Gel-sphere-pac reactor fuel fabrication and its application to a variety of fuels

The gel-sphere-pac fuel fabrication option was evaluated for its possible application to commercial scale fuel fabrication for 19 fuel element designs that use oxide fuel in metal clad rods. The dry gel spheres are prepared at the reprocessing plant and are then calcined, sintered, inspected, and loaded into fuel rods and packed by low-energy vibration. A fuel smear density of 83 to 88% theoretical can be obtained. All fuel fabrication process steps were defined and evaluated from fuel receiving to finished fuel element shipping. The evaluation also covers the feasibility of the process, the current status of technology, estimates of the required time and cost to develop the technology to commercial status, and the safety and licensability of commercial scale plants. The primary evaluation was for a Light-Water Reactor fuel element containing (U,Pu)O/sub 2/ fuel. The other 18 fuel element types - 3 for Light-Water Reactors, 1 for a Heavy-Water Reactor, 1 for a Gas-Cooled Fast Reactor, 7 for Liquid-Metal-Cooled Fast Breeder Reactors, and 3 pairs for Light-Water Prebreeder and Breeder Reactors - were compared with the Light-Water Reactor. The gel-sphere-pac option was found applicable to 17 of the 19 element types; the characteristics of a commercial scale plant were defined for these for making cost estimates for such plants. The evaluation clearly shows the gel-sphere-pac process to be a viable fuel fabrication option. Estimates indicate a significant potential fabrication cost advantage for the gel-sphere-pac process if a remotely operated and remotely maintained fuel fabrication plant is required.