Compaction Scale Up and Optimization of Cylindrical Fuel Compacts for the Next Generation Nuclear Plant

Multiple process approaches have been used historically to manufacture cylindrical nuclear fuel compacts. Scale-up of fuel compacting was required for the Next Generation Nuclear Plant (NGNP) project to achieve an economically viable automated production process capable of providing a minimum of 10 compacts/minute with high production yields. In addition, the scale-up effort was required to achieve matrix density equivalent to baseline historical production processes, and allow compacting at fuel packing fractions up to 46% by volume. The scale-up approach of jet milling, fluid-bed overcoating, and hot-press compacting adopted in the U.S. Advanced Gas Reactor (AGR) Fuel Development Program involves significant paradigm shifts to capitalize on distinct advantages in simplicity, yield, and elimination of mixed waste. A series of designed experiments have been completed to optimize compaction conditions of time, temperature, and forming pressure using natural uranium oxycarbide (NUCO) fuel. Results from these experiments are included. The scale-up effort is nearing completion with the process installed and operational using nuclear fuel materials. The process is being certified for manufacture of qualification test fuel compacts for the AGR-5/6/7 experiment at the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL).