Design and development of a cathode processor for electrometallurgical treatment of spent nuclear fuel

The electrometallurgical processing of spent fuel developed at Argonne National Laboratory produces a cathode which contains dendrites of heavy metal (principally U), salts, and residual cadmium. The cathode requires further treatment which is accomplished by loading it into a cathode processor to first purify and then consolidate the heavy metal. The principal steps in cathode processing are: the cathode is loaded into a crucible and both loaded into the cathode processor; the crucible is heated under vacuum to an intermediate temperature to distill the salt and cadmium from the crucible; the crucible is heated further to melt and consolidate the heavy metal; the crucible and charge are then cooled forming a heavy metal ingot in the crucible mold. The cathode processor development program has progressed through the design, fabrication, qualification, and demonstration phases. Two identical units were built. One (a prototype unit) has been installed at Argonne's site in Illinois and the other (the production unit) has been installed in the Fuel Conditioning Facility (FCF) at Argonne's Idaho site. Both units are presently in operation. The most recent activities completed in the FCF fuel processing project were the EBR-II driver fuel and blanket fuel demonstration phases. All of the cathode processor success criteria were met during these demonstration phases. These included finalizing the operation conditions applicable to irradiated fuel and process throughput criteria.