Multiphase Ceramic Waste Form Research Articles

Preparation and chemical stability evaluation of Ln2Zr2O7‐SrZrO3 novel composite ceramics cured simultaneously with An and 90Sr

AbstractIn response to the low separation efficiency of actinide nuclide (An) and fission product (FP) in the separation process of high‐level radioactive waste, as well as the large amount of secondary waste. A novel Ln(1‐x)SrxZrO(3.5‐0.5x) (0 ≤ x ≤1) multiphase ceramic waste form (Nd3+ simulating An3+), which can cure both An and Sr simultaneously, was in‐situ synthesized by sol‐gel spray pyrolysis method. The series of multiphase ceramics are composed of cubic pyrochlore phase Nd2Zr2O7 (NZO) and orthorhombic perovskite phase SrZrO3 (SZO), without any accompanying impurities. The two phases exhibit excellent compatibility, and their content can change regularly with the change of x. Nd and Sr occupy their most stable crystal lattice positions, with low transposition doping levels. The density of the composite ceramics is high, and the measured density is as high as 88 % of the theoretical density. The above experimental results confirm that the new multiphase ceramics can cure An and Sr simultaneously and separately, showing strong adaptability to waste components and high chemical stability.

Exploring the effects of Sr/Ce/Nd co-incorporation on the phase evolution and chemical stability of Sr0.5Zr2(PO4)3-(Ce, Nd)PO4 multiphase ceramics designed for nuclear waste forms

In this work, 0.6Sr0.5Zr2(PO4)3-0.4Ce1-xNdxPO4 (x = 0–1) multiphase ceramics were fabricated using a one-step microwave sintering technique, where Sr and Ce/Nd were utilized as the substitutes for the fission products 90Sr and actinide nuclides in high-level radionuclide wastes, respectively. The influences of Sr/Ce/Nd co-incorporation on the phase evolution, crystal structure, micromorphology, densification, and chemical stability of the as-prepared multiphase ceramic waste forms were systematically investigated. It was detected that the multiphase ceramics were composed of Sr0.5Zr2(PO4)3 (SrZP) phase and monazite phase regardless of x value, and (Ce, Nd)PO4 monazite solid solution was formed with Ce/Nd substitution. Rietveld refinement results further verified the cell parameters of (Ce, Nd)PO4 monazite solid solution regularly decreased with increasing Nd replacement, and the structural change of crystalline monazite did not affect the structure of SrZP phase. All samples presented a well-compacted and homogeneous microstructure, and their micromorphology did not change significantly with the replacement of Ce by Nd. Moreover, the relative density of the as-prepared multiphase ceramics all reached more than approximately 94.5 %, demonstrating excellent densification. Importantly, the good compatibility of SrZP and (Ce, Nd)PO4 monazite phases brought out superior chemical stability. The normalized elemental leaching rate showed no significant change for different Ce/Nd substituted samples, whose normalized leaching rates of Sr, Ce, and Nd were about 10−4 g/(m2·d), 10−7 g/(m2·d), and 10−6 g/(m2·d) order of magnitude, respectively. It is demonstrated that SrZP-(Ce, Nd)PO4 multiphase ceramics can be used as candidate materials for simultaneously immobilizing fission products and actinide nuclides of high-level nuclear wastes.

Preparation and characterization of multiphase ceramic designer waste forms

The long-term performance, or resistance to elemental release, is the defining characteristic of a nuclear waste form. In the case of multiphase ceramic waste forms, correlating the long-term performance of multiphase ceramic waste forms in the environment to accelerated chemical durability testing in the laboratory is non-trivial owing to their complex microstructures. The fabrication method, which in turn affects the microstructure, is further compounding when comparing multiphase ceramic waste forms. In this work, we propose a “designer waste form” prepared via spark plasma sintering to limit interaction between phases and grain growth during consolidation, leading to monolithic high-density waste forms, which can be used as reference materials for comparing the chemical durability of multiphase waste forms. Designer waste forms containing varying amounts of hollandite in the presence of zirconolite and pyrochlore in a fixed ratio were synthesized. The product consistency test (PCT) and vapor hydration test (VHT) were used to assess the leaching behavior. Samples were unaffected by the VHT after 1500 h. As measured by the PCT, the fractional Cs release decreased as the amount of hollandite increased. Elemental release from the zirconolite and pyrochlore phases did not appear to significantly contribute to the elemental release from the hollandite phase in the designer waste forms.

Partitioning of Ce, as a simulant for Pu, in a multiphase ceramic nuclear waste form

AbstractA pyrochlore‐rich multiphase ceramic waste form was prepared by the alkoxide‐route and consolidated by sintering in air. Cerium (Ce) was used as a surrogate for plutonium (Pu), which was found in both the major pyrochlore and minor perovskite phases, but not the minor rutile phase. A synchrotron‐based fluorescence X‐ray absorption near‐edge spectroscopy (XANES) imaging technique was employed to determine the Ce oxidation state in each of the two Ce‐containing phases. It was shown that the major pyrochlore phase contains only tetravalent Ce, whereas the minor perovskite phase incorporates exclusively trivalent Ce. The effect of sintering atmosphere was also investigated, which revealed a very different phase assemblage when sintered in argon (Ar). A major perovskite phase was produced under Ar with a minor zirconolite‐4M phase, both containing trivalent Ce. The composition of the minor rutile phase remained the same whether it was sintered in air or Ar. The results demonstrate the importance of controlling the oxidation state of multivalent waste ions in the design of ceramic waste forms.

Simultaneous three‐dimensional elemental mapping of Hollandite and Pyrochlore material phases in ceramic waste form materials

AbstractDifferential X‐ray absorption contrast tomography was performed on model ceramic composite systems to image the 3D spatial distributions of Ga and Nd containing phases. The model material systems were fabricated such that they contained two constituent phases. Ga–doped Ba hollandite (Ba1.33Ga2.66Ti5.34O16), and pyrochlore (Nd2Ti2O7) which are under consideration as nuclear waste immobilization matrices. Two complementary techniques have been used to characterize the 3D distribution of phases. The analysis suggests that the 3D spatial distributions of hollandite and pyrochlore can be readily identified through the distributions Ga and Nd, respectively. These results represent a critical development towards characterizing the complex microstructure inherent to practical materials such as multiphase ceramic composite waste forms. Moreover, these methods can be applied to elucidate microstructural features that fundamentally determine the performance and properties of complex systems, which is central to the design of durable waste forms as well as many other real materials such fuel cells, batteries, ultra‐high temperature ceramics.

Glass structure and crystallization in boro-alumino-silicate glasses containing rare earth and transition metal cations: a US-UK collaborative program

ABSTRACTNuclear wastes generated from reprocessing of used nuclear fuel tend to contain a large fraction of rare earth (RE, e.g., Nd3+), transition (TM, e.g., Mo6+, Zr4+), alkali (A, e.g., Cs+), and alkaline earth cations (AE, e.g., Ba2+, Sr2+). Various strategies have been considered for immobilizing such waste streams, varying from nominally crystal-free glass to glass-ceramic to multi-phase ceramic waste forms. For glass and glass-ceramic waste forms, the added glass-forming system is generally alkali-alkaline earth-aluminoborosilicate (i.e., Na-Ca-Al-B-Si oxide). In a US-UK collaborative project, summarized here, we investigated the glass structure and crystallization dependence on compositional changes in simulated nuclear waste glasses and glass-ceramics. Compositions ranged in complexity from five – to – eight oxides. Specifically, the roles of Mo and rare earths are investigated, since a proposed glass-ceramic waste form contains crystalline phases such as powellite [(AE,A,RE)MoO4] and oxyapatite [(RE,AE,A)10Si6O26], and the precipitation of molybdenum phases is known to be affected by the rare earth concentration in the glass. Additionally, the effects of other chemical additions have been systematically investigated, including Zr, Ru, P, and Ti. A series of studies were also undertaken to ascertain the effect of the RE size on glass structure and on partitioning to crystal phases, investigating similarities and differences in glasses containing single RE oxides of Sc, Y, La, Ce, Nd, Sm, Er, Yb, or Lu. Finally, the effect of charge compensation was investigated by considering not only the commonly assessed peralkaline glass but also metaluminous and peraluminous compositions. Glass structure and crystallization studies were conducted by spectroscopic methods (i.e., Raman, X-ray absorption, nuclear magnetic resonance (NMR), optical absorption, photoluminescence, photoluminescence excitation, X-ray photoelectron spectroscopy), microscopy (i.e., scanning electron microscopy, transmission electron microscopy, electron probe microanalysis), scattering (i.e., X-ray and neutron diffraction, small angle measurements), and physical characterization (i.e., differential thermal analysis, liquidus, viscosity, density). This paper will give an overview of the research program and some example unpublished results on glass-ceramic crystallization kinetics, microstructure, and Raman spectra, as well as some examples of the effects of rare earths on the absorption, luminescence, and NMR spectra of starting glasses. The formal collaboration described here has resulted in the generation of a large number of results, some of which are still in the process of being published as separate studies.

Comparison of structure, morphology, and leach characteristics of multi-phase ceramics produced via melt processing and hot isostatic pressing

Melt processing of multi-phase ceramic waste forms offers potential advantages over traditional solid-state synthesis methods given both the prevalence of melters currently in use and the ability to reduce the possibility of airborne radionuclide contamination. In this work, multi-phase ceramics with a targeted hollandite composition of Ba1.0Cs0.3Cr1.0Al0.3Fe1.0Ti5.7O16 were fabricated by melt processing at 1675 °C and hot isostatic pressing (HIP) at 1250 and 1300 °C. X-ray diffraction analysis (XRD) confirmed hollandite as the major phase in all specimens. Zirconolite/pyrochlore peaks and weaker perovskite reflections were observed after melt processing, while HIP samples displayed prominent perovskite peaks and low-intensity zirconolite reflections. Melt processing produced specimens with large (>50 μm) well-defined hollandite grains, while HIP yielded samples with a more fine-grained morphology. Elemental analysis showed “islands” rich in Cs and Ti across the surface of the 1300 °C HIP sample, suggesting partial melting and partitioning of Cs into multiple phases. Photoemission data revealed multiple Cs 3d spin-orbit pairs for the HIP samples, with the lower binding energy doublets likely corresponding to Cs located in more leachable phases. Among all specimens examined, the melt-processed sample exhibited the lowest fractional release rates for Rb and Cs. However, the retention of Sr and Mo was greater in the HIP specimens.

Radiation damage of hollandite in multiphase ceramic waste forms

Radiation damage was simulated in multiphase titanate-based ceramic waste forms using an ion accelerator to generate high energy alpha particles (He+) and an ion implanter to generate 7 MeV gold (Au3+) particles. X-ray diffraction and transmission electron microscopy were used to characterize the damaged surfaces and nearby regions. Simulated multiphase ceramic waste forms were prepared using two processing methods: spark plasma sintering and melt-processing. Both processing methods produced ceramics with similar phase assemblages consisting of hollandite-, zirconolite/pyrochlore-, and perovskite-type phases. The measured heavy ion (Au3+) penetration depth was less in spark plasma sintered samples than in melt-processed samples. Structural breakdown of the hollandite phase occurred under He+ irradiation indicated by the presence of x-ray diffraction peaks belonging to TiO2, BaTiO5, and other hollandite related phases (Ba2Ti9O20). The composition of the constituent hollandite phase affected the extent of damage induced by Au3+ ions.

Cold crucible induction melter test for crystalline ceramic waste form fabrication: A feasibility assessment

The first scaled proof-of-principle cold crucible induction melter (CCIM) test to process a multiphase ceramic waste form from a simulated combined (Cs/Sr, lanthanide and transition metal fission products) commercial used nuclear fuel waste stream was recently conducted in the United States. X-ray diffraction, 2-D X-ray absorption near edge structure (XANES), electron microscopy, inductively coupled plasma-atomic emission spectroscopy (and inductively coupled plasma-mass spectroscopy for Cs), and product consistency tests were used to characterize the fabricated CCIM material. Characterization analyses confirmed that a crystalline ceramic with a desirable phase assemblage was produced from a melt using a CCIM. Primary hollandite, pyrochlore/zirconolite, and perovskite phases were identified in addition to minor phases rich in Fe, Al, or Cs. The material produced in the CCIM was chemically homogeneous and displayed a uniform phase assemblage with acceptable aqueous chemical durability.

Crystallization behavior during melt-processing of ceramic waste forms

Multiphase ceramic waste forms based on natural mineral analogs are of great interest for their high chemical durability, radiation resistance, and thermodynamic stability. Melt-processed ceramic waste forms that leverage existing melter technologies will broaden the available disposal options for high-level nuclear waste. This work reports on the crystallization behavior in selected melt-processed ceramics for waste immobilization. The phase assemblage and evolution of hollandite, zirconolite, pyrochlore, and perovskite type structures during melt processing were studied using thermal analysis, x-ray diffraction, and electron microscopy. Samples prepared by melting followed by annealing and quenching were analyzed to determine and measure the progression of the phase assemblage. Samples were melted at 1500 °C and heat-treated at crystallization temperatures of 1285 °C and 1325 °C corresponding to exothermic events identified from differential scanning calorimetry measurements. Results indicate that the selected multiphase composition partially melts at 1500 °C with hollandite coexisting as crystalline phase. Perovskite and zirconolite phases crystallized from the residual melt at temperatures below 1350 °C. Depending on their respective thermal histories, different quenched samples were found to have different phase assemblages including phases such as perovskite, zirconolite and TiO2.

Evidence of technetium and iodine release from a sodalite-bearing ceramic waste form

Sodalites have been proposed as a possible host of certain radioactive species, specifically 99Tc and 129I, which may be encapsulated into the cage structure of the mineral. To demonstrate the ability of this framework silicate mineral to encapsulate and immobilize 99Tc and 129I, single-pass flow-through (SPFT) tests were conducted on a sodalite-bearing multi-phase ceramic waste form produced through a steam reforming process. Two samples made using a steam reformer samples were produced using non-radioactive I and Re (as a surrogate for Tc), while a third sample was produced using actual radioactive tank waste containing Tc and added Re. One of the non-radioactive samples was produced with an engineering-scale steam reformer while the other non-radioactive sample and the radioactive sample were produced using a bench-scale steam reformer. For all three steam reformer products, the similar steady-state dilute-solution release rates for Re, I, and Tc at pH (25 °C) = 9 and 40 °C were measured. However, it was found that the Re, I, and Tc releases were equal or up to 4.5x higher compared to the release rates of the network-forming elements, Na, Al, and Si. The similar releases of Re and Tc in the SPFT test, and the similar time-dependent shapes of the release curves for samples containing I, suggest that Re, Tc, and I partition to the sodalite minerals during the steam reforming process.

Mineral assemblage transformation of a metakaolin-based waste form after geopolymer encapsulation

Mitigation of hazardous and radioactive waste can be improved through conversion of existing waste to a more chemically stable and physically robust waste form. One option for waste conversion is the fluidized bed steam reforming (FBSR) process. The resulting FBSR granular material was encapsulated in a geopolymer matrix referred to here as Geo-7. This provides mechanical strength for ease in transport and disposal. However, it is necessary to understand the phase assemblage evolution as a result of geopolymer encapsulation. In this study, we examine the mineral assemblages formed during the synthesis of the multiphase ceramic waste form. The FBSR granular samples were created from waste simulant that was chemically adjusted to resemble Hanford tank waste. Another set of samples was created using Savannah River Site Tank 50 waste simulant in order to mimic a blend of waste collected from 68 Hanford tank. Waste form performance tests were conducted using the product consistency test (PCT), the Toxicity Characteristic Leaching Procedure (TCLP), and the single-pass flow-through (SPFT) test. X-ray diffraction analyses revealed the structure of a previously unreported NAS phase and indicate that monolith creation may lead to a reduction in crystallinity as compared to the primary FBSR granular product.

Melt processed multiphase ceramic waste forms for nuclear waste immobilization

Ceramic waste forms are promising hosts for nuclear waste immobilization as they have the potential for increased durability and waste loading compared with conventional borosilicate glass waste forms. Ceramics are generally processed using hot pressing, spark plasma sintering, and conventional solid-state reaction, however such methods can be prohibitively expensive or impractical at production scales. Recently, melt processing has been investigated as an alternative to solid-state sintering methods. Given that melter technology is currently in use for High Level Waste (HLW) vitrification in several countries, the technology readiness of melt processing appears to be advantageous over sintering methods. This work reports the development of candidate multi-phase ceramic compositions processed from a melt. Cr additions, developed to promote the formation and stability of a Cs containing hollandite phase were successfully incorporated into melt processed multi-phase ceramics. Control of the reduction–oxidation (Redox) conditions suppressed undesirable Cs–Mo containing phases, and additions of Al and Fe reduced the melting temperature.

Experimental determination of the speciation, partitioning, and release of perrhenate as a chemical surrogate for pertechnetate from a sodalite-bearing multiphase ceramic waste form

A key component to closing the nuclear fuel cycle is the storage and disposition of nuclear waste in geologic systems. Multiphase ceramic waste forms have been studied extensively as a potential host matrix for nuclear waste. Understanding the speciation, partitioning, and release behavior of radionuclides immobilized in multiphase ceramic waste forms is a critical aspect of developing the scientific and technical basis for nuclear waste management. In this study, we evaluated a sodalite-bearing multiphase ceramic waste form (i.e., fluidized-bed steam reform sodium aluminosilicate [FBSR NAS] product) as a potential host matrix for long-lived radionuclides, such as technetium (99Tc). The FBSR NAS material consists primarily of nepheline (ideally NaAlSiO4), anion-bearing sodalites (ideally M8[Al6Si6O24]X2, where M refers to alkali and alkaline earth cations and X refers to monovalent anions), and nosean (ideally Na8[AlSiO4]6SO4). Bulk X-ray absorption fine structure analysis of the multiphase ceramic waste form, suggest rhenium (Re) is in the Re(VII) oxidation state and has partitioned to a Re-bearing sodalite phase (most likely a perrhenate sodalite Na8[Al6Si6O24](ReO4)2). Rhenium was added as a chemical surrogate for 99Tc during the FBSR NAS synthesis process. The weathering behavior of the FBSR NAS material was evaluated under hydraulically unsaturated conditions with deionized water at 90°C. The steady-state Al, Na, and Si concentrations suggests the weathering mechanisms are consistent with what has been observed for other aluminosilicate minerals and include a combination of ion exchange, network hydrolysis, and the formation of an enriched-silica surface layer or phase. The steady-state S and Re concentrations are within an order of magnitude of the nosean and perrhenate sodalite solubility, respectively. The order of magnitude difference between the observed and predicted concentration for Re and S may be associated with the fact that the anion-bearing sodalites contained in the multiphase ceramic matrix are present as mixed-anion sodalite phases. These results suggest the multiphase FBSR NAS material may be a viable host matrix for long-lived, highly mobilie radionuclides which is a critical aspect in the management of nuclear waste.

Dissolution of a Nuclear Waste Ceramic: An Experimental and Modeling Study

The degree of alteration of a multiphase ceramic waste form (Synroc-D) exposed to flowing water at 75/sup 0/C is reported. After 117 days, a 25- to 30-..mu..-deep leach zone developed from which all silicate phases have congruently dissolved. The associated spinel and titanate phases appear unaltered, whereas an Al(OH)/sub 3/ precipitate approx. = 5-..mu..m-thick develops at the sample surface. The dissolution of silicates and deposition of the precipitate are simulated using a modification of the crackling-core model. The model predictions closely match the observed behavior of the material. Implications of these results for long-term stability of the waste form are discussed.