BLENDING LOW ENRICHED URANIUM WITH DEPLETED URANIUM TO CREATE A SOURCE MATERIAL ORE THAT CAN BE PROCESSED FOR THE RECOVERY OF YELLOWCAKE AT A CONVENTIONAL URANIUM MILL

Throughout the United States Department of Energy (DOE) complex, there are a number of streams of low enriched uranium (LEU) that contain various trace contaminants. These surplus nuclear materials require processing in order to meet commercial fuel cycle specifications. To date, they have not been designated as waste for disposal at the DOE's Nevada Test Site (NTS). Currently, with no commercial outlet available, the DOE is evaluating treatment and disposal as the ultimate disposition path for these materials. This paper will describe an innovative program that will provide a solution to DOE that will allow disposition of these materials at a cost that will be competitive with treatment and disposal at the NTS, while at the same time recycling the material to recover a valuable energy resource (yellowcake) for reintroduction into the commercial nuclear fuel cycle. International Uranium (USA) Corporation (IUSA) and Nuclear Fuel Services, Inc. (NFS) have entered into a commercial relationship to pursue the development of this program. The program involves the design of a process and construction of a plant at NFS' site in Erwin, Tennessee, for the blending of contaminated LEU with depleted uranium (DU) to produce a uranium source material ore (USM Ore{trademark}). The USM Ore{trademark} will then be further processed at IUC's White Mesa Mill, located near Blanding, Utah, to produce conventional yellowcake, which can be delivered to conversion facilities, in the same manner as yellowcake that is produced from natural ores or other alternate feed materials. The primary source of feed for the business will be the significant sources of trace contaminated materials within the DOE complex. NFS has developed a dry blending process (DRYSM Process) to blend the surplus LEU material with DU at its Part 70 licensed facility, to produce USM Ore{trademark} with a U235 content within the range of U235 concentrations for source material. By reducing the U235 content to source material levels in this manner, the material will be suitable for processing at a conventional uranium mill under its existing Part 40 license to remove contaminants and enable the product to re-enter the commercial fuel cycle. The tailings from processing the USM Ore{trademark} at the mill will be permanently disposed of in the mill's tailings impoundment as 11e.(2) byproduct material. Blending LEU with DU to make a uranium source material ore that can be returned to the nuclear fuel cycle for processing to produce yellowcake, has never been accomplished before. This program will allow DOE to disposition its surplus LEU and DU in a cost effective manner, and at the same time provide for the recovery of valuable energy resources that would be lost through processing and disposal of the materials. This paper will discuss the nature of the surplus LEU and DU materials, the manner in which the LEU will be blended with DU to form a uranium source material ore, and the legal means by which this blending can be accomplished at a facility licensed under 10 CFR Part 70 to produce ore that can be processed at a conventional uranium mill licensed under 10 CFR Part 40