ConverDyn

Last updated
ConverDyn
Type General Partnership
Industry Nuclear Fuel Cycle
Founded1992
Headquarters Greenwood Village, CO, U.S.
Area served
Worldwide
Key people
Malcolm Critchley (President and CEO) [1]
ServicesUranium Hexafluoride Conversion
Parent Honeywell International, Inc.
General Atomics

ConverDyn is a general partnership between American multinational firms General Atomics and Honeywell that provides uranium hexafluoride (UF6) conversion and related services to utilities operating nuclear power plants in North America, Europe, and Asia. The company is the sole marketing agent of UF6 produced at the Honeywell Uranium Hexafluoride Processing Facility in Metropolis, Illinois. [2]

Contents

History

Nuclear fuel cycle begins when uranium is mined, converted, enriched and manufactured to nuclear fuel (1) which is delivered to a nuclear power plant. After usage in the power plant the spent fuel is delivered to a reprocessing plant (if fuel is recycled) (2) or to a final repository (if no recycling is done) (3) for geological disposition. In reprocessing 95% of spent fuel can be recycled to be returned to usage in a nuclear power plant (4). Nuclear Fuel Cycle.png
Nuclear fuel cycle begins when uranium is mined, converted, enriched and manufactured to nuclear fuel (1) which is delivered to a nuclear power plant. After usage in the power plant the spent fuel is delivered to a reprocessing plant (if fuel is recycled) (2) or to a final repository (if no recycling is done) (3) for geological disposition. In reprocessing 95% of spent fuel can be recycled to be returned to usage in a nuclear power plant (4).

From 1970 to 1992, there were two operating uranium hexafluoride conversion facilities in the United States. These included Allied Signal's Metropolis Works Facility and General Atomics' Sequoyah Fuels Facility in Gore, Oklahoma. Facing low conversion prices and the implementation of the Megatons to Megawatts Program, both companies recognized the forthcoming struggles surrounding excess market supply of conversion services. In 1992, Allied Signal and General Atomics agreed to close the Gore, Oklahoma facility and take joint and equal ownership of profits from Allied Signal's plant in Metropolis, Illinois. [3] ConverDyn was formed as a general partnership between the two companies as the sole marketing organization of uranium hexafluoride produced at the Metropolis plant. As a result, any and all uranium hexafluoride produced at Metropolis Works is marketed and sold by ConverDyn. In 1999, Honeywell and Allied Signal merged resulting in the partnership structure that exists currently.

Honeywell Metropolis Works

Built in 1958, the Honeywell Metropolis Works Facility is the only uranium hexafluoride conversion facility in the United States. The plant has an annual conversion capacity of approximately 15,000 tU as UF6 accounting for approximately 20% of worldwide production capacity. [4] The plant feeds U3O8 yellowcake received from uranium mines and produces uranium hexafluoride gas for enrichment at one of the primary enrichment sites around the world. After being enriched, product is fabricated into nuclear fuel that ends up generating electricity at a nuclear power plant.

Conversion Process

Honeywell Metropolis Works deploys a unique technology and process by which it converts yellowcake to uranium hexafluoride gas. The other Western conversion facilities, Areva and Cameco, each utilize a process that requires two different facilities, one to convert yellowcake to either uranium tetrafluoride or uranium trioxide and another to convert to uranium hexafluoride. Honeywell developed a process known as the dry fluoride volatility conversion process that allows for complete yellowcake to UF6 at a single facility and also yielding a greater level of UF6 purity at 99.99% or higher. [5]

The dry fluoride volatility conversion process at Metropolis works goes through five basic steps: feed preparation, reduction, hydrofluorination, fluorination, and distillation. [6]

Uranium ore concentrate storage at the Metropolis Works Facility MDP8867z.jpg
Uranium ore concentrate storage at the Metropolis Works Facility

The aim of this initial step it to ensure that uranium concentrates have the optimum particle size and density necessary to move forward in the process of conversion.

During this stage, uranium ore concentrates are converted to uranium dioxide and impurities are removed from the system into a waste gas stream. The sized yellowcake is reacted with hydrogen in a fluidizing medium to form uranium dioxide

2U
3
O
8
+H
2
→ 3UO
2
+ 2H
2
O

The UO2 resulting from the previous reduction stage is then converted into uranium tetrafluoride intermediate (Green Salt) and additional impurities are removed from the system.

UO
2
+4HFUF
4
+ 2H
2
O
Honeywell Metropolis Works Facility in Metropolis, Illinois MTW Picture.jpg
Honeywell Metropolis Works Facility in Metropolis, Illinois

The Metropolis Works Plant operates the largest gaseous fluorine capacity in the world. Fluorine is produced in this process by the electrolysis of HF in a Potassium Bifluoride substrate. The fluorine is pulled to the fluorination process under vacuum so as to increase the safety of this step. The result of this step is crude uranium hexafluoride gas.

UF
4
+F
2
UF
6

Finally, uranium hexafluoride from the previous step is purified in a two-stage distillation system. The crude UF6 is vaporized and transferred through a boiling system into cold traps. After cooling, the final product is filled into cylinders for transport. This stage is proprietary Honeywell technology which allows output of 99.99% or greater UF6. [5]

2012 Required Plant Upgrades

After the Fukushima Daiichi nuclear disaster in 2011, the United States Nuclear Regulatory Commission conducted inspections at all US nuclear facilities for seismic deficiencies and general resistance to natural disasters. Although initial inspections confirmed that the Metropolis Works Facility was in full compliance with its operating license, the NRC shutdown the plant in May 2012 and required a series of upgrades to improve resilience to natural disasters including earthquakes and tornadoes. Honeywell elected to complete required upgrades and the plant restarted production of uranium hexafluoride in July 2013, after more than a year offline. [7] [8]

Photo of Feed Materials Building at Honeywell Metropolis Works MDP9168z.jpg
Photo of Feed Materials Building at Honeywell Metropolis Works
Cylinder used to transport uranium hexafluoride DUF6PH38.jpg
Cylinder used to transport uranium hexafluoride
Moving UF6 Cylinder at Honeywell Metropolis Works Cylinder Load.jpg
Moving UF6 Cylinder at Honeywell Metropolis Works

Related Research Articles

Isotope separation is the process of concentrating specific isotopes of a chemical element by removing other isotopes. The use of the nuclides produced is varied. The largest variety is used in research. By tonnage, separating natural uranium into enriched uranium and depleted uranium is the largest application. In the following text, mainly uranium enrichment is considered. This process is crucial in the manufacture of uranium fuel for nuclear power plants, and is also required for the creation of uranium-based nuclear weapons. Plutonium-based weapons use plutonium produced in a nuclear reactor, which must be operated in such a way as to produce plutonium already of suitable isotopic mix or grade.

Enriched uranium is a type of uranium in which the percent composition of uranium-235 has been increased through the process of isotope separation. Naturally occurring uranium is composed of three major isotopes: uranium-238, uranium-235, and uranium-234. 235U is the only nuclide existing in nature that is fissile with thermal neutrons.

<span class="mw-page-title-main">Uranium hexafluoride</span> Chemical compound

Uranium hexafluoride, sometimes called hex, is an inorganic compound with the formula UF6. Uranium hexafluoride is a volatile white solid that reacts with water, releasing corrosive hydrofluoric acid. The compound reacts mildly with aluminium, forming a thin surface layer of AlF3 that resists any further reaction from the compound. UF6 is used in the process of enriching uranium, which produces fuel for nuclear reactors and nuclear weapons.

<span class="mw-page-title-main">Yellowcake</span> Uranium concentrate powder

Yellowcake is a type of uranium concentrate powder obtained from leach solutions, in an intermediate step in the processing of uranium ores. It is a step in the processing of uranium after it has been mined but before fuel fabrication or uranium enrichment. Yellowcake concentrates are prepared by various extraction and refining methods, depending on the types of ores. Typically, yellowcakes are obtained through the milling and chemical processing of uranium ore, forming a coarse powder that has a pungent odor, is insoluble in water, and contains about 80% uranium oxide, which melts at approximately 2880 °C.

<span class="mw-page-title-main">Gaseous diffusion</span> Old method of enriching uranium

Gaseous diffusion is a technology that was used to produce enriched uranium by forcing gaseous uranium hexafluoride (UF6) through microporous membranes. This produces a slight separation (enrichment factor 1.0043) between the molecules containing uranium-235 (235U) and uranium-238 (238U). By use of a large cascade of many stages, high separations can be achieved. It was the first process to be developed that was capable of producing enriched uranium in industrially useful quantities, but is nowadays considered obsolete, having been superseded by the more-efficient gas centrifuge process (enrichment factor 1.05 to 1.2).

<span class="mw-page-title-main">K-25</span> Manhattan Project codename for a program to produce enriched uranium

K-25 was the codename given by the Manhattan Project to the program to produce enriched uranium for atomic bombs using the gaseous diffusion method. Originally the codename for the product, over time it came to refer to the project, the production facility located at the Clinton Engineer Works in Oak Ridge, Tennessee, the main gaseous diffusion building, and ultimately the site. When it was built in 1944, the four-story K-25 gaseous diffusion plant was the world's largest building, comprising over 5,264,000 square feet (489,000 m2) of floor space and a volume of 97,500,000 cubic feet (2,760,000 m3).

<span class="mw-page-title-main">Honeywell Uranium Hexafluoride Processing Facility</span>

The Honeywell Uranium Hexafluoride Processing Facility, a uranium conversion facility, is located 1.9 miles (3 km) northwest of Metropolis, Illinois, United States. The plant, Honeywell Specialty Chemicals in Metropolis, Illinois, has a nominal capacity of 15,000 tU as uranium hexafluoride per year. ConverDyn, a general partnership between affiliates of Honeywell and General Atomics, is the exclusive agent for conversion sales from the Honeywell Uranium Hexafluoride Processing Facility.

Fluoride volatility is the tendency of highly fluorinated molecules to vaporize at comparatively low temperatures. Heptafluorides, hexafluorides and pentafluorides have much lower boiling points than the lower-valence fluorides. Most difluorides and trifluorides have high boiling points, while most tetrafluorides and monofluorides fall in between. The term "fluoride volatility" is jargon used particularly in the context of separation of radionuclides.

Molecular laser isotope separation (MLIS) is a method of isotope separation, where specially tuned lasers are used to separate isotopes of uranium using selective ionization of hyperfine transitions of uranium hexafluoride molecules. It is similar to AVLIS. Its main advantage over AVLIS is low energy consumption and use of uranium hexafluoride instead of vaporized uranium.

<span class="mw-page-title-main">Triuranium octoxide</span> Chemical compound

Triuranium octoxide (U3O8) is a compound of uranium. It is present as an olive green to black, odorless solid. It is one of the more popular forms of yellowcake and is shipped between mills and refineries in this form.

<span class="mw-page-title-main">Uranium tetrafluoride</span> Chemical compound

Uranium tetrafluoride is the inorganic compound with the formula UF4. It is a green solid with an insignificant vapor pressure and low solubility in water. Uranium in its tetravalent (uranous) state is important in various technological processes. In the uranium refining industry it is known as green salt.

Separation of isotopes by laser excitation (SILEX) is a process under development to enrich uranium on an industrial scale for nuclear reactors. It is strongly suspected that it utilizes laser condensation repression to excite the uranium-235 isotope in uranium hexafluoride (UF6), allowing this lighter molecule to move more rapidly to the outer rim of a gaseous jet and resist condensing compared to the heavier, unexcited 238UF6. This differs greatly from previous methods of laser enrichment explored for their commercial prospects: one using atomic uranium (Atomic Vapor Laser Isotope Separation (AVLIS)) and another molecular method that uses lasers to dissociate a fluorine atom from 235UF6 (Molecular Laser Isotope Separation (MLIS)), allowing the enriched product to precipitate out as a solid.

Uranium compounds are compounds formed by the element uranium (U). Although uranium is a radioactive actinide, its compounds are well studied due to its long half-life and its applications. It usually forms in the +4 and +6 oxidation states, although it can also form in other oxidation states.

The National Enrichment Facility (NEF) is a nuclear facility for the enrichment of uranium associated with the Los Alamos National Laboratory. The plant uses a gas centrifuge technology known as Zippe-type centrifuges. It is located 5 miles (8.0 km) east of Eunice, New Mexico. The NEF is operated by Louisiana Energy Services (LES), which is in turn owned by the Urenco Group. As of 2011, LES operates as URENCO USA.

<span class="mw-page-title-main">Fernald Feed Materials Production Center</span> Uranium fuel factory in the United States

The Fernald Feed Materials Production Center is a Superfund site located within Crosby Township in Hamilton County, Ohio, as well as Ross Township in Butler County, Ohio, in the United States. It was a uranium processing facility located near the rural town of New Baltimore, about 20 miles (32 km) northwest of Cincinnati, which fabricated uranium fuel cores for the U.S. nuclear weapons production complex from 1951 to 1989. During that time, the plant produced 170,000 metric tons uranium (MTU) of metal products and 35,000 MTU of intermediate compounds, such as uranium trioxide and uranium tetrafluoride.

<span class="mw-page-title-main">Plutonium hexafluoride</span> Chemical compound

Plutonium hexafluoride is the highest fluoride of plutonium, and is of interest for laser enrichment of plutonium, in particular for the production of pure plutonium-239 from irradiated uranium. This isotope of plutonium is needed to avoid premature ignition of low-mass nuclear weapon designs by neutrons produced by spontaneous fission of plutonium-240.

Sequoyah Fuels Corporation owned and operated a uranium processing plant near Gore, Oklahoma. The company was created in 1983 as a subsidiary of Kerr-McGee. In 1988 it was sold to General Atomics.

<span class="mw-page-title-main">Neptunium(VI) fluoride</span> Chemical compound

Neptunium(VI) fluoride (NpF6) is the highest fluoride of neptunium, it is also one of seventeen known binary hexafluorides. It is an orange volatile crystalline solid. It is relatively hard to handle, being very corrosive, volatile and radioactive. Neptunium hexafluoride is stable in dry air but reacts vigorously with water.

<span class="mw-page-title-main">Malvési</span>

Depleted uranium hexafluoride (DUHF; also referred to as depleted uranium tails, depleted uranium tailings or DUF6) is a byproduct of the processing of uranium hexafluoride into enriched uranium. It is one of the chemical forms of depleted uranium (up to 73-75%), along with depleted triuranium octoxide (up to 25%) and depleted uranium metal (up to 2%). DUHF is 1.7 times less radioactive than uranium hexafluoride and natural uranium.

References

  1. "ConverDyn News Wire" (PDF). Retrieved 17 July 2013.
  2. "US Nuclear Fuel Cycle". World Nuclear Association. Retrieved 17 July 2013.
  3. "Uranium Plant, Beset by Trouble, Is Closing". Los Angeles Times. Retrieved 17 July 2013.
  4. "Conversion and Deconversion". World Nuclear Association. Archived from the original on 9 January 2016. Retrieved 17 July 2013.
  5. 1 2 "Uranium Hexafluoride Specifications" (PDF). Archived from the original (PDF) on 4 March 2016. Retrieved 17 July 2013.
  6. "The Conversion Process". ConverDyn. ConverDyn. Archived from the original on 24 February 2020. Retrieved 17 July 2013.
  7. "Honeywell set to restart in Metropolis". The Southern Illinoisan. The Southern Illinoisan. Retrieved 17 July 2013.
  8. "NRC Authorizes Honeywell Metropolis Facility to Resume Operations" (PDF). Retrieved 17 July 2013.