Nuclear fuel

Uranium dioxide is a black semiconducting solid. It can be made by reacting uranyl nitrate with a base (ammonia) to form a solid (ammonium uranate). It is heated (calcined) to form U₃O₈ that can then be converted by heating in an argon / hydrogen mixture (700 °C) to form UO₂. The UO₂ is then mixed with an organic binder and pressed into pellets, these pellets are then fired at a much higher temperature (in H₂/Ar) to sinter the solid. The aim is to form a dense solid which has few pores.

The thermal conductivity of uranium dioxide is very low compared with that of zirconium metal, and it goes down as the temperature goes up.

Corrosion of uranium dioxide in water is controlled by similar electrochemical processes to the galvanic corrosion of a metal surface.

Mixed oxide, or MOX fuel, is a blend of plutonium and natural or depleted uranium which behaves similarly (though not identically) to the enriched uranium feed for which most nuclear reactors were designed. MOX fuel is an alternative to low enriched uranium (LEU) fuel used in the light water reactors which predominate nuclear power generation.

Some concern has been expressed that used MOX cores will introduce new disposal challenges, though MOX is itself a means to dispose of surplus plutonium by transmutation.

Reprocessing of commercial nuclear fuel to make MOX was done in the Sellafield MOX Plant (England). As of 2015, MOX fuel is made in France (see Marcoule Nuclear Site), and to a lesser extent in Russia (see Mining and Chemical Combine), India and Japan. China plans to develop fast breeder reactors (see CEFR) and reprocessing.

The Global Nuclear Energy Partnership, was a U.S. proposal in the George W. Bush Administration to form an international partnership to see spent nuclear fuel reprocessed in a way that renders the plutonium in it usable for nuclear fuel but not for nuclear weapons. Reprocessing of spent commercial-reactor nuclear fuel has not been permitted in the United States due to nonproliferation considerations. All of the other reprocessing nations have long had nuclear weapons from military-focused "research"-reactor fuels except for Japan. Normally, with the fuel being changed every three years or so, about half of the Pu-239 is 'burned' in the reactor, providing about one third of the total energy. It behaves like U-235 and its fission releases a similar amount of energy. The higher the burn-up, the more plutonium in the spent fuel, but the lower the fraction of fissile plutonium. Typically about one percent of the used fuel discharged from a reactor is plutonium, and some two thirds of this is fissile (c. 50% Pu-239, 15% Pu-241). Worldwide, some 70 tonnes of plutonium contained in used fuel is removed when refueling reactors each year.

TRIGA fuel is used in TRIGA (Training, Research, Isotopes, General Atomics) reactors. The TRIGA reactor uses UZrH fuel, which has a prompt negative fuel temperature coefficient of reactivity, meaning that as the temperature of the core increases, the reactivity decreases—so it is highly unlikely for a meltdown to occur. Most cores that use this fuel are "high leakage" cores where the excess leaked neutrons can be utilized for research. TRIGA fuel was originally designed to use highly enriched uranium, however in 1978 the U.S. Department of Energy launched its Reduced Enrichment for Research Test Reactors program, which promoted reactor conversion to low-enriched uranium fuel. A total of 35 TRIGA reactors have been installed at locations across the US. A further 35 reactors have been installed in other countries.

In a fast neutron reactor, the minor actinides produced by neutron capture of uranium and plutonium can be used as fuel. Metal actinide fuel is typically an alloy of zirconium, uranium, plutonium, and minor actinides. It can be made inherently safe as thermal expansion of the metal alloy will increase neutron leakage.

Molten plutonium, alloyed with other metals to lower its melting point and encapsulated in tantalum,[1] was tested in two experimental reactors, LAMPRE I and LAMPRE II, at LANL in the 1960s. "LAMPRE experienced three separate fuel failures during operation."[2]

This is often the fuel of choice for reactor designs that NASA produces, one advantage is that UN has a better thermal conductivity than UO₂. Uranium nitride has a very high melting point. This fuel has the disadvantage that unless ¹⁵N was used (in place of the more common ¹⁴N) that a large amount of ¹⁴C would be generated from the nitrogen by the (n,p) reaction. As the nitrogen required for such a fuel would be so expensive it is likely that the fuel would have to be reprocessed by pyroprocessing to enable the ¹⁵N to be recovered. It is likely that if the fuel was processed and dissolved in nitric acid that the nitrogen enriched with ¹⁵N would be diluted with the common ¹⁴N.

Much of what is known about uranium carbide is in the form of pin-type fuel elements for liquid metal fast reactors during their intense study during the 1960s and 1970s. However, recently there has been a revived interest in uranium carbide in the form of plate fuel and most notably, micro fuel particles (such as TRISO particles).

The high thermal conductivity and high melting point makes uranium carbide an attractive fuel. In addition, because of the absence of oxygen in this fuel (during the course of irradiation, excess gas pressure can build from the formation of O₂ or other gases) as well as the ability to complement a ceramic coating (a ceramic-ceramic interface has structural and chemical advantages), uranium carbide could be the ideal fuel candidate for certain Generation IV reactors such as the gas-cooled fast reactor.

Molten salt fuels have nuclear fuel dissolved directly in the molten salt coolant. Molten salt-fueled reactors, such as the liquid fluoride thorium reactor (LFTR), are different from molten salt-cooled reactors that do not dissolve nuclear fuel in the coolant.

Molten salt fuels were used in the LFTR known as the Molten Salt Reactor Experiment, as well as other liquid core reactor experiments. The liquid fuel for the molten salt reactor was a mixture of lithium, beryllium, thorium and uranium fluorides: LiF-BeF₂-ThF₄-UF₄ (72-16-12-0.4 mol%). It had a peak operating temperature of 705 °C in the experiment, but could have operated at much higher temperatures since the boiling point of the molten salt was in excess of 1400 °C.

The aqueous homogeneous reactors (AHRs) use a solution of uranyl sulfate or other uranium salt in water. Historically, AHRs have all been small research reactors, not large power reactors. An AHR known as the Medical Isotope Production System is being considered for production of medical isotopes.[4]

Pressurized water reactor (PWR) fuel consists of cylindrical rods put into bundles. A uranium oxide ceramic is formed into pellets and inserted into Zircaloy tubes that are bundled together. The Zircaloy tubes are about 1 cm in diameter, and the fuel cladding gap is filled with helium gas to improve the conduction of heat from the fuel to the cladding. There are about 179–264 fuel rods per fuel bundle and about 121 to 193 fuel bundles are loaded into a reactor core. Generally, the fuel bundles consist of fuel rods bundled 14×14 to 17×17. PWR fuel bundles are about 4 meters long. In PWR fuel bundles, control rods are inserted through the top directly into the fuel bundle. The fuel bundles usually are enriched several percent in ²³⁵U. The uranium oxide is dried before inserting into the tubes to try to eliminate moisture in the ceramic fuel that can lead to corrosion and hydrogen embrittlement. The Zircaloy tubes are pressurized with helium to try to minimize pellet-cladding interaction which can lead to fuel rod failure over long periods.

In boiling water reactors (BWR), the fuel is similar to PWR fuel except that the bundles are "canned". That is, there is a thin tube surrounding each bundle. This is primarily done to prevent local density variations from affecting neutronics and thermal hydraulics of the reactor core. In modern BWR fuel bundles, there are either 91, 92, or 96 fuel rods per assembly depending on the manufacturer. A range between 368 assemblies for the smallest and 800 assemblies for the largest U.S. BWR forms the reactor core. Each BWR fuel rod is backfilled with helium to a pressure of about three atmospheres (300 kPa).

CANDU fuel bundles Two CANDU ("CANada Deuterium Uranium") fuel bundles, each about 50 cm long, 10 cm in diameter.

CANDU fuel bundles are about a half meter long and 10 cm in diameter. They consist of sintered (UO₂) pellets in zirconium alloy tubes, welded to zirconium alloy end plates. Each bundle is roughly 20 kg, and a typical core loading is on the order of 4500–6500 bundles, depending on the design. Modern types typically have 37 identical fuel pins radially arranged about the long axis of the bundle, but in the past several different configurations and numbers of pins have been used. The CANFLEX bundle has 43 fuel elements, with two element sizes. It is also about 10 cm (4 inches) in diameter, 0.5 m (20 in) long and weighs about 20 kg (44 lb) and replaces the 37-pin standard bundle. It has been designed specifically to increase fuel performance by utilizing two different pin diameters. Current CANDU designs do not need enriched uranium to achieve criticality (due to their more efficient heavy water moderator), however, some newer concepts call for low enrichment to help reduce the size of the reactors.

Magnox (magnesium non-oxidising) reactors are pressurised, carbon dioxide–cooled, graphite-moderated reactors using natural uranium (i.e. unenriched) as fuel and Magnox alloy as fuel cladding. Working pressure varies from 6.9 to 19.35 bar for the steel pressure vessels, and the two reinforced concrete designs operated at 24.8 and 27 bar. Magnox alloy consists mainly of magnesium with small amounts of aluminium and other metals—used in cladding unenriched uranium metal fuel with a non-oxidising covering to contain fission products. This material has the advantage of a low neutron capture cross-section, but has two major disadvantages:

• It limits the maximum temperature, and hence the thermal efficiency, of the plant.
• It reacts with water, preventing long-term storage of spent fuel under water.

Magnox fuel incorporated cooling fins to provide maximum heat transfer despite low operating temperatures, making it expensive to produce. While the use of uranium metal rather than oxide made reprocessing more straightforward and therefore cheaper, the need to reprocess fuel a short time after removal from the reactor meant that the fission product hazard was severe. Expensive remote handling facilities were required to address this danger

0.845 mm TRISO fuel particle which has been cracked, showing multiple layers that are coating the spherical kernel

Tristructural-isotropic (TRISO) fuel is a type of micro fuel particle. It consists of a fuel kernel composed of UO_X (sometimes UC or UCO) in the center, coated with four layers of three isotropic materials deposited through fluidized chemical vapor deposition (FCVD). The four layers are a porous buffer layer made of carbon that absorbs fission product recoils, followed by a dense inner layer of protective pyrolytic carbon (PyC), followed by a ceramic layer of SiC to retain fission products at elevated temperatures and to give the TRISO particle more structural integrity, followed by a dense outer layer of PyC. TRISO particles are then encapsulated into cylindrical or spherical graphite pellets. TRISO fuel particles are designed not to crack due to the stresses from processes (such as differential thermal expansion or fission gas pressure) at temperatures up to 1600 °C, and therefore can contain the fuel in the worst of accident scenarios in a properly designed reactor. Two such reactor designs are the prismatic-block gas-cooled reactor (such as the GT-MHR) and the pebble-bed reactor (PBR). Both of these reactor designs are high temperature gas reactors (HTGRs). These are also the basic reactor designs of very-high-temperature reactors (VHTRs), one of the six classes of reactor designs in the Generation IV initiative that is attempting to reach even higher HTGR outlet temperatures.

TRISO fuel particles were originally developed in the United Kingdom as part of the Dragon reactor project. The inclusion of the SiC as diffusion barrier was first suggested by D. T. Livey.[5] The first nuclear reactor to use TRISO fuels was the Dragon reactor and the first powerplant was the THTR-300. Currently, TRISO fuel compacts are being used in the experimental reactors, the HTR-10 in China, and the High-temperature engineering test reactor in Japan. Spherical fuel elements utilizing a TRISO particle with a UO₂ and UC solid solution kernel are being used in the Xe-100 in the United States.

QUADRISO Particle

In QUADRISO particles a burnable neutron poison (europium oxide or erbium oxide or carbide) layer surrounds the fuel kernel of ordinary TRISO particles to better manage the excess of reactivity. If the core is equipped both with TRISO and QUADRISO fuels, at beginning of life neutrons do not reach the fuel of the QUADRISO particles because they are stopped by the burnable poison. During reactor operation, neutron irradiation of the poison causes it to "burn up" or progressively transmute to non-poison isotopes, depleting this poison effect and leaving progressively more neutrons available for sustaining the chain-reaction. This mechanism compensates for the accumulation of undesirable neutron poisons which are an unavoidable part of the fission products, as well as normal fissile fuel "burn up" or depletion. In the generalized QUADRISO fuel concept the poison can eventually be mixed with the fuel kernel or the outer pyrocarbon. The QUADRISO[6] concept has been conceived at Argonne National Laboratory.

RBMK reactor fuel rod holder 1 – distancing armature; 2 – fuel rods shell; 3 – fuel tablets.

RBMK reactor fuel was used in Soviet-designed and built RBMK-type reactors. This is a low-enriched uranium oxide fuel. The fuel elements in an RBMK are 3 m long each, and two of these sit back-to-back on each fuel channel, pressure tube. Reprocessed uranium from Russian VVER reactor spent fuel is used to fabricate RBMK fuel. Following the Chernobyl accident, the enrichment of fuel was changed from 2.0% to 2.4%, to compensate for control rod modifications and the introduction of additional absorbers.

CerMet fuel consists of ceramic fuel particles (usually uranium oxide) embedded in a metal matrix. It is hypothesized that this type of fuel is what is used in United States Navy reactors. This fuel has high heat transport characteristics and can withstand a large amount of expansion.

ATR Core The Advanced Test Reactor at Idaho National Laboratory uses plate-type fuel in a clover leaf arrangement. The blue glow around the core is known as Cherenkov radiation.

Plate-type fuel has fallen out of favor over the years. Plate-type fuel is commonly composed of enriched uranium sandwiched between metal cladding. Plate-type fuel is used in several research reactors where a high neutron flux is desired, for uses such as material irradiation studies or isotope production, without the high temperatures seen in ceramic, cylindrical fuel. It is currently used in the Advanced Test Reactor (ATR) at Idaho National Laboratory, and the nuclear research reactor at the University of Massachusetts Lowell Radiation Laboratory.

Sodium-bonded fuel consists of fuel that has liquid sodium in the gap between the fuel slug (or pellet) and the cladding. This fuel type is often used for sodium-cooled liquid metal fast reactors. It has been used in EBR-I, EBR-II, and the FFTF. The fuel slug may be metallic or ceramic. The sodium bonding is used to reduce the temperature of the fuel.

Two main modes of release exist, the fission products can be vaporised or small particles of the fuel can be dispersed.

An atomic battery (also called a nuclear battery or radioisotope battery) is a device which uses the radioactive decay to generate electricity. These systems use radioisotopes that produce low energy beta particles or sometimes alpha particles of varying energies. Low energy beta particles are needed to prevent the production of high energy penetrating bremsstrahlung radiation that would require heavy shielding. Radioisotopes such as plutonium-238, curium-242, curium-244 and strontium-90 have been used. Tritium, nickel-63, promethium-147, and technetium-99 have been tested.

There are two main categories of atomic batteries: thermal and non-thermal. The non-thermal atomic batteries, which have many different designs, exploit charged alpha and beta particles. These designs include the direct charging generators, betavoltaics, the optoelectric nuclear battery, and the radioisotope piezoelectric generator. The thermal atomic batteries on the other hand, convert the heat from the radioactive decay to electricity. These designs include thermionic converter, thermophotovoltaic cells, alkali-metal thermal to electric converter, and the most common design, the radioisotope thermoelectric generator.

Inspection of Cassini spacecraft RTGs before launch

A radioisotope thermoelectric generator (RTG) is a simple electrical generator which converts heat into electricity from a radioisotope using an array of thermocouples.

²³⁸
Pu
has become the most widely used fuel for RTGs, in the form of plutonium dioxide. It has a half-life of 87.7 years, reasonable energy density, and exceptionally low gamma and neutron radiation levels. Some Russian terrestrial RTGs have used ⁹⁰
Sr
; this isotope has a shorter half-life and a much lower energy density, but is cheaper. Early RTGs, first built in 1958 by the U.S. Atomic Energy Commission, have used ²¹⁰
Po
. This fuel provides phenomenally huge energy density, (a single gram of polonium-210 generates 140 watts thermal) but has limited use because of its very short half-life and gamma production, and has been phased out of use for this application.

Photo of a disassembled RHU

A radioisotope heater unit (RHU) typically provides about 1 watt of heat each, derived from the decay of a few grams of plutonium-238. This heat is given off continuously for several decades.

Their function is to provide highly localised heating of sensitive equipment (such as electronics in outer space). The Cassini–Huygens orbiter to Saturn contains 82 of these units (in addition to its 3 main RTGs for power generation). The Huygens probe to Titan contains 35 devices.

Deuterium and tritium are both considered first-generation fusion fuels; they are the easiest to fuse, because the electrical charge on their nuclei is the lowest of all elements. The three most commonly cited nuclear reactions that could be used to generate energy are:

²H + ³H → n (14.07 MeV) + ⁴He (3.52 MeV)

²H + ²H → n (2.45 MeV) + ³He (0.82 MeV)

²H + ²H → p (3.02 MeV) + ³H (1.01 MeV)

Second-generation fuels require either higher confinement temperatures or longer confinement time than those required of first-generation fusion fuels, but generate fewer neutrons. Neutrons are an unwanted byproduct of fusion reactions in an energy generation context, because they are absorbed by the walls of a fusion chamber, making them radioactive. They cannot be confined by magnetic fields, because they are not electrically charged. This group consists of deuterium and helium-3. The products are all charged particles, but there may be significant side reactions leading to the production of neutrons.

²H + ³He → p (14.68 MeV) + ⁴He (3.67 MeV)

Third-generation fusion fuels produce only charged particles in the primary reactions, and side reactions are relatively unimportant. Since a very small amount of neutrons is produced, there would be little induced radioactivity in the walls of the fusion chamber. This is often seen as the end goal of fusion research. ³He has the highest Maxwellian reactivity of any 3rd generation fusion fuel. However, there are no significant natural sources of this substance on Earth.

³He + ³He → 2 p + ⁴He (12.86 MeV)

Another potential aneutronic fusion reaction is the proton-boron reaction:

p + ¹¹B → 3 ⁴He (8.7 MeV)

Under reasonable assumptions, side reactions will result in about 0.1% of the fusion power being carried by neutrons. With 123 keV, the optimum temperature for this reaction is nearly ten times higher than that for the pure hydrogen reactions, the energy confinement must be 500 times better than that required for the D-T reaction, and the power density will be 2500 times lower than for D-T.

• "NEI fuel schematic". Archived from the original on 2004-10-22. Retrieved 2005-12-14.
• "Picture of a PWR fuel assembly". Archived from the original on 2015-04-23. Retrieved 2005-12-14.
• Picture showing handling of a PWR bundle
• "Mitsubishi nuclear fuel Co". Archived from the original on 2012-02-24. Retrieved 2005-12-14.

• "Picture of a "canned" BWR assembly". Archived from the original on 2006-08-28. Retrieved 2005-12-14.
• Physical description of LWR fuel
• Links to BWR photos from the nuclear tourist webpage

• CANDU Fuel pictures and FAQ
• Basics on CANDU design
• The Evolution of CANDU Fuel Cycles and their Potential Contribution to World Peace
• "CANDU Fuel-Management Course" (PDF). Archived from the original (PDF) on 2006-03-15. Retrieved 2005-12-17.
• CANDU Fuel and Reactor Specifics (Nuclear Tourist)
• Candu Fuel Rods and Bundles

• TRISO fuel descripción
• Non-Destructive Examination of SiC Nuclear Fuel Shell using X-Ray Fluorescence Microtomography Technique
• GT-MHR fuel compact process
• Description of TRISO fuel for "pebbles"
• LANL webpage showing various stages of TRISO fuel production
• Method to calculate the temperature profile in TRISO fuel

• Conceptual Design of QUADRISO Fuel

• "A Review of Fifty Years of Space Nuclear Fuel Development Programs" (PDF). Archived from the original (PDF) on 2005-12-30. Retrieved 2005-12-14.
• Thoria-based Cermet Nuclear Fuel: Sintered Microsphere Fabrication by Spray Drying
• "The Use of Molybdenum-Based Ceramic-Metal (CerMet) Fuel for the Actinide Management in LWRs" (PDF). Archived from the original (PDF) on 2006-03-19. Retrieved 2005-12-14.

• List of reactors at INL and picture of ATR core
• ATR plate fuel

• "General Atomics TRIGA fuel website". Archived from the original on 2005-12-23. Retrieved 2005-12-14.

• Advanced fusion fuels presentation