High-temperature distillation and consolidation of U–Zr cathode product from molten salt electrorefining of simulated metallic fuel

Abstract High-temperature distillation experiments were performed using U–Zr cathode products of various compositions to obtain knowledge on suitable operation conditions and equipment design such as the container material. The LiCl–KCl–UCl3 electrolyte adhering to the U–Zr cathode products was almost completely vaporized at 1273–1573 K, under pressure of 10–300 Pa. Massive ingots were obtained from the remaining cathode products by heating them at 1573–1673 K. Three different phases were identified in a distillation product of a higher Zr content. A U-rich bulk (3.9 wt% Zr) and a deposit of a relatively low Zr content (17.2 wt% Zr) were considered to be formed during the cooling process of the distillation product. Another Zr-rich deposit (64.7 wt% Zr), which might cause the inhomogeneity of product ingots, was expected to result from Zr-rich spots that originally existed in the cathode product. The Cl content in the cathode product was decreased by distillation to less than 1/200 of that after electrorefining, while it was markedly larger at a higher Zr concentration. To limit the amount of Zr-rich deposit and the Cl content, the amount of Zr in the distillation product should be controlled to a sufficiently low level by optimization of the operating procedures and conditions in the electrorefining and distillation steps. The zirconia coating material developed in this study showed superior performance in inhibiting reaction between the melted U–Zr alloy melt and the graphite crucible and also in the easy release of the U–Zr ingot from the crucible.