Fuel

Framatome Inc. and Ultra Safe Nuclear Corp. (USNC) signed an agreement on November 28 at the World Nuclear Exhibition in Paris, France, establishing a joint venture to manufacture nuclear fuel for USNC’s gas-cooled microreactor and other advanced reactor designs. Working together, the companies plan to produce commercial quantities of TRISO fuel particles and USNC’s proprietary Fully Ceramic Microencapsulated (FCM) fuel, which contains TRISO fuel particles within a ceramic fuel pellet.

The Department of Energy plans to award one or more contracts to deconvert high-assay low-enriched uranium (HALEU) from its post-enrichment gaseous uranium hexafluoride (UF₆) state to other chemical forms, such as metal or oxide. The DOE’s final request for proposals (RFP) for deconversion services was issued November 28 as one part of the agency’s effort—under the HALEU Availability Program—to establish a reliable domestic supply of advanced reactor fuel. The DOE will store the deconverted material until it is required by a fuel fabricator or other end user.

Researchers at Idaho National Laboratory in early 2023 manufactured commercial-grade high-assay low-enriched uranium (HALEU) fuel pellets to the specifications of a General Electric accident tolerant fuel design, INL announced November 21. A team working at INL’s Experimental Fuels Facility at the Material and Fuels Complex fabricated about two dozen uranium dioxide pellets using HALEU enriched up to 15 percent U-235.

Centrus Energy and the Department of Energy announced November 7 that Centrus has produced 20 kilograms of HALEU at the DOE-owned American Centrifuge Plant in Piketon, Ohio, satisfying Phase One of a DOE contract to stand up and operate 16 advanced centrifuges. Centrus will now move on to Phase Two of the contract, which requires a full year of HALEU production at a rate of 900 kilograms per year.

Just a few hours after a new Speaker of the House of Representatives was elected on October 25, the White House sent a list of funding priorities for “critical domestic needs” to Congress for consideration as legislators restart the stalled annual appropriations process. Those priorities include $2.2 billion for low-enriched uranium (LEU) and high-assay low-enriched uranium (HALEU) enrichment capabilities. And to ensure that investment in domestic HALEU enrichment pays off, the White House is also calling for a long-term ban on enriched uranium from Russia.

Westinghouse has signed a contract with Rolls-Royce SMR to develop a fuel design for the British firm’s small modular reactor program, the companies announced last week.

The design work, to be undertaken in the United Kingdom and the United States, will include associated core components and will be based on an existing Westinghouse pressurized water reactor fuel assembly design.

American Centrifuge Operating (ACO), a subsidiary of Centrus Energy, has started enriching uranium hexafluoride gas to high-assay low-enriched uranium (HALEU) levels at the Department of Energy’s enrichment facility in Piketon, Ohio, the DOE announced October 11. The HALEU will be used to help fuel the initial cores of two demonstration reactors awarded under DOE’s Advanced Reactor Demonstration Program and will also support fuel qualification and the testing of other new advanced reactor designs.

Penn State’s Radiation Science and Engineering Center (RSEC) has received the first new TRIGA fuel shipped to the United States since 2012, the university announced on September 28. The fuel reached University Park, Pa., on September 27 and is destined for RSEC’s Breazeale Reactor, the nation’s longest continuously operating university research reactor.

Southern Nuclear last Friday announced that its Vogtle Unit 2 reactor has become the first U.S. commercial reactor to be authorized by the Nuclear Regulatory Commission to use accident tolerant fuel exceeding 5 percent uranium-235 enrichment.

The Nuclear Regulatory Commission is requesting comments on the regulatory basis for a proposed rule for light water reactor fuel designs featuring high-assay low-enriched uranium (HALEU), including accident tolerant fuel (ATF) designs, and on draft guidance for the environmental evaluation of ATFs containing uranium enriched up to 8 percent U-235. Some of the HALEU feedstock for those LWR fuels and for advanced reactor fuels could be produced within the first Category II fuel facility licensed by the NRC—Centrus Energy’s American Centrifuge Plant in Piketon, Ohio. On September 21, the NRC approved the start of enrichment operations in the plant’s modest 16-machine HALEU demonstration cascade.

Jessica Woynerowski

As a student, I had the opportunity to tour Urenco USA in Eunice, N.M.—the only commercially operated uranium enrichment facility in the United States. Seeing a fuel cycle facility for the first time and learning about the centrifugal technology used to separate U-235 from U-238 was enriching (pun intended). In the nuclear utility sector, where I am currently working as a core design engineer, the focus is on creating safe, reliable, carbon-free nuclear energy; too often, however, we miss out on other key players in the nuclear fuel cycle.

As a visiting student, I listened to the introductions, the tour guides, the operators, and the engineers at Urenco, and I was hooked. It was so different from what I learned in college about commercial reactors. I was so fascinated with how Urenco operated and their role in the nuclear industry that I started my career there in 2016. The company did an incredible job educating their personnel not only on their processes but also on the work of other fuel cycle facilities (mining, conversion, and fabrication, to name a few).

From the pages of the September 2023 issue of Nuclear News.

For decades, more energy has meant more fuel: fossil fuels.

But nuclear fuel—unlike coal, oil, or even natural uranium—is a feat of engineering, not a commodity extracted from the earth. Now, “more” means more engineering—to boost uranium density or to close the fuel cycle.

W. A. “Art” Wharton III

Multiple market forces on nuclear fuel have arisen seemingly at the same time since the Russian war in Ukraine started. Accident tolerant fuels (ATF), lead test rods, and lead test assemblies have had their first shot in real operating conditions, in recent cycles. But the popularity of their so-called accident tolerance has nothing to do with accidents, since any practical nuclear professional knows that the safety of nuclear energy is already higher than that of any other electricity generation source. The popularity comes down to fuel performance. Are we on the cusp of a revolution in nuclear fuel performance under the guise of accident tolerance?

According to the World Nuclear Association’s newly released Nuclear Fuel Report: Global Scenarios for Demand and Supply Availability 2023–2040, there will be more of an increased demand than previously anticipated for nuclear fuel services and nuclear power capacity over the next several years. The report notes that the increased need for nuclear energy is associated with government efforts to decarbonize energy supplies and achieve energy security as well as growing interest in deploying new large nuclear reactors and small modular reactors (SMRs). The report is available to order now.

Wagner

Rufner

Advanced manufacturing is more than just additive manufacturing, as Jorgen Rufner and Adrian Wagner—both group leads at Idaho National Laboratory—would be quick to point out. Researchers at INL have been working with additive manufacturing (that’s 3D printing, colloquially) for decades. These days, INL boasts the largest industrial-scale electric field -assisted sintering (EFAS) machine of its kind and four other EFAS systems, including one coupled with a glove box for work with radioactive materials. That equipment and more can make samples, fuels, and components for both light water reactors and advanced reactors and for both publicly and privately funded programs.

BWX Technologies, Inc. has announced the details of a contract with the Department of Energy’s National Nuclear Security Administration to process thousands of kilograms of government-owned scrap material containing enriched uranium and produce more than two metric tons of high-assay low-enriched uranium (HALEU) in an oxide form at an enrichment level of 19.75 percent U-235. That HALEU oxide could supply a fraction of the 22 metric tons the DOE has estimated will be needed by the mid-2020s to fuel advanced reactor demonstrations and meet existing commitments for research reactor fuel.

Centrus Energy’s HALEU demonstration cascade. (Photo: Centrus Energy)

Centrus Energy announced on September 6 that it is conducting final system tests and expects to begin producing high-assay low-enriched uranium (HALEU) in October from its 16-machine gaseous centrifuge enrichment demonstration cascade at the American Centrifuge Plant in Piketon, Ohio. After achieving initial HALEU production, Centrus has specific goals to meet under contract as the company ramps the demonstration cascade to its target annual production rate of 900 kg per year.

Centrus is required under a cost-share contract with the Department of Energy to produce 20 kg of 19.75 percent–enriched HALEU in uranium hexafluoride (UF₆) form by the end of this year. That contract, announced in November 2022, replaced an earlier contract signed in October 2019 that called for first production of HALEU by June 2022. The current contract calls for production at an annual rate of 900 kg of HALEU UF₆ per year in 2024, with additional options—subject to appropriations—to produce material in future years.

Ken Petersen
president@ans.org

The front end of the fuel cycle is getting a lot of attention lately—and it needs it. The war in Ukraine has disrupted the global supply chain for many products, nuclear fuel being one. Several countries have determined that they no longer want to rely on nuclear fuel from Russia. This can be anything from fabricated fuel including uranium, conversion, and enrichment to just enrichment.

Since the Cold War, Russia has been a major supplier of nuclear fuel to the West. Replacing Russia as the main supplier will take both time and money—a fact that has become even more clear as the small modular reactor community grows, and with it, the demand for high-assay low-enriched uranium (HALEU) for fuel.

The American Nuclear Society has been highlighting the immediacy of the fuel supply problem—which will become a crisis without immediate action—for years. In 2021, ANS wrote to Congress, urging swift action. This year, Nuclear News and ANS’s Nuclear Newswire have run a three-part series by energy writer and consultant Matt Wald on the domestic nuclear fuel shortage. The first article, “On the verge of a crisis: The U.S. nuclear fuel Gordian knot,” was published on Newswire on April 14; the second, “The U.S. nuclear fuel Gordian knot: From global supplier to vulnerable customer,” on May 19. The final piece of the series, “The U.S. nuclear fuel Gordian knot: The uncertain path forward,” was posted on September 1.

The Nuclear Regulatory Commission staff will hold a hybrid public meeting on September 7 to discuss the agency’s licensing and oversight of Centrus/American Centrifuge Operating’s American Centrifuge Plant, in Piketon, Ohio. The discussion will focus primarily on the company’s enrichment of high-assay low-enriched uranium, or HALEU.

In the last few weeks of 2021, when it was clear that the Russian invasion of Ukraine had put this country’s uranium fuel supply in jeopardy, nuclear energy advocates lobbied hard to attach provisions to various pieces of “must-pass” legislation—such as the National Defense Appropriations Act (NDAA), the Ukraine Supplemental Appropriations Act, the Infrastructure Investment and Jobs Act, and the CHIPS and Science Act—to have the government get the ball rolling on new domestic uranium fuel production capacity. Four times they thought they had succeeded, that Congress was going to allocate enough money to start the United States on the road to a secure supply of reactor fuel, including the higher-enriched fuel needed for advanced reactors.