Abstract

A continuous, four stage fluidized bed process for converting uranium hexafluoride (UF6) to ceramic-grade uranium dioxide (UO2) powder suitable for use in the manufacture of fuel pellets for nuclear reactors is disclosed. The process comprises the steps of first reacting UF6 with steam in a first fluidized bed, preferably at about 550° C, to form solid intermediate reaction products UO2 F2, U3 O8 and an off-gas including hydrogen fluoride (HF). The solid intermediate reaction products are conveyed to a second fluidized bed reactor at which the mol fraction of HF is controlled at low levels in order to prevent the formation of uranium tetrafluoride (UF4). The first intermediate reaction products are reacted in the second fluidized bed with steam and hydrogen at a temperature of about 630° C. The second intermediate reaction product including uranium dioxide (UO2) is conveyed to a third fluidized bed reactor and reacted with additional steam and hydrogen at a temperature of about 650° C producing a reaction product consisting essentially of uranium dioxide having an oxygen-uranium ratio of about 2 and a low residual fluoride content. This product is then conveyed to a fourth fluidized bed wherein a mixture of air and preheated nitrogen is introduced in order to further reduce the fluoride content of the UO2 and increase the oxygen-uranium ratio to about 2.25.