and then annealed in air for 8 h at 1400 C;
Figure 8 depicts Fraction F of the fluorite-phase material segregated from the U30a versus the at.% La for lanthanum-doped U02 oxidized to U3O 8 and then annealed in air for 8 h at 1400 C;
Figure 9 depicts Fraction F of the fluorite-phase material segregated from the U30$ versus the at.% Yb for ytterbium-doped U02 oxidized to U3O 8 and then annealed in air for 8 h at 1400 C;
Figure 10 is the X-ray diffraction pattern (XRD) for powders generated by oxidizing neodymium-doped sintered pellets with the process of the present invention;
Figure 11 is the XRD pattern of the powder produced by treating a sample of SIMFUEL (4 atom % simulated burnup) with the process of the present invention;

Figures 12(a) and (b) depict the XRD and Scanning Electron Microscopy (SEM) patterns respectively for a sample of used H.B. Robinson LWR fuel which was obtained by air oxidation (440 C, 4.5h) and subsequent heat treatment (1400 C, 4 h).
Arrows indicate the position of XRD peaks associated with the fluorite-type phase;
Figure 13 depicts typical wavelength dispersive X-ray emission (WDX) spectra of U308 grains and rare-earth-rich nodules in a sample obtained by two-stage air oxidation (4.5 h at 440 C) and heat treatment (4h at 1400 C) of used LWR fuel; I
Figure 14 is the SEM image of a powder produced by oxidizing sintered, Nd-doped U02 at 400 C (16 hours), then beating in air at 1400 C (8 hours);
Figure 15 is the SEM image of a powder produced by oxidizing sintered, Nd-doped U02 at 400 C (16 hours); and Figure 16 depicts the number of particles as a function of diameter in neodymium-doped U02 after treatment with the process of the present invention.
Description of the Preferred Embodiment The rare-earth (or RE) elements account for about 30% of the fission products and half of the neutron burden in used fuel. Thus, any modification to the dry processing techniques for used fuel that includes removal of a significant fraction of the rare-earth elements would have a major impact on the commercial viability of such a process.

The present invention relates to a process using high temperature treatment under non-reducing conditions which induces an effective segregation from the U308 phase of the RE elements into an RE-rich fluorite-type phase, (U,RE)02+ic (for the sake of simplicity the terms fluorite-type phase and fluorite phase will be used throughout this application to mean samples of (U,RE)02+,, belonging to the same crystal-structure class as fluorite, CaF2). The results of the experiments carried out by the applicant show that not only does RE
segregation occur, it appears to occur in such a manner that the smaller particles are enriched in rare-earths. As a result, combined with the differences in densities of U3Ofi and (U,RE)Oz,X, a simple mechanical separation ~e.g., sedimentation, air classification, sieving) can be used to remove a portion of the RE from the U308. By contrast, in the existing AIROX and OREOX processes, samples are not heated to high enough temperatures that a significant degree of RE segregation occurs. Furthermore, in AIROX and OREOX, reduction drives = 5 any minute amount of RE which may have segregated back into the single-phase fluorite region so that no net segregation of RE occurs.

Various aspects of the ternary U-RE-O phase diagrams have been studied extensively (Fujino and Miyake 1991, In Handbook on the Physics and Chemistry of the Actinides, Elsevier Science Publishers, New York, Vol. 6, p.
155). Although there are subtle differences among the phase diagrams for the various RE, the general features are the same for most rare earths. The UO-(RE)O-O portion of a typical U-RE-O phase diagram is shown in Figure 1 for a temperature range from 1000 to 1500 C.
The features of Figure 1 most important to the dry oxidation of irradiated fuel are:

1. The fluorite field, which occupies a single-phase region (F) con-sisting of a solid solution of UOZf.. and (RE)0,.5. This phase typically covers most of the region bounded by U02, U409, point A and (RE)01.5, except the region labelled "M" (see below).

2. The triangular region bounded by U409, U308 and point A, which is a two-phase region in which the solid-solution fluorite phase and U30$ are both present. It has been reported that the solubility of (RE)O1_5 in U308 is below the detection limit of the X-ray diffraction (XRD) technique (i.e., below -0.2 to 0.5 mol.%) (Keller, 1975, Ternare und polynare oxide des urans. In Gmelins Handbuch der Anorganischen Chemie, 8 Erganzungswerk, Band 55, Teil C3, Springer-Verlag, Berlin, p.
97).

3. The region labelled "M" in Figure 1, which is a field in which (RE)0,.5 coexists with other RE-rich compounds (e.g., U03 -6PrO1.5 This region is not relevant to the present invention and will not be discussed in any further detail.
OXIDATION BEHAVIOUR OF UO, AND IRRADIATED FUEL
Oxidation of Unirradiated UO, The major features of the U-O binary phase diagram are well established.
As a sample of pure U02 is oxidized, its composition moves from the U02 point on Figure 1 towards the oxygen apex of the phase diagram. Between U02 and U4O9, oxygen anions are incorporated into interstitial vacancies in the fluorite lattice; concomitant changes to the average uranium ion valency occur and the fluorite-type lattice is retained. Only one phase (fluorite) is found in samples in the UO2 to U4O9 region over the temperature range from 1000 to 1500 C.
If a sample of pure UO2 is oxidized past the U409 point so that the overall O/U ratio lies between 2.25 and 2.67, then two phases, U409 (fluorite) and U3O8 (orthorhombic) will be present in the sample. Intermediate phases are stable (or metastable) only at relatively low temperatures (e.g., U307 ) or at high pressures (e.g., U205). The relative amounts of the orthorhombic and fluorite phases in this two-phase region can be calculated by the lever rule.

If further oxygen is added to the system so that the overall composition lies in the range from U308 to 0, then U308 will be present along with gas-phase oxygen. Above about 1100 C, U3O$ loses small quantities of oxygen and above about 1500 C it decomposes in air to form U02+, where x is -r0.25.
Oxidation of Irradiated Fuel The oxidation behaviour of irradiated fuel is more complex than that of unirradiated U02 because of the numerous fission products found in the irradiated fuel and also because of differences in the fuel microstructure.
When estimating the chemical properties of RE in irradiated fuel it is assumed, as a first approximation, that irradiated fuel can be considered as a solid solution of one RE in U02. The concentration of the single RE is -1.7 at.%, which is the total quantity of rare earths in a PWR fuel after a fairly typical burnup of MW od/kg U. The RE content of typical irradiated PWR fuel is given in Table 1.

Throughout this application the terms at.% and mol.% refer to the fraction of the total metal content on an oxygen-free basis; for example, 1.7 at.% RE describes a mixture where the mole fraction RE/[RE + U] is 0.017.

RARE-EARTH ELEMENT CONTENT OF TYPICAL IRRADIATED PWR
FUEL WITH A BURNUP OF 35 MW d/kg U
(from Guenther et al., 1988, Characterization of spent fuel approved testing material - ATM-106, Pacific Northwest Laboratory Report, PNL-5109-106.) Element wt.% at.%

La 0.126 0.216 Ce 0.245 0.417 Pr 0.115 0.194 Nd 0.416 0.687 Pm 0.002 0.003 Sm 0.083 0.132 Eu 0.016 0.024 Gd 0.015 0.023 Total 1.019 1.696 The equilibrium oxidation behaviour of a sample of U02 doped with 1.7 at.% RE is illustrated in Figure 2. A stoichiometric solid solution of U02 and (RE)Ol.s will lie along the line joining the points that denote these compounds in Figure 2. The composition corresponding to 1.7 at.% is point B. Oxidation of such a sample shifts its composition towards the oxygen apex of the phase diagram along line BC. As with U02, a single fluorite phase is present in this region up to point C. However, if the sample is further oxidized past point C, important differences are observed between U02 and the RE-doped material.
With RE-doped material, sample compositions along the line segment CD
consist of two phases, an RE-depleted U308 phase and an RE-enriched fluorite phase. Thus as oxidation proceeds past point C, the composition of the fluorite phase moves along line segment CA as the U308 phase segregates out. When oxidation has proceeded so that the total sample composition is that of point D, the total mixture consists of U308 and a fluorite phase of composition A. The relative amounts of U308 and fluorite phase can again be calculated using the lever rule. The composition of the fluorite phase can be calculated by extrapolating the line OA to the UO-(RE)O axis and determining the relative proportions of RE and U from the position of point E.

In practice, RE-doped U02 treated with the process of the present invention does not follow this equilibrium pathway exactly, because the rate of oxidation is much faster than the rate of RE segregation. The initial oxidation product is therefore a metastable RE-doped U308 phase. Thus, in the process described below, oxidation and segregation occur in two stages. The final phase assemblage, however, is as described for point D in the preceding paragraph.
Based on the preceding discussion, two parameters in the U-RE-O phase diagram that are of crucial importance to possible application in the process of the present invention was recognized. First, it was implicitly assumed that U308, which segregates in the region U409 - A - U30g, has a negligible solubility for RE. The bulk of experimental work suggests that RE solubility in U308 is low with typical upper solubility bounds of 0.2 to 0.5 at.%. The second important consideration is the position of point A in the phase diagram (Figures 1 and 2). The process of the present invention is directed to the production of a very RE-rich fluorite phase. Such a scenario corresponds to the case where A is located as close as possible to the (RE)O apex of the phase diagram. The exact position of point A varies with both temperature and the elemental identity of RE.

It is estimated that where used fuel is separated into essentially pure U308 and a fluorite phase having the composition ((RE)0.351U0.65)O2, then the processing of 1.0 kg of irradiated PWR fuel containing 1.7 at.% RE would yield 37 g of a RE-rich fluorite waste. Less than 3% of the uranium in the original kilogram of fuel would be lost in the RE-rich waste material. One important difference between U02 and irradiated fuel is the presence of significant quantities of plutonium in the irradiated fuel. The similarity in oxidation behaviour of U02 and mixed-oxide (U,Pu)02 fuels suggests that plutonium is unlikely to have a dramatic effect on the RE-segregation stage of the process of the present invention. However, its presence is important since any dry processing technique must not readily lend itself to the separation of plutonium from the used fuel, and there must be practical methods for plutonium accounting for safeguards purposes. Retention of most of the plutonium in the processed fuel stream is also economically desirable.

In order to evaluate the feasibility of separating rare earths from uranium oxides, two different types of neodymium-doped U02 were produced.
Neodymium was chosen as a typical rare-earth element since it is the most abundant RE fission product (Table 1). The first set of doped U02 samples consisted of powders prepared by co-precipitating neodymium and uranium as = ammonium diuranate, followed by reduction to (U,Nd)O 2. The second set of samples consisted of sintered U02 pellets; some of these were doped with 2%
neodymium, while others were SIMFUEL, i.e., UOZ doped with a mixture of fission products designed to simulate used fuel as disclosed in Lucuta et al.
(1991, Microstructural features of SIMFUEL, Journal of Nuclear Materials 178, 48-60.). Most of the tests were performed on the Nd-doped powders and pellets. The degree of segregation of the Nd-rich fluorite phase (from the U30g) was determined by X-ray diffraction (XRD). Crude particle-size fractionation tests (by sedimentation and by filtration) were performed on powders oxidized 5 with the process of the present invention, and the Nd content of the various fractions was assayed. It was thus possible to determine whether a simple mechanical separation is likely to remove significant quantities of rare-earth elements from doped UOZ.

Sample Preparation Samples of U02 doped with varying quantities (0, 0.1, 0.2, 0.5, 1.0, 2.0 at.%) of RE (where RE was one of Nd, La, Yb or Ce) were prepared by the co-precipitation method disclosed in Clayton and Aronson (1961, Some preparative methods and physical characteristics of Uranium Dioxide Powders, Journal of Chemical and Engineering Data 6,43-51). Most of the experiments on RE-doped powders were performed on samples with RE = Nd. Ammonium hydroxide (25%) was used to co-precipitate neodymium and uranium from a solution of their nitrates. The resulting Nd-doped ammonium diuranate (ADU) was collected by centrifuging, and was washed several times with dilute ammonium hydroxide before being air-dried at 105 C. The ADU powders were then heated in air at 900 C for 4 h to convert them to U30g. The resulting samples were analyzed by XRD, and showed only U308 peaks (mainly a-U308, with up to -6% (3-U308 as determined by the intensity of the XRD "peaks).
There was no indication of a separate Nd-rich phase, and no correlation between the neodymium content and the relative amounts of a- and R-U3O8 . Shortly before the powders were air oxidized, the doped U30g was reduced to UOZ in Ar/3% H2 for 3 h at 1150 C. XRD analysis of the reduced powders showed only UO2 and, in some cases, small quantities of U3Oõ but no U308 or other impurities.

Air Oxidation Experiments on Nd-Doped UO2 Powders The doped UOZ samples prepared via the ADU synthetic route were oxidized in flowing air in a Simultaneous Differential Thermal Analysis (DTA)/Thermogravimetric Analysis (TGA) apparatus. The samples were heated from room temperature to -400 C at a rate of 10 C/min, and held at that temperature for 16 h. While a temperature of 400 C was used in this example, the temperature could range between 200 and 600 C. The samples were subsequently heated to 1400 C, again at a rate of 10 C/min, and were held at this temperature for 8 h. A temperature range of 1000 to 1600 C for this step can be utilized. Peaks associated with the well-known two-step oxidation reaction of U02 were observed, but there was no indication of any peak associated with the segregation of the RE-rich fluorite phase (Figures 3 and 4).
However, such a result is not surprising since the segregation process is diffusion-controlled, and the relatively low diffusion rates would give a barely discernible reaction exotherm.

X-ray diffraction analysis of the powders produced by the DTA runs gave convincing evidence that a neodymium-rich fluorite phase segregated from the U308 during the oxidation and heat treatment. Figure 5 shows the XRD
peaks associated with the Nd-rich fluorite phase. The quantitative data discussed below show a correlation between the neodymium content of the original neodymium-doped UOZ and the peak intensity of the fluorite phase in the oxidized powder. The average cell parameter of the fluorite phase in the 1 and 2% Nd-doped material was calculated to be 0.5434 nm, which is 'in good agreement with previously reported values of -0.5435 nm for Nd-doped UO2 sintered in the range from 1200 to 1400 C (Keller and Boroujerdi, 1972, Journal of Inorganic and Nuclear Chemistry 34, 1187-1193.).

Solubility of Rare Earths in U30 As discussed above, the low solubility of rare earths in U3O8 is one of the key factors in the process of the present invention. Thus, the oxidation products of the doped U02 powder were analyzed quantitatively by XRD to determine the solubility of neodymium in U308 at 1400 C. In such a quantitative analysis, the integrated area of the doublet at -26.0 was used as a measure of the intensity (I U308) of the U308 signal, and the area of the peak at 28.4 for the intensity (Ifluoriu) of the fluorite-phase signal. The quantity of fluorite phase present in a sample was considered to be proportional to the ratio F = lflooriu/(IflooRU + IU3Os)= N~Ule such an approximation is crude since it assumes equal absorption coefficients for U308 and the fluorite phase, it will affect the slope of the graph of F as a function of neodymium content at low neodymium concentrations (Figure 6), but will only have a minor effect on the measured neodymium solubility, i.e., the x-intercept. The ratio F was calculated for each of the samples and the results are shown in Table 2. The data in Table 2 are plotted in Figure 6; from this figure the solubility of neodymium in at 1400 C is estimated to be less than 0.3 at.%.

Air Oxidation Experiments and Solubility of Rare earths in U30 where RE _ Ce. La or Yb The air oxidation experiments and solubility tests described above in respect of neodymium doped samples were conducted in the same manner where RE = Ce, La or Yb. The results are summarized in Tables 3, 4 and 5.
The data in tables 3, 4 and 5 are plotted respectively in Figures 7, 8 and 9.
From these Figures, the solubility of cerium, lanthanum and ytterbium in U3O8 at 1400 C is estimated to be 0.3 at.% or less.

RATIO F I~oo~u/~ttoorire + I U3O8) IN THE PRODUCT
OBTAINED BY TREATING UO? POWDER (DOPED WITH VARYING
AMOUNTS OF NEODYMIUMI WITH A TWO-STAGE AIR
OXIDATION (400 C, 16 h) AND HEAT TREATMENT (1400 C. 8 h) % Neodymium in U02 F

0.00 0.0000 0.27 0.0075 0.53 0.0318 0.80 0.0454 1.06 0.0588 1.33 0.0836 RATIO F = Iflõalil/-CI õariti + I U3O8) IN THE PRODUCT
OBTAINED BY TREATING UOZ POWDER (DOPED WITH VARYING
AMOUNTS OF CERIUM) WITH A TWO-STAGE AIR
OXIDATION (400 C. 16 h) AND HEAT TREATMENT (1400 C 8 h) % Cerium in U02 Ratio F

0.00 0.0000 0.25 0.0000 0.50 0.0065 0.74 0.0325 0.99 0.0404 1.24 0.0494 1.86 0.0866 RATIO F I U3Os) IN THE PRODUCT
OBTAINED BY TREATING UO2 POWDER (DOPED WITH VARYING
- 5 AMOUNTS OF LANTHANUM) WITH A TWO-STAGE AIR
OXIDATION (400 C, 16 h) AND HEAT TREATMENT (1400 C, 8 h) % Lanthanum in UO2 Ratio F

0.00 0.0000 10 0.23 0.0271 0.46 0.0467 0.69 0.0651 0.92 0.0797 1.15 0.1100 15 1.73 0.1449 RATIO F Iflõo~~/~õ riu + I U3O8) IN THE PRODUCT
OBTAINED BY TREATING UOZ POWDER (DOPED WITH VARYING
AMOUNTS OF YTTERBIUM) WITH A TWO-STAGE AIR
OXIDATION (400 C, 16 h) AND HEAT TREATMENT (1400 C, 8 h) % Ytterbium in UOZ Ratio F

0.00 0.0000 0.25 0.0054 0.50 0.0157 0.74 0.0352 0.99 0.0456 1.24 0.0477 1.86 0.0781 A

EXPERIMENTS ON SINTERED PELLETS
Sample Preparation Oxidation experiments were also performed on sintered pellets of U02 doped with 2 at.% neodymium, which were obtained from J. Sullivan (Fuel Materials Branch, Chalk River Laboratories). The sintered pellets were obtained by mixing finely divided oxide powders in the appropriate amounts, and then sintering in a hydrogen atmosphere. A slice of one of the Nd-doped -UO2 pellets was polished to a 0.05- m finish and examined by scanning electron microscopy/energy dispersive X-ray spectrometry. This examination did not reveal any evidence of neodymium segregation, and it was thus concluded that the sintering process was successful in forming a solid solution between the neodymium and uranium in (U,Nd)02+,,.

Tests were also performed on a sample of simulated high-burnup nuclear fuel (i.e., SIMFUEL). The 4 at.% simulated-burnup material used was prepared at Chalk River Laboratories by mixing the appropriate powdered materials and sintering as described in earlier published accounts (Lucuta et al. 1991, su~ra Journal of Nuclear Materials 178, 48-60.).

Oxidation Experiments on Nd-Doped UO2 Pellets Four specimens of Nd-doped U02, cut from a sintered pellet, were oxidized at 400 C (16 h) to U308, and were then individually heated in air for -16 h at 750, 1000, 1250, and 1380 C. XRD analysis of the resulting powders revealed only U308 in the samples subjected to the 750 and 1000 C heat treatments. However, a fluorite phase had segregated from the U3O8 in the course of treatments at both 1250 and 1380 C (Figure 10). The intensity of the XRD peaks associated with the Nd-rich fluorite phase (relative to the U308 peaks) is approximately the same in those produced by oxidizing the 2 at.%
Nd-doped U02 pellet as the 2 at.% Nd-doped U02 powders (compare Figures 5 and 10). The lattice parameter of the fluorite phase was 0.5437. nm in the samples oxidized at 1250 C, and 0.54332 nm for those oxidized at 1380 C.

Oxidation Experiments on SIMFUEL
One test was done on a 4% SIMFUEL sample. A fragment of a disc cut from the sintered pellet was powdered by oxidizing it in air at 400 C for 4 h, and- then heated to 1200 C in air for a further 16 h. The XRD pattern given in Figure 11 shows clearly the presence of a significant quantity of fluorite phase, indicating that segregation of the RE has occurred. Such a result is important since it suggests that the numerous nonvolatile fission products 'present in a sample of used fuel do not have a dramatic effect on the U-RE-O phase relationships. The lattice parameter calculated for the fluorite phase that segregated from the SIMFUEL sample was 0.54283 nm, which is consistent with published results for doped U02 (Keller and Boroujerdi, 1972, Journal Inorganic and Nuclear Chemistry 34= 1187-1193).

EXPERIMENTS ON USED PWR FUEL
Experimental The process of the present invention was applied to samples of used PWR fuel in a series of tests performed at Chalk River Laboratories, with subsequent product analysis at Whiteshell Laboratories. Samples of used PWR
fuel were from H.B. Robinson Unit 2. The burnup was 672 IvIWh/kg U.
Examination by SEM revealed that segregation of a RE-rich phase occurred when the used fuel was treated according to the present invention.
Detailed analysis was performed on one sample of H.B. Robinson fuel, which was oxidized 4.5 h at 440 C and subsequently heated (4h at 1400 C).
Examination by SEM revealed the presence of RE-rich nodules, while XRD
patterns displayed significant peaks associated with the fluorite-type phase (Figure 12). Detailed examination of the RE-rich nodules by wavelength-dispersive x-ray emission (WDX) revealed the presence of significant quantities of each of the major RE fission products (Nd, Ce, La, Pr and Sm) in used PWR
fuel. Similar examination of the U308 grains did not display any significant amount of rare earths (Figure 13).

PARTICLE SIZE OF THE PRODUCT AND RARE-EARTH SEGREGATION
Characterization of the Particle-Size Distribution Scanning electron microscopy (SEM) examination of the powders produced by oxidizing Nd-doped sintered pellets at 400 C, then heating to 1250 C, revealed the presence of, many large (-10 m), well-faceted U308 crystals (Figure 14). In addition, there were numerous small (---1 m) particles, which in some cases adhered to the side of the larger U3O$ grains. This microstructure contrasts with materials heated at 750 C or 1000 C in the second stage of the process of the present invention. Samples treated at these lower temperatures display the irregular "popcorn" morphology characteristic of U3O8 formed by low-temperature oxidation of U02 (Figure 15). This indicates that solid-state recrystallization of U308 occurred at 1250 C but not at or below 1000 C, and suggests that secondary crystallization of the RE-rich fluorite phase occurred concurrently with this recrystallization. Examination of the U308 grains and the smaller RE-rich fluorite phase by energy-dispersive X-ray emission (EDX) consistently displayed significant quantities of neodymium in the latter, but not in the former.
A set of samples treated by the process of the present invention was analyzed for particle-size distribution by slurrying a small quantity of the product in 100 ml of water and using a Climet Particle Counter. The measured particle size distribution (Figure 16) confirms that there are two groups of particle sizes observed in these powders, one group approximately 10 to 20 m in diameter and the other less than 5 m in diameter. A simple test was therefore used to check the feasibility of separating some of the RE by a particle-size-based process.

Rare-Earth Separation Tests A small quantity (---0.25 g) of the 2 at.% Nd-doped U308 treated by the process of the present invention at 1250 C was slurried in 75 cm3 of distilled water, followed by ultrasonic dispersion for 2 min to dislodge any small Nd-rich particles that may have been weakly attached to the larger U308 grains. A very small quantity of ultrafme particulate was noticed floating on the surface of the water; this material was decanted and filtered through a 0.8- m nylon filter.
The remaining mixture was then stirred vigorously, and the coarse particles were allowed to settle for 40 s. The finer particulate, still suspended at this time, was filtered through a 0.8- m nylon filter. Finally, the remaining "coarse"
fraction was removed from the water by filtration. All three size fractions (coarse, fme, ultrafine) were washed with isopropanol and air-dried. The various size fractions were analyzed by inductively coupled plasma (ICP) spectrophotometry for the Nd/U ratio, and the results (Table 6) show that a significant concentration of Nd in the finer particle fractions was achieved.
However, it should be noted that only a very small percentage of the starting material was present in the fine and ultrafine fractions.

NEODYMIUM:URANIUM MOLE RATIO IN COARSE, FINE AND
ULTRAFINE SIZE FRACTIONS SEPARATED BY SEDIMENTATION
FROM A POWDER OBTAINED BY TREATING A 2 at.% Nd-DOPED UO2 Sample Nd/LT
(atom ratio) Coarse 0.0176 10 Fine 0.0571 Ultrafine' 0.0448 In a second test, a disk from an Nd-doped sintered pellet was treated by 15 the process of the present invention by heating at 400 C for 16 h and then 1250 C for 16 h. A small quantity (0.26 g) of the material was slurried in 100 ml of water, and the mixture was filtered through an 8- m millipore filter.
The filtered particulate was washed several times with distilled water, and the solid sample was saved. The filtration process was then repeated by filtering the 20 remaining solution through 5-, 1.2- and 0.22- m filters sequentially. The resulting powders were then assayed by ICP spectrophotometry for neodymium and uranium content. The results, are given in Table 7. Although the total amounts of material in the finer fractions were very low, it is apparent that significant neodymium enrichment has occurred in the 1.2-u,m fraction.

URANIUM AND NEODYMIUM CONTENT OF THE 0.22-. 1.2-. 5- AND
8-um SIZE FRACTION AFTER TREATMENT BY THE PROCESS OF
THE PRESENT INVENTION

Sample Uranium Neodymium Neodymium (1-lg) (gg) (at.%) 0.22 m 16.3 <2.0*
-1.2 m 23.0 3.5 20.1 5 m 3 140 37.5 1.94 8 m 196000 2330 1.93 *The neodymium content of the 0.22- m sample was not detectable because of the very small sample mass.

CONCLUSIONS
Examination of the ternary U-RE-O phase diagram has shown that air oxidation of RE-doped UO2 (or irradiated fuel), followed by treatment at temperatures from 1000 to 1600 C results in the formation of an RE-rich fluorite phase and U308. Although there are significant differences between the various rare-earth elements, the RE content of the fluorite phase should be approximately 25 to 40 mol.%, while that of the U3O8 phase should be quite, low (less than or equal to approximately 0.3 at.% at the temperatures used in our process).

Experimental results using U02 doped with neodymium (taken as a:
typical RE) have shown that such a segregation does in fact occur. Typical experiments were done in two stages:

~il 1. a low-temperature oxidation (400 to 600 C) to convert the U02 to U308 powder, and 2. a high-temperature treatment (1250 to 1400 C) to cause segregation of the rare-earth elements into the fluorite phase.
The use of the process of the present invention showed good segregation of the Nd-rich fluorite phase for both sintered, pellets and U02 powder prepared by the ammonium diuranate (co-precipitation) method. A further test using SIMFUEL also showed RE segregation. Application of the process of the present invention to used PWR fuel confirmed that such treatment results in the formation of a fluorite-type phase, and that a significant quantity of each of the major RE fission products is found in this phase.

Sedimentation and filtration experiments have shown that the RE-rich fluorite phase has a significantly smaller particle-size distribution than the U308.
Thus, significant quantities of the RE-rich material can be removed by a mechanical separation such as sieving, air classification or sedimentation, by volatilization, or by absorption into an inert phase such as A1203, Zr02 or Si021 which is capable of absorbing rare earths. Removal of RE may be enhanced by post-segregation sample treatment by attrition, sample reduction (to convert the U30g back to U02), or other methods which reduce the fraction of RE-rich nodules which adhere to the larger U308 grains.

The invention is not limited to the rare earths exemplified in the disclosure and has equal application to the removal of any rare earths from spent nuclear fuel.

While the present invention has been described in connection with a specific embodiment thereof and in a specific use, various modifications will occur to those skilled in the art without departing from the spirit and scope of the invention as set forth in the appended claims. The terms and expressions used in the specification are used as terms of description and not of limitation and there is no intention that the use of such terms and expressions exclude equivalents of the features shown and described. It is recognized that various modifications are possible within the scope of the invention claimed. We therefore wish to embody within the scope of the patent which may be granted hereon all such embodiments as reasonably and properly come within the scope of our contribution to the art. In particular, the present process can be used with a variety qf spent nuclear fuels including spent nuclear fuel from light water reactors, heavy water reactors and fast breeder reactors.

Claims (10)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE AS FOLLOWS:

1. A method of removing rare earths from spent nuclear fuel comprising the steps of:

oxidizing said spent nuclear fuel at a temperature of between about 200°C to about 800°C thereby oxidizing UO2 to U3O8;

heating said spent nuclear fuel at a temperature of between about 1000°

to about 1600°C thereby causing U3O8 to segregate into a RE-rich fluorite phase and an RE-poor U3O8 phase;

separating the RE-rich fluorite phase.

2. The method of claim 1 wherein the rare earths are selected from the group consisting of neodymium, samarium, cerium, lanthanum, praseodymium and ytterbium.

3. The method of claim 2 wherein the rare earths are selected from the group consisting of neodymium, cerium, lanthanum and ytterbium.

4. The method of the claim 1 wherein the oxidation of the spent nuclear fuel is carried out in the presence of an oxidant selected from the group consisting of air, oxygen, N2O, NO and NO2.

5. The method of claim 1 wherein the spent nuclear fuel is oxidized at a temperature of between about 400 to 600°C.

6. The process of claim 1 wherein the spent nuclear fuel is heated at a temperature of between about 1250 to 1500°C.

7. The process of claim 1 wherein the RE-rich fluorite phase is separated by sieving, air classification, electrostatic separation, magnetic separation, sedimentation, volatilization or by absorption into an inert matrix.

8. The process of claim 1 comprising the following additional steps:
reducing the remaining RE-poor U3O8 phase to a RE-poor UO2 phase;
sintering the RE-poor UO2 phase into fuel pellets.

9. The process of claim 8 wherein the RE-poor U3O8 phase is reduced by a gas phase reductant.

10. The process of claim 9 wherein the gas phase reductant is selected from the group consisting of H2 and CO.