Chemical stability of zirconolite for proliferation resistance under conditions typically required for the leaching of highly refractory uranium minerals

In this study, synthetic zirconolite samples with a target composition Ca0.75Ce0.25ZrTi2O7, prepared using two different methods, were used to study the stability of zirconolite for nuclear waste immobilisation. Particular focus was on plutonium, with cerium used as a substitute. The testing of destabilisation was conducted under conditions previously applied to other highly refractory uranium minerals that have been considered for safe storage of nuclear waste, brannerite and betafite. Acid (HCl, H2SO4) leaching for up to 5 h and alkaline (NaHCO₃, Na2CO3) leaching for up to 24 h was done to enable comparison with brannerite leached under the same conditions. Ferric ion was added as an oxidant. Under these conditions, the synthetic zirconolite dissolved much slower than brannerite and betafite. While the most intense conditions were observed previously to result in near complete dissolution of brannerite in under 5 h, zirconolite was not observed to undergo significant attack over this timescale. Fine zirconolite dissolved faster than the coarse material, indicating that dissolution rate is related to surface area. This data and the long term stability of zirconolite indicate that it is a good material for long-term sequestration of radioisotopes. Besides its long term durability in the disposal environment, a wasteform for fissile material immobilisation must demonstrate proliferation resistance such that the fissile elements cannot be retrieved by leaching of the wasteform. This study, in conjunction with the previous studies on brannerite and betafite leaching, strongly indicates that the addition of depleted uranium to the wasteform, to avert long term criticality events, is detrimental to proliferation resistance. Given the demonstrated durability of zirconolite, long term criticality risks in the disposal environment seem a remote possibility, which supports its selection, above brannerite or betafite, as the optimal wasteform for the disposition of nuclear waste, including of surplus plutonium

Development of phosphate glass and multi-phase titanate ceramic compositions for thermal treatment of irradiated nuclear fuel residues

The highly heterogeneous nature of UK legacy damaged and degraded spent nuclear fuels and so called, 'orphan fuels', prohibits the use of standard conditioning methods. An inventory of UK residual fuels yielded an account for three main fuel types: Magnox, AGR (advanced gas-cooled reactor) and MOx (mixed oxides). A series of glass and ceramic type host systems have been investigated for potential conditioning of these high uranium content spent fuel materials. Electron microscopy and powder X-ray diffraction techniques were used to characterise the prototypical wasteforms. Two sets of low-melt temperature phosphate glass compositions were trialled with additions of CeO2 to simulate the fluorite structure and large ionic radius of U in oxide fuels. Evolution of monazite-type phases at simulant oxide fuel loadings above 15 wt.% highlighted a potential development into a glass-ceramic hybrid assemblage. Investigation into the use of an alkoxide nitrate synthesis route for SYNROC-F type ceramic precursors has allowed for the demonstration of a sintered host pyrochlore phase containing up to ~40 wt.% fuel simulant CeO2. Gas evolution has led to increased porosity at higher temperatures and longer sintering times, this may be mitigated by higher pre-calcination temperatures

Synthesis and characterisation of high ceramic fraction brannerite (UTi2O6) glass-ceramic composites

Brannerite, UTi2O6, glass-ceramic composites have been prepared, using UO2 and TiO2 as the ceramic phase precursors. A range of cold-press and sinter samples with varying glass:ceramic ratios have been prepared under argon at 1200 °C to investigate the effect of glass content on formation of brannerite. Ceramic brannerite formed well in all compositions, even at low (10% by weight) glass fractions, with UO2 as a minor product. Three further brannerite glass-ceramics have been prepared by hot isostatic pressing to investigate the compatibility of this system to HIPing. The samples HIPed at 1200 °C form brannerite, with UO2 as a minor phase with slightly higher abundance than in the cold-press and sinter samples

Hot isostatically pressed zirconolite wasteforms for actinide immobilisation

In order to demonstrate the deployment of Hot Isostatic Pressing (HIP) for the immobilisation of Pu stocks and residues, a series of active and inactive zirconolite formulations have been processed and characterised. In this instance, Ce, U, and Th have been applied as chemical surrogates for Pu4+. A range of formulations targeting isovalent Zr4+ site substitution (i.e. to simulate CaZr1-xPuxTi2O7) have been processed by HIP and characterised by powder X-ray diffraction, and scanning electron microscopy, in order to determine surrogate partitioning between the host zirconolite phase, and accessory phases that may have formed during the HIP process

Influence of transition metal charge compensation species on phase assemblage in zirconolite ceramics for Pu immobilisation

Immobilisation of Pu in a zirconolite matrix (CaZrTi2O7) is a viable pathway to disposition. A-site substitution, in which Pu4+ is accommodated into the Ca2+ site in zirconolite, coupled with sufficient trivalent M3+/Ti4+ substitution (where M3+ = Fe, Al, Cr), has been systematically evaluated using Ce4+ as a structural analogue for Pu4+. A broadly similar phase assemblage of zirconolite-2M and minor perovskite was observed when targeting low levels of Ce incorporation. As the targeted Ce fraction was elevated, secondary phase formation was influenced by choice of M3+ species. Co-incorporation of Ce/Fe resulted in the stabilisation of a minor Ce-containing perovskite phase at high wasteloading, whereas considerable phase segregation was observed for Cr3+ incorporation. The most favourable substitution approach appeared to be achieved with the use of Al3+, as no perovskite or free CeO2 was observed. However, high temperature treatments of Al containing specimens resulted in the formation of a secondary Ce-containing hibonite phase

Phase evolution in the CaZrTi2O7–Dy2Ti2O7 system : a potential host phase for minor actinide immobilization

Zirconolite is considered to be a suitable wasteform material for the immobilization of Pu and other minor actinide species produced through advanced nuclear separations. Here, we present a comprehensive investigation of Dy3+ incorporation within the self-charge balancing zirconolite Ca1–xZr1–xDy2xTi2O7 solid solution, with the view to simulate trivalent minor actinide immobilization. Compositions in the substitution range 0.10 ≤ x ≤ 1.00 (Δx = 0.10) were fabricated by a conventional mixed oxide synthesis, with a two-step sintering regime at 1400 °C in air for 48 h. Three distinct coexisting phase fields were identified, with single-phase zirconolite-2M identified only for x = 0.10. A structural transformation from zirconolite-2M to zirconolite-4M occurred in the range 0.20 ≤ x ≤ 0.30, while a mixed-phase assemblage of zirconolite-4M and cubic pyrochlore was evident at Dy concentrations 0.40 ≤ x ≤ 0.50. Compositions for which x ≥ 0.60 were consistent with single-phase pyrochlore. The formation of zirconolite-4M and pyrochlore polytype phases, with increasing Dy content, was confirmed by high-resolution transmission electron microscopy, coupled with selected area electron diffraction. Analysis of the Dy L3-edge XANES region confirmed that Dy was present uniformly as Dy3+, remaining analogous to Am3+. Fitting of the EXAFS region was consistent with Dy3+ cations distributed across both Ca2+ and Zr4+ sites in both zirconolite-2M and 4M, in agreement with the targeted self-compensating substitution scheme, whereas Dy3+ was 8-fold coordinated in the pyrochlore structure. The observed phase fields were contextualized within the existing literature, demonstrating that phase transitions in CaZrTi2O7–REE3+Ti2O7 binary solid solutions are fundamentally controlled by the ratio of ionic radius of REE3+ cations

Synthesis and characterisation of HIP Ca0.80Ce0.20ZrTi1.60Cr0.40O7 zirconolite and observations of the ceramic–canister interface

A sample of zirconolite with nominal composition Ca0.80Ce0.20ZrTi1.60Cr0.40O7 was processed via Hot Isostatic Pressing (HIP), with a dwell temperature and pressure of 1320 °C/100 MPa maintained for 4 h. The produced wasteform was characterised by powder XRD, SEM–EDS, Ce L3 and Cr K-edge XANES. A significant portion of the Ce inventory did not fully partition within the zirconolite phase, instead remaining as CeO2 within the microstructure. Inspection of the stainless steel–ceramic interface detailed the presence of an interaction region dominated by a Cr-rich oxide layer. No significant Cr or Fe migration was observed, although a greater concentration of perovskite was observed at the periphery, relative to the bulk ceramic matrix. The X-ray absorption features of Cr remained analogous with Cr3+ accommodation within TiO6 octahedra in the zirconolite matrix. The absorption edge of Ce was comprised of contributions from zirconolite-2M and unincorporated CeO2, with an average oxidation state of Ce3.9+. As zirconolite-2M accounted for > 92 wt% of the overall phase assemblage, it is clear that the dominant oxidation state of Ce in this phase was Ce4+

Diffusion bonding of aluminium alloys

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Influence of Lubricants and Attrition Milling Parameters on the Quality of Zirconolite Ceramics, Consolidated by Hot Isostatic Pressing, for Immobilization of Plutonium

The effect of attrition milling on the processing of precursor oxides was investigated, with reference to the fabrication of titanate ceramics for the immobilization of plutonium and actinides, consolidated by hot isostatic pressing. Difficulties encountered during the lubricant removal step masked any correlation between the milling conditions and the final product. Four lubricants were investigated zinc stearate, Ceridust™, polyethylene glycol and oleic acid. The precursor blends were added to these lubricants to ensure the powders remained free flowing while dry milling in an attrition mill. All except Ceridust™ allowed the milled powders to be freely discharged. Examination of the products showed that each sample was highly porous and all were below the target minimum of 92 % of theoretical density. XRD and SEM analysis showed the production of a multiphase ceramic (zirconolite, perovskite, ilmenite) rather than the single target phase zirconolite. The impact of incomplete lubricant burn out on the oxidation states of Ce and Fe was investigated by XANES and Mössbauer spectroscopy, respectively. Suggested modifications to the HIP processing line, including the addition of an in situ sintered metal filter, the use of fumed metal oxides and the introduction of electrical conductivity in the precursors, are presented. © 2014 The American Ceramic Society

A systematic investigation of the phase assemblage and microstructure of the zirconolite CaZr1-xCexTi2O7 system

A series of zirconolite ceramics with nominal stoichiometry CaZr1-xCexTi2O7 (0.0 ≤ x ≤ 0.4) were synthesised under oxidizing, inert and reducing conditions, by a conventional solid-state cold press and sinter method. The evolution of phase assemblage and microstructure were characterized by XRD, SEM-EDS, Ce-L3 XANES and Raman spectroscopy techniques. It was determined that the relative yield of zirconolite-2M and zirconolite-4M polytypes, alongside secondary perovskite phases, was influenced by processing environment via the control of Ce3+/4+ speciation. Oxidizing conditions produced a mixture of zirconolite-2M and zirconolite-4M polytypes due to the formation of Ce4+. Inert and reducing conditions yielded predominantly zirconolite-2M and a Ce-bearing perovskite phase through favouring Ce3+ speciation