Oxynitride fuel kernel for gas-cooled reactor fuel particles
United States Patent [1 1 Leitnaker et al.  
 [451 Apr. 15, 1975 OXYNITRIDE FUEL KERNEL FOR GAS-COOLED REACTOR FUEL PARTICLES Inventors: James M. Leitnaker, Kingston;  
 Terrence B. Lindemer, Oak Ridge, both of Tenn.  
 The United States of America as represented by the Administrator of the Energy Research and Development Administration, Washington, DC.  
 Filed: Aug. 8, 1973 Appl. No.: 386,657  
 Assignee:  
 US. Cl. 176/67; 176/82; 176/91 SP; 252/30l.l R; 264/O.5 Int. Cl G2lc 3/06; C2lc 3/20 Field of Search... 176/67, 82, 89, 91 R, 91 SP, 176/90; 252/30l.1 R; 264/O.5  
 [56] References Cited UNITED STATES PATENTS 3,230,177 l/l966 Blum et al 252/30l.l R 3,36l,638 1/1968 Bokros et al .4 1761/91 R 3,746,616 7/1973 Leitnaker et a1 252/30l.l R 3,798,123 3/1974 Lindemer 176/67 Primary ExaminerBenjamin A. Borchelt Assistant Examiner-C. T. Jordan Attorney, Agent, or Firm-John A. Horan; David S. Zachry; John B. Hardaway [57] ABSTRACT A new nuclear fuel for use in gas-cooled reactors comprising a carbon coated kernal of UO N I where O x s l.  
 6 Claims, 2 Drawing Figures OXYNITRIDE FUEL KERNEL FOR GAS-COOLED REACTOR FUEL PARTICLES BACKGROUND OF THE INVENTION This invention was made in the course of, or under, a contract with the United States Atomic Energy Commission. It relates generally to a new fuel for use in gascooled reactors.  
  As is disclosed in commonly assigned copending ap plication Ser. No. 235,206 filed Mar.l6, I972. now U.S. Pat. No. 3,798,123, fuel used in gas-cooled nuclear reactors is subject to coating thinning and the amoeba effect due to oxygen released during the fissioning of a UO fuel kernel. A typical fuel particle is sectionally shown in FIG. I of the drawings. Such a particle comprises an approximately spherical oxide kernel (l a cover of porous carbon (2), a sealer layer of dense pyrolytic graphite (3), a layer of silicon carbide (4) and a final layer of dense pyrolytic graphite (5). The inner or buffer layer of porous carbon (2) with a porosity about to 70% absorbs any expansion or swelling of the kernel (I and minimizes damage to the other layers due to fission fragment recoil from the kernel. The adjacent dense graphite layer (3) is applied to isolate the kernel and layer (2) from attack by deleterious gases, such as chlorine, used in depositing the silicon carbide layer (4). The silicon carbide layer (4) gives dimensional stability to the overall fuel particle and provides containment for metallic fission fragments. The silicon carbide layer may be omitted in experimental fuels but is included in all present particles for practical nuclear application.  
  Failure of the above fuel particle design during operational conditions has been attributed to oxygen release during fissioning so as to produce CO and CO by reaction with the carbon buffer layer. This reaction has been observed to cause a thinning of the coatings and in some cases a migration of the kernel out of the coatings. The latter phenomenon is known as the amoeba effect. In either instance, the failure of the particle is attributable to excessive CO and CO pressures within the particle as a result of oxygen released during fissioning of the fuel.  
 SUMMARY OF THE INVENTION I It is thus an object of this invention to provide a new fuel particle for use in gas-cooled reactors.  
 It is a further object to provide a fuel particle which accommodates oxygen released during fissioning so as to minimize CO and CO pressures within the fuel particle.  
 These, as well as other objects, are accomplished by utilizing a fuel kernel comprising UO N I where O x 1 within a conventional fuel particle.  
 BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a sectional view of a HTGR fuel particle. FIG. 2 is a ternary phase diagram of the uranium, oxygen, nitrogen system.  
 DETAILED DESCRIPTION According to this invention, it has been found that UO ,N I where O x l maintains a low oxygen 2 of the drawings. This is a single phase region which contains no UN. At elevated temperatures, UO N (area B) will form, thus causing the composition in area ,A to move toward U0 However, this reaction has no adverse effect on the gas phase equilibria which is of interest to this invention.  
  In general, the fuel kernel of this invention comprises either a physical mixture of U0 and U N or the solid solution formed thereby. Under operational conditions U0 and U N will normally not exist individually but will exist as the solid solution UO N I which is formed by Either state, however, is effective to establish the desired equilibrium and thus maintain the CO and CO pressures at a level below that which will cause fuel failure.  
  The apparent reason that the fuel of this invention reduces fuel degradation due to the presence of CO and CO within the fuel kernel is that oxygen released during fission is accommodated into the UNO system by gas-solid equilibrium reactions. Simply stated, this accommodation is expressed by The brackets in the above equation are used for thermodynamic convenience to indicate the presence of the compounds in the single-phase solid solution. In practice, the equilibrium of oxygen with carbon monoxide and carbon is also maintained via the reaction (Ill) and the addition of these two reactions gives [UN] 2C0: [U0 2C %N The latter equation represents equilibrium between all the major solid and gaseous phases present in the fuel particle. The presence of minor amounts of CO is established by the equilibrium 2C0 CO C in which P is generally P In either event the 0 CO and CO pressures are maintained at a level at which fuel failure will not result from coating thinning or the amoeba effect. It should be noted that nitrogen is released as a consequence of removing oxygen from the kernel atmosphere; however, nitrogen does not deleteriously affect the carbon coatings.  
  The selection of the value x in UO N I is based on estimates of the chemical behavior of the fuel-fission product system within a coated particle. By considering the release of oxygen from U0 during fission, a value of x can be preselected so as to accommodate the released oxygen. The oxygen release is not precisely known, but for the present purposes the following expressions encompass the available estimates:  
 C 92 33103 M 0 0.30 CO C UO liifl 1.07 M 0 0.15 CO C U0 1.10 M 0, 0.01 CO a. (l-.01F) moles UO -N v11) b. (.OlF) M/U moles of fission product oxide (Vlll) c. /2[%x%w(10lF)]=moles OfNz gas=NN 1x d. negligible moles of CO or CO gas e. no solid-phase nitrides The conservation of mass requires that (moles of oxygen) initial (moles of oxygen) after burnup (moles of nitrogen) initial (moles of nitrogen) after burnup.  
 Use of these relations to solve for w gives in which M/U is the ratio of fission product metal oxide formed per uranium fission, Equation VI, and O/M is the average ratio of oxygen-to-fission product metal in the fission-product oxides, Equation V1.  
  Equation X can thus be used to calculate the minimum value of x necessary in the original oxynitride fuel. A requirement here is that the value of w after a given final burnup, F,, be no less than zero. Equation X is thus used for w 0 to give iniliril Typical minimum values of x are given in Table I.  
 TABLE I Typical Minimum Values of x (M/U) (O/M) xatF= (Eq. v1 25 50 75 100(theoretical) The maximum initial value ofx should be about three times the minimum allowable value to compensate for any errors in the estimation of the chemical behavior of the system. From Table l, the maximum value of x can be calculated to be 0.9.  
  The fuel particle of this invention may be produced by either forming microspheres ofa mixture of U0 or U N with about 0.01 to 5.2 weight percent&#39;of U N or preferably by forming the solid solution from previously formed U0 microspheres.  
  The solid solution is best formed by reacting U0 microspheres with nitrogen to form UO N This is done by placing UO in a bed of carbon and heating in the presence of N and CO. Since x moles of oxygen are removed from the U0 to form UO N it follows that at least x moles of carbon must be present to remove the oxygen as CO. Table 11 lists fabrication conditions which can be used to produce the fuel of this invention with the desired value of x.  
 TABLE 11 Range of x in Exact T P P UO -;,.u x &#34;C Torr Torr Preparation of the UO N I is typically accomplished by a variation of the process disclosed in U. S. Pat. No. 3,510,434. Microspheres of U0 prepared by a conventional method such as the sol-gel technique are used as feed material. These microspheres may have an O/U ratio of exactly two or they may be hyperstoichiometric (O/U 2 y) or hypostoichiometric (O/U 2 y) in oxygen. The microspheres are mixed with carbon or graphite particles, the amount being at least [(Zi&#39;y) (2x)] moles of graphite per mole of U02 y- The carbon particles are conveniently a mesh size that is smaller than the U0 so that excess carbon may be removed after heat treatment by a screening process. Excess carbon may be added to the system and, in fact, this is desirable in order to maximize the UO -carbon contact during the heat treatment; such close proximity is necessary so that oxygen removed from the U0 can react immediately with the carbon to form CO.  
  The UO -carbon mixture is placed in a graphite, tungsten, or molybdenum vessel and is placed in a furnace. A gas mixture containing CO and N at the desired partial pressures (Table l) is flowed through the furnace at a given temperature (Table l) and at a rate that insures that approximately ten volumes of CO and N are swept past the UO -carbon charge for each volume of CO removed from the U0 For example, if one mole of UO l I were produced, then 0.4 mole of CO is released, or 8.96 liters of CO at STP. Thus, about 90 liters (STP) of C0 N should be flowed past the charge during the heat treatment. This is done to insure that the CO/N ratio remains at the value necessary to give the desired value of at. Other gases may also be added to the CO and N gases; argon is conveniently added to provide a total gas pressure of one atmosphere. Hydrogen additions in the amount of 1-8 volume percent are also beneficial because this procedure is generally known to enhance the gas-phase transport of nitrogen, carbon and/or oxygen between the U0 and carbon.  
  The time necessary for the processing is about one hour at 1,700C and about hours at l,200C for 1,000 micrometer U0 microspheres. The time is independent of the amount of U0 charged.  
  After the desired reaction time, the charge should be cooled to ambient temperature as rapidly as is practicable (e.g., furnace turned off) to minimize changes in x during cooling. Removing the crucible and charge from the hot zone of the furnace is even more desirable. The gas flow can then be stopped. After the charge is at ambient temperature the excess carbon particles can be removed by screening.  
  Many variations of the above process are possible. For example, resin-derived microspheres may be used with excess carbon in the microspheres providing the necessary carbon content. The reaction may also be carried out in a fluidized bed.  
  Coating layers may be applied by conventional techniques. The initial low density, highly porous carbon coating may be applied, for example, using the method disclosed in U. S. Pat. No. 3,472,677. A high density coating may then be applied using the method disclosed in U. S. Pat. No. 3,471,314. A SiC layer, if desired, may be applied in a fluidized bed with the SiC being derived by the thermal decomposition of, for example, methyl trichlorosilane. The outer carbon layer may be produced by again using the process of U. S. Pat. No. 3,471,314.  
 EXAMPLE The pressure of carbon monoxide (P in a pure U0 HTGR particle can be obtained from an adaptation of the ideal gas law in which where a ratio, void volume in kernel and buffer layer/- superficial volume of kernel 0 molar volume of U0 R 82.06 cm&#34;-atm/mole K T temperature, &#34;K  
 F percent FIMA N moles of carbon monoxide in Equation (VI).  
  This equation was used to calculate the values of P in Table III as a function of burnup at 1,800K with a typical value ofa 2.5. As a comparison, the values of P and P in the fuel particle of this invention are included. The pressure of N during burnup is calculated from the moles of nitrogen released, which is obtained from relations (IX) and (X). This is (Xlll) The P during burnup is calculated from the relation for the equilibrium constant of reaction (IV); this is approximately C0 initial Gas Pressures During Burnup of U0 At Approximately l800K and a 2.5  
  Fully-enriched UO ,N;, 235 x 0.5 PX! PK! PFO PIU PS2 71 FlMA Atm. Atm. Atm. Atm.  
  As is seen from the above example, the fuel particle of this invention provides a superior advance over the prior art U0 fuel particles in that the P is greatly reduced, thus minimizing fuel failure due to coating thinning and the amoeba effect.  
  While this invention has been explained with reference to U0 and U N it is equally applicable to mixed oxide-nitride systems in the U-Pu, U-Th, and Th systems.  
 What is claimed is:  
  1. A high temperature gas-cooled reactor fuel particle comprising a spheroidal kernel of a metal oxide and a metal nitride with up to 33%; mole percent nitride, said oxide and nitride being selected from the group consisting of a mixture of U0 and U N a mixture of (U,Pu)O and U N a mixture of ThO and Th N and a carbon cover adjacent said kernel.  
  2. The particle of claim 1 wherein said oxide and nitride are U0 and U N 3. The particle according to claim 2 wherein said U0 and U N are present as a solid solution UO N wherein 0 x l.  
  4. The particle according to claim 2 wherein said U0 and U N are within the area A of FIG. 2.  
  5. The particle according to claim 2 wherein said U N is present in an amount of from 0.06 to 22- /2 mole percent.  
  6. The particle according to claim 2 further comprising a dense graphite layer adjacent said carbon cover, a SiC layer adjacent said graphite layer and a second dense graphite layer adjacent said SiC layer.