1. IAEA Sources of Radiation Nuclear Fuel Cycle – Fuel Fabrication Day 4 – Lecture 7 1

2. IAEA Object is to convert enriched UF 6 into UO 2 fuel pellets, suitable for use as fuel in a reactor Fuel Fabrication 2

3. IAEA Basic Chemical Approaches  “Wet” process chemistry  hydrolyze UF 6 in solution  precipitate with ammonia compounds  calcine/reduce to UO 2  ADU = ammonium diuranate  “Dry” process chemistry  hydrolyze UF 6 with steam  convert to UO 2 with steam/H 2  IDR = Integrated Dry Route (BNFL term) 3

4. IAEA Importance of Fuel  First two layers of confinement:  Fuel form itself  (Metal) cladding  Must be high quality - “Perfect”  Leakers often require reactor shutdown  Special handling/canning of leaking spent nuclear fuel (SNF)  Money, radiation dose and waste if wrong 4

5. IAEA Importance of Fuel  Fuel around for “decades”  usually 3 cycles (about 5 years) in reactor  minimum of 5 years in wet SNF storage  minimum of 20 years in dry SNF storage  some power reactor fuel 35+ years old  Repository - 100+ years  Fuel is the “tail that wags the dog” 5

6. IAEA Fuel Considerations  Enriched UF 6 not suitable for fuel  Requires chemical conversion to more stable and robust form  Requires mechanical activities, cladding, and assembly  Fuel requires high density to achieve adequate nucleonics and properties 6

7. IAEA Chemical Forms of Uranium Fuel  UO 2 (a compromise) is used in most power reactors as cylindrical pellets  Pebble bed would use coated UO 2 and would probably be a UO 2 /UC mix 7

8. IAEA UF 6 received from enrichment facility in cylinders Cylinders removed from package, weighed, and transferred to UF 6 storage pad UF 6 Cylinders Arriving at Facility Fuel Fabrication 8

9. IAEA Typical Cylinders at Fuel Fabrication Facilities 9

10. IAEA Greatest Environmental Hazards in Fuel Fabrication  Whether wet or dry …  chemical conversion of UF 6 into UO 2  chemical operations in scrap/recovery 10

11. IAEA Typical UO 2 Powder Brown/Black appearance 11

12. IAEA Machined pellets are typically about 0.5 inch in length & about 0.33 inch in diameter. They are "dished" slightly on each end. End taper allows pellets to expand and contract through drastic temperature changes inside reactor without damaging fuel or cladding materials Fuel Fabrication 12

13. IAEA Sample Sintered Pellets 13

14. IAEA Pellet Trays 14

15. IAEA Fuel Pellet “Stacks” 15

16. IAEA Fuel Rods 16

17. IAEA The completed fuel assembly is washed and inspected Fuel Assembly in Fixture Fuel Assembly Clean Check Assemblies 17

18. IAEA Storage  Assemblies stored in racks to  preclude water accumulation  maintain minimal separation/distances 18

19. IAEA PWR/BWR Assemblies PWR 17 x 17 BWR 9 x 9 19

20. IAEA Upon final acceptance of the fuel assembly, units are packed in shipping containers for transfer to utility power reactor site Fuel Assembly Packing Shipping Container Loading Fuel Fabrication 20

21. IAEA Assembly is shock-mounted so that damage does not occur during transport (usually by truck) to customer Fuel Fabrication 21

22. IAEA Assembled Fuel Bundle At the Nuclear Power Plant, new fuel assemblies are inspected and loaded into the reactor core where the 235 U in the fuel pellets fissions producing heat for electric power generation Fuel Fabrication 22

23. IAEA UF 6 release Criticality Chemicals used in process Fuel Fabrication Hazards 23

24. IAEA Reference  International Atomic Energy Agency, Postgraduate Educational Course in Radiation Protection and the Safety of Radiation Sources (PGEC), Training Course Series 18, IAEA, Vienna (2002) 24