Westinghouse develops safer, long-lasting uranium fuel pellets for nuclear plants

The first batch of nuclear fuel pellets with uranium levels enriched to eight percent was pressed at Westinghouse Electric Company’s Springfield manufacturing facility in Lancashire, UK. Developed in association with the US Department of Energy, the fuel cells will be tested at the Vogtle Unit 2 reactor in Waynesboro, Georgia, in 2025.

With the world looking for ways to meet its energy demands without emitting carbon dioxide, the demand for nuclear energy is rising. Unlike wind and solar power, nuclear power plants can supply energy around the clock. They can also work to stabilize the grid when green energy production is predicted to be low.

Nuclear power, however, has a chequered past. One of the highest concerns about the technology is the fear of a reactor meltdown. To allay these fears, the DOE began working with the nuclear industry to develop new accident-tolerant fuel cells that survive harsh conditions for longer periods.

Accident-tolerant nuclear fuel cells

Conventional fuel cells use zircaloy cladding around uranium dioxide, which does not protect it from extreme reaction conditions. The new fuels developed in collaboration with the nuclear energy industry have additives that reduce the buildup of hydrogen and are structurally more resistant to higher temperatures, corrosion, and radiation.

An additional feature of these newer fuel cells is that they operate more efficiently inside the reactor and, therefore, last longer. The DOE estimates that the reactors deploying these new cells will use 30 percent less fuel, increasing the duration between refueling to up to two years or even more.

These features also allow nuclear fuel to run for longer periods and at higher power while reducing plant downtime, which can deliver profitability for the nuclear energy industry.

UK-based Westinghouse took the first step toward commercializing this approach by producing eight percent enriched uranium nuclear fuels. It has termed these new cells Low Enriched Uranium (LEU+) ADOPT nuclear fuel pellets to denote their accident-tolerant nature.

LEU+ ADOPT nuclear fuel

While conventional nuclear pellets are enriched for anywhere between three to five percent uranium, LEU+ cells contain eight percent enriched uranium by weight and other additives that allow it to generate more power while lasting longer.

This helps reduce the outages needed to refuel the reactor. Westinghouse expects the demand for such fuel to increase in the coming years since it can provide carbon-free electricity.

“The first production of LEU+ ADOPT fuel is a key step for achieving longer fuel cycles and reducing operational costs in the nuclear fuel industry,” said Tarik Choho, President of Westinghouse Nuclear Fuel, in a press release. “This significant milestone, will help us provide safer, more economical, reliable, clean energy to our customers across the world.”

The pellets will now be fabricated into pins and included in lead test assemblies in the UK. Next year, the fuel will be shipped to the US for irradiation testing at the Vogtle plant in Georgia.