Conceptual Process for the Manufacture of Low-Enriched Uranium/Molybdenum Fuel for the High Flux Isotope Reactor

The U.S. nonproliferation policy 'to minimize, and to the extent possible, eliminate the use of HEU in civil nuclear programs throughout the world' has resulted in the conversion (or scheduled conversion) of many of the U.S. research reactors from high-enriched uranium (HEU) to low-enriched uranium (LEU). A foil fuel appears to offer the best option for using a LEU fuel in the High Flux Isotope Reactor (HFIR) without degrading the performance of the reactor. The purpose of this document is to outline a proposed conceptual fabrication process flow sheet for a new, foil-type, 19.75%-enriched fuel for HFIR. The preparation of the flow sheet allows a better understanding of the costs of infrastructure modifications, operating costs, and implementation schedule issues associated with the fabrication of LEU fuel for HFIR. Preparation of a reference flow sheet is one of the first planning steps needed in the development of a new manufacturing capacity for low enriched fuels for U.S. research and test reactors. The flow sheet can be used to develop a work breakdown structure (WBS), a critical path schedule, and identify development needs. The reference flow sheet presented in this report is specifically for production of LEU foil fuel for the HFIR. The need for an overall reference flow sheet for production of fuel for all High Performance Research Reactors (HPRR) has been identified by the national program office. This report could provide a starting point for the development of such a reference flow sheet for a foil-based fuel for all HPRRs. The reference flow sheet presented is based on processes currently being developed by the national program for the LEU foil fuel when available, processes used historically in the manufacture of other nuclear fuels and materials, and processes used in other manufacturing industries producing a product configuration similar to the form required in manufacturing a foil fuel. The processes in the reference flow sheet are within the bounds of known technology and are adaptable to the high-volume production required to process {approx} 2.5 to 4 tons of U/Mo and produce {approx}16,000 flat plates for U.S. reactors annually ({approx}10,000 of which are needed for HFIR operations). The reference flow sheet is not intended to necessarily represent the best or the most economical way to manufacture a LEU foil fuel for HFIR but simply represents a 'snapshot' in time of technology and is intended to identify the process steps that will likely be required to manufacture a foil fuel. Changes in some of the process steps selected for the reference flow sheet are inevitable; however, no one step or series of steps dominates the overall flow sheet requirements. A result of conceptualizing a reference flow sheet was the identification of the greater number of steps required for a foil process when compared to the dispersion fuel process. Additionally, in most of the foil processing steps, bare uranium must be handled, increasing the complexity of these processing areas relative to current operations. Based on a likely total cost of a few hundred million dollars for a new facility, it is apparent that line item funding will be necessary and could take as much as 8 to 10 years to complete. The infrastructure cost could exceed $100M