A 3-D continuous electrorefiner is designed and investigated using multiphysics simulation for the separation of uranium and neptunium from spent nuclear fuel in molten salt. The concentration distribution field, the electric field, the ionic flux density field, and the flow field are evaluated under galvanostatic and pulse electrorefining by numerical integration of the governing equations using finite element method. During the electrorefining without molten salt recirculation, the transport of the electroactive cations is controlled by diffusion and electromigration and high concentration gradient is built near electrodes. In a galvanostatic electrorefining with a current density of 50 A·m–2, the concentration of U3+ decreases to 26.7 mol·m–3 near cathode and increases to 62.5 mol·m–3 near anode within 40 s, and no co-deposition of uranium and neptunium occurs. In a galvanostatic electrorefining with a current density of 200 A·m–2, the concentration of U3+ decreases to 1.3 mol·m–3 near cathode and increases to 62.6 mol·m–3 near anode within 6.7 s, and the co-deposition of uranium and neptunium occurs after 0.28 mg of pure uranium is collected. With moderate molten salt recirculation, the transport of the electroactive cations is controlled by convection. The local concentrations of uranium ions approach steady near the electrodes within 32 s in a galvanostatic electrorefining of 50 A·m–2, and no co-deposition of uranium and neptunium occurs. Though the concentration of U3+ decreases to 21.1 mol·m–3 near cathode and increases to 62.6 mol·m–3 near anode within 6.7 s with a current density of 200 A·m–2, there is no co-deposition of uranium and neptunium occurred. In addition, it is proved that the pulse electrorefining does not improve the recovery of uranium compared with galvanostatic electrorefining with a corresponding average current.
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