T.K.Haldar & P.R.Mohanty Heavy Water Board Dept of Atomic Energy

1. Uranium Recovery from Phosphoric Acid – promising Hydro-metallurgical application of Solvent Extraction T.K.Haldar & P.R.Mohanty Heavy Water Board Dept of Atomic Energy Solvent Extraction Revisited: IIP-IIChE:NRC, New Delhi , February 2010

2. National Priority GDP Growth 6.5%-7.5% Food Security Energy Security POPULATION 1.1 Billion

3. Food Security • Projected Growth rate : 6.5% – 7% • Rising Fertilizer Consumption • P2O5 Consumption : more than 30 lakh tpy • Equivalent to 1000 MT Uranium per year • 1000 MT Uranium is let out to agricultural land every year • Accumulation is cause for Concern • Can be addressed if Uranium is removed at source i.e. Phosphoric acid

4. Energy Security • Current Power demand: 250 GWe • Current Power generation: 200 GWe • Nuclear : 4.4 GWe • Expected demand in 2050 :1260 GWe • Projected share of Nuclear Power : 670 GWe • Quantum jump in Nuclear power generation primarily to reduce carbon emission • Needs Augmentation of Uranium resources besides exploiting abundant Thorium resources

5. Indian Nuclear Option • Indigenous PHWR : • 13,000 MW by 2018 • Fuel : (Indigenous + Imported) • Imported PWR/LWR • 40,000 MW by 2030 • Fuel : (Imported) • Indigenous FBR • 400,000 by 2050 • Fuel (Indigenous U, PU & Th)

6. Why Uranium from Phosphoric Acid • Cleanup of Phosphoric Acid & lessen environmental load • Inadequate mineral Resource • Quality • Quantity • Considering Indian mineral sources U-recovery from Phosphoric Acid make economic sense

7. Indian Perspective Energy Security Food Security POPULATION U in Phos. Acid U to Nuclear Fuel Cycle Nuclear Comunity

8. Technology Status & Options • Global scenario • SX Technology deployed & proven • No known operating plant since 1999 • Technology can be fine tuned for cost effectiveness using previous experience • Indian scenario • Comprehensive Technology Development, Demonstration & Deployment • Credible approach towards programme implementation for economic viability

9. Comprehensive Approach • Technology development in all related fields for large scale industrial deployment. • Technology initiative encompasses wide ranging and multi-dimensional issues.

10. Research, Development, Demonstration & Deployment (RD3) Technology for Uranium from Phosphoric Acid Solvents & other inputs Solvent Extraction Solid - liquid & Liquid-liquid Devices

11. SX Process Development PROCESS DEVELOPMENT PROCESS CHEMISTRY URANIUM FROM PHOSPHORIC ACID PROCESS EQUIPMENT ENGINEERING CHALLENGES SAFETY & ENVIRONMENT ECONOMIC FEASIBILITY

12. SX Chemistry for U-recovery from Phosphoric Acid Extraction 2(RH)2(aq)+UO2(H2PO4)2(aq) <=> (R2H)2UO2(aq) +2H3PO4 (aq) (R2H)2UO2 (aq) <=> (R2H)2UO2 (org) Stripping (R2H)2UO2 (org) <=> (R2H)2UO2 (aq) (R2H)2UO2 (aq) + 2H3PO4 (aq) <=> 2(RH)2 (aq) + UO2(H2PO4)2

13. CH2CH3 | CH3CH2CH2CHCH2O O P CH3CH2CH2CHCH2O OH | CH2CH3 Structure of D2EHPA RO O---H ―O OR P P RO O― H---O OR   Hydrogen bonded dimer Metal Extractant – D2EHPA

14. H O O O2EH 2EHO P P - O2EH - 2EHO O O H O O O2EH 2EHO P P O2EH - O O 2EHO O2EH H O O 2EHO P P - - O2EH 2EHO O O H O O O2EH 2EHO P P O2EH 2EHO O O D2EHPA Dimeric Anion

15. H O O O2EH 2EHO P P O O2EH 2EHO O O U O O 2EHO O2EH O P P 2EHO O2EH O H O O O O U O O O U IN TETRAHEDRAL D2EHPA MATRIX

16. PROCESS SCHEMATICS SOLVENT REGENERATION SOLVENT REGENERATION SX 1ST CYCLE SX 2ND CYCLE FEED PRE-TREATMENT POST TREATMENT RM RECOVERY WPA PRODUCER PRODUCT

17. ACID PRE-TREATMENT FLOCULATED & FILTERED ACTIVE CARBON TREATED RAW WPA OD : 0.5 OD : 0.05 OPAQUE

18. Process Issues • Feed acid profile • Pre & Post treatment requirement • Solvent mix / selection • Extractant, Diluent, Synergistic agent, Modifier etc • Choice of Stripping agent • Process control inputs • Waste & Effluents

19. Process Development MINI SCALE LAB SCALE DEMONSTRATION SCALE BENCH SCALE

20. Process Development Studies

21. Search For Right Solvent(s) • Promising molecules • Short listing (Screening & Selectivity) – in isolation and in synergistic combinations with other molecules • Qualifying the short listed species for initial evaluation • Selection of potential candidates for further development

22. Identified Solvents, Quality & availability • Primary Solvents • D2EHPA , TBP , TOPO , TAPO, DNPPA • Quality • Nuclear grade purity • Impurities in ppm level detrimental • Secured Availability • In-house Capability • 100 MTPA D2EHPA, 190 MTPA TBP, 40 MTPA TOPO / TAPO / DNPPA

23. Development of Solvent Production Capability • Process Chemistry / Synthesis route • Process design • Equipment Selection & detailed engineering • Sound O&M Practices • Quality Assurance • Emissions and Effluents • Safety & Environment • User Acceptability & Cost Competitiveness

24. The Journey Lab Scale Pilot Scale Bench Scale Industrial Scale Production Facility

25. Process EquipmentSolid-liquid Separation Belt Filter Clarifier

26. Process EquipmentLiquid-liquid Contactors Mixer-Settler Centrifugal Extractor Rotating disc Column

27. Engineering Challenges • Materials of construction • Plant lay out • Regulatory compliances • Seamless integration with conventional Fertiliser Industry • Economics

28. Environmental Issues • Effluent Management • Local Statutory requirement • Radiological Monitoring and Protection

29. Taking a Call by Indian Nuclear Community • Concern for environment voluntary, not regulatory • Potential Energy Resource Exploitation Vs. Wastage • Investment Decision Economic & Strategic • Challenge for Nuclear Community Growth of SX - Process

30. Thank You