Resin-based preparation of HTGR fuels: operation of an engineering-scale uranium loading system

The fuel particles for recycle of 233U to High-Temperature Gas-Cooled Reactors are prepared from uranium-loaded carboxylic acid ion exchange resins which are subsequently carbonized, converted, and refabricated. The development and operation of individual items of equipment and of an integrated system are described for the resin-loading part of the process. This engineering-scale system was full scale with respect to a hot demonstration facility, but was operated with natural uranium. The feed uranium, which consisted of uranyl nitrate solution containing excess nitric acid, was loaded by exchange with resin in the hydrogen form. In order to obtain high loadings, the uranyl nitrate must be acid deficient; therefore, nitric acid was extracted by a liquid organic amine which was regenerated to discharge a NaNO3 or NH4NO3 solution waste. Water was removed from the uranyl nitrate solution by an evaporator that yielded condensate containing less than 0.5 ppM of uranium. The uranium-loaded resin was washed with condensate and dried to a controlled water content via microwave heating. The loading process was controlled via in-line measurements of the pH and density of the uranyl nitrate. The demonstrated capacity was 1 kg of uranium per hour for either batch loading contractors or a continuous column as the resin loading contractor. Fifty-four batch loading runs were made without a single failure of the process outlined in the chemical flowsheet or any evidence of inability to control the conditions dictated by the flowsheet